Compuprint Sp40 Service Manual

SP 40
MAINTENANCE
MANUAL
Maintenance Manual SP 40
TABLE OF CONTENTS
Page
Preface 1
Chapter 1 General Information

1.1 Overview 3
1.2 Scope of the Product 3
1.3 Main Features 3
1.4 Printer Parts 4
1.5 Product Structure 6
1.5.1 Mechanism and Electromechanical devices 6
1.5.2 Electronics 7
1.6 Technical Specifications 10
1.7 Maintaining Parameters 12
Chapter 2 Removals
2.1 Overview 13
2.2 Covers 14
2.2.1 Top Cover 14
2.2.2 Main Cover 14
2.3 Print Head 16
2.4 Mechanical Assy 18
2.5 Electronic Boards 19
2.5.1 Optional (LAN or USB) and Backpanel Boards 19
2.5.2 Engine Board 19
2.5.3 Controller Board 20
2.5.4 Power Supply Assy 20
2.6 Operator Panel 23
2.7 Motors Assy 24
2.7.1 Carriage Motor Assy 24
2.7.2 Carriage Pulley 24
2.7.3 Selector Motor Assy 26
2.7.4 Paper Motor Assy 26
2.8 Home Sensor Assy 28
2.9 Ribbon Sensor Assy 29
2.10 Ribbon Drive Assy 30
2.11 Carriage Assy 32
2.12 Mylar Bar Assy 34
2.13 Rear Roller Assy 36
2.14 Front Roller Assy 38
2.15 Selector Cam 40
2.16 Lower Roller Assy (Rear Side) 42
2.17 Lower Roller Assy (Front Side) 43
2.18 Sensor Board and Sensor Cable 44
2.19 Platen Assy 46
2.20 Print Head Cables 48
Rev. 005
i.1 Index
TABLE OF CONTENTS cont’d

Page
Chapter 3 Operability and Configuration
3.1 Overview 49
3.2 Operability 49
3.2.1 Operator Panel 49
3.2.2 Function keys 50
3.2.3 Leds 50
3.3 Printer Set-up Mode by Operator Panel 51
3.3.1 Print of Self Test Page 52
3.3.2 Printer Configuration 53
3.3.2.1 Print of the Setup Forms 53
3.3.2.2 Filling in the Printer Setup Forms 54
3.3.2.3 Reading the Preprinted Forms 54
3.3.2.4 Setup Forms and Parameters 55
3.3.2.5 Offset Adjustments 61
3.4 Printer Set-Up Mode by Web Browser (NIC card) 63
3.5 Printer Set-Up Mode through the application SP40setup (via serial i/F) 68
3.5.1 Entering the printer Setup Mode 68
3.5.2 Install the SP40setup application 68
3.5.3 Run the SP40setup application 70
3.5.4 How to download to SP40 an existing configuration file 73
3.6 Print of NIC Configuration Page 74
Chapter 4 Service Maintenance

4.1 Overview 75
4.2 Initial Inspection and tools 75
4.3 Set-up 75
4.4 Cleaning 75
4.5 Lubrication 76
4.6 Paper Specifications 76
4.7 Consumables 76
4.8 Software Update 77
4.8.1 Basic Software update through parallel or serial interface 77
4.8.2 NIC Software update through parallel or serial interface 78
4.8.3 LAN Parameters Setup through parallel interface 79
4.8.4 Software update through LAN interface 80
4.8.4.1 Software update through LAN using FTP 80
4.9 Troubleshooting 81
4.9.1 Hexadecimal Dump 81
4.9.2 Printer Errors 81
4.9.2.1 Recoverable errors 81
4.9.2.2 Unrecoverable errors 82
4.10 Troubleshooting Tables 84
4.10.1 Power malfunction 84
4.10.2 Faulty probability guide 85
4.11 Reset the Consumable Parts 86
Rev. 005
i.2 Index
TABLE OF CONTENTS cont’d

Page
Chapter 5 Test & Diagnostic

5.1 Overview 87
5.2 How to run T&D (with Standard Operator Panel) 87
5.3 General Rules for T&D Operations 87
5.4 T&D USER Tests Description 89
5.5 Step by Step T&D Mode Flow Chart 90
5.6 Step by Step T&D Mode Sequential Table 91
5.7 T&D Errors Handling 96
5.7.1 Led Meaning during T&D Error Condition 97
5.8 T&D Errors Codes 100
5.9 Requested Tools 102
5.9.1 Operator Panel with LCD 102
5.9.2 RS232 Serial Interface Loop-Back Connector 102
5.9.3 Parallel Interface Loop-Back Connector 103
5.10 Analysis of T&D Printouts 104
5.10.1 Printing Adjustment Printout (T&D 9) 104
5.10.2 Standard Pattern Printout (T&D 10) 105
5.11 Monitor Though Serial Interface 108
5.12 Log File Printout (T&D 12) 111
Chapter 6 Paper Specifications

6.1 Overview 113
6.2 Single Sheet 114
6.3 Passbook 115
6.3.1 Passbooks with horizontal fold 116
6.3.2 Passbooks with vertical fold 117
Chapter 7 Electromechanical Devices

7.1 Overview 119
7.2 Print Head 119
7.3 Carriage Motor 122
7.4 Paper Motor 123
7.5 Selector Motor 124
7.6 Sensors 125
Chapter 8 Adjustments
8.1 Overview 127
8.2 Print Head Gap Adjustment 128
8.3 Paper Belt Adjustment 130
8.4 Carriage Belt Adjustment 131
8.5 Selector Cam Adjustment 132
Rev. 005
i.3 Index
TABLES
Page
Table 1.1 Printer Specification Summary 10
Table 3.1 O.P. keys meaning 50

Table 3.2 O.P. Leds meaning 50
Table 3.3 Configuration Form Parameters description 56
Table 3.4 Program 1 (Program 2) Form Parameters description 59
Table 4.1 Not-recoverable leds errors code N° 82

Table 4.2 Not-recoverable errors error table 83
Table 4.3 Power malfunction Troubleshooting 84
Table 4.4 Faulty Probability Guide 85
Table 5.1 General Rules for T&D operations 88

Table 5.2 T&D USER Tests Description 89
Table 5.3 Step by Step USER Complete Sequential Actions 91
Table 5.4 T&D Error Phase Sequential Actions 96
Table 5.5 Led Status for N° of Test in error condition 97
Table 5.6 Led Status for O.R.U. in error 98
Table 5.7 Led Status for specific/common error codes 99
Table 5.8 T&D Error Codes 100
Table 5.9 T&D O.R.U. Codes 101
Table 5.10 T&D Common Errors (sensors) codes 101
Table 5.11 T&D Common Errors (mechanical) codes 101
Table 5.12 Serial Cable Connection for Remote T&D 108
Table 6.1 Single Sheet Dimensions 114

Table 6.2 Passbook Dimensions 115
Table 6.3 Horizontal Passbook Dimensions 116
Table 6.4 Vertical Passbook Dimensions 117
Table 7.1 Print Head Electrical pin-out 120

Table 7.2 Sensors Board pin-out 126
Rev. 005
i.4 Index
ILLUSTRATIONS
Page
Fig. 1.1 Front View 4

Fig. 1.2 Rear View (Standard model) 4
Fig. 1.4 Rear View (LAN model) 4
Fig. 1.3 Inside View 5
Fig. 1.5 Lay-out Electronic Parts 8
Fig. 1.6 Lay-out Electromechanical Parts 9
Fig. 2.1 Open Top Cover 15

Fig. 2.2 Cover removal 15
Fig. 2.3 Rise up Upper Mechanical Assy 16
Fig. 2.4 Ribbon Guide 17
Fig. 2.5 Print Head removal 17
Fig. 2.6 Mechanical Assy removal 18
Fig. 2.7 Boards removal 21
Fig. 2.8 Operator Panel removal 23
Fig. 2.9 Carriage Motor Assy removal 25
Fig. 2.10 Selector and Paper Motor removal 27
Fig. 2.11 Home Sensor Assy 28
Fig. 2.12 Ribbon Sensor Assy removal 29
Fig. 2.13 Ribbon Drive Assy removal 31
Fig. 2.14 Carriage Assy removal 33
Fig. 2.15 Mylar Bar Assy removal 35
Fig. 2.16 Rear Roller Assy removal 37
Fig. 2.17 Front Roller Assy removal 39
Fig. 2.18 Selector Cam removal 41
Fig. 2.19 Lower Roller Assy removal (Rear Side) 42
Fig. 2.20 Lower Roller Assy removal (Front Side) 43
Fig. 2.21 Sensor Board and Sensor Cable removal 45
Fig. 2.22 Platen Assy removal 47
Fig. 2.23 Print Head Cable removal 48
Fig. 3.1 Operator Panel 49

Fig. 3.2 Set-up Mode Flow-Chart 51
Fig. 3.3 Self Test Printout 52
Fig. 3.4 Leds meaning in Setup Mode 53
Fig. 3.5 Markers meaning in Setup Mode 54
Fig. 3.6 How to fill Markers in Setup Mode 54
Fig. 3.7 Configuration Setup Form 55
Fig. 3.8 Program 1 Setup Form 58
Fig. 3.9 Offset Tuning Setup Form 61
Fig. 3.10 Offset Tuning Example 62
Fig. 3.11a Home Page of SP40 using a web browser 63
Fig. 3.11b System Page of SP40 through web browser 64
Fig. 3.11c Security Setting (first time) 64
Fig. 3.11d Security Setting Page of SP40 through web browser 65
Fig. 3.11e Warning message of SP40 through web browser 65
Fig. 3.11f Reboot Page of SP40 through web browser 65
Fig. 3.11g Configuration Setup Page through web browser 66
Fig. 3.11h Program 1/2 Setup Page through web browser 66
Fig. 3.1i NIC Setup Page through web browser 67
Fig. 3.11j Printer Status Page through web browser 67
Rev. 005
i.5 Index
ILLUSTRATIONS
Page
Fig. 3.12a Initial mask for SP40setup installation 68

Fig. 3.12b Other mask for SP40setup installation 68
Fig. 3.12c Other mask for SP40setup installation 69
Fig. 3.12d Other mask for SP40setup installation 69
Fig. 3.12e Other mask for SP40setup installation 69
Fig. 3.12f Other mask for SP40setup installation 70
Fig. 3.12g Other mask for SP40setup installation 70
Fig. 3.13 Initial mask for SP40setup application 70
Fig. 3.14a Read NVM mask of the SP40setup application 71
Fig. 3.14b Read NVM mask of the SP40setup application 71
Fig. 3.15 Write NVM mask of the SP40setup application 72
Fig. 3.16 Button to print NIC Configuration 74
Fig. 3.17 Network Interface Configuration 74
Fig. 4.1 Basic FW steps through LAN using FTP 80

Fig. 4.2 Power Supply pin-out 84
Fig. 5.1 Operator Panel Sketch 87

Fig. 5.2 Schematic flow-chart of the T&D USER in Step by Step mode 90
Fig. 5.3 Operator Panel with Display for T&D activities 102
Fig. 5.4 Serial I/F loop-back 102
Fig. 5.5 Parallel I/F bi-directional loop-back 103
Fig. 5.6 Pattern for Printout T&D9 of standard model (reduced) 104
Fig. 5.7 Pattern for Printout T&D9+T&D10 of Standard model (reduced) 107
Fig. 5.8 Remoter mode display (Hyper Terminal under W98) 108
Fig. 5.9 Remote mode display (Sensor 2 error during T&D9) 109
Fig. 5.12 Example of T&D12 Log File (without errors) 112
Fig. 5.13 Example of T&D12 Log File (with maximum N° of errors) 112
Fig. 6.1 Single Sheet dimensions 114

Fig. 6.2 Passbook Dimensions 115
Fig. 6.3 Horizontal Passbook 116
Fig. 6.4 Vertical Passbook 117
Fig. 7.1 Print Head Architecture 119

Fig. 7.2 Print Head Connection (rear view) 120
Fig. 7.3 Needles Position (rear view) 121
Fig. 7.4a P.H. Operation 121
Fig. 7.4b P.H. Operation 121
Fig. 7.5 Carriage Motor Layout 122
Fig. 7.6 Paper Motor Layout 123
Fig. 7.7 Selector Motor Layout 124
Fig. 7.8 Home Position Sensor 125
Fig. 7.9 Edge Sensor 126
Fig. 7.10 Ribbon Sensor 126
Fig. 7.11 Sensor Board and Optical Fibre 127
Rev. 005
i.6 Index
ILLUSTRATIONS
Page
Fig. 8.1 Gap Adjustment 129

Fig. 8.2 Print Head Gap versus Platen 129
Fig. 8.3 Paper Belt Adjustment 130
Fig. 8.4 Carriage Belt Adjustment 131
Fig. 8.4 Selector Cam Adjustment 132
Rev. 005
i.7 Index
Page intentionally left blank
Rev. 005
i.8 Index
Preface
Rev. AE (005) September 2005

Rev. AD (004) April 2005
Rev. AC (003) May 2004
Rev. AB (002) January 2004
Rev. AA (001) June 2003
This Maintenance Manual focuses on the maintenance activities on the printer SP 40.
All defects originated by incorrect paper insertion, wrong menu setting or mistaken controls commands, are not
covered by this document to avoid duplication of informations available on the USER MANUAL forwarded to each
end user within printer package.
When the malfunction eludes all the solutions proposed in the USER MANUAL or deducible from it, a severe
failure within the printer hardware, firmware or mechanisms should be suspected.
Then follow the troubleshooting sequence advised in this manual together with defective part removal and
replacement.
The informations on this document are subject to change without notice.
All efforts have been made to ensure the accuracy of the contents of this manual.
Rev. 005 Preface

1
FCC Regulations
Note: This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to
Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in
a residential installation. This equipment generates, uses and can radiate radio frequency energy and, if not installed
and used in accordance with the instructions, may cause harmful interference to radio communications. However,
there is no guarantee that interference will not occur in a particular installation. If this equipment does cause harmful
interference to radio or television reception, which can be determined by turning the equipment off and on, the user is
encouraged to try to correct the interference by one or more of the following measures:
• Reorient or relocate the receiving antenna.

• Increase the separation between the equipment and receiver.
• Connect the equipment and the receiver to outlets on different circuits.
• Consult the dealer or an experienced radio/TV technician for help.
Changes or modifications not expressly approved by the party responsible for compliance could void the user's
authority to operate the equipment.
The use of a non-shielded interface cable with the referenced device is prohibited. The length of the parallel interface
cable must be 3 meters (10 feet) or less. The length of the serial interface cable must be 15 meters (50 feet) or less.
Canadian D.O.C. Radio Interference Regulation
This digital apparatus does not exceed the Class B limits for radio noise emission from digital apparatus as set out
in the radio interference regulations of the Canadian Department of Communications.
Le présent appareil numérique n'émet pas de bruits radioélectriques dépassant les limites applicables aux appareils
numériques de classe B prescrites dans le règlement sur le brouillage radioélectrique édicté par le ministère des
communications du Canada.
EEC Regulations
This equipment conforms to the EEC Directive 89/392 (the sound pressure, measured according to ISO 7779, does
not exceed 70 dBA).
Rev. 005 Preface

2
Chapter 1 General Information
1.1 Overview
This section describes the product and its intrinsecal main characteristics..
1.2 Scope of the Product
The product is intended to satisfy most of the counter applications in a ergonomic environment.
It is designed for versatile and reliable paper handling.
A specialized flat-bed mechanism allows paper to be fed without bending: in this way special documents, such as
multiple invoices, postcards, labels, tickets can be trouble-free printed.
1.3 Main Features
The following points put in evidence the main features of this product.
• Printing on a wide range of paper media: different types of cut sheets, multi-parts and passbooks.
• High print pressure for multi-parts documents
• High print quality supplied by a 24 wire print head
• High reliability paper handling
The straight paper path allows the printing on particular documents such as envelopes, multipart forms and
passbooks.
• Automatic paper thickness adjustment
The print head detects automatically the paper thickness for correct printing on any type of document. This printer
can print also on documents with a variable thickness, such as passbooks.
• Easy paper handling
The operator places the paper on the front table and the printer loads it without any other user intervention. The
paper ejection towards the front or the rear of the printer allows an easy access to the printed document.
• Automatic document alignment feature
The printer checks automatically the alignment of the top margin and the left margin of the document and adjusts
it, if necessary. The printout is therefore performed correctly independently from the paper loading position.
• Storage of two complete configurations for instant recall
• Standard parallel and serial interface and automatic switch-over function. The financial interface is available for
the IBM 4722 and the IBM 9068 protocols.
• Optional LAN 10/100BaseT or USB interface.
• Easy printer setup through an optically managed menu.
• Emulations: Epson 570, IBM Proprinter XL24E, XL24E AGM, IBM 2390+, 4722, 9068 and Olivetti PR40+, PR2,
2845.
Rev. 005 Chapter 1

3 General
1.4 Printer Parts
Printer Cover
Operator Panel
Paper Stand
Power-on Push-button
Figure 1.1 - Front View
Power Cable Connector

Serial Interface Cable Connector
Parallel Interface Cable Connector
Figure 1.2 - Rear View (standard model)
Rev. 005 Chapter 1

4 General
1
2
3
Figure 1.3 - Rear View (LAN model)
Printhead
Print Head
Assembly
Print Area
Paper Jam
Removal Cog-wheel
Figure 1.4 - Inside View
Rev. 005 Chapter 1

5 General
1.5 Product Structure
1.5.1 Mechanism and Electromechanical Devices
The basic mechanism has been designed to support a flat-bed path oriented to an high reliability of the paper
handling.
Paper Handling
A stepper motor, supporting 1/180" paper step together with a minipitch belt, provides the movement to the paper
alignment and pressing front and rear rollers.
Rollers opening and Aligner selection

A stepper motor drives a guide installed in the left side of the printer that allows to open/close the paper pressing
rollers and to activate the Aligner mechanism (special rollers + stop bar) to provide the Auto Document Alignment or
Skew Adjustment feature.
Carriage Movement
A stepper motor provides the movement of a carriage, carrying the print head, which is driven by a stepper motor and
a minipitch belt.
Ribbon movement
The motion of the ribbon is driven by mechanical coupling and plastic gears assy that translate the bidirectional
movenent of the carriage to one way movement for the the pivot driving the ribbon. The ribbon drive assy is installed on
the left side of the vertical frame, near the pulley of the carriage motor.
Gap Distance
A special wheel installed on the body of the print head and a flexiible platen realize together the function of Automatic
Adjustment of the printhead gap according to the paper thickness in real time. The AGA wheel forcing continuosly on
the platen with a force depending from the thickness of the media interposed between them.
Sensors
There are 5 sensors in this printer for the following features:
Cut Sheet Loading (on the sensor board)
Cut Sheet Skewing (on the sensor board)
Paper Edge Detection (on the print head assy)
Home Position Detection (on the mechanical assy)
Ribbon Present and Movement (on the mechanical assy)
See chapter 7 for the electrical schematics.
Printhead
The printhead to be used is the ER24W with the following characteristics:
Printhead type: ER24W

Number of wires: 24
Needle diameter: 0.25 mm
Configuration: diamond
Technology: Electromagnetic not Ballistic
Max. frequency 2400 Hz (Text Mode)
2100 Hz (Graphic Mode)
Energy per dot 5 mJ
Life 400 Million chars @ Draft 10 cpi
Copies 1+5
Dimensions Length (53 mm), Diameter (62 mm), Weight (300 g)
See chapter 7 for the electrical schematics.
Rev. 005 Chapter 1

6 General
1.5.2 Electronics
Electronic parts of the printer are:
• Power Supply autoswitching type.

• Controller Board including parallel and 9 pin serial interface connector for standard model.
On the controller are also present the flash memory with firmware and generator on it.
This structure is intended to make easy update the controller with a new firmware version through a
downloading operation.
• Engine Board that receive input command by the controller board and drive all the electromechanical
devices of the printer.
• LAN or USB Board (only for the models with optional interface), that drives the proper interface and is
connected to the controller board.
• Operator Panel Board (3 keys, 4 leds).
Rev. 005 Chapter 1

7 General
Here below the lay-out of the Electronic parts (the LAN and the USB can be installed one per time).
USB
BOARD
CONTROLLER
BOARD
LAN
BOARD
BACK
PANEL
ENGINE
POWER BOARD
SUPPLY O.P.
BOARD
Figure 1.5 - Lay-out Electronic parts
Rev. 005 Chapter 1

8 General
Figure 1.6 - Lay-out Electromechanical parts
Rev. 005 Chapter 1

9 General
1.6 Technical Specifications
Printing Technology
Print head: ER24W 24 pin – Ø 0,25 mm
Print head life 400 million characters
Resolution: 360 x 360 dpi (HxV)
Line Length (@ 10 cpi)
94 columns (cut sheets)
Printing Speed
400 cps @ 10 cpi (Draft)
133 cps @ 10 cpi (LQ)
Emulation
IBM ® Personal Printer 2390+, Proprinter XL24E, Proprinter XL24AGM, IBM 4722, 9068, Epson 570 and
Olivetti PR40+, PR2, 2845
Resident Fonts
Draft, Courier, Gothic, Prestige, Presentor, Script, OCR-A, OCR-B, Boldface
Character Sets (IBM and Epson protocols)
PC standard set (CS1-CS2) - 13 National Epson sets - CP437 (USA) - CP437G (Greek) -
CP850 (Multilanguage) – CP851 (Greek) - CP852 (Latin 2) - CP853 (Turkish) - CP855 (Russian) -
CP857 (Turkish) - CP 858 (Euro) - CP860 (Portuguese) - CP862 (Hebrew) -
CP863 (French/Canadian) - CP864 (Arabic) - CP865 (Norwegian) - CP866 (Cyrillic) -
CP867 (Turkish) – CP876 (OCRA) - CP877 (OCRB) - CP1250 (Central Europe) – CP1251 (Cyrillic) –
CP1252 (Windows Latin1 Ansi) - Gost - Tass – Mazowia - ISO 8859/1/2/3/4/5/6/7/8/9/15 - 96GREEK-
Ukrainian – ID 12 – ID 14 – ID 17 – CP1098 (Farsi Arabic) – Roman-8, CP437 Slavic – Sanyo –
Ku - Philip
Character Sets (OLIVETTI protocols)
CS000 – CS010 International, CS020 Germany, CS030 Portugal, CS040 Spain1,
CS050 Denmark/Norway, CS060 France, CS070 Italy, CS080 Sweden/Finland, CS090 Switzerland,
CS100 Great Britain, CS110 USA ASCII, CS140 Greece, CS150 Israel, CS170 Spain 2,
CS200 Jugoslavia, CS410 Olivetti TCV 370, CS510 SDC, CS520 Turkey, CS540 CIBC,
CS680 OLI-UNIX, CS701 PC-220 Spain2, CS711 PC-Denmark/Norway, CS712 PC-Denmark OPE,
CS771 PC-210 Greek
Barcodes
UPC/A, UPC/E, EAN8, EAN13, Code 39, Code 128, Postnet, Codabar, ADD-ON 2, ADD-ON 5, Code
11, Code 93, BCD, MSI, 2/5 Interleaved, 2/5 Matrix, 2/5 Industrial
Interfaces
Parallel IEEE 1284 bidirectional, nibble and byte modes
Serial RS-232/C
Automatic Interface Switching
LAN 10/100 baseT (optional)
USB (otpional)
Memory
32 Kbytes buffer
Table 1.1 Printer Specifications Summary
Rev. 005 Chapter 1

10 General
Special Functions
Automatic Gap Adjustment (AGA)
Auto Alignment
Auto Border Recognition
Ribbon Life
4 million characters (black)
Reliability
MTBF: 10,000 hours
Duty cycle
28000 pages/month
Physical Dimensions & Weight
400 (W) x 295 (H) x 200 (D) mm
< 12 Kg
Power Supply
Type Universal - autoswitching
Power consumption: < 120 W (printing – ECMA test),
< 10 W (idle)
Environmental conditions
Temperature: working +10 to +40 °C
Humidity: working 40% to 60% RH (without condensation)
Noise Level
< 54dbA
Environment
Energy star compliant
Compliances
120 VAC, 60 Hz UL 1950, CSA C22.2 N.950, IEC 950, FCC CFR 47 (certified), CSA
C108.8, EPA2 STAR
220/240 VAC, 50 Hz CE Marking, EN 60950, IEC 950, NEMKO-TSE (74-SEX) 203/92,
EN55022, German Postal Decrees 243/1991 and 46/1992, EPA2 STAR
Table 1.1 Printer Specifications Summary cont'd
Rev. 005 Chapter 1

11 General
1.7 Maintaining Parameters
MTTR
The Mean Time To Repair is the estimated mean time to repair the printer at Optimum Replaceable Unit (ORU)
level.
For this printer the MTTR is 16 minute and includes:
- Identifying the faulty ORU

- Changing the ORU
- Cleaning
- Testing
MTBF / RELIABILITY
Mean Time Between Failure depends on duty cycle rate (D.C.).

For this printer the MTBF is 10.000 hours @ 25% D.C. (excluding print head).
Duty Cycle rate estimated for this printer is calculated as follows:
Paper Movement & Print Time

Duty Cycle = ------------------------------------------------- = 25%
Power on Time
Reference usage of 25% duty cycle is assumed on the basis of the following parameters:
60% column density, 50% line density, 40% character density, 40 hours at week.
LIFE
Unit 5 years
Print Head 400 M Characters (Draft Mode)
Ribbon 4 M Characters (Draft Mode)
Rev. 005 Chapter 1

12 General
Chapter 2 Removals
2.1 Overview
This section describes the removal and installation procedures of the major printer parts.
Danger notices warn against personal injury that is lethal or extremely hazardous.
Caution notices warn against personal injury that is neither lethal nor extremely hazardous.
Attention notices warn against damage to machine, equipment or programs.
Remark notices warm against some particular procedure to be run.
Necessary Tools:
• Assortment of cross-head and blade screwdrivers.
• Wrench allen type.
• Pliers.
• Set of fastener loop-self lock.
• Cutting nippers.
• Fork wrench 10mm.
• Feeler Gauge.
List of the removal and installation parts:
- ch 2.2 Covers (Top Cover and Main Cover)

- ch 2.3 Print Head
- ch 2.4 Mechanical Assy
- ch 2.5 Boards (Optional I/F, Backpanel, Engine, Controller and Power Supply Boards)
- ch 2.5 Power Supply
- ch 2.6 Operator Panel
- ch 2.7 Motors Assy (Carriage Motor, Carriage Pulley, Selector Motor, Paper Motor)
- ch 2.8 Home Sensor Assy
- ch 2.9 Ribbon Sensor Assy
- ch 2.10 Ribbon Drive Assy
- ch 2.11 Carriage Assy
- ch 2.12 Mylar Bar
- ch 2.13 Rear Roller Assy
- ch 2.14 Front Roller Assy
- ch 2.15 Selector Cam
- ch 2.16 Lower Roller Assy (Rear Side)
- ch 2.17 Lower Roller Assy (Front Side)
- ch 2.18 Sensor Board, Sensor Cable
- ch 2.19 Platen Assy
- ch 2.20 Print Head Cables
- Cariage Belt (see ch 2.11)

- Paper Belt (see ch 2.7 or 2.16 or 2.17)
- Open Lever (see ch 2.11)
- Mylar Protection Cable (see ch 2.20)
- Print Head Safety Cover (see ch 2.3)
- Switch Lever P.S. (see ch 2.5)
Rev. 005 Chapter 2

13 Removals
2.2 Covers
DANGER : To prevent serious personal injury from electrical shock always turn the printer off and unplug
the power cable before remove the cover parts.
ATTENTION: The electronic parts of this printer are easily damaged by Electronic Static Discharge(ESD).
Ensure that ESD protection devices and procedures, including the static discharge
wrist wrap, are used while working on this printer.
Do not remove the operator panel cable from the o.p board before unplug the AC
cable. The power supply is powered on / off through the P.S. switch lever on the front
left side of the printer.
2.2.1 Top Cover
Top cover is item 26 of figure in next page.

Flap is item 28 of figure 2.2 on next page.
To Remove:
1) Open the top cover as showed in figure 2.1 .
2) Unhook the flap paying attention to not damage its lateral pivots and remove it from the top cover.
3) Disingage the top cover from the main cover acting on ingage pivot (item 1 of figure 2.2) with a gently
push force toward the internal side of the printer.
4) Remove the top cover
To Install:
To install the top cover, follow the removal step in reverse order.
2.2.2 Main Cover
Main cover is item 25 of figure 2.2 on next page.
To Remove:
1) Remove the top cover
2) While acting with a gently force toward the internal side on the four plastic hook (item 2 of figure 2.2) of
the base, unhook the main cover from the base. The two hooks located in the rear part of the cover can
be accessed through the respective little holes present in the cover.
3) Remove the main cover.
To Install:
To install the main cover, follow the removal step in reverse order.
Rev. 005 Chapter 2

14 Removals
Figure 2.1 - Open Top Cover
Figure 2.2 - Cover Removals
Rev. 005 Chapter 2

15 Removals
2.3 Print Head
DANGER : To prevent serious personal injury from electrical shock always turn off the printer and unplug
the power cable before remove the print head.
CAUTION: The print head may have hot surface. Wait for it to cool down.
ATTENTION: Only the two allen screws have to be unscrewed to remove the print head.
Do not touch other three screws on the print head that are fixing the correct
AGA wheel position. (Adjustment done at manufacturing level).
Removal
1) Open the top cover.
2) Pushing the proper green lever rise up the upper part of machanical assy (like in figure 2.3).
3) Put the Print Head in a center position.
4) Remove the ribbon guide from the print head (figure 2.4) and then remove the inked ribbon cartridge.
5) Remove the print head safety cover (item 23 of figure 2.5) by manually acting on its left and right hooks.
6) Unscrew the two allen screws (item 24 of figure 2.5) securing the print head to the carriage with the flat
and stars washers.
7) Extract the print head (item 22 of figure 2.5) from the carriage assy.
8) Unplug the flat cables from the print head and remove it.
Replacement
To install, follow the removal step in reverse order.
Remark:
When reassembly the print head, before to secure the screws, pay attention for the correct position of the print
head. This is assured by two lateral pins on the metal part of the print head that fit together print head with the
carriage assy.
Secure the screws allen type with a driving torgue of 7 Kg/cm.
Figure 2.3 - Rise up Upper Mechanical Assy
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Figure 2.4 - Ribbon Guide
Figure 2.5 Print Head Removal
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2.4 Mechanical Assy
To Remove:
1) Remove the top and the main cover (see chapter 2.2).
2) Unplug the seven cables from the connector on the front side of the engine board.
From right to left, the connectors are op. panel, ribbon sensor, paper motor, home sensor, selector
motor, carriage motor.
3) Unscrew the four screws (item 19 of figure 2.6) fixing the mechanical assy on the base.
4) Acting from the front side, gently rise a little bit the mechanical assembly from the base and unplug the
two print head cables from the engine board located in the rear part of the board.
5) Remove the mechanical assy from the base.
To Install:
Follow the removal step in reverse order.
Remark:
Viasual check from the right side of the printer, the correct bend of the print head cable.
They must be bended in the rear part of the printer.
Figure 2.6 - Mechanical Assy Removal
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2.5 Electronic Boards
the power cable before to remove the engine and the controller board.
Ensure that ESD protection devices and procedures, including the static discharge wrist wrap,
are used while working on this printer.
NOTE: Print or obtain from the operator the configuration modules of the Setup for this printer.
See how to print the Setup on chapter 3.3.3.
2.5.1 Optional Board (LAN or USB) and Backpanel Board
The optional board is item 40, the backpanleboard is item 41 of figure 2.7.
To Remove:
1) Remove the mechanical assy from the base (see chapter 2.4).
2) Unscrew the two screws securing the optional board to the rear frame and the two screws securing the
board to its metal spacers (item 39 of figure 2.7).
3) Unplug the optional board from the backpanel board.
4) Extract the optional board board.
5) Unplug the backpanl board from the controller board.
6) Ectract the backpanel board.
To Install:
2.5.2 Engine Board
Engine board is item 9 of figure 2.7.
To Remove:
If the optional board is installed, look at all steps of chapter 2.5.1 described before.
2) Unplug the power supply cable from the engine board.
3) Unscrew the five screws (item 8 of figure 2.7) securing the engine board to the base assy.
4) Unplug the engine board from the controller board.
5) Extract the engine board.
To Install:
Remark:
The engine board replacement requires an appropriate T&D test and a complete re-configuration of the printer,
because all the setup parameters are stored in a NVM (not volatile memory) i.c. installed on this board.
Run all the tests in Step by Step Mode to complete readjust all the parameters (see chapter 5).
Use the configuration modules to automatically configure the printer (see chapter 3).
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2.5.3 Controller Board
Controller board is item 10 of figure 2.7.
To Remove:
1) Remove the engine board following the chapter 2.5.2 described before.
2) Remove the two screws (item 30) fixing the parallel I/F connector from the rear side of the printer.
3) Remove the two screws (item 13) fixing the serial I/F connector from the rear side of he printer.
4) Extract the controller board.
To Install:
2.5.4 Power Supply Assy
Power Supply is item 7 of figure 2.7.
DANGER : To prevent serious personal injury from electrical shock turn the printer off and unplug the
power cable before to remove the power supply.
ATTENTION: The electronic parts of this printer are easily damaged by Electronic Static Discharge (ESD).
Ensure that ESD protection devices and procedures, including the static discharge wrist wrap,
are used while working on this printer.
To Remove:
2) Unplug the power supply cable from the engine board.
3) Unscrew the two screws securing the power switch.
4) Unscrew the screw fixing the ground cable on the lower shield.
5) Unscrew the five screws fixing the power supply (item 7 of figure 2.7) on the base.
6) Slide out of the guide the AC socket and remove the power supply.
To Install:
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Figure 2.7 - Boards Removal
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2.6 Operator Panel
the power cable before to remove the operator panel.
Ensure that ESD protection devices and procedures, including the static discharge
wrist wrap, are used while working on this printer.
Do not remove the operator panel cable from the o.p board before unplug the AC
cable.
To Remove:
1) Open the top cover.
2) Remove the two screws (item 8 of figure 2.8) fixing the operatot panel support on the right side frame
and on the bed.
3) Unplug the O.P. cable (item 21 of figure 2.8) and remove the operator panel with its support.
4) Remove the two screws fixing the operator panel with its support and remove it.
To Install:
Figure 2.8 - Operator Panel Removal
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2.7 Motors Assy
2.7.1 Carriage Motor Assy
the power cable before to remove the carriage motor assy.
Carriage motor is item 66 of figure 2.9. It is assembled together whith its support (item 63 of figure 2.9) and
ribbon drive assy (item 67 of figure 2.9). To remove the motor, firstly remove the assembly and then extract the
carriage motor from the other parts.
To Remove:
2) Remove the inked ribbon cartridge.
3) Cut the fastner loop-self lock which retain the carriage motor cable.
4) Unplug the carriage motor cable from the engine board and slip off it from the retainers.
5) Moving the carriage, drive off the carriage belt from the pulley of the carriage motor.
6) Using a blade screwdriver, unscrew the three screws (item 65 of figure 2.9) from the rear side of the
printer.
7) Remove the carriage motor together its support and the ribbon drive assy from the vertical frame.
8) Unscrew the three screws (item 13 of figure 2.9) fixing the motor with its support.
9) Extract the carriage motor assy.
To Install:
2.7.2 Carriage Pulley
the power cable before to remove the carriage pulley assy.
Carriage pulley assy is item 60 of figure 2.9. It is fixed through its metal support on the right side of the vertical
frame.
To Remove:
3) Remove the screw and the washer (items 13 and 14 of figure 2.9) fixing the support on the vertical
frame from the rear side of the printer.
4) From the rear side unhook the spring keeping tensioned the belt. Unhook before the spring from the
more lateral side of the frame and than remove it from the more central side.
5) Drive off the belt from the pulley.
6) Extract the metal support (item 59 of figure 2.9) from the vertical frame.
7) Remove the circlip (item 38 of figure 2.9) fixing the pulley on the support.
8) Remove the pulley.
To Install:
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Figure 2.9 - Carriage Motor Assy removal
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2.7.3 Selector Motor Assy
the power cable before to remove the selector motor assy.
Selector motor assy is item 57 of figure 2.10.
To Remove:
1) Remove the top and the main cover assy (see chapter 2.2).
2) Unplug the cable connector of the selector motor from the engine board.
1) Cut the fastener loop-self lock which retain the selector motor assy cable on the mechanical assy and
extract it from the wiring routing clamp.
2) Remove the two screws fixing the selector motor to the left frame.
3) Remove the selector motor assy from the left frame.
To Install:
2.7.4 Paper Motor Assy
the power cable before to remove the paper motor assy.
Selector motor assy is item 31 of figure 2.10.
To Remove:
2) Unplug the seven connector cables from the front side of the engine board.
3) Unscrew the four screw fixing teh mechanical assy on the base.
4) Acting from the front side, gently rise a little bit the mechanical assembly from the base and unplug the
two print head cables from the engine board.
5) Remove the mechanical assy from the base.
6) Drive off the paper belt from the pulley of the motor.
7) Unscrew the two screws (item 13 of figure 2.10) fixing the paper motor to the right frame.
8) Extract the paper motor assy.
To Install:
Remark:
The tension of the paper belt has to be verified and if it is need adjusted before assembly operations.
For adjustment procedure see chapter 8.
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Figure 2.10 - Selector and Paper Motor removal
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2.8 Home Sensor Assy
Home sensor assy is item 69 of figure 2.11 and is fixed on the vertical frame of the printer.
To Remove:
2) Push the green levers to rise the upper side of the mechanical assy and remove the inked ribbon.
3) Unplug the connector cable from the engine board (the 5th starting from the right side).
4) Cut the fastener loop-self lock which retain the home sensor cable on the mechanical assy and extract
it from the wiring routing clamp.
5) Unscrew the screw (item 13 of figure 2.11) fixing the sensor to the vertical frame.
6) Extract the home sensor assy from the front side of the printer.
To Install:
Figure 2.11 - Home Sensor Assy Removal
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2.9 Ribbon Sensor Assy
Ribbon sensor assy is item 99 of figure 2.12 and is fixed on the upper side of the right frame of the printer.
To Remove:
2) Push the green levers to rise the upper side of the mechanical assy and remove the inked ribbon.
3) Unplug the connector cable from the engine board (the 2nd starting from the right side).
4) Remove the metal cable retainer (item 92 of figure 2.12) from the rear side of the right frame.
5) Unscrew the screw (item 73 of figure 2.12) fixing thr sensor on the right frame.
6) Remove the ribbon sensor assy being careful to slip off the connector cable through the vertical frame
toward the front side.
To Install:
Figure 2.12 - Ribbon Sensor Removal
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2.10 Ribbon Drive Assy
the power cable before to remove the ribbon drive assy.
Ribbon drive assy is item 67 of figure 2.13. It is fixed on the support of the carriage motor assy. To remove the
ribbon drive assy, firstly remove the assembly and then remove the ribbon drive assy from the support.
To Remove:
1) Remove the top cover (see chapter 2-2).
3) Using a blade screwdriver loose the screw (item 65 of figure 2.13) fixing the upper side of the carriage
motor.
4) Remove the two screws (item 68 of figure 2.13) fixing the ribbon drive assy on the support (item 63 of
figure 2.13).
5) Remove the ribbon drive assy from the support on the vertical frame.
To Install:
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Figure 2.13 - Ribbon Drive Removal
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31 Removals
2.11 Carriage Assy
the power cable before to remove the carriage assy.
ATTENTION: DO NOT REMOVE THE GREEN LEVERS BEFORE TO HAVE REMOVED THE TWO BIG
SPRINGS (items 86 and 87 of figure 2.14) ON THE REAR SIDE OF THE PRINTER.
Thanks to its very strong force this two springs open the upper parts of the machanical
assy when the green levers are pushed. The green levers assure the proper start / stop
movement generated by the springs.
So, if the green levers are removed with the big spring still under tension, a
mechanical assy opening will be performed without proper control and some parts,
like the print head cable, may be bamaged.
Carriage Assy is item 75 of figure 2.14
To Remove:
2) Remove the inked ribbon cartridge and the print head (see chapter 2.3).
3) Remove the plastic retainer (item 82 of figure 2.14) in order to remove the print head cables from the
carriage.
4) From the rear side remove the screw fixing the support of the pulley to the vertical frame. Pushing the
support with the pulley toward the center of the printer, drive off the belt from the pulley.
5) Unhook and remove the two big springs (items 86 and 87 of figure 2.14) keeping open the upper side of
the mechanical assy.
6) Unhook and remove the two springs (item 89 of figure 2.14) from the green levers.
7) Remove the circlips (item 38 of figure 2.14) fixing the green lever to the mechanical assy.
8) Remove the green levers.
9) Slack and remove the nuts (item 77 of figure 2.14) fixing the upper and the lower shafts (item 74 of the
figure 2.14) to both the side of the lateral frame.
8) Drive off the carriage from the upper shaft and nextly slide off the carriage from the lower shaft.
9) Extract the belt from the retainer of the carriage.
10) Remove the carriage.
To Install:
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Exploded View
Fifure 2.14 - Carriage Assy Removal
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2.12 Mylar Bar Assy
the power cable before to remove the mylar bar assy.
Mylar bar assy is item 34 of figure 2.15.
To Remove:
2) Push the green levers in order to rise the upper side of the mechanical assy.
3) Unhook and remove the little spring (item 52 of figure 2.15) on the left side of the printer.
4) Remove the circlip (item 38 of igure 2.15) from the external side of the printer and remove the plastic
lever (item 37 of figure 2.15).
5) Remove other circlip (item 38 of figure 2.15) from the square bar.
6) Moving the square bar toward left extract it from the right frame.
7) Moving the square bar toward right remove it from the left frame and then from the mechanical assy.
To Install:
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Figure 2.15 - Mylar Bar Removal
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2.13 Rear Roller Assy
the power cable before to remove the rear roller assy.
Rear roller assy are item 71 of figure 2.16. Rear roller assy is composed by a couple of roller. On the printer are
installed three rear roller assy together ingaged by plastic couplings.
To Remove:
3) Using a long screwdriver, through the hole of the vertical frame, unscrew the four screw (item 73A of
figure 2.16) fixing the group of the rear roller assy to the vertical frame.
4) Pushing on the green lever rise the upper side of the mechanical assy.
5) With a movement toward left disingage the group from the rightmost coupling.
6) Remove the group.
7) Remove the screw (item 73B of figure 2.16) fixing the bracket spring relating to the roller assy that has
to be changed.
8) Remove the roller assy.
To Install:
REMARK:
When the printer has already worked several time, it is strongly suggest to replace all the rear roller assy.
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Figure 2.16 - Rear Roller Assy Removal
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2.14 Front Roller Assy
the power cable before to remove the front roller assy.
Front roller assy are item 45 of figure 2.17. Front roller assy is composed by a double couple of roller. Each of
the couple has a metal roller near a rubber one. On the printer are installed three front roller assy together
ingaged by plastic couplings.
To Remove:
3) Unhook the springs (item 27 of figure 2.17) from both the side of the algner (item 51 of figure 2.17).
4) Extract and remove the aligner from the drive aligner assy (item 40 of figure 2.17).
5) Remove the circlip (item 29 of figure 2.17) fixing the spring bar to the left frame.
6) Loose the allen screw (item 53 of figure 2.17) without remove it. Just to give enough clearance to the
spring bar (item 39 of figure 2.17).
7) Move before the spring bar toward the right side through the hole on the right frame and then extract it
together to the drive aligner assy from the center of the printer.
8) Remove the roller assy.
To Install:
REMARK:
This installation requires an appropriate selector cam adjustment here below described and showed also in the
chapter 8 (Adjustment).
At the point 6) of reassembly operations is important to tight the allen screw in the correct way.
a- Rotate the selector cam forward until the stop point is found.
b- Push down the drive aligner assy together to the spring bar in order to put in touch the spring pressor (item
41 of figure 2.16) with the spring.
c- Respecting the point a- anb b- tight the allen screw.
REMARK:
When the printer has already worked several time, it is strongly suggest to replace all the front rollers assy.
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Exploded View
Figure 2.17 - Front Roller Assy Removal
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2.15 Selector Cam
the power cable before to remove the selector cam.
Selector cam is item 28 of figure 2.18
To Remove:
2) Remove the aligner, the drive aligner assy and the spring bar following until point 7 the instructions of
the chapter 2.14.
3) Remove the four screws (item 33 of figure 2.18) fixing the plastic support of the front roller to the front
bed.
4) Remove all the group of the front roller assy.
5) Remove the circlip (item 29 of figure 2.18).
6) Remove the selector cam.
To Install:
REMARK:
For a correct reassembly operations see the selector cam adjustment instructions reported in the chapter 2.14
or in the chapter 8.
The cam must be lubricate with Molykote PG30L grease as indicated in chapter 4.4.
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Figure 2.18 - Selector Cam Removal
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2.16 Lower Roller Assy (Rear Side)
the power cable before to remove the lower roller assy.
Lower roller assy installed under the rear bed of the printer is item 7 of figure 2.19.
To Remove:
3) Unplug the seven cable from the connector on the front side of the engine board.
4) Remove the four screws fixing the mechanical assy on the base.
5) Acting from the front side, gently rise the mechanical assy and unplug the print head cables from the
engine board.
6) Remove the mechanical assy.
7) Drive off the paper belt from its path.
8) Remove the circlip (item 9 of figure 2.19) and the bush (item 8 of figure 2.19) fixing the lower roller assy
to the left frame.
9) Acting from the lower side of the mechanical assy, extract the lower roller assy from the left frame.
10) Again from the lower side of the mechanical assy, remove the lower roller assy extracting it from the
external right side throgh the hole on right frame.
To Install:
Figure 2.19 - Lower Roller Assy Removal (Rear Side)
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2.17 Lower Roller Assy (Front Side)
the power cable before to remove the lower roller assy.
Lower roller assy installed under the front bed of the printer is item 7 of figure 2.20.
To Remove:
engine board.
7) Acting from the lower side of the mechanical assy, remove the two screws (item 16 of figure 2.20)
securing the bracket (item 15 of figure 2.20) to the mechanical assy and remove the bracket.
8) Unscrew the two screws securing the green wheel and remove it from the right side of the printer.
9) Drive off the paper belt from its path.
10) Remove the circlip (item 9 of figure 2.20) and the bush (item 8 of figure 2.20).
11) Acting from the lower side of the mechanical assy, extract the lower roller assy from the left frame.
12) Again from the lower side of the mechanical assy, remove the lower roller assy extracting it from the
external right side throgh the hole on right frame.
To Install:
Figure 2.20 - Lower Roller Assy (Front Side)
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2.18 Sensor Board and Sensor Cable
the power cable before to remove the sensor board or its cable.
Sensor board and sensor cable are respectively item 10 and 98 of figure 2.21.
They are installed under the front bed of the printer.
To Remove:
1) Remove the lower roller assy (front side) following all the removal operations described in the chapter
2.17.
2) Remove the two screws and related washers (item 13 and 14 of figure 2.21) and remove the sensor
board with the cable pugged on it.
3) Unplug the sensor cable from the sensor board.
To Install:
REMARK:
Before to install the sensor board, check for the presence of the insulating mylar (item 12 of figure 2.21) stiked
under the connector area of the board. This is important to avoid electrical short circuit touching the metal bed.
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Figure 2.21 - Sensor Board and Sensor Cable Removal
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2.19 Platen Assy
the power cable before to remove the platen assy.
Platen assy includes items 17, 18 and 94 of figure 2.22.
To Remove:
engine board.
7) Remove the two allen screws and related washers (item 19 and 20 of figure 2.22) securing the platen
assy to the left and the right frame.
8) Loose the screws (item 6 and 4 of figure 2.22) in order to give a little clearance between lateral frames
and central part of the mechanical assy.
9) Extract the platen assy from the left and the right frame and remove it from the lower side of the
mechanical assy.
To Install:
REMARK:
An appropriate adjustment is required in order to have a correct parallelism and a correct gap between platen
and AGA wheel. Adjustment procedure is showed also in the chapter 8 in deeper way.
1) Loose the allen screws (item 19 of figure 2.22). Platen assy will slide in the lowest position.
2) Move the print head in the right most position.
3) Keeping the allen screwdriver in the screw on the right side, gently rise the platen until it touch the
AGA wheel.
4) Gently fix the allen screw. Just to fix the position.
5) Move the print head in the left most position.
6) Keeping the allen screwdriver inthe screw on the left side, gently rise the platen assy until it touche the
AGA wheel.
9) Gently loose the allen screw on the right side. Keeping the allen screwdriver on the screw, fix it as
soon as the contact position between AGA wheel and platen assy (without any other force) has been
found.
11) Gently loose the allen screw on the left side. Keeping the allen screwdriver on the screw, fixit as soon
as the contact position between AGA wheel and platen assy (without any other force) has been found.
REMARK:
Due to te fact that the platen assy is movable on its supports (there are two springs which maintained the
platen in its correct position) check for the correct platen free movement (down by pressure and up by springs
release) by force it both in right an left side.
The internal guides of the platen must be lubricate with Molykote PG30L grease as indicated in chapter 4.4.
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Figure 2.22 - Platen Assy Removal
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2.20 Print Head Cables
the power cable before to remove the print head cables.
Print head cables are item 95 of figure 2.23 and are protected by the mylar film (item 96 of figure 2.23).
To Remove:
3) Unplug the seven cacles from the connector on the front side of the engine board.
engine board.
6) Remove the print head safety cover.
7) Pushing down extract the plastic flat lock (item 82 of figure 2.23).
8) Extract the two retainer (item 84 of figure 2.23) securing the cables and the mylar film on the vertical
frame.
9) Unscrew the screw (item 6 of figure 2.23) fixing the flat bracket (item 92 of figure 2.23) on the right
frame and remove it.
10) Unplug the cables from the print head.
11) Remove the print head cables sliding them off from the rear side of the printer.
To Install:
Figure 2.23 - Print Head Cables Removal
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Chapter 3 Operability and Configuration
3.1 Overview
This chapter describes the main operability and configuration functionalities.

For complete and detailed description, please refer to the specific User manual.
The control panel provides access to used functions and to set-up the printer for software environment.
The control panel works in different ways according to the printer operating status
3.2 Operability
The operability of this printer is done through a specific operator panel.
3.2.1 Operator Panel
The operator panel of these printers is located to the right side of the front part.
It has 3 keys and 4 leds as indicated in the figure below.
STATION STATION
1 2
EJECT LQ
ON LINE
Fig. 3.1 Operator panel
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49 Operabilty and Configuration
3.2.2 Function Keys
KEY NORMAL MODE SETUP MODE SPECIAL MODE
STATION1 Pressing this key, when the printer is offline, When the Printer is in the Pressed while powering on
or when the printer is online and no print Printer Setup mode, pressing the printer on with ON LINE
data are in the buffer, the printer ejects the this key the operator selects selects the T&D Mode.
paper, if inserted (EJECT function). In the the Configuration Page to be See chapter 5 in this manual.
Olivetti emulation, the EJECT function may printed. See ” Printer Setup "
be performed only if the printer is offline. later in this manual.
When using the IBM 4722, IBM 9068 and the
Olivetti protocols in two operators (“booking”)
mode, the application software determines
the function of this key.
STATION2 When the printer is offline or when the printer When the Printer is in the If this key is pressed, while
is online and no print data are in the buffer, Printer Setup mode, pressing powering on the printer, the
pressing this key, the printer toggles this key the Configuration hexadecimal printing is
between Letter Quality and Draft printing Page selected with the selected.
mode. STATION1 key will be printed.
When using the IBM 4722, IBM 9068 and the See “ Printer Setup ” later in
Olivetti protocols in two operators (“booking”) this manual.
mode, the application software determines
the function of these keys.
ON LINE Toggles the printer between online and If pressed in the Printer Pressed while powering on,
offline status. Setup mode, the printer selects the Printer Setup
prints the Self Test Page. Mode. See ” Printer Setup "
See “ Printer Setup " later in later in this manual.
this manual. Pressed while powering on
with STATION1 selects the
T&D Mode.
Table 3.1 - O.P. Keys meaning
3.2.3 Leds
On, if the printer is powered on.
Off, if the printer is powered off.
Blinks, when the printer is in Setup Mode.
Lit, when the printer is on line.
Unlit, when the printer is off line.
ON LINE Blinks, when the printer is receiving data from the host.
If the printer is in Setup Mode, this led indicates which setup page is selected for printing.
When using the IBM 4722, IBM 9068 and the Olivetti protocols in two operators (“booking”) mode, the STATION
STATION 1 led is lit, to indicate that the corresponding settings apply.
1 If the printer is in Setup Mode, this led indicates which setup page is selected for printing.
EJECT
Blinks, together with the other operator panel leds, if a printer error occurs. See chapter 4.8.2 for details.
When using the IBM 4722, IBM 9068 and the Olivetti protocols in two operators (“booking”) mode, the STATION
STATION 2 led is lit, to indicate that the corresponding settings apply.
2 If the printer is in Setup Mode, this led indicates which setup page is selected for printing.
LQ
Blinks, together with the other operator panel leds, if a printer error occurs. See chapter 4.8.2 for details.
Table 3.2 - O.P. Leds meaning
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3.3 Printer Set-Up Mode by Operator Panel
The following figure shows the actions flow to configure the printer using the operator panel.
Next chapters details each step.
Figure 3.2 - Set-up Mode flow-chart
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3.3.1 Print of Self Test Page
To understand if the printer has been correctly installed a self test page may be printed following these steps:
1. Press the ON LINE key while powering the printer on and hold the key pressed until all leds turn briefly on.
2. Insert a single sheet in A4 or Letter format.
3. Press the ON LINE key again. The printer prints the Self-Test page. Check that the printout is correct.
4. Press the ON LINE key again to put the printer in ready status.
Note: the parameters can be changed in different version of the Code, always see the User Manual for the correct set-
up parameters. The figure 3.3 shows a Self Test with the LAN Interface installed.
Figure 3.3 - Self Test printout
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3.3.2 Printer Configuration
The steps necessary to configure the printer are the following:
1) Printing of the Setup forms

2) Filling in of the printed forms.
3) Reading of the filled in modules to store the parameters in NVM.
REMARK:
If the printed forms are available also in photocopies (not reduced), only the step 3 is necessary to configure
the printer.
After every reading phase it is possible to select the print phase to immediately see the new setup.
The default configuration of this printer matches most of the commonly used environments, but it may be necessary
to change some printer parameters. With this printer you print the forms for the setup, you fill them in, and then you
insert them back into the printer for reading.
Once the printer read the form, the new values are set.
The following is the complete description of the Setup Procedure.
To enter the Printer Setup Mode press and hold the ON LINE key pressed for at least 1 second while powering the
printer on. The printer enters the Setup Mode.
3.3.2.1 Print of the Setup Forms
1. Insert a blank sheet in A4 or Letter format.

2. The printer loads the sheet and stops.
3. The STATION1, ON LINE and STATION2 leds are unlit.
If the LQ key is pressed immediately after the printer enters in Setup Mode, all printer setup modules are
printed.
Pressing the ON LINE key:

• the printer prints the Self-test Page. In this way it is possible to check the current printer parameters.
• once the self-test is finished, the printer remains in Setup Mode.
Pressing the STATION1 key:
• the STATION1, ON LINE and STATION2 leds change and you can select the Setup Page you want to print as
follows:
= lit = unlit
EJECT LQ
Configuration Page
EJECT LQ
Program 1 – Setup Page
EJECT LQ
Program 2 – Setup Page
EJECT LQ
Offset Tuning Setup Page
Figure 3.4 - Leds meaning in Setup Mode
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The printer setup forms contain all printer parameters and the values that can be set. The current value is indicated by
an asterisk (*).
Each Setup form is identified by a marker in the upper left corner of the page as follows:
Configuration Setup
Program 1
Program 2
Offset Tuning Setup
Figure 3.5 - Markers meaning in Setup Mode
Pressing the STATION 2 key:

The printing of the printer setup forms starts. The forms are printed according to the selection made with the
STATION1 key.
The selection of the Program Setup is made simply pressing the STATION1 key. When passing from one Program
Setup to another, the printer resets before setting the parameters as defined in the new program setup.
3.3.2.2 Filling in the Printer Setup Forms

To change the values of the parameters, fill in the marker ( ) beside the value you want to set with a black or blue ball-
point pen or a fiber-pen.
Note: Do not use pencils.
AUTOFEED SIGNAL ( ) ( )
disabled * enabled
SLCT-IN SIGNAL ( ) ( )
disabled * enabled
BUFFER CONTROL ( ) ( ) ( )
DTR XON/XOFF*XON/XOFF +
Figure 3.6 - How to fill Markers in Setup Mode
Note: If more than one value is set for a parameter, the printer ignores these parameters and maintains the currently
set value.
Do not fill in the marker beside the title of the preprinted form, otherwise the printer will not be able to read that page.
3.3.2.3 Reading the Preprinted Forms

When the Printer Setup Forms have been filled in, insert them back into the printer. The printer is able to recognize
the Setup Forms by means of the markers on these pages. The printer reads the values marked for the various
parameters and configures the printer accordingly.
The settings are confirmed by a # symbol printed on the left of the corresponding marker.
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3.3.2.4 Setup Forms and Parameters
The following figures and tables are the setup forms printed by the printer with their meaning.
The Program 2 is identical to the Program 1 except for the black markers as indicated in figure 3-4.
Note: the parameters can be changed in different version of the Code, always see the User Manual for the correct set-
up parameters.
Figure 3.7 - Configuration Setup Form
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Setup Parameter Values Description
RESTORE TO MFG No* The selected values are not set to factory defaults.
all The values set in all printer setups are reset to factory default values.
config The values set in the configuration setup are reset to factory default values.
progr. 1, progr. 2 The values set in the corresponding program setup are reset to the factory
default values.
RIBBON REPLACED No*, yes Selects yes when the ribbon has been replaced to reset the ribbon life counter.
PROGRAM progr. 1*, progr. 2, Defines the default Program Setup. Selecting progr.1 or progr.2 the setup
parameters set in the corresponding Program Setup are set.
on interface Selecting on interface the printer matches the Program 1 settings with the data
arriving on the Centronics interface, and the Program 2 settings with the data it
receives from the serial interface. When changing from one interface to the
other, the default values are set for the corresponding Program Setup.
ERROR BUZZER Disabled, enabled* Selects or not the buzzer.
JOB BUZZER no beep*, 1 beep, continuous Selects the behavior of the buzzer when a new print job starts: no signal (no
beep), one beep (1 beep) or a continuous signal (continuous).
INTERFACE TYPE parallel, serial, lan, automatic* Selects the interface type. Selecting ‘automatic’ the interface type is selected
between serial, parallel or lan by the printer depending on data coming from
host.
IBM FINANCIAL No*, honorCTS, ignoreCTS This setting is significant only if the 4722 or 9068 protocol have been selected.
It sets the CTS signal, that may be considered or not.
INPUT BUFFER 1 Kb, 8 Kb*, 16 Kb, 32 Kb, 64Kb Selects the buffer size.
IGNORE PE disabled, enabled* Selects the printer signals the paper empty condition (disabled) or not
(enabled).
AUTOFEED SIGNAL Disabled*, enabled The parallel interface uses (enabled) or not use (disabled) the AUTOFEED
signal.
SLCT-IN SIGNAL Disabled*, enabled The parallel interface uses (enabled) or does not use (disabled) the SELECT-IN
signal.
BUFFER CONTROL DTR+SRTS*, SRTS, XON/XOFF, Selection of the buffer protocol.

ETX/ACK, XON/XOFF+DTR+SRTS
ROBUST XON disabled, enabled* Perform the Robust XON (enabled) or not (disabled).
WORD LENGTH 7 bit, 8 bit* Sets the number of the data bits.
BAUD RATE 1200, 2400, 4800, 9600*, 19200, Sets the data transfer rate.
38400 bps
PARITY BIT even, odd, space, mark, none* Selects the number of stop bits.
STOP BIT 1*, 2 Selects the parity control for the data.
COPIES No, yes* When yes sets an higher impact force of the print head for multicopy media.
LOW NOISE No*, yes When yes sets a double pass of the printout each one with a reduced number
of dots.
Table 3.3 - Configuration Form Parameters description
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EDGE DETECTION Normal*, Safe When safe is select the edge detection is always from outside to inside of the
paper.
SAFE BOTTOM EDGE No, yes When yes sets the bottom printing margin is 6.6mm instead of 2.8mm.
GET EDGE QUOTE 0/4”*, 1/4”, 2/4”, 3/4”, 4/4”, 5/4”, Sets the position in which the left paper edge is checked. If set to 0, the check
6/4”, 7/4” is performed at the first line. The other values correspond to the physical
distance from the first line.
PASSBOOK TYPE Setup, SW control* Sets the type of pass-book control.
Fixed thick*, Vertical, Horizontal If Setup if selected, printing on passbooks fixed thickness, with vertical fold,
with horizontal fold.
Table 3.3 - Configuration Form Parameters description cont'd
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Figure 3.8 - Program 1 Setup Form
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Setup Parameter Values Description
PROTOCOL EPSON 570, IBM X24E*, X24E Defines the printer protocol.
AGM, IBM 2390,
OLI. PR40+, OLI. PR2,
OLI. PR2845, IBM 4722, IBM 9068
FONT Draft*, Courier, OCR-B, Gothic, Selects the font.

Prestige, Present, OCR-A, Script,
Boldface
DOWNLINE LOADING Disable, enable* Sets or not the capability of soft font loading in 4722, 9068 protocols.
HORIZONTAL PITCH 10 cpi*, 12 cpi, 15 cpi, Selects the character spacing in characters per inch (cpi).
16.6 cpi, 17.1 cpi, 20 cpi
VERTICAL PITCH 5 lpi, 6 lpi*, 8 lpi Selects the line spacing in lines per inch (lpi).
LOCK no lock*, font, hor. pitch, The following selections made via operator panel may be locked: font,
font+hor.pitch horizontal pitch (hor.pitch), or both the font and horizontal pitch (font+hor.
pitch). The locked settings cannot be changed via software commands.
FORM LENGTH # lines, A4*, letter, A5, legal Sets the page length in number of lines or standard formats A4, Letter, A5 or
Legal. If you select # lines, you must indicate the number of lines you want to
set. The values range between 1 and 255. To set the values combine the
numbers considering that the first line corresponds to the hundreds, the
second line to the tens and the third line to the units. Default is 70.
LEFT MARGIN # You have to indicate the number of chars you want to set. The values range
between 0 and 90. To set the values combine the numbers considering that
the first line corresponds to the the tens and the second line to the units.
Default is 0.
RIGHT MARGIN # You have to indicate the number of chars you want to set. The values range
Default is 93.
TOP MARGIN # You have to indicate the number of lines you want to set. The values range
Default is 0.
BOTTOM MARGIN # You have to indicate the number of lines you want to set. The values range
Default is 0.
IBM C-SET IBM set 1*, IBM set 2 Selects the IBM character set.
IBM COMPRESS 17.1 cpi*, 20 cpi Selects the pitch for the compressed mode printing in IBM emulation.
EPSON C-SET Italic, graphic* Selects italic or graphic Epson character set.
NATION C-SET USA*, FRANCE, GERMANY, Selects the national character sets.
ENGLAND, DENMARK1, SWEDEN,
ITALY, SPAIN1, JAPAN,
NORWAY, DENMARK2, SPAIN2,
LATIN A1
Table 3.4 - Program 1 (Program 2) Form Parameters description
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CODE PAGE CP437*, CP437G, 96GREEK, Selects the character sets for the IBM and EPSON protocols.
CP850, CP851, CP852, CP853,
CP855, CP857, CP858, CP860,
CP862, CP863, CP864, CP865,
CP866, CP867, CP876, CP877,
CP1098, CP1250, CP1251,
CP1252, CP1257, GOST,
TASS, MAZOWIA, CP437SL,
UKRAIN, KOI8-U, 8859/1,
8859/2, 8859/3, 8859/4,
8859/5, 8859/6, 8859/7,
8859/8, 8859/9, 8859/15,
ROMAN-8, ID12, CP874, ID14,
SANYO, KU, PHILIP
OLIVETTI C-SET CODE PAGE, INTERN.*, Selects the character sets for the OLIVETTI protocol.
GERMANY, PORTUGAL,
SPAIN1, DEN/NORW, FRANCE, Selecting CODE PAGE, it is possible to select one of the above Code Pages to
ITALY, SWE/FIN, SWISS, G. be used with the Olivetti protocol.
BRITAIN, USA ASCII, GREECE,
ISRAEL, SPAIN 2,
JUGOSLAVIA, TCV 370,
CANADA, SDC, TURKEY, CIBC,
PC-DEN/NORW, PC-DEN OPE,
PC-210, PC-220, OLI-UNIX
VERT. RESOLUTION 1/216 inch, 1/240 inch* Sets the vertical character resolution. Setting used for the OLIVETTI protocols.
PRINT DIRECTION unidir., bidir., sw control* Selects the printing direction of the print head: unidirectional (unidir.),
bidirectional (bidir.) or selected via software (sw control).
RESET WITH EJECT no, yes When the printer receives a reset command, selecting yes it ejects the paper,
selecting no it performs only the reset command. Setting used for the
OLIVETTI protocols.
LINE MODE LF=LF, CR=CR* If the printer receives a LF code (LF), it only performs a line feed. If the printer
receives a CR code (CR), it only performs a carriage return.
CR=LF+CR If the printer receives a CR code (CR), it performs a carriage return followed
by a line feed. If the printer receives a LF code (LF), it performs a line feed.
LF=LF+CR If the printer receives a LF code (LF), it performs a line feed followed by a
carriage return. If the printer receives a CR code (CR), it only performs a
carriage return.
LF&CR=LF+CR
If the printer receives a LF code (LF) or a CR code (CR), it performs both a line
feed and a carriage return.
WRAP MODE truncate, autowrap* The data exceeding the line length are truncated (truncate) or printed on the
following line (autowrap).
REFERENCE EDGE Left*, right Selects the reference edge for the printing.
SLASHED ZERO No*, yes Selects the printing character for zero, with a slash (yes) or without (no).
EJECT ON FF no, yes* Performs a form feed according to the selected page format (no) or ejects a
cut sheet loaded into the printer (yes).
RESET WITH EJECT no, yes* When the printer receives a reset command, if this item is set to yes the
paper inserted in the printer is ejected. If the item is set to no the printer
performs only the reset command. This item is used with the OLIVETTI
emulation.
CUT SHEET EJECT On front*, on rear Selects where the cut sheet is ejected.
Table 3.4 - Program 1 (Program 2) Form Parameters description cont'd
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3.3.2.5 Offset Adjustments
For a precise adjustment of the position of the printed characters on a preprinted form, this printer allows to easily
adjust the first line and the first printing column as follows:
The following sheet will be printed:
Figure 3.9 - Offset Tuning Setup Form
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The Vertical Offset Tuning values correspond to 1/60 inches and set the vertical offset of the first print line starting
from the default standard position at 1 mm from the upper paper margin.
The Horizontal Offset Tuning values correspond to 1/60 inches and set the horizontal offset of the first print line
starting from the default standard position at 3 mm from the left paper margin.
If you need to change the default position of the first print line the vertical offset can be set in the Vertical Position
Offset lines and/or the horizontal offset in the Vertical Position Offset lines. Both these values correspond to 1/10 inch
values.
1 mm
X X
X X X
Vertical Offset Tuning
VERT. DEF. POS

3 mm
X X
X X X
Vertical Offset Tuning
HORIZ
DEF.
POS
= FIRST PRINT POSITION
X X
X X
X X
X X
X X
Horizontal Offset Tuning
Figure 3.10 - Offset Tuning Example
1. Fill in the marker corresponding to the value you want to set and reinsert the sheet into the printer. The printer
reads the selected values and sets them.
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3.4 Printer Set-Up Mode by Web Browser (NIC board)
If the printer has the LAN interface board installed, using an Internet Browser, it is possible monitoring the status of
the printer (a virtual operator panel with display shows the messages) and do the remote configuration Setup.
The printer has buitl-in html pages. It can be reached by prompt the IP address on the browser.
Before install the printer in LAN environment, it is necessary to configure the LAN parameters.
See chapter 4 and the User Manual of the LAN interface for details.
The html pages are the following:
HOME PAGE, PRINTER CONFIGURATION PAGES (Configuration Setup, Program1 with Offset Setup , Program2
with Offset Setup, NIC Setup, System) PRINTER STATUS PAGE (current ribbon and print head life), PRINTER
RESET PAGE, PRODUCT SUPPORT PAGE.
Figure 3.11a - Home Page of SP40 using a web browser
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To assure a security access to the remote configuration, a security Password can be set.
Figure 3.11b - System Page of SP40 through web browser
In the System page ckick on the Security Setting button.

The first time the following screen appears:
Figure 3.11c - Security Setting (first time)
The User Name is: root

The default password is : root
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The following screen appears.
Figure 3.11d - Security Setting Page of SP40 through web browser
It is now possible to indicate a password to protect the setting.

Click on the submit button, the following scree appears remind you that it is necessary to select Reboot printer
in the Printer Reset page to save the changes.
Figure 3.11e - Warning message
Figure 3.11f - Reboot Page of SP40 through web browser
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Figure 3.11g - Configuration Setup Page of SP40 through web browser
Figure 3.11h - Program 1/2 Setup Page of SP40 through web browser
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Figure 3.11i - NIC Setup Page of SP40 through web browser
When the parameters of each of the previous tables representing the different Configurations setups have been
set as necessary, click on the Submit button at the end of the table.
If a password has already been set in the Securiry item, to enter the remote printer configuration mode, you
need to type the network password.
Figure 3.11j - Printer Status Page of SP40 through web browser
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3.5 Printer Set-Up Mode through the application "SP40setup" (via serial i/F)
The SP40 printer can be easily configured through the serial interface, using the SW application tool described here.
The printer must be in Setup mode and install the basic FW release 1.78 or later.
The SP40SetUp application is stored in the Area Partner of the web in the file SP40setup.zip
Download this file from the web and exctract the files from it.
3.5.1 Entering the printer Setup Mode
To enter the Printer Setup Mode press and hold the ON LINE key pressed for at least 1 second while powering the
printer on. The printer enters the Setup Mode.
Once in SetUp mode, before inserting any form, the printer can operate in conjunction with the SP40setup
application.
The files for the SP40setup must be in the same folder and are the following:
Setup.exe
SP40setup.cab
Setup.lst
3.5.2 Install the SP40Setup application
Double click on Setup.exe, the following masks will appear on the video.
Figure 3.12a - Initial mask for SP40setup installation
Figure 3.12b - Other mask for SP40setup installation
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Figure 3.12c - Other mask for SP40setup installation
Figure 3.12d - Other mask for SP40setup installation
Figure 3.12e - Other mask for SP40setup installation
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Figure 3.12f - Other mask for SP40setup installation
Figure 3.12g - Other mask for SP40setup installation
3.5.3 Run the SP40Setup application
Double click on the icon created in the Program of Windows, and you can get an empty page:
Figure 3.13 - Initial mask of the SP40setup application
Pressing the button the current printer configuration is read from the printer and it is displayed :
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Figure 3.14a - Read NVM mask of the SP40setup application
All configuration items are displayed in the same order as they appear in the Printer Setup Forms described in the
SP40 User Manual.
Please refeer to it for the items description.
Using the scroll bar is possible to reach all items and then modify them :
Figure 3.14b - Read NVM mask of the SP40setup application
In any moment is possible to revert to the actual printer configuration simply pressing the button.
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Pressing the button, the factory default configuration is restored into the printer NVM and showed
in the SP40setup window.
When all modification are done, the new configuration can be stored in the printer NVM pressing the
button.
In case of successfully downloading, the new configuration can be also saved in a file ( i.e. wnvm.dmp ) to be used
for updating other SP40 units.
Figure 3.15 - Write NVM mask of the SP40setup application
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3.5.4 How to download to SP40 an existing configuration file
A configuration file, generated with the SP40 setup tool as previously described, can be simply used to duplicate the
same configuration on more printers.
SP40 unit has to be powered on in normal mode, connected to the PC through any active interface (Centronics or
Serial port).
Type: copy wnvm.dmp lpt1: /b command from a DOS shell,
where wnvm.dmp is the configuration file name.
The printer receives the file, checks for valid configuration format and in such a case the received content is recorded
into the non volatile memory.
After that the printer restarts the execution and downloaded configuration becomes the active.
Warning :
Configuration files generated by SP40setup tool are allowed to be used only on printers having te same firmware
version of the unit used to generate the file!
In any other case the received file is discarded by the printer without any change on NVM!
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3.6 Print of NIC Configuration Page
The complete NIC configuration parameters can be printed by simply press the little button near the Ethernet RJ
conenctor for more than 5 seconds with the paper loaded and the printer already powered on.
The figure below shows the location of the button and thhe printout.
Figure 3.16 - Button to print NIC Configuration
Figure 3.17 - Network Interface Configuration
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Chapter 4 Service Maintenance
4.1 Overview
This chapter describes how to maintain the printer in order to always obtain the best performances from it.
In this chapter it is possible to find also some helps to test printer and to identify defective components using
Test & Diagnostic facilities.
First-Level maintenance is based at O.R.U. (Optimum Replaceable Unit).
4.2 Initial Inspection and Tools
When the printer presents a trouble, before proceeding to the service maintenance, an initial inspection must
be done. In fact, a problem in the printout often is due to a bad or wrong condition of the printer itself.
The parameters that must be previous checked are: set-up, cleaning, paper specification.
After that, if the problem remains, a troubleshooting session can be activated.
Requested Tools
• A Multimeter for resistance and voltage measurements.
• Soft Cloth
4.3 Set-Up
Check for the following items to make sure they are full-filled.
• Is the printer placed in a correct position ?

• Is the environmental temperature in the nominal range ?
• Is the relative humidity in the nominal range ?
• Is the unit installed in a bad location ?
(Close to high temperatures or humidity, near heat sources, dusty areas, areas where gas is generated,
exposed to direct sunlight)
• Has the printer a good configuration ?
Please refer to the user manual or chapter 1 and 3 of this manual for more details on all these items.
4.4 Cleaning
No preventive maintenance, on a schedule basis, is required.

Periodic cleaning will help to keep your printer in top condition.
Clean the printer as follows:
• Every time that a maintenance operation has to be done or the ribbon cartridge has to be removed and
replaced by a new one, clean the lateral sides of the platen removing the paper dust. Use for this a soft
cloth or a little brush. This operation will be helpful for a correct behaviour of the edge sensor.
• Use a neutral detergent or water solution on a soft cloth to clean dirt and grease from the cabinet of the
printer.
• Do not use an abrasive cloth, alcohol, paint thinner or similar agents because they may cause
discoloration and scratching.
• Be especially careful not do damage the electronic and mechanical components.
Check for the paper paths condition and to make sure they are correct.
If they are dirty (by paper residues or by ink), please clean them using a soft cloth.
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75 Service Maintenance
4.5 Lubrication
The following point of the mechanical assy should be lubricated when a maintenance activities is done in the
printers to avoid any seize in the movement of the parts.
• DO NOT LUBRICATE the main shaft, but only clean dirt.

Only a drop of oil can be put on the felts inside the carriage if they are dry. Before oiled the felts check
for their clean conditions. If it needs clean or replace them.
NOTE: the oil must be FOMBLIN YN06 (Ausimont, Montedison).
• Lubricate with Molykote PG30L silicon grease (Dow Corning Corporation) the following parts:
1) The surface of the selector cam (item 28 of figure 2.18) in contact with the associated lever.
2) Lateral side of the support of the platen assy (item 17 of figure 2.22) in contact with left and right metal
frame (item 18 of figure 2.22).
4.6 Paper Specifications
Also the paper is important to have high performances.
Check for the correct paper specifications.

See chapter 6 for more details.
4.7 Consumables
Compuprint recommends to use only its original consumables with original packaging.
In this way, a proper use of the printer at the quality level and reliability stated in the product characteristics
can be assured.
All usage problems typically related to not certified consumables can be avoided, such as:
an overall degradation of the printing quality level and often, the reduction of the total life of the product due to
the fact that the proper working conditions of the print head and other parts are not assured.
Moreover, the original consumables are controlled in compliance with the international standard rules
concerning:
• no cancerous materials
• no inflammability of the plastic materials
• other standard
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4.8 Software Update
The printer has the basic controller FW and the font generator on FLASH device.
Also the LAN FW is on flash.
This allows an easily up-date of the Code through the parallel, serial or LAN interface.
On the Main Board used as spare part, the firmware pre-loaded has to be intended just as a predisposition allowing to
load the specific firmware.
4.8.1 Basic Software update through parallel or serial interface
Software updating operations are done in Windows / DOS environment.

Default is Parallel interface LPT1.
To use serial interface it is necessary to redirect the port with the following parameters:
COM1 (baud rate 115200, bits 8, no parity).
Remark: Starting from code release 1.7x, the LAN interface has been handled.
To dowload the filename.img though LAN interface using FTP the format of the .IMG file has
been changed and a new bootdll.dll has been created.
On the partner area folder of our Web Site in the SP40, firmware folder, the following files are available for the updating
of the FW:
SP40_154.ZIP
Containing the files:
filename.img Base+CG firmware image code (SP40154.IMG Rel.1.54)
SP40_17x.ZIP
filename.img Base+CG firmware image code (SP4017x.IMG Rel 1.7x)
bootdll.dll dll to handle the boot file when updating code Rel. 1.70 or later
Updating steps (to download code before 1.7x)

1. Create a sub-directory and position on it.
2. Copy from the WEB the file SP40_154.ZIP.
3. Exctract the file.
4. Connect the printer to a PC on the parallel port LPT1 or the serial one COM1.
5. Open the cover.
6. Push and hold the key Station 1 while Power-on the printer.
All the leds on the panel are contemporary blinkining. (Waiting for a new firmware).
Prompt on the P.C. following syntax:
C:>\ COPY filename.img LPT1:/b
(filename is the name of the file.IMG of the new firmware that have to be loaded).
During the downloading the light leds configuration identifies various phases. (Image receiving, image
decoding, delete and write of new code in flash, updating of the boot).
When the download is ended with success, the leds on the panel blinking alternatively :
( Station 1 + Station 2, Power on + On line ).
7. Now the printer can be powered off.

8. Print the Self test to assure the new code has been correctly loaded.
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Updating steps (to download code 1.7x and later)

2. Copy from the WEB the file SP40_17x.ZIP.
3. Exctract the files.
5. Open the cover.
C:>\COPY bootdll.dll LPT1:/b

C:>\COPY filename.img LPT1:/b
When the download is ended with success, the leds on the panel blinking alternatively :
( Station 1 + Station 2, Power on + On line ).
7. Now the printer can be powered off.
4.8.2 NIC Software update through parallel or serial interface
On the partner area folder of our Web Site in the SP40, firmware folder, the following file is available for the updating of
the NIC FW:
SP40LAN_40x.ZIP
filename.bin NIC firmware image code (SP40L40x.BIN Rel. 4.0x)
Updating steps
2. Copy from the WEB the file SP40LAN_40x.ZIP.
5. Open the cover.
C:>\ COPY filename.bin LPT1:/b
When the download is ended with success, the printer REBBOT and goes in the ready status.
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4.8.3 LAN Parameters Setup through parallel interface
The NIC board shipped from the factory has defualt paramaters, therefore before use it it is mandatory to configure the
LAN parameters.
On the partner area folder of our Web Site in the SP40, firmware folder, the following file is available for the updating of
the NIC parameters:
SP40LANCFG.ZIP
lanpar.bat Batch file to handle the following two files through the parallel interface.
lanpar.hdr NIC configuration header command (do not modify it!)
lanpar.txt NIC configuration parameters (change for Customer LAN environment setup, see below)
The lanpar.txt file is a pure ASCII text file contains the following lines with the default values as indicated below.
Important rules:
1) Every command line must be in a single line separated by CR+LF.
2) Do not remove the start-of text "{" and end-of text "}" characters.
3) The key words (i.e.: IP ADDRESS) must be at the beginning of the line and must terminate with the "="
character.
4) It is not necessary to define all the parameters. Parameters not defined, maintain the old value.
5) Every formal error (key word unknown or values over the specifications) cause the interruption of the command.
Example of LANPAR.TXT
Key Word=parameter Default Values Specification
{
HOST NAME=string CPG_AABBCC max 15 characters
LOCATION=string No location max 15 characters
CONTACT=string No contact max 15 characters
IP ASSIGN=Arp, Fixed, DHCP Fixed
IP ADDRESS=ip-address 127.000.000 ddd.ddd.ddd format
NET MASK=net-mask address 255.255.000 ddd.ddd.ddd format
DEF.GATEWAY=default gateway address 000.000.000 ddd.ddd.ddd format
WORKGROUP=string P_NFFPS_TO max 15 charactes
SMTP=disabled, enabled Disabled
MAIL SERV.ADD.=mail server address 000.000.000 ddd.ddd.ddd format
SENDER ADDRESS=string No address max 48 charactes
DESTIN.ADDRESS=string No address max 48 charactes
}
Updating steps
2. Copy from the WEB the file SP40LANCFG.ZIP.
5. Power-on the printer and put it in ready status.
C:>\ lanpar lanpar LPT1:
6. Print the Self test to assure the LAN configuration has been correctly loaded.
Rev. 005 Chapter 4

4.8.4 Software update through LAN interface
After the LAN parameters initialization explained in previous chapter 4.7.2, it is possible to send both
Basic+CG firmware or NIC firmware through the LAN interface using FTP tool.
Download the proper file from the WEB as explained in previous chapters.
For the Basic+CG software:

SP40_17x.ZIP
For the NIC software:

SP40LAN_40x.ZIP
4.8.4.1 Software update through LAN using FTP
Open the FTP session on the printer specific IP ADDRESS (ddd.ddd.ddd.ddd) and follow these steps:
FTP
Open ddd.ddd.ddd.ddd
User: root
Password: root
Cd firmware
Bi
Ha
Put SP40_17X.IMG (or Put SP40LAN_40x.BIN for LAN sw)
Bye
This figure shows the step on the video.
Figure 4-1 Basic FW steps through LAN using FTP
Rev. 005 Chapter 4

4.9 Troubleshooting
This chapter is intended to help technical people in the fault finder.

The recommended sequences for the printer fault detection are:
• To observe initializing procedure and led status.
• To check power malfunctions.
• To run the T&D (Test and Diagnostic) procedure.
• If necessary, run the HEXADECIMAL dump procedure (see 4.8.4 here below).
At any stage where appropriate, refer to the troubleshooting guide.
4.9.1 Hexadecimal Dump
Power on the printer pushing "STATION 2" key to put the printer in Hex Dump mode.
The printer will remain in Hex Dump mode until next power off.
The left part of the printout is showing data in the normal appearance.
The right part of the printout is showing data in their HEX VALUES.
4.9.2 Printer Errors
When an error occurs on the printer, the kind of errror identification can be done looking at the leds
configuration on the panel.
These errors can be divided into two main groups:
• Recoverable errors
• Not recoverable errors
4.9.2.1 Recoverable Errors
When an error of this kind occurs, the printer enters in WAIT status and the STATION 1 and STATION 2 leds
are flashing together and the ON LINE led is unlit (Not Ready), POWER ON led is lit.
Errors of this kind can be (the messages below are visible if the O.P. with display will be installed):
• Ribbon Blocked
• Carriage fault/Print Integrity
• Park is not succesfully
• Eject is not succesfully
• Push-front jam sensor fault
• Push-rear jam sensor fault
• Cover open
• Out of paper
• Input buffer overflow
• DSR signal fault
• Serial i/f parity error
• Serial i/f framing error
• Serial i/f overrun error
• Generic communication error
All these errors can be reset pressing the ON LINE key or through specific actions to remove the problem and
nextly pressing the ON LINE key.
Rev. 005 Chapter 4

4.9.2.2 Unrecoverable Errors
When an error of this kind occurs, the printer is halted and enters in error state.
Errors of this kind can be:
• SPV FAULT
• INTERPRETER ANSWER ERROR
• PRINT MANAGER ANSWER ERROR
• DOE ERROR
• LAN ERROR
• PREPARSER ANSWER ERROR
• FONT ERROR
All these errors cannot be reset through specific actions and require the powering-off .
The numerical codes showed on table on next page are represented though the o.p. leds in the following mode:
l = OFF status
¡ = ON status
Code N° LEDS
L4
L3 L2 L1
l
0
l l l
l
1
l ¡ l
l
2
¡ l l
l
3
¡ ¡ l
l
4
l l ¡
l
5
l ¡ ¡
l
6
¡ l ¡
l
7
¡ ¡ ¡
¡
8
l l l
Table 4.1 Not-Recoverable leds errors code N°
Rev. 005 Chapter 4

The not recoverable error detection is done in four steps each 1 second of time in which on the leds of the
operator panel are represented the error codes with this sequence:
1. Device in failure identification N°.

2. Macro-block in failure identification N°.
3. Supervisor error N°.
4. LAN error N°.
Time of 3 second is done between the end of each cycle and the begin of the next ( 1 cycle = 4 step).
The error leds detection are repeated until a power-off action is done.
LED CODE N° ID DEVICE MACRO-BLOCK SUPERVISOR ERROR LAN ERROR
1° step 2° step 3° step 4° step
0 Supervisor Generic Interpreter answer -

1 Interpreter Line Font Open
2 Printer manager Paper handling Nvm read -
3 Doe Carriage handling Nvm write -
4 Lan Master command Home position detection -
5 - - Print manager -
6 - - Preparser -
7 - - - -
8 - - - -
Table 4.2 Not-Recoverable errors table
Rev. 005 Chapter 4

4.10 Troubleshooting Tables
NOTE: For the electrical value of the electromechanical parts, please refer to chapter 7.
4.10.1 Power malfunction
SYMPTOM PROBABLE CAUSE CORRECTIVE ACTION
The printer is not powered No AC power is reaching the Check power cord insertion.
up printer Check power at wall.
Replace power cord.
The printer is not powered The switch lever don' t Check for the correct behaviour of the switch lever and
up. correctly acting on the power the springs on the base assy involved in the movement
on switch of the power supply. of the lever. Replace the defective part.
The printer is powered on An incorrect voltage is present Check for the voltages present on the power supply
but it is not working on power supply. P01 connector. Remove the P01 from the main board.
properly. It is recommended to apply a minimum load to the
+5VDC and +38VDC to assure the power supply
stability.
Replace the Power Supply.
Replace the Engine Board.
The printer is powered off An overload is present on Check for the correct cables connections.
after short time power on. power supply. Check for electromechanical parts impedance and
replace the faulty one.
Replace the Engine Board.
Replace Mechanical Assy
Table 4.3 Power Malfunction Troubleshooting
OUTPUT VOLTAGE:
5 VDC
+ 38 VDC
VREC from +78 to + 84 VDC @ 100 mA injected
The VREC circuit (clamping & recovery voltage) provided with an electronic circuit to clamp the collector voltage of the
needles drivers during their switching in OFF state (see chapter 7 for detail).
This circuit absorb the print head coils energy stored during the needle firing phase.
All the voltage are protected for Overvoltage, short-circuit and over-current.
The sketch of the Power supply is described at chapter 1.

The pin out of the Power Supply is :
P01-01 = ZGND
P01-02 = ZGND
P01-03 = +80VClamp
P01-04 = +80VClamp
P01-05 = +5V
P01-06 = +5V
P01-07 = ZGND
P01-08 = ZGND
P01-09 = +38V
P01-10 = +38V
P01-11 = +38V
P01-12 = N.C.
Figure 4.2 Power Supply pin-out
Rev. 005 Chapter 4

4.10.2 Faulty Probability Guide
This table resumes some (not all) of the most frequently symptoms of incorrect functionalities that can appear in the
normal usage of the printer with their related probable cause and the corrective actions.

Inconsistent character The ribbon may not be correctly Re-install the inked ribbon cartridge.
printing installed
The ribbon cartridge may be faulty Replace with a new one.
(check for its free movement)
The ribbon does not work properly. Check for the correct movement of the Ribbon
Drive Assy.
Replace Ribbon Drive assy
Some dots are not printed The print head cables may be Run T&D10 to check the printout.
incorrectly installed or damaged. Check for the print head cables insertion on
p.h. and engine board.
Replace print head cables.
The print head may be faulty Check for coils impedance. Replace P.H.
The main board may be faulty. Replace engine board.
The printer stops printing The thermal sensor in the print head Check the sensor resistance.
may be faulty Replace P.H..
The connection between p.h. and Check for the print head cable connection.
engine board is defective. Replace p.h. cable.
The circuit on engine board may be Replace engine board.
faulty.
The carriage doesn' t move The home position sensor may be Check for the correct insertion of sensor cable
in a properly way. faulty. Run T&D10 to checking.
Replace home position sensor..
The character printing are The printer may be not properly Run T&D09 to readjust the vertical alignment.
vertical disaligned. adjusted.
The sensor edge may be not correctly Run T&D09 to check edge sensor.
adjusted. Replace edge sensor.
The ruby on print head is not installed Run T&D10 to verify.
correctly. Replace the print head.
The paper is loaded but The skew sensors does not work Check for the skew sensors connection by the
not correctly positioned properly. optical fibre.
(skew). Run T&D09 to checking.
Replace sensor board or optical fibre.
Replace engine board.
The paper does not The paper motor is not correctly Check for paper motor connection on engine
advance properly. installed. board.
The paper motor may be faulty Check for its impedance.
Replace paper motor assy.
The paper belt tension is not properly Check paper belt tension adj.
adjusted. Readjust if it is need.
The paper is out of specifications Check for the paper specification to be correct.
The paper is loaded but The paper edge sensor does not work Check edge connection on p.h.
immediately ejected properly. Run T&D09 to check edge sensor.
Replace edge sensor assy.
Check for print head cable connection.
Replace prinr head cable.
Replace engine board.
Table 4.4 Faulty Probability Guide
Rev. 005 Chapter 4


The paper is not feeder The paper path is not free. Check for the paper path to be free.Open the
properly. mechanical assy through the right and the left
green levers and remove residual of paper also
through the paper knob.
The mechanical assy is not closed. Close the mechanical assy.
The selector motor is not correctly Check for selector motor connection on engine
installed. board.
The selector motor may be faulty Check for its impedance.

Replace selector motor assy
The printer does not The controller may be faulty or not Check for the correct connection between the
initializes. properly plugged together the engine boards.
All the leds are lit. board. Replace the controller board
Table 4.4 Faulty Probability Guide cont'd
4.11Reset the consumable parts
Starting from the software release 1.7x, two important parameters for the service has been added and are printed on
the Self Test printout.
Ribbon Life counter

Print Head Life counter
The first item is under User responsability.

The User can reset it in three ways:
1 An item has been added in the Configuration Setup (Ribbon Replaced=no*, yes) in order to reset the ribbon life
counter (see chapter 3.3.2.4).
2 On html Printer Status Page this counter can be displayed and resetted under permission remotely (see
chapter 3.4).
3 It can be resetted also in T&D, when launching the T&D13 (conters reset), see chapter 5 for details.
The second item is under Service responsability.

On html Printer Status Page this counter can be only displayed.
It can be resetted only in T&D, when launching the T&D13 (conters reset), see chapter 5 for details.
Rev. 005 Chapter 4

Chapter 5 Test & Diagnostic
5.1 Overview
For the field maintenance of this printer, a specific Test & Diagnostic feature has been developed.
This feature is built -in the basic firmware of the printer.
The version of the T&D is reported in the T&D printout together with the version of the basic FW and (if
present) the optional LAN FW.
The T&D may be executed with the standard Operator Panel of the printer or with a specific maintenance
Operator Panel with a 16 digits LCD display to take more easy and immediate the reading of the messages.
See chapter 2.2 to remove the standard o.p. assy and install the maintenance one.
The echo of the messages is also available on the serial interface, therefore it is possible to connect the
printer with a P.C. as a remote panel to read the message.
See chapter 5.11 later in this chapter how to use it.
5.2 How to run T&D USER (with standard operator panel)
Power on with ON LINE + STATION 1 keys starts the USER T&D procedure.
ON LINE + STATION 1
Push again
STATION 1
within 3 seconds to choose the STEP BY STEP mode.

If no action is done after 3 seconds or STATION 2 is pressed, the COMPLETE T&D (VERIFY mode) will be run.
5.3 GENERAL RULES FOR T&D OPERATIONS
The display is not present on the standard Operator Panel, therefore the message are done by specifi
combinations of the leds.
l = OFF status
¡ = ON status
£ = low frequency flashing status
¥ = high frequency flashing status
ST1 ST2
L4
L3 L2 L1
ON L.
Figure 5.1 Operator Panel Sketch
Rev. 005 Chapter 5

87 Test & Diagnostic
Messages are codified in order to provide a proper identification of:
- Test execution
- Test KO
- Error code
- Message to operator
For the detail see tables on next pages.
The general rules condition which can appear are reported in the following table.
Type of Operator Message LEDS Note

L4
L3 L2 L1
Test number in execution l/¡ The leds are lit following the binary sequence
l/¡ l/¡ l/¡ where L1 is the LSB and L4 is the MSB
Error Code l/¡/£
£ l/¡/£ l/¡
O.R.U. Code £ The leds L1, L2 and L3 are lit or off depending
l/¡ l/¡ l/¡/£ by the binary configuration to be showed
Waiting for operator intervention ¥ The L4 is high frequency blinking if an action
£ l £ of operator is requested (cover open)
Waiting for paper loading l The L2 is high frequency blinking if paper
£ ¥ £ handling is requested (load or exctract paper)
Waiting for key or paper ¥ The L2 & L4 are high frequency blinking if an
£ ¥ £ action on operator panel is requested
Test KO ¡ See chapter 5.7. for the error handling
£ ¡ £
End T&D £
£ £ £
Table 5.1 General rules for T&D operations
During T&D execution in Step by Step, the keys have the following meaning:
STATION 1 Decrement test number

STATION 2 Increment test number
ON LINE Execute test
After the execution of the selected test a submenu comes activated, so the meaning of the keys becomes:
STATION 1 Repeat test

STATION 2 Skip test (and return to the previous menu)
ON LINE Loop on the test
Rev. 005 Chapter 5

5.4 T&D USER Tests Description
TEST# DESCRIPTION OF TEST (from T&D Rel. 1.50) Step By Step Complete
mode mode
T&D2 Test of writing/reading of NVM with 55/aa pattern and subsequent storing of YES NO
DEFAULT parameters.
T&D3 Test of reading accessibility and checksum of NVM. YES YES
T&D4 Test of optional interfaces YES YES
T&D5 Test of serial interface with a passive loop-back (see figure 5.1). YES (*) NO
If the remote terminal is present the test fails.
T&D6 Test of parallel interface with an active loop-back to check the bi-directional YES YES
functionality (see figure 5.2).
T&D7 Interactive Test of the operator Panel keys (pressure of each of them) and YES YES
leds. During the test the sequence ON LINE-STATION 1-STATION 2 is
showed by the flashing of the respective led ON LINE=L2, STATION 1=L3
and STATION 2=L1.
T&D8 Interactive test to check the interlock feature. YES YES
The closure is checked, then the opening (under time-out) and the closure
(without time-out) of the front cover is requested
T&D9 Interactive test to automatically check and adjust the printing parameters YES YES
(vertical, horizontal and bidiretionality adj.) and the sensors PWM calibration.
See chapter 5.8.1
T&D10 Some patterns are printed in order to give a feedback about the YES YES
performances of various components of the printer itself.
See chapter 5.8.2
T&D11 Interactive test to adjust the scanners (front and rear) for the model which YES YES
providing this feature.
This test is not covered by this manual.
T&D12 This test handles and updates the T&D log file (for MFG only) YES YES
See chapter 5.12
T&D13 This test resets the ribbon life and print head life counters NO YES
* = the T&D5 fails if the remote connection is running
Table 5.2 T&D USER Tests Description
Rev. 005 Chapter 5

5.5 Step By Step T&D Mode Flow Chart
This is a schematic flow-chart of the whole T&D USER procedure in Step By Step mode.
ON LINE
+
STATION 1
IN 3SEC
STATION 1
STATION 1 STATION 1 STATION 1

TEST# -1 REPEAT TEST# REPEAT TEST#
RUN TEST#
ON LINE
RUN ERROR
TEST # SKIP (PREV. MENU) SKIP (PREV. MENU)
TEST # TEST #
STATION 2 STATION 2
TEST# +1 LOOP TEST# ERROR LOG

STATION 2 ON LINE ON LINE
ERROR TEST#
ON LINE
ERROR ORU#
ON LINE
ERROR CODE#
T&D STEP BY STEP MAIN MENU TEST RUN SUBMENU ERROR TEST SUBMENU
Figure 5.2 Schematic flow-chart of the T&D USER in Step By Step mode
Rev. 005 Chapter 5

5.6 Step By Step T&D Mode Sequential Table
This is a table of the whole T&D USER procedure in sequential Step By Step mode.
The column have these meaning:
1) T&D SbS Phases

2) Messages on the Operator Panel with Display.
3) The same message converted on the leds for the standard Operator Panel.
4) Operator panel key to be pressed.
5) Action done by the operator panel key pressure.
T&D SbS PHASE DISPLAY MESSAGE LEDS PUSHED KEY KEY's ACTION
Initialization phase “STARTING” ¡ ON LINE Run T&D

¡ ¡ ¡ +
STATION 1
Initialization phase “STARTING” l

¥ ¡ l
Initialization phase “INIT” l

l ¡ l
Initialization phase “INIT” l

l l l
Choice of mode "SBS CMPL LST” ¥ STATION 1 Choose of Step by

SBS= Step by Step £ ¡ £ (in 2 sec) Step Mode
CMPL=complete
LST=complete
NVM WRITING Test “T&D 02 S_B_S” l ON LINE ON LINE to run

(available only in l ¡ l or STATION 1
Step by Step mode) STATION 1 to decrement test
or STATION 2
STATION 2 to increment test
“REPT LOOP SKIP” ¥ ON LINE ON LINE to loop

£ l £ or STATION 1
STATION 1 to repeat the test
or STATION 2
STATION 2 to skip the test
NVM Checksum “T&D 03 S_B_S” l ON LINE ON LINE to run

Test l ¡ ¡ or STATION 1
STATION 1 to decrement test
or STATION 2
Table 5.3 Step by Step T&D USER Sequential Actions
Rev. 005 Chapter 5

T&D SbS PHASE DISPLAY MESSAGE LEDS PUSHED KEY KEY's ACTION

£ ¡ £ or STATION 1
or STATION 2
Optional Board Test “T&D 04 S_B_S” l ON LINE ON LINE to run

¡ l l or STATION 1
or STATION 2

or STATION 2
Serial Interface Test “T&D 05 S_B_S” l ON LINE ON LINE to run

¡ l ¡ or STATION 1
or STATION 2

or STATION 2
Parallel Interface “T&D 06 S_B_S” l ON LINE ON LINE to run

Test ¡ ¡ l or STATION 1
or STATION 2

or STATION 2
Operator Panel Test “T&D 07 S_B_S” l ON LINE ON LINE to run

¡ ¡ ¡ or STATION 1
or STATION 2
“KEY 1 (^) (*) (^)“ ¡ ON LINE ON LINE to test

¡ £ ¡ The Key 1
Table 5.3 Step by Step T&D USER Sequential Actions cont'd
Rev. 005 Chapter 5

RUNNING TEST DISPLAY MESSAGE LEDS PUSHED KEY KEY's ACTION
“KEY 2 (*) (v) (-)“ ¡ LOAD ON LINE to test

£ ¡ ¡ The Key 2
“KEY 3 (-) (v) (*)“ ¡ ON LINE ON LINE to test

¡ ¡ £ The Key 3

or STATION 2
Cover Open Test “T&D 08 S_B_S” ¡ ON LINE ON LINE to run

l l l or STATION 1
or STATION 2
“OPEN COVER” £ Raise the front cover

¥ ¡ ¥
“CLOSE COVER” £ Close the front cover

¥ ¡ ¥

or STATION 2
Printing Adjustment “T&D 09 S_B_S” ¡ ON LINE ON LINE to run

Test l l ¡ or STATION 1
or STATION 2
“LOAD PAPER” ¡ Load an A4 single

¡ £ ¡ sheet paper.
“LOAD PAPER” ¡ The adjustment test

l l ¡ is printed
“REPT LOOP SKIP” ¥ ON LINE A buzzer ON LINE to loop

£ ¡ £ or beep is STATION 1
STATION 1 sound to repeat the test
or STATION 2
Rev. 005 Chapter 5

Printing Standard “T&D 10 S_B_S” ¡ ON LINE A buzzer ON LINE to run

Pattern Module l ¡ l or beep is STATION 1
Test STATION 1 sound to decrement test
or STATION 2
“LOAD PAPER” ¡ Load the same A4

¡ £ ¡ single sheet paper
used in T&D9
“LOAD PAPER” ¡ The standard pattern

l ¡ l module test is printed
“PAPER OR KEY” ¥ ANY KEY The standard pattern

£ ¥ £ module can be
inserted again to
better adjust the
bidirectionality.
Sign with a pen the
line considered the
best one and reload
the single sheet or
press ANY KEY to
skip the test.

or STATION 2
Scanner “T&D 11 S_B_S” ¡ ON LINE A buzzer ON LINE to run

Adjustment Test l ¡ ¡ or beep is STATION 1
(not used) STATION 1 sound to decrement test
or STATION 2
Rev. 005 Chapter 5

Printing the error “T&D 12 S_B_S” ¡ ON LINE A buzzer ON LINE to run

log Test ¡ l l or beep is STATION 1
STATION 1 sound to decrement test
or STATION 2
“PAPER OR KEY” ¥ ANY KEY A buzzer Load an A4 single

£ ¥ £ beep is sheet paper to print
sound the error loggin Test
or press ANY KEY to
skip the test.

or STATION 2
Reset the life “T&D 13 S_B_S” ¡ ON LINE A buzzer ON LINE to run

counters ¡ l ¡ or beep is STATION 1
STATION 1 sound to decrement test
or STATION 2
“CL. RIBBON Y <-> N” ¥ ANY KEY A buzzer Press STATION 1 to

£ ¡ £ beep is reset the ribbon
sound counter or STATION 2
to skip the test
“CL. HEAD Y <-> N” ¥ ON LINE A buzzer Press STATION 1 to

£ ¡ £ or beep is reset the print head
STATION 1 sound counter or STATION 2
or to skip the test
STATION 2
Rev. 005 Chapter 5

5.7 T&D Errors Handling
When a Test fails in every type of T&D mode, all the four leds (except Power) are lit together and the buzzer
sounds a beep every 1 second. Follow these steps:
ANY “KO n1 ORU n2 [n3] ¡

¡ ¡ ¡
“REPT ERR SKIP” ¡ ON LINE ON LINE

£ ¡ £ or to display on the leds
STATION 1 three different led
or meaning:
STATION 2
1- N. of Test in
error
(see table 5.4)
2- N. of ORU
(see table 5.5)
3- Specific or Common
Error Codes
(see table 5.6)
STATION 1
to repeat the same
test
STATION 2
to skip the test
Table 5.4 T&D Error Phase Sequential Actions
If the operator panel with display is installed, the display immediately shows the error condition.
The error message is made by the following item (see tables 5.7, 5.8 and 5.9 for their meaning):
KO n1 ORU n2 [n3]
n1 means the failed test index

n2 means the ORU (optimal replacement unit which has caused the error)
n3 means the diagnostic specific or common error code (detailed information)
For example, if the third key is not properly pressed during the T&D 8 Test, after a time-out the T&D falls in
the error condition, showing the follow message: KO 08 ORU 01 [03]
If the display is not installed, these n1, n2 and n3 information’s can be showed through four different actions
on the ON LINE key as indicated in the tables 5.4, 5.5, and 5.6 on next chapter.
Rev. 005 Chapter 5

5.7.1 Led Meaning during T&D Error Condition
If the operator panel has not the LCD display installed, when the printer recognizes an error, a pressure on LQ key
allows to show up to 4 different led combinations (in the meantime the buzzer sound switch from normal to short
beep every 1 sec).
The table below shows the led condition after the first pressure of ON LINE key (test in error) during the test
failure detection.
Nº Test LEDS
L4
L3 L2 L1
Test 1 l
l l ¡
Test 2 l
l ¡ l
Test 3 l
l ¡ ¡
Test 4 l
¡ l l
Test 5 l
¡ l ¡
Test 6 l
¡ ¡ l
Test 7 l
¡ ¡ ¡
Test 8 ¡
l l l
Test 9 ¡
l l ¡
Test 10 ¡
l ¡ l
Test 11 ¡
l ¡ ¡
Test 12 ¡
¡ l l
Test 13 ¡
¡ l ¡
Table 5.5 Led Status for N. of test in error
Rev. 005 Chapter 5

The table below shows the led condition after the second pressure of ON LINE key (ORU in error) during
the test failure detection.
Nº O.R.U. LEDS
L4
L3 L2 L1
ORU 0 £
l l l
ORU 1 £
l l ¡
ORU 2 £
l ¡ l
ORU 3 £
l ¡ ¡
ORU 4 £
¡ l l
ORU 5 £
¡ l ¡
ORU6 £
¡ ¡ l
ORU 7 £
¡ ¡ ¡
ORU 8 £
l ¡ £
ORU 9 £
¡ l £
Table 5.6 Led Status for ORU in error
Rev. 005 Chapter 5

The table below shows the led condition after the third pressure of ON LINE key (specific/common error codes)
during the test failure detection.
N° Error Code LEDs

L4
L3 L2 L1
Code 1 l
£ l ¡
Code 2 l
£ ¡ l
Code 3 l
£ ¡ ¡
Code 4 l
£ l l
Code 5 ¡
£ l ¡
Code 6 ¡
£ ¡ l
Code 7 ¡
£ ¡ ¡
Code 8 ¡
£ l l
Code 9 £
£ l ¡
Code 10 £
£ ¡ l
Code 11 £
£ ¡ ¡
Code 12 £
£ l l
Code 13 £
£ £ ¡
Code 14 £
£ £ l
Table 5.7 Led Status for specific/common error codes cont’d
Rev. 005 Chapter 5

5.8 T&D Errors Codes
The executed tests are 11.
The table below shows the complete list of tests with description and the O.R.U. (Optimum Replaceable
Unit) under test.
Nº Test Description Error Code Error Description

1 Reserved - -
2 Test complete E2PROM 1 Writing error
2 Reading error
3 Checksum E2PROM 2 Checksum error
4 Test Optional i/f 1 USB error
3 LAN: initialization
4 LAN: command
5 LAN: receive command
6 LAN: receive reply
7 LAN: trasmission command
8 LAN: trasmission reply
9 LAN: generic test channel
10 LAN: internal ram
11 LAN: ethernet test
5 Test loop i/f serial 1 test pattern rx-tx
2 loop dtr – dsr
3 loop rts - cts
4 loop srts - dcd
6 Test loop parallel 1 loop busy strobe
2 loop slct init
3 loop ack autofeed
4 loop pe^flt – sctin
5 test pattern rx-tx
7 Test panel operator 1 Key 1 (ON LINE)
2 Key 2 (STATION 1)
3 Key 3 (STATION 2)
7 General error
8 Test cover 1 Cover closed
2 Cover open
9 Printing Adjustments * Common errors tables
10 Standard Pattern Module * Common errors tables
11 Scanner Error (not used) 1 Front error
2 Rear error
3 Front/Rear error
* Common errors tables
12 Log File * Common errors tables
13 Test life counter reset - -
Table 5.8 T&D Error Codes
Rev. 005 Chapter 5

O.R.U. Reference
0 Pwa
1 Operator Panel
2 Sensors
3 Mechanical
4 Eproms / Flash / Rom
5 Supervisor (s/w)
6 LAN
7 USB
8 Option (MSRW/ MICR)
9 Scanner (not used)
Table 5.9 T&D O.R.U. Codes
Error Code Error Meaning

1 Sensors S1 / S2 (PPS)
2 Sensors S3 / S6 (CSLS)
3 Sensor S8
4 Threshold S8
5 Sensor S8
6 Sensor ribbon
Table 5.10 T&D Common errors (sensors) Codes
Error Code Error Meaning

1 Movement (generic)
2 Paper movement
3 First Line out of tolerance
4 Engine general error
9 Thermal sensor in print head out of tolerance (10°C ÷ 60°C)
10 Dynamic error on thermal sensor in print head
11 Data integrity
12 Not used
13 Selector Error
14 Not used
Table 5.11 T&D Common errors (mechanical) Codes
Rev. 005 Chapter 5

5.9 Requested Tools
For a correct maintenance are necessary the following parts:
1) Single sheet paper 80 gr/m2 (0.1 mm thickness) N.A.

2) RS232 Serial Loop-back T.B.D.
3) Parallel loop-back P.N. 78900884-001
4) Operator Panel with display (recommended) P.N. 78901347-001
5) Magnet for Interlock P.N. 78201635-001
6) Scanner module T.B.D.
5.9.1 Operator Panel with LCD
This special operator panel has been issued to help when the T&D activities have been run.
The position of the keys and the leds are as indicated in the figure below.
Follow the chapter 2.6 how to remove the standard operator panel.
The cable of this tool is plug 1 to 1 in the controlelr connector.
Fig. 5.3 Operator Panel with display for T&D activities
5.9.2 RS232 Serial Interface Loop-Back Connector
TX (03) __________________________ (02) RX

RTS (07) __________________________ (08) CTS
DCD (01) __________________________ (09) SRTS
DTR (04) __________________________ (06) DSR
Fig. 5.4 Serial I/F Loop-back
Rev. 005 Chapter 5

5.9.3 Parallel Interface Loop-Back Connector
The schematic diagram is the following:
R3 R4
P1 0
0
J1
19 1 BUSYSTR
1
20 2 DATA3 VCC
21 3 2 DATA2
22 4 3 DATA1
23 5 4 DATA0
24 6 5 DATA4
25 7 6 DATA5
26 8 7 DATA6 R1 R2
8 10K
27 9 DATA7 10K
9
28 10 ACKAUTO
10
29 11 U1A 14
11
30 12 PE 1
12
31 13 SLCTINI 3
13
32 14 2
14
33 15
15
34 16 FAULT 74HC86 7
16
35 17
17
36 18
18
FINGHER L1 L2 SLCTIN
CONN. CENT36
LEDR LEDY VCC
20
U2
R6 R5 3 2
D0 Q0
VCC
1K 1K 4 5
D1 Q1
7 6
D2 Q2
8 9
D3 Q3
13 12
D4 Q4
14 15
D5 Q5
17 16
D6 Q6
18 19
TP1 D7 Q7
1
GND
1 11 OC
CLK
TP2 TP5 TP6
10
74HC374
1 1 1
U1B
4
TP3
6
5
1
74HC86
TP4
U1C
1
9
8
10
74HC86 VCC
U1D
12
11
13 C1
1KpF
74HC86
Fig. 5.5 Parallel I/F bi-directional Loop-back
Rev. 005 Chapter 5

5.10 Analysis of T&D Printouts
5.10.1 Printing Adjustment Printout (T&D 9)
In this test the printer prints three black patterns and with the edge sensor checks and automatically
adjusts the following parameters:
The standard A4 paper must be loaded.

If loading fails the message of " Waiting for key or paper" as indicated in operator message status table 5.2.
If the o.p. with display or line monitor is used the message will be "REMOVE PAP->KEY".
The operator has to remove the paper and push any key to confirm the operation.
The printer adjusts the sensors S1 through S6.
At the end the printer enetr in the message of "Waiting for paper loading" status as indicated in table 5.2 or shows
"LOAD PAPER" message to display.
After the paper loading, the carriage and the paper are moved in a proper position and the S8 pwm adjustment and
the white threshold calibration are executed (White).
Furthermore is check the difference between the white and black level must be at least 200 steps.
If during this phase, the pwm adjustment of the S1 tru S6 sensors is not jet done, the paper is completely feeded
rearly of the the sensors (eject from the rear) and the adjustment is done.
The paper is frontly parked and reloaded utilizing the adjusted sensors.
Three squared mark are printed respectively in the left, middle and right position of the sheet (A1, B1, C1) with
carriage moving from left to right and then three more squared mark are printed respectively in the left, middle and
right position of the sheet (A2, B2, C2) with carriage moving from right to left as indicated in figure 5.4.
After this, using the S8 sensor these adjustments are automatically done:
- First printing row (F. Col.)

- First printing colunm (F. Lin)
- Alignment check (L/R)
This is the difference between the upper edge and the markers A1 and C1 less than 10/180"= 1,4mm.
- Bidirectional printing check (Bid.)
This is the skew between B1 and B2 and set for the best value.
At the end of the test the following printout is done in which there are printed :
- The S8 medium values for printed Black, White and Platen black check.
- The old and new values for the four adjustments above described in the first line
- The pwm adj for the S1 to S8 sensors in the second one.
After all the paper is automatically ejected.
Fig. 5.6 Pattern for Printout T&D 9 of Standard Model (reduced)
Rev. 005 Chapter 5

5.10.2 Standard Pattern Printout (T&D 10)
In this test the printer prints a patter with a lot of information to check all the correct functionalities.
If the T&D9 was previously done and the same sheet used is loaded, the printers automatically prints the
whole pattern as indicated in next figure 5.5A, otherwise a blank area appears in correspondance of the
T&D19 pattern.
At the beginning of this test is also checked the presence of mechanical options (MSRW /MICR).
On the pattern is printed the result of this test:
OPTIONAL DEVICE NOT FOUND (not detected)

OPTIONAL DEVICE <Iidentify device>
In the case in which the optional device is present, but in error, the pattern is halted and the specific error condition
are displayed on the operator panel with the printout::
OPTIONAL DEVICE FAULT
1. The paper is loaded with 8 step less than the stored value of the first printable line, than it prints:
- 4 underlined signs on the left and right sides to check the loading line skew.
- 9 groups of “EE” separated by a space with an incremental vertical paper movement of 1/180”
between each group (from –8 to +8 values).
Under each group except for the central one (0 value) is printed the check marker which must be
signed after the end of the test .
- A continuous line is printed for the reference of the step 9.
2. A line is printed with the controller code ID and version, the character generator ID and version, the
quantity of Ram size and the release of built -inT&D.
If the LAN interface is installed its status, version and MAC address are printed.
3. In the following two lines are reported :

The current Adjustments parameters as indicated in previous chapter (F.Col, F.Lin, Bid, White) and
also the themperature of the print head (T) in degrees.
The Log parameters of the T&D (see chapter 5.11).
4. A complete pattern which exercises all the 24 needles of the printer (the single bar printed on the right
side is the specific printed needle reported below).
5. A paper movement test (with forward and backward movements) composed by:
A) First the printer prints the first and third chopped-lines.
B) After the point 12. a backward movement is made and the central chopped-line is printed.
This line must be between the two previous chopped-lines.
6. A special vertical bar pattern to choose the best vertical alignment.

The first time this test is printed, the 5 lines show the current value in the middle line (3rd line)
associated with an asterisk (*) with the other two lines before and after with the value immediately around
the current one associated with a check marker which must be signed after the end of the test .
7. Six patterns of characters set with different type of printing attributes (CPI e Quality).
8. A special mono-directional bars pattern is printed to check the correct most external white-colored guide
print-head needle position. If this lines are not regular, the problem depends by the print head itself and
not by a vertical disalignment (carriage movement).
Rev. 005 Chapter 5

9. At about 203,2mm (8") from the continuous line printed in the step 1., a pattern with 8 signs under which
a check marker which must be signed after the end of the test or a couple of asterisks are printed to mark
the current interline.
10. After a backward movement a special decremental/incremental "H" character pattern of 19 lines to stress
the carriage movement.
11. After a backward movement of 19 lines

19 groups of a single “H” on each line horizontally shifted from the first colunm adjustment (the current
one is marked by two ** and it is printed in the central one.
Under each group except for the central one (0 value) is printed the check marker which must be signed
after the end of the test .
12. A graphic pattern to check the printing during intensive graphic test.
13. The paper is moved backward again to print the line between the chopped ones (see step 5b).
14. A forward paper movement is done to reach the bottom position and a continuous line pattern.
After all the paper is ejected and the printer waits for the best adjustments for the :
- First Printing Line

- Bidirectionality
- First Column
- Current interline
For each of these item is is possible to choose the best value and sign it in the proper line bracket [l].
The printer automatically recognizes it by printing a # sign near selected the value and store it.
Rev. 005 Chapter 5

Fig. 5.7 Pattern for Printout T&D9+T&D10 of Standard Model (reduced)
Rev. 005 Chapter 5

5.11 Monitor through serial interface
This mode can be very useful in walk-in maintenance of the printer in a repair center.
It has been developed to have the same (or in some cases much more) informations that appear on the display of
the operator panel assy directly to the serial interface connector.
It is necessary connect the printer in serial mode using the TERMINAL accessory of WIN 3.x, or HYPER-
TERMINAL accessory of WIN95 environments.
Through the serial connection all the T&D messages and informations are displayed in the video of a normal PC.
The handshaking setting must have the following parameters: XON-XOFF, 9600 baud, 8 bit, no parity, 1 stop
bit.
Setting the application for these values.
The serial connection cable has these wires :
Conn. 9 Female Conn. 9 Female

Signal Name Signal Name
(Host) (Printer)
DCD/DSR 1/6 ----------------------------------- 4 DTR
RX 2 ----------------------------------- 3 TX
TX 3 ----------------------------------- 2 RX
RTS 7 ----------------------------------- 8 CTS
GND 5 ----------------------------------- 5 GND
DTR 4 ----------------------------------- 1/6 DCD/DSR
CTS 8 ----------------------------------- 7 RTS
RI 9 Not connected 9 RI
Connect shield with metallic cover Shield Connect shield with metallic cover
Table 5.12 Serial Cable Connections for Remote T&D
The following figure shows some steps displayed in the video.
Fig. 5.8 Remote mode display (Hyper Terminal under W98)
Rev. 005 Chapter 5

The serial monitor is used also for showing the sensors PWM values and the memory dump with engine
configuration data (DoeConfig).
LOAD PAPER
csls_calibrate_pwm:
s1_pwm=60 s2_pwm=60
0 000000010 000000010
4 000000011 000000008
8 000002576 000000031
12 000004482 000000047
16 000006084 000000062
20 000007523 000000073
24 000007819 000000088
28 000007872 000000101
32 000007903 000000115
36 000007915 000000129
40 000007927 000000143
44 000007933 000000159
48 000007939 000000168
52 000007950 000000183
56 000007953 000000200
60 000007953 000000215
64 000007963 000000226
68 000007965 000000240
72 000007969 000000255
76 000007974 000000267
80 000007980 000000283
84 000007978 000000297
88 000007983 000000312
92 000007981 000000329
96 000007988 000000342
100 000007990 000000352
104 000007991 000000368
108 000007991 000000385
112 000007995 000000400
116 000007999 000000418
120 000007999 000000438
124 000008000 000000448
KO 09 ORU 02[01]
REPT ERR SKIP
Fig. 5.9 Remote mode display (Sensor 2 error during T&D09)
Rev. 005 Chapter 5

LOAD PAPER
fpps_calibrate_pwm:
s3_pwm=60 s4_pwm=60 s5_pwm=60 s6_pwm=60
0 000000008 000000008 000000008 000000008
4 000000008 000000008 000000008 000000008
8 000002010 000000008 000001822 000000672
12 000003644 000000010 000003215 000001231
16 000005126 000000013 000004395 000001744
20 000006522 000000017 000005525 000002250
24 000007641 000000016 000006599 000002757
28 000007790 000000016 000007565 000003259
32 000007837 000000017 000007783 000003749
36 000007856 000000020 000007840 000004251
40 000007867 000000023 000007862 000004742
44 000007885 000000024 000007877 000005224
48 000007889 000000026 000007896 000005708
52 000007898 000000030 000007904 000006179
56 000007902 000000032 000007908 000006657
60 000007911 000000032 000007917 000007112
64 000007912 000000033 000007924 000007534
68 000007918 000000036 000007926 000007719
72 000007918 000000040 000007927 000007784
76 000007926 000000040 000007929 000007810
80 000007928 000000040 000007935 000007832
84 000007927 000000041 000007936 000007838
88 000007928 000000048 000007937 000007857
92 000007930 000000047 000007938 000007861
96 000007930 000000048 000007947 000007865
100 000007933 000000049 000007951 000007868
104 000007936 000000056 000007947 000007879
108 000007941 000000056 000007950 000007884
112 000007941 000000056 000007958 000007886
116 000007940 000000058 000007960 000007889
120 000007943 000000064 000007957 000007895
124 000007949 000000064 000007958 000007899
KO 09 ORU 02[01]
REPT ERR SKIP
<<< T&D 09 S_B_S >>>

LOAD PAPER
peds_white_calibrate_pwm:
peds_pwm =45
0018 0017 0016 0017 0034 0086 0124
0164 0198 0233 0260 0294 0328 0361 0392
0427 0456 0492 0528 0560 0599 0634 0668
0705 0740 0776 0811 0848 0886 0923 0961
0999 1037 1075 1113 1152 1192 1228 1269
1307 1348 1385 1426 1467 1505 1546 1586
1624 1666 1704 1745 1787 1831 1868 1912
1952 1989 2032 2074 2115 2153 2195 2239
2276 2319 2363 2402 2443 2489 2526 2568
2614 2653 2697 2736 2778 2824 2868 2909
2950 2993 3037 3081 3125 3165 3207 3250
3294 3338 3387 3426 3467 3516 3556 3600
3646 3688 3733 3777 3819 3867 3911 3953
4001 4045 4094 4137 4185 4233 4281 4323
4375 4423 4467 4517 4565 4617 4669 4714
4767 4816 4871 4914 4936 4937 4944 4957
KO 09 ORU 02[03]
REPT ERR SKIP
Rev. 005 Chapter 5

5.12 Log File Printout (T&D 12)
This test is for MFG site only.

It prints the following three basic informations:
1) LOG FILE
Reports the evolution and the results of the different phases of the T&D executed during the life of the printer, until
the basic controller is replaced.
Remark: In the Step by Step mode the log is not saved and no informations are registered.
For the other phases used in MFG only are stored the following informations:
• Execution status:
Not executed = not-executed phase
Executed = executed phase (at least 1 time)
Current = phase running
• Number of executions.
Up to 11 errors are saved which reported for each one: phase in execution during the error, test in error,
ORU and error code.
The nvm area containing the log can be cancelled only in the assembly phase.
The informations related to the execution status log are printed on the standard pattern printout and are
sent to the serial interface (monitor as described in chapter 5.11) at the beginning of the T&D launch.
In the T&D10 the string is:

T&D Log: Assembly: <St>(ex. #) - Running: <St>(ex. # lp. #) - Verify: <St>(ex. #)
St can be : Yes (executed), No (not-executed), Cur (running), KO (error)

# is the number of execution or the Loop in running phase (mfg only).
2) DOE_config
The overall adjustments parameters area of NVM is printed for R&D analisys.
3) CURRENT PWM ADJ

The values of the pwm test for the sensors are printed.
These valuers are the same printed in the T&D10.
The complete report is sent to the serial monitor at the end of the T&D12 and can be printed if a sheet is loaded
within 10 seconds.
Rev. 005 Chapter 5

==================== T&D LOG FILE ====================

Assembly: Not exec (ex. 0)
Running: Not exec (ex. 0 Loop 0 - Pg r 0 v 0)
Verify: Not exec (ex. 0)
--------- DOE_config --------------

0x408d018 : fc 00 00 00 01 00 00 1f 00 14 00 f8 00 f8 00 f8 ,,,,,,,,,,,,,,,,
0x408d028 : 00 f8 00 f8 00 f8 00 7e 02 34 00 00 00 1e 18 10 ,,,,,,,,,,,,,,,,
0x408d038 : 18 1c 14 14 fa 00 00 00 00 00 00 90 02 00 00 00 ,,,,,,,,,,,,,,,,
0x408d048 : 00 00 00 00 00 00 07 af 00 00 00 00 00 00 00 00 ,,,,,,,,,,,,,,,,
0x408d058 : 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 ,,,,,,,,,,,,,,,,
--------- Current Pwm Adj ----------

S1 16, S2 24, S3 28, S4 24, S5 20, S6 20, S8 30
------------------------------------------------------
Fig. 5.12 Example of T&D 12 Log File (without errors)
==================== T&D LOG FILE ====================

Assembly: Not exec (ex. 0)
Running: Not exec (ex. 0 Loop 0 - Pg r 0 v 0)
Verify: Not exec (ex. 0)
---------- Error report ----------

N. | Phase | Test | Oru | Code |
01 | VERIFY | 06 | 00 | 01 |
02 | VERIFY | 06 | 00 | 01 |
03 | VERIFY | 06 | 00 | 01 |
04 | VERIFY | 09 | 02 | 01 |
05 | VERIFY | 06 | 00 | 01 |
06 | VERIFY | 10 | 02 | 01 |
07 | VERIFY | 07 | 01 | 03 |
08 | VERIFY | 06 | 00 | 01 |
09 | VERIFY | 06 | 00 | 01 |
10 | VERIFY | 06 | 00 | 01 |
11 | VERIFY | 06 | 00 | 01 |
------->> Log error overflow <<----
--------- DOE_config --------------

0x408d018 : fc 00 00 00 01 00 00 1f 00 14 00 f8 00 f8 00 f8 ,,,,,,,,,,,,,,,,
0x408d028 : 00 f8 00 f8 00 f8 00 7e 02 34 00 00 00 1e 18 10 ,,,,,,,,,,,,,,,,
0x408d038 : 18 1c 14 14 fa 00 00 00 00 00 00 90 02 00 00 00 ,,,,,,,,,,,,,,,,
0x408d048 : 00 00 00 00 00 00 07 af 00 00 00 00 00 00 00 00 ,,,,,,,,,,,,,,,,
0x408d058 : 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 ,,,,,,,,,,,,,,,,
--------- Current Pwm Adj ----------

S1 16, S2 24, S3 28, S4 24, S5 20, S6 20, S8 30
------------------------------------------------------
Fig. 5.13 Example of T&D 12 Log File (with max number of errors)
Rev. 005 Chapter 5

Chapter 6 Paper Specification
6.1 Overview
The documents must all guarantee the following characteristics:
• Use paper matching the indicated characteristics.

• They must have well defined top and left edges, with a square angle tolerance of 0.1° on all edges.
• The paper must not have holes, perforations, folds or tears anywhere within the print area of the document.
• The radius on a corner of the form must be within 9.5 mm from the left or right edge.
• The form to be printed must not contain foreign material.
• Form opacity must be at least 75%. Forms with a lower opacity may cause feed errors.
• Never print on documents with metallic or hard plastic fasteners or staples, they may damage the printer. Use
only sewn passbooks.
• To get the maximum print contrast you should print on white or light colored paper. You may overstrike to improve
the low contrasting paper.
• It is preferable to use single and multiple documents with the fibre running in the insertion direction of the printing
unit.
• Recycled paper is permitted on principle.
• It is preferable to print on multiple forms with a narrow glue strip or top-gluing. The gluing must not cause waving in
the set of forms.
Rev. 005 Chapter 6

113 Paper Specification
6.2 Single Sheet
Insertion direction
D
C C
Print Area B
E
A
Figure 6.1 - Single Sheet Dimensions
Dimensions Maximum Minimum

A Form width 244 mm 65 mm
B Form length 470 mm 70 mm
C Distance between dot position and - 3.0 mm
left or right paper edge
D Distance between top of the first - 1 mm
printed line and top margin of the
document
E Distance between the lower - 6.6 mm
margin and the lower part of the
last printed line
Weight (original) 120 g/m2 40 g/m2
st 2
Weight 1 75 g/m 1st 55 g/m2
2
(original + 1 to 5 copies) other 75 g/m other 45 g/m2
2
carbon 35 g/m carbon 14 g/m2
Thickness Form thicker than 0,35 mm may cause print quality degradation.
Table 6.1 - Single Sheet dimensions
Rev. 005 Chapter 6

6.3 Passbooks
Minimum Maximum
Paper Weight 75 120 g/m2
Thickness
Multiple Page Passbooks
Horizontal Fold 0.28 mm (0.011 in.) 1.80 mm (0.071 in.)
Thickness difference across the fold of an open passbook
Horizontal Fold - 1.52 mm (0.059 in.)
Vertical Fold - 1.52 mm (0.059 in.)
Single Page Passbook or Ledger Cards 0.18 mm (0.0071 in.) 0.28 mm (0.011 in.)
Covers 0.18 mm (0.0071 in.) 0.46 mm (0.018 in.)
Table 6.2 - Passbook Dimensions
• Passbooks with torn, folded, creased, incomplete or warped pages or covers should not be used.
• Printing on or across holes, edges, cut outs or folds is not permitted.
• Passbook covers must be of uniform thickness under the printing area.
• The fold of all pages and the stitching must coincide with the cover fold. The stitches should be spaced at 6
to 10 stitches per inch.
• Fiber flow on the inner sheets should be parallel to the center fold.
• The cover bulge and stitches (spine) must not exceed the following dimensions:
2,5 mm
(0,098 in.)
MAX.
1 mm
MAX. (0,039 in.)
Figure 6.2 - Passbook Dimensions
Rev. 005 Chapter 6

6.3.1 Passbooks with Horizontal Fold
Insertion direction
D
C C
Print Area
G
ABCD
B
ABCD
H
Print Area
Figure 6.3 - Horizontal Passbook
Dimension Maximum Minimum

A Passbook width 241 mm 110 mm
B Passbook length 220 mm 130 mm
C Distance between print character position and left or - 3.0 mm
right edge
D Distance between top edge of the document and top - 1 mm
edge of first printed line
E Distance between bottom of last printed line and - 6.6 mm
bottom edge of the document
F Outer corner radius 9.35 mm -
G Distance from fold to bottom of the first printed line - 5.1 mm
above the fold.
H Distance from fold to top of the first printed line below - 5.1 mm
the fold.
Table 6.3 - Horizontal Passbook Dimension
Rev. 005 Chapter 6

6.3.2 Passbooks with Vertical Fold
Insertion direction
D
H
ABCD
C C
Print Area
ABCD ABCD
B
G H
L
F E K
Figure 6.4 - Vertical Passbook
Dimension Maximum Minimum

A Passbook width 241 mm 110 mm
B Passbook length 220 mm 85 mm
C Distance for the dot position nearest to the left or right - 3,0 mm
edge
D Distance from the top edge of the document to the top - 1 mm
edge of the first printed line
E Distance from the bottom of the last printed line to the - 6,6 mm
bottom edge of the document
F Outer corner radius 9,35 mm -
G Distance from the fold to the first character position - 6,87 mm
beside the fold.
H Distance from the fold to the first character position - 6,87 mm
beside the fold.
K-L Short Page Offset - 0,0 mm
Book thickness, while open 1,8 mm 0,28 mm
Table 6.4 - Vertical Passbook Dimensions
Rev. 005 Chapter 6

BLANK PAGE
Rev. 005 Chapter 6

Chapter 7 Electromechanical Devices
7.1 Overview
This chapter contains technical information on all the electromechanical devices installed on this printer in order to be
able to detect an electrical problem on them.
7.1 Print Head
- Coil resistance : 4.0 ohm ±10% at 20 °C

- Thermal sensor : 1.000 ohm ±1% at 25 °C
- Insulation resistance : Min. 4 Mohm at DC 500 V
- Needle diameter : 0.25 mm (0.0098")
- Allowable coil temp. : 160 °C
1) Support
2) Wheel Support
3) Wheel
4) Edge Sensor
5) Electromagnetic Group
6) Connector
Fig. 7.1 - Print Head Architecture
Rev. 005 Chapter 7

119 Electromechanical Devices
Fig. 7.2 - Print Head Connection (rear view)
CONNECTIONS:
P1-1 GND 1 (P3-1) J1-1 GND 1

P1-2 COLL (P3-2) J1-2 Needle 9
P1-3 ANOD (P3-3) J1-3 Needle 7
P1-4 KATOD (P3-4) J1-4 +38V
P1-5 Needle 24 J1-5 Needle 5
P1-7 Needle 20 J1-7 +38V
P1-8 + 38 V J1-8 Needle 3
P1-10 Needle 14 H (+38 V) J1-10 +38V
P1-11 + 38 V J1-11 Needle 13
P1-13 Needle 14 J1-13 +38V
P1-14 + 38 V J1-14 Needle 17
P1-17 + 38 V J1-17 Needle 21
P1-18 Needle 6 J1-18 GND 1
P1-19 Needle 8
P1-20 + 38 V
P1-21 Needle 10
P1-22 Needle 12
P1-23 Therm. Sens
P1-24 GND sens
Table 7.1 - Print Head Electrical pin-out

Rev. 005 Chapter 7
Fig. 7.3 - Needles position (rear view)
OPERATION:
With reference to Fig 7.4a / 7.4b, when the actuator is at rest, the Clapper < 1 > is pushed against the central
Stopper < 2 > by the hinge O-Ring < 3 > Fig. 7.4a.
When a dot has to be printed, a proper current pulse is applied to the Coil < 4 > the Clapper < 1 > is attracted by the
Core < 5 > and the needles are pushed against the Media < 6 > Fig. 7.4b.
3
1
4
2
Fig. 7.4a - P.H. Operation Fig. 7.4b - P.H. Operation
Rev. 005 Chapter 7

7.2 CARRIAGE MOTOR
Electrical phase resistance 0.84 Ω ± 15% measured at 25°C.
Phase inductance 2 mH ± 20%

Measured at 1 KHz, 100 mVpp with energized coil. Each coil should be within the tolerance range, independently of
the detent position.
Rated motor voltage 2.1 V

With rated voltage applied to both phases (parallel), the coils reach the limit of insulation class with motor in air and
ambient temperatur 25°C.
Rated phase current 2.5 A

With rated phase current applied to both phases (parallel), the coils reach the limit of insulation class with motor in air
and ambient temperature 25°C.
Insulation Class B
Insulation classification is in accordance with IEC publication 85, the coils maximum temperature is 120°C.
Coil temperature is measured using the resistance method.
Insulation Resistance 100 MΩ with 550 Vdc.
Insulation Voltage 500 Vac. 1 minute
Fig. 7.5 - Carriage Motor layout
Rev. 005 Chapter 7

7.3 PAPER MOTOR

Measured at 1 KHz, 100 mVpp with energized coil. Each coil should be within tolerance range, independently of the
detent position.

ambient temperatur 25°C.

Insulation Class B
Fig. 7.6 - Paper Motor layout
Rev. 005 Chapter 7

7.4 SELECTOR MOTOR

Measured at 1 KHz, 100 mVpp with energized coil. Each coil should be within tolerance range, independently of the
detent position.

ambient temperature 25°C.

Insulation Class B
Fig. 7.7 - Selector Motor layout
Rev. 005 Chapter 7

7.5 SENSORS
Home Sensor - To detect home position for the carriage assy. It is an optointerrupter installed on the left side
of the vertical frame.
Fig. 7.8 - Home Position Sensor
Edge Sensor - To detect the paper edge. It is an optical reflection sensor installed on the carriage assy
together with the print head.
Fig. 7.9 - Edge Sensor
Ribbon Sensor - To detect presence and movement of the ribbon. It is a unipolar Hall switch magnetic sensor
installed on the upper part of the right frame.
Fig. 7.10 - Ribbon Sensor
Rev. 005 Chapter 7

Sensor Board - To detect loading and skewing of the media. The light emitted by pfhotodiodes on the board is
transmitted by the optical fibres to the phototransistors on the same board.
The two following sensor are able to detect loading paper:

D1 ⇒ Q1 
D2 ⇒ Q2 
The four following sensor are able to detect skewing:

D3 ⇒ Q3 
D4 ⇒ Q4 
D5 ⇒ Q5 
D6 ⇒ Q6 
Fig. 7.11 - Sensor Board and Optical Fibre
P1-1 Katode D3 P1-8 Collectors (all transistors)

P1-2 Katode D1 P1-9 Emitter Q6
P1-5 Katode D2 P112 Emitter Q1
P1-7 Anodes (all leds) P1-14 Emitter Q3
Table 7.2 Sensors Board pin-out
Rev. 005 Chapter 7

Chapter 8 Mechanical Adjustments
8.1 Overview
This section describes the procedures for the basic printer mechanical adjustments.
• Print Head Gap Adjustment

• Paper Belt Tension Adjustment
• Carriage Belt Tension Adjustment
• Selector Cam Adjustment
Rev. 005 Chapter 8

127 Mechanical Adjustments
8.2 Print Head Gap Adjustment
This adjustment is required only if the platen assy is removed.

Its verification it is also recommended when some parts of the mechanical assy related to the gap are removed and
the distance between the print head needles / AGA wheel and the platen is changed.
To assure the correct parallelism and the correct gap between platen and AGA wheel, follow this procedure:
1) Remove the top and the main cover.

3) Loose the allen screws (item 19 of figure 8.2). The platen assy will slide in the lowest position.
5) Keeping the allen screwdriver on the screw on the right side, gently rise the platen until it touch the
AGA wheel.
8) Keeping the allen screwdriver on the screw on the left side, gently rise the platen assy until it touche
the AGA wheel.
11) Gently loose the allen screw on the right side. Keeping the allen screwdriver on the screw, fix it as
soon as the contact position between AGA wheel and platen assy (without any other force) has been
found.
13) Gently loose the allen screw on the left side. Keeping the allen screwdriver on the screw, fix it as soon
as the contact position between AGA wheel and platen assy (without any other force) has been found.
REMARK:
Due to te fact that the platen assy is movable on its supports (there are two springs which maintains the platen in its
correct position) check for the correct platen free movement (down by pressure and up by springs release) by force it
both on the right and on the left side.
Rev. 005 Chapter 8

Fig. 8.1 - Gap Adjustment
Fig. 8.2 - Print Head Gap versus Platen
Rev. 005 Chapter 8

8.3 Paper Belt Adjustment
This adjustment is required when the paper motor or some mechanical parts related to the paper belt installation are
removed.
Standard value: 2000gr ± 100gr

Tool: Pull force dynamometer
1) Remove the top and the main cover.

2) Loose the two screws (item 13 of figure 8.3) securing the paper motor assy to the right frame.
3) Apply the specific load F1 pulling the pulley of the motor toward the front side like indicate by the arrow.
4) Securing the screws.
After this adjustment is necessary to run the T&D procedures (see chapter 5) to check if there is problems in the
paper movement.
Fig. 8.3 - Paper Belt Adjustment
Rev. 005 Chapter 8

8.4 Carriage Belt Adjustment
The correct belt tension is assured by the spring that keep under proper mechanical tension the support of the pulley
on the right side of the vertical frame.
Standard value: 6-7 mm

Tool: Feeler gauge
Check for a correct installation of the spring and the pulley support.
Light window between vertical frame and pulley bracket must be 6 ÷ 7 mm as showed in the figure below.
This measure assure a correct tension of the belt. So check for the correct measure by means of a feeler gauge. Set
it at 6 mm. and it must pass in the window. Then set the gauge at 7 mm. and it must not pass in the window.
Adjust if it is necessary fixing properly the pulley bracket in order to have correct measure of the window.
This gives a tension value of the carriage belt of 7 Kg ± 0,5Kg.
Figure 8.4 - Carriage Belt Adjustment
Rev. 005 Chapter 8

8.5 Selector Cam Adjustment
This adjustment is done to assure a correct gap between the upper and lower rollers.
The item are related to the figure 8.5. below.
Standard Value: 0.5mm ± 0.3mm

Tool: Feeler gauge
1) Turn clockwise the Cam selector (item 1) until the stop.

2) Turn the Spring bar (item 2) until the Spring pressor (item 3) are in touch with the spring (item 4).
- Put a lower force of 70-80 gr. (item 7) on the middle spring pressor.
- Put a thickness tool of 0.35mm between all the upper and lower rollers (item 8). It can be a mylar sheet
or, alternatively, 3 sheets of standard 80gr/m2 photocopy paper.
3) Move the Lever assy selector (item 5) against the Drive aligner assy putting between them a thickness of 0.3
mm and turn it against the Cam selector.
4) Tight the screw (item 6) and remove the force (item 7) and the thickness tool (item 8).
5) Turn the Spring bar (item 2)as described at point 2) and check for the gap between the wheel of the Lever
Assy (item 5) and Cam selector (item 1) must be 0.5 (± 0.3) mm.
Figure 8.5 - Selector Cam Adjustment
Rev. 005 Chapter 8

Via Martiri d’Italia, 26
10014 Caluso
TORINO - ITALY
SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE.

This manual refers to various company and products by their trade names.
In most of the cases, these designations are claimed as trademarks or registered
trademarkes by their respective companies.
Copyright 2005 CPG-I, Printed in Italy.

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SP 40

Chapter 1 General Information

TABLE OF CONTENTS cont’d

Chapter 4 Service Maintenance

TABLE OF CONTENTS cont’d

Chapter 5 Test & Diagnostic

Chapter 6 Paper Specifications

Chapter 7 Electromechanical Devices

Table 1.1 Printer Specification Summary 10

Table 3.1 O.P. keys meaning 50

Table 4.1 Not-recoverable leds errors code N° 82

Table 5.1 General Rules for T&D operations 88

Table 6.1 Single Sheet Dimensions 114

Table 7.1 Print Head Electrical pin-out 120

Fig. 1.1 Front View 4

Fig. 2.1 Open Top Cover 15

Fig. 3.1 Operator Panel 49

Fig. 3.12a Initial mask for SP40setup installation 68

Fig. 4.1 Basic FW steps through LAN using FTP 80

Fig. 5.1 Operator Panel Sketch 87

Fig. 6.1 Single Sheet dimensions 114

Fig. 7.1 Print Head Architecture 119

Fig. 8.1 Gap Adjustment 129

Page intentionally left blank

Rev. AE (005) September 2005

The informations on this document are subject to change without notice.

Rev. 005 Preface

• Reorient or relocate the receiving antenna.

Canadian D.O.C. Radio Interference Regulation

Rev. 005 Preface

Chapter 1 General Information

1.2 Scope of the Product

1.3 Main Features

Rev. 005 Chapter 1

1.4 Printer Parts

Figure 1.1 - Front View

Power Cable Connector

Parallel Interface Cable Connector

Figure 1.2 - Rear View (standard model)

Rev. 005 Chapter 1

Figure 1.3 - Rear View (LAN model)

Figure 1.4 - Inside View

Rev. 005 Chapter 1

1.5 Product Structure

1.5.1 Mechanism and Electromechanical Devices

Rollers opening and Aligner selection

See chapter 7 for the electrical schematics.

Printhead type: ER24W

See chapter 7 for the electrical schematics.

Rev. 005 Chapter 1

Electronic parts of the printer are:

• Power Supply autoswitching type.

Rev. 005 Chapter 1

Figure 1.5 - Lay-out Electronic parts

Rev. 005 Chapter 1

Figure 1.6 - Lay-out Electromechanical parts

Rev. 005 Chapter 1

1.6 Technical Specifications

Table 1.1 Printer Specifications Summary

Rev. 005 Chapter 1