Genicom 3460 Maint Manual

GENICOM
MODEL 3460/3480/3480+ MAINTENANCE MANUAL GEK-89537
Maintenance Contents
Manual
Table of Contents
CHAPTER 1 GENERAL OVERVIEW Introduction Scope of the Products Printer Features Summary General Description Physical Overview Physical Dimension Printer Structure Mechanical Assy Tractor Unit Assy Print Head Cabinet Electronic Hardware Inked Ribbon Cartridge Mechanical Options Product Components Basic Printer Options Inked Ribbons Automatic Sheet Feeder Optional Tractor Color Kit Pedestal Prnters Technical Specifications Page 1.2 1.2 1.2 1.3 1.4 1.6 1.6 1.6 1.7 1.7 1.7 1.8 1.8 1.8 1.9 1.11 1.11 1.11 1.11 1.11 1.11 1.11 1.12
1.1 1.1.1 1.1.2 1.2 1.2.1 1.2.2 1.2.3 1.2.3.1 1.2.3.1.1 1.2.3.2 1.2.3.3 1.2.3.4 1.2.3.5 1.2.3.6 1.3 1.3.1 1.3.2 1.3.2.1 1.3.2.2 1.3.2.3 1.3.2.4 1.3.2.5 1.4
CHAPTER 2 PAPER HANDLING OVERVIEW 2.1 2.1.1 2.1.2 2.1.3 2.1.3.1 2.1.3.2 2.1.3.3 2.2 Introduction Paper Handling Architecture Paper Feeder Movements Paper Path Configurations Basic Configurations Dual Fanfold Configurations ASF Configuration Actions to put Rear Tractor in Pull Mode 2.2 2.2 2.5 2.8 2.8 2.10 2.11 2.13
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CHAPTER 3 REMOVAL AND REPLACEMENT FOR 3460 (A3) / 3480 (A3) / 3480+ 3.1 3.2 3.3 3.3.1 3.3.2 3.3.3 3.3.4 3.3.5 3.3.6 3.3.7 3.3.8 3.3.9 3.3.10 3.3.11 3.3.12 3.3.13 3.3.14 3.3.15 3.3.16 3.3.17 3.3.18 3.3.19 3.3.20 3.3.21 3.3.22 Overview Recommended Hand Tools and Equipment O.R.U.Order of Access Front Push-Pull Tractor Group Operator Panel Boards Print Head Front Cover Parts Rear Cover Parts Serial Interface Main Board Power Supply Board Ribbon Motor AGA Motor AGA Support and T/F Lever Carriage Motor Bail Assy Cut Sheet Assy Upper Feeder Assy Platen Assy Lower Feeder Assy Carriage Assy Sensor Assy Mechanical Assy Paper Motor Assy Friction Bar Assy Page
3.2 3.2 3.3 3.4 3.5 3.7 3.8 3.9 3.10 3.11 3.12 3.13 3.14 3.15 3.16 3.17 3.18 3.19 3.20 3.21 3.23 3.24 3.26 3.27 3.28
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CHAPTER 4 REMOVAL AND REPLACEMENT FOR 3460 (A2) / 3480 (A2) 4.1 4.2 4.3 4.3.1 4.3.2 4.3.3 4.3.4 4.3.5 4.3.6 4.3.7 4.3.8 4.3.9 4.3.10 4.3.11 4.3.12 4.3.13 4.3.14 4.3.15 4.3.16 4.3.17 4.3.18 4.3.19 4.3.20 4.3.21 4.3.22 4.3.23 Overview Recommended Hand Tools and Equipment O.R.U.Order of Access Front Push-Pull Tractor Group Operator Panel Boards Print Head Front Cover Parts Rear Cover Parts Main Board Power Supply Board Ribbon Motor AGA Motor AGA Support and T/F Lever Carriage Motor Bail Assy Cut Sheet Assy Upper Feeder Assy Platen Assy Carriage Assy Lower Feeder Assy Sensor Assy Mechanical Assy Paper Motor Friction Bar Assy Ribbon Mask Lower Mylar Page
4.2 4.2 4.2 4.2 4.2 4.2 4.2 4.2 4.4 4.5 4.5 4.5 4.5 4.5 4.5 4.5 4.5 4.5 4.7 4.9 4.9 4.9 4.9 4.9 4.9 4.10
CHAPTER 5 ADJUSTMENTS 5.1 5.1.1 5.1.2 5.1.3 5.1.4 5.1.5 5.1.6 5.1.7 5.1.8 Overview Carriage Belt Paper Belt Print Head Gap AGA Calibrate First Printing Line Vertical (bidirectional printing) Tear-off Line Sensor Tuning 5.2 5.2 5.3 5.4 5.8 5.10 5.11 5.13 5.14
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CHAPTER 6 SERVICE MAINTENANCE 6.1 6.2 6.2.1 6.2.2 6.2.3 6.2.4 6.3 6.3.1 6.3.2 6.3.2.1 6.3.2.2 6.3.2.3 6.3.3 6.3.3.1 6.3.4 6.3.5 6.3.6 6.4 6.4.1 6.4.2 6.4.3 6.4.4 6.4.5 6.4.5.1 6.4.6 6.4.6.1 6.4.6.2 6.4.7 6.4.8 6.4.9 6.4.10 6.4.11 6.4.10.1 6.4.10.2 Overview Initial Ispection Set-Up Cleaning Paper Specifications Consumables Troubleshooting Guide Initializing Phase Printer Errors Status Errors Recoverable Errors Unrecoverable Errors Power Malfunctions P.S. Troubleshooting Guide Self-Test Hex-Dump Faulty Probability Guide Test & Diagnostic Introduction T&D Structure T&D Kit Execution of USER T&D Loop-Back Connectors Loop-Back Connector Diagrams Diagnostic Program Management Diagnostic Flow Chart Diagnostic Error Management T&D Tests List ORU List Diagnostic Errors Table Tests Description Analisys of Standard Modules Fanfold Printout Single Sheet Printout Page 6.2 6.2 6.2 6.3 6.3 6.3 6.4 6.4 6.4 6.4 6.5 6.7 6.9 6.10 6.12 6.13 6.14 6.18 6.18 6.18 6.18 6.19 6.20 6.20 6.22 6.23 6.26 6.27 6.27 6.28 6.29 6.34 6.34 6.37
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CHAPTER 7 ELECTROMECHANICAL DEVICES 7.1 7.1.1 7.1.2 7.1.2.1 7.1.2.2 7.1.2.3 7.1.2.4 7.1.2.5 7.1.2.6 7.1.2.7 7.1.2.8 7.1.3 7.1.3.1 7.1.3.2 7.1.3.3 7.1.3.4 Overview Print Head Motors Carriage Motor Paper Motor AGA Motor Ribbon Motor Alternance Motor ASF Motor Color Motor Stacker Motor Cables Sensors Cable Alternance Cable Paper Stacker Cable Operator Panel Cable Page 7.2 7.2 7.5 7.5 7.6 7.7 7.8 7.9 7.9 7.10 7.11 7.12 7.12 7.13 7.13 7.14
CHAPTER 8 INTERFACES 8.1 8.1.1 8.2 8.2.1 8.2.2 8.2.3 8.2.4 8.2.4.1 8.2.5 8.2.6 8.3 8.3.1 8.3.1.1 8.3.1.2 8.3.1.3 8.3.2 8.3.2.1 8.3.2.2 8.3.2.3 8.3.3 8.4 8.4.1 8.4.2 8.4.3 Overview Hot Interfaces IEEE 1284 Parallel Interface Communication Modes Operating Phases Negotiation Parallel Interface Signals Parallel Interface Signals Behaviour Electrical and Physical Characteristics Interface Timing Serial Interface RS232/C Full Duplex Connection Serial Interface RS232/C Signals RS232/C Signals Behaviour RS232/C Electrical and Physical Characteristics 8.14 RS422/A Interface RS422/A Interface Signals RS422/A Signals Behaviour RS422/A Electrical and Physical Characteristics 8.16 Other characterisitcs of RS232/C & RS422/A Link Protocols DTR & 2nd RTS Data Flow Control Xon/Xoff Data Flow Control Buffer Management 8.2 8.2 8.2 8.3 8.3 8.4 8.5 8.6 8.9 8.10 8.11 8.11 8.11 8.12 8.14 8.14 8.15 8.16 8.17 8.17 8.18 8.19
CHAPTER 9 OPTIONS 9.1 9.1.1 9.1.2 GENICOM 3460 / 3480 / 3480+ Overview Automatic Sheet Feeder Color Motor ii.5
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Figures
Page 1.1 1.2 1.3 1.4 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 3.12 3.13 3.14 3.15 3.16 3.17 3.18 3.19 3.20 3.21 3.22 Basic Printer Parts Location (front view) Basic Printer Parts Location (rear view) Printer Internal Architecture Operator Panel Overview 1.3 1.4 1.5 1.17 2.4 2.6 2.6 2.8 2.9
Paper Handling Architecture Paper Feeder Parts on Right Side Paper Feeder Parts on Left Side Automatic Movement of Friction Rollers 2.7 Front Load Push-Mode Rear Load Push-Mode Rear (bottom) Load Push-Mode 2.9 Front Load Push-mode and Rear Front Push-mode with two tractors Front Load Push-Pull with two tractors Automatic Sheet Feeder Actions to do to put Rear Tractor in Pull-mode Front Push-Pull Tractor Group Operator Panel Boards Print Head Front Cover Parts Rear Cover Parts Serial Interface Board Main Board Power Supply Board Ribbon Motor AGA Motor AGA Support and T/F Lever Carriage Motor Bail Assy Cut Sheet Assy Upper Feeder Assy Platen Assy Lower Feeder Assy Carriage Assy Sensor Assy Mechanical Assy Paper Motor Friction Bar Assy
2.10 2.11 2.12 2.13 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 3.12 3.13 3.14 3.15 3.16 3.17 3.18 3.19 3.21 3.22 3.23 3.24 3.25
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Page 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11 4.12 4.13 4.14 4.15 4.16 4.17 4.18 4.19 4.20 4.21 4.22 5.1 5.2 5.3 5.4 5.5 6.1 6.2 6.3 6.4 6.5A 6.5b 6.6 6.7 6.8 6.9 6.10 6.11 Front Push-Pull Tractor Group Operator Panel Boards Print Head Front Cover Parts Rear Cover Parts Serial Interface Board Main Board Power Supply Board Ribbon Motor AGA Motor AGA Support and T/F Lever Carriage Motor Bail Assy Cut Sheet Assy Upper Feeder Assy Platen Assy Lower Feeder Assy Carriage Assy Sensor Assy Mechanical Assy Paper Motor Friction Bar Assy Carriage Assy Belt Adjustment Paper Belt Adjustment Print Head Adjustment AGA Marker Adjustment Vertical Adjustment Test Power Supply Cover Tool Installation Power Supply Test Points Self-Test Printout Hex-Dump Printout 232/C Serial Interface Loop-back Diagram 422/A Serial Interface Loop-back Diagram Parallel Interface Loop-back Diagram Mechanical Option Loop-back Diagram Friction Bar Assy Position 3460 T&D Standard Fanfold Printout 3480 T&D Standard Fanfold Printout T&D Standard Single Sheet Printout 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11 4.12 4.13 4.14 4.15 4.16 4.17 4.18 4.19 4.21 4.22 4.23 4.24 4.25 4.26 5.2 5.3 5.7 5.7 5.12 6.9 6.11 6.12 6.13 6.20 6.20 6.21 6.21 6.31 6.35 6.36 6.38
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Page 7.1 7.2 7.3 7.4 7.5 7.6 7.7 7.8 7.9 7.10 7.11 7.12 8.1 8.2 8.3 8.4 8.5 8.6 9.1 9.2 9.3 9.4 9.5 9.6 9 Needles Print Head Pinout 24 Needles Print Head Pinout Carriage Motor Paper Motor AGA Motor Ribbon Motor Color Motor Stacker Motor Sensors Cable Alternance Cable Paper Stacker Cable Operator Panel Cable Compatibility, Nibble and Byte Mode phases Transitions Centronics Timing IEEE 1284 Timing DTR & 2nd RTS Timing XON-XOFF Timing Buffer Management First ASF Components ASF and Stacker Blocks Diagrams ASF Installation (rear view) Second Bin ASF Installation Color Motor Installation Color Ribbon Installation 7.3 7.4 7.5 7.6 7.7 7.8 7.10 7.11 7.12 7.13 7.13 7.14
8.8 8.10 8.10 8.17 8.18 8.19 9.2 9.3 9.4 9.5 9.6 9.7
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Tables
Page 2.1 3.1 4.1 6.1A 6.1B 6.2 6.3 6.4 6.5 7.1 7.2 7.3 8.1 8.2 8.3 Paper Path Configurations 2.4 Printer Connections Table ORU Order of Access Unrecoverable Error Display Messages (Bootstrap Phase) Unrecoverable Error Display Messages (Normal Phase) T&D USER Flow Chart T&D Tests List T&D ORU List T&D Error Codes Print Head Resistance/Temperature Characteristics 7.1 9 Needles Print Head Pin assignment 24 Needles Print Head Pin assignment Parallel Interface Pin Assignent RS-232/C Serial Interface Pin Assignment RS-422/A Serial Interface Pin Assignment
3.4 4.3 6.7 6.8 6.23 6.27 6.27 6.28 7.3 7.4 8.5 8.11 8.15
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September 1998
Rev. 002
This Maintenance Manual focuses over the bare printer plus their specific options. All defects originated by incorrect paper insertion, wrong menu setting or mistaken controls commands, are not covered by this document to avoid duplications of information available on the USER MANUAL forwarded to each end user within printer package, and available in five local languages. 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 replacement. The information in this document is subject to change without notice. For every evolution regarding the maintainability aspects refers also to the specific technical bulletin issued by the Product Support. All efforts have been made to ensure the accuracy of the contents of this manual. However, GENICOM Corporation cannot assume responsability for any errors that may appear in this document or their consequences.
TRADEMARK ACKNOWLEDGEMENTS - IBM Proprinter XLIII, IBM Proprinter XL, IBM Proprinter XLAGM are trademarks of International Business Machines Co. - EPSON LQ 1050 and EPSON FX1000 are registered trademarks of Epson Corporation. - Centronics is a registered trademarks of Genicom Corporation.
COPYRIGHT 1998 - GENICOM CORPORATION Printed in Italy All Rights Reserved
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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 esponsible 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 prsent appareil numrique n'met pas de bruits radiolectriques dpassant les limites applicables aux appareils numriques de classe B prescrites dans le rglement sur le brouillage radiolectrique dict par le ministre 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).
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Maintenance Manual Overview
General
Chapter 1 General Overview
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1.1 Introduction
This Manual describes the features and the maintenance procedures for the Serial Impact Dot Matrix printers 3460, 3480, 3480+ and their options. These printers are part of the GENICOM Corporation Product Line.
Difference about 3460/3480 (A2), 3460/3480 (A3) and 3480+

The main difference between these three differents profile are the following: Compuprint P/N 78399160-001 78399636-003 78399638-002 78407242-001 78399661-001 78399660-002 78399639-002 78403364-003 78402198-001 78407658-001 78406948-001 DESCRIPTION Kit P.H. mask Carriage Assy Support Spring Assy P.H. mask Carriage Assy Lower Mylar Assy Support spring Assy new Fan Carriage Assy Carriage motor Print Head Pwa 2V4C24 3460/3480 (A2) x x x 3460/3480 (A3) 3480+
x x x x
x x x x x x x x
Pratically, the (A3) profile introduce the following difference respect the (A2) profile. -The support sring with the removable lower mylar. -A new carriage assy with a new print head mask. -A new main board and related firmware for electronic AGA. -The serial interface is integrated in the main board. The 3480+ is a more speedy model of the 3480 (A3). Its printing speed is 450 cps at 10 cpi in draft mode. For this reason, a new pwa/fw, a new print head, a new carriage motor and a fan carriage has been introduced in this model.
1.1.1 Scope of the Products

These printers are advanced impact printers which give real and efficient solutions to the actual and future printer needs. They are designed to be extremely flexible in paper handling and capable to manage different paper types and formats, able to print on thick and multipart forms, specialized on dual fanfold management in non-attended mode. In the same time, these printers are intended to support EDP, Office and "Administrative" environments applications requiring very high throughput, high level print quality and graphic capabilities, either in black or in colors, in order to print listing, invoicing & billing, spread sheets, diagrams, business or technical graphics and machine readable texts. GENICOM 3460 / 3480 / 3480+ 1.2 GEK-89537
Maintenance Manual Overview These printers enter in the top segment of the SIDM pinter market and can be a valide and convenient alternative to the low end line-printers.
General
1.1.2 Printers Features Summary

9 (3460) or 24 (3480) wire print head. Draft print at 400 cps and LQ print at 120/133 cps (3460/3480) Draft print at 450 cps and LQ print at 120/133 cps (3480+) High resolution Graphics Printing at 240x144 dpi for 3460 model, 360x180 dpi for 3480/3480+ models. IBM Proprinter XLIII and EPSON FX1000 resident emulation for 3460 model. IBM Proprinter X24 and XL24 and EPSON LQ1050 resident emulation for 3480/3480+ models. (ANSI emulation also available). Paper path switching selected by operator panel or SW commands. Easy print function selection and printer configuration via the operator panel or with SW commands. Centronics parallel and RS-232-C and RS-422-A serial interfaces. Font styles in multiple international character sets. Optional second tractor assembly for dual fanfold operation. Optional Automatic Sheet Feeder that handles cut sheets, multicopies & envelopes. Optional color motor for color feature printing.
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1.2 General Description

1.2.1 Physical Overview
A sketch of the resulting appearance is reported on figures 1.1 and 1.2. 1. Top Cover 2. Operator Panel 3. Power Switch 4. Single Sheet Support 5. Paper Knob 6. Front Tractor Unit Cover
Fig. 1.1 Basic Printer Parts Location (front view)
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1. Interface Cover 2. Rear Tractor Unit Cover 3. Paper Stacker Covers
4. ASF Location Cover 5. AC Power Inlet 6. Paper Deflector
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Maintenance Manual Overview Fig. 1.2 Basic Printer Parts Location (rear view)
General
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1.2.2 Physical Dimension

Basic printer without options Dimensions - HEIGHT - WIDTH - DEPTH - WEIGHT (unpacked) 12.1" 26.2" 13.3" 38 lbs (310 mm) (665 mm) (390 mm) (18 Kg)
1.2.3 Printer Structure

The printer can be described as the complex of the following parts. In the next figure it is possible to see the internal printer architecture and where the major blocks described below are located. ### ### ### ### ### MECHANICAL ASSY PRINT HEAD CABINET ELECTRONIC HARDWARE INKED RIBBON
Fig. 1.3 Printer Internal Architecture GENICOM 3460 / 3480 / 3480+ 1.7 GEK-89537
General
1.2.3.1 Mechanical Assy

This block is composed of a rubber platen roller with a carriage carrying a print head with 9 needles (3460 model) or 24 needles (3480/3480+ models) in front of the platen. This movement is obtained via a step-motor (providing 1/120" movement per step) and a minipitch belt. The movement of the rubber drum for paper traslation is obtained via a specific step motor providing a minimum movement of 1/144" for 9 needle model or 1/180" for 24 needles model and a couple of minipitch belts. The motion of the ribbon cartridge is obtained through a specific step-motor indipendently from the actual carriage speed, movement, direction and width. In this way in front of the print head there is a continuously renewing well inked ribbon. The ribbon speed is optimized to reduce conflicts with ribbon and graphic printout appearance when ribbon and print head are moving in the same direction. The color ribbon and the extended life black cartridges are moved up and down through a linear actuator (step motor) with a plastic coupler that transmits the axial movement to the plastic print head mask installed on the color ribbon cartridge. Another step motors is used for the A.G.A. (automatic gap adjustment) of the print head movement to have the best perfomance on the paper in use. The printer is able to increase/decrease the strength of the needle stroke via MENU (selectable by User) to allow a high impact force also for multi-part forms (up to 7 copies).
1.2.3.1.1 Tractor Unit Assy

A removable push-pull tractor unit is installed on the printer. Inside of it, a DC motor switches to engage/disengage the gear to allow the fanfold or the single sheet to be fed. The tractor unit can be installed in two different positions depending on the type of fanfold management (front - rear - both). In the next chapter all the paper handling possibilities of this mechanism are detailed.
1.2.3.2 Print Head

The core of the printer is the print head, which is for both models an electromagnetic non- ballistic type with a life of 400 MChrs. There are three different print heads: 9 needles for 3460. 24 needles for 3480. 24 needles for 3480+.
1.2.3.3 Cabinet
The cabinet allows safety-proof lifting of frontal part for ribbon substitution and paper path check. It is composed of various parts to allow an easy access to all the printer internal parts.
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1.2.3.4 Electronic Hardware

This section is composed of the following boards: MAIN BOARD located in the bottom right side of the printer which controls the motors movement, the various input sensors, the parallel interface and the print head needles. It also provides the management of the asynchronous host serial interface, external synchronous serial interface for mechanical options and fonts cartridge. POWER SUPPLY BOARD located in the bottom left side of the printer which provides specific voltages for logical area, printhead needles and drive motors. There are two power supply boards: 120 and 220/240 Vac respectively. OPERATOR PANEL BOARD placed on the front side of the printer driving 9 push buttons and 8 leds (3 for printer status and 5 for paper path selection). This board also drives a 16 Digit LCD Alphanumeric display to easily interact with parameters setting for menu operation. SERIAL INTERFACE board located on the rear right side and plugged to the main board which drives the proper drivers for serial interface.
1.2.3.5 Inked Ribbon Cartridge

The ribbon cartridge is installed in different ways according to the ribbon types. In case of the black ribbon, the cartridge is fixed on both sides on four points. Its position is obliquous to the print line to automatically show the complete height of the ribbon in front of print head while printing on the full print line. The inked ribbon inside of these cartridges is a continuous loop. In case a color ribbon or an extended life black ribbon installed, the cartridge is fixed on both sides only on the two rear points, so that is is free to move its frontal part upward and downward. Its installation is parallel to the print line to assure the correct color band selection. A specific step motor is used to move the ribbon band up and down for color selection.
1.2.3.6 Mechanical Options

This printer can provide some mechanical options : AUTOMATIC SHEET FEEDER (up to 3 bins). Each bin has a DC motor inside it to automatically load the single sheet paper. Internally on the bin a series of gears takes the movement of the motor to the rubber roller shaft. Together with the first bin a PAPER STACKER is provided to collect the output printed paper. Also this part has an internal step motor to select the path where the paper should be output.
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1.3 Product Components

1.3.1 Basic Printers
Product Name: Marketing Identifier: The product is composed of: 3460 3P3461A1 or 3P3461A2 or 3P3461A1A - 9 needles Basic Printer - 9 MC Black Ribbon Cartridge - 120 Vac Power Cable - Push/Pull Tractor Unit - Parallel & Serial Interfaces - User Manual
Product Name: Marketing Identifier: The product is composed of:
3460 3P3462A1 or 3P3462A2 - 9 needles Basic Printer - 9 MC Black Ribbon Cartridge - 220/240 Vac Power Cable - Push/Pull Tractor Unit - Parallel & Serial Interfaces - User Manual
3460 3P3461A3 - 9 needles Basic Printer - new mech. profile and 400 cps speed - 9 MC Black Ribbon Cartridge - 120 60Hz Vac Power Cable - Push/Pull Tractor Unit - Parallel & Serial Interfaces - User Manual
3460 3P3462A3 - 9 needles Basic Printer - new mech. profile and 400 cps speed - 9 MC Black Ribbon Cartridge - 220/240 Vac 50Hz Power Cable - Push/Pull Tractor Unit - Parallel & Serial Interfaces - User Manual
3480 3P3481A1 or 3P3481A2 or 3P3481A1A - 24 needles Basic Printer - 9 MC Black Ribbon Cartridge - 120 Vac Power Cable - Push/Pull Tractor Unit - Parallel & Serial Interfaces - User Manual
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3480 3P3482A1 or 3P3482A2 - 24 needles Basic Printer - 9 MC Black Ribbon Cartridge - 220/240 Vac Power Cable - Push/Pull Tractor Unit - Parallel & Serial Interfaces - User Manual
3480 3P3481A3 - 24 needles Basic Printer - new mech. profile and 400 cps speed - 9 MC Black Ribbon Cartridge - 120 Vac 60Hz Power Cable - Push/Pull Tractor Unit - Parallel & Serial Interfaces - User Manual
3480 3P3482A3 - 24 needles Basic Printer - new mech. profile and 400 cps speed - 9 MC Black Ribbon Cartridge - 220/240 50Hz Vac Power Cable - Push/Pull Tractor Unit - Parallel & Serial Interfaces - User Manual
3480+ 3P3481A4 - 24 needles Basic Printer - new mech. profile and 450 cps speed - 9 MC Black Ribbon Cartridge - 120 Vac 60Hz Power Cable - Push/Pull Tractor Unit - Parallel & Serial Interfaces - User Manual
3480+ 3P3482A4 - 24 needles Basic Printer - new mech. profile and 450 cps speed - 9 MC Black Ribbon Cartridge - 220/240 50Hz Vac Power Cable - Push/Pull Tractor Unit - Parallel & Serial Interfaces - User Manual 1.11 GEK-89537
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General
Note: printers whose marketing identifiers ends with A1A or A2, have the GENICOM ANSI emulation installed.
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1.3.2 Options 1.3.2.1 Inked Ribbons

Marketing Identifier: The product is composed of: Marketing Identifier: The product is composed of: Marketing Identifier: The product is composed of: Marketing Identifier: The product is composed of: 1A3000B01 1 Black Ribbon Cartridge 1A3000B02 1 Color Ribbon Cartridge (4 band) 1A3000B03 1 Black/Red Color Ribbon Cartridge 1A3000B04 1 Extended Life Black Ribbon Cartridge
1.3.2.2 Automatic Sheet Feeder

Marketing Identifier: The product is composed of: 1A3003B01 - ASF 1st Bin Unit (up to 120 sheets) - Paper Stacker (up to 150 sheets) - User Manual
Marketing Identifier: The product is composed of:
1A3003B02 - ASF 2nd Bin Unit (up to 120 sheets) - User Manual
1.3.2.3 Optional Tractor

Marketing Identifier: The product is composed of: 1A3003B03 - Push/Pull Tractor Unit - Installation Manual
1.3.2.4 Color Kit

Marketing Identifier: The product is composed of: 1A3003B04 - Color motor - User Manual
1.3.2.5 Pedestal
Marketing Identifier: The product is composed of: 1A3003B05 - Inclinable two levels floor pedestal (for document on demand application) - Installation Manual 1.13 GEK-89537
GENICOM 3460 / 3480 / 3480+
Maintenance Manual Overview Marketing Identifier: The product is composed of: 1A3003B06 - Three levels floor pedestal (for dual fanfold application) - Installation Manual
General
1.4 Printers Technical Specifications

The following features refer mainly to intrinsic characteristics and can change without notice.
### PRINT HEAD N. of Needles Life (MChrs draft) V. Pitch V. Pitch Needle Diameter
Model 3460 9 400 1/72" n.a. 0.3 mm (0.0118")
Model 3480/80+ 24 400 1/120" 1/180" 0.2 mm
(0.0078")
### PRINT SPEED CPI= DPI= CPS= DPS=
Model 3460
Model 3480/80+
characters per inch dots per inch characters per second dots per second CPI DPI CPS DPS 400 480 480 400 400 120 120 120 200 200 2100 2100 2100 2100 2100 2100 2100 CPI DPI 10 12 15 17 20 24 10 12 15 17 20 24 60 60 60 120 120 120 180 180 180 180 180 180 60 80 90 120 180 240 360 CPS DPS 400 480 600 343 400 400 133 160 200 229 267 320 2100 1660 1245 2100 2100 2100 2100
Draft mode:
10 12 15 17 20 10 12 15 17 20 -
60 60 75 103 120 100 120 150 102 120 60 72 72 120 144 240 288
Letter Quality mode:
Dot Graphic Mode:
### THROUGHPUT PPH ECMA 132 PPH= PPH GENICOM 3460 / 3480 / 3480+ pages per hour Model 3460 Fanfold ASF 1.14 Model 3480/80+ Fanfold ASF GEK-89537
Maintenance Manual Overview Letter Draft: Letter Quality: Graphic: Spread 17: Spead 10: 405 132 244 235 247 330 106 135 78 402 208 75 226 246 330 150 95 170 -
General
GENICOM 3460 / 3480 / 3480+
1.15
GEK-89537
Maintenance Manual Overview ### CHARACTER PITCH Basic: Compressed: Double-Wide: Other: 10, 12, 15 16.7, 17.14, 20, 24 5, 6, 7.5, 8.33, 8.5 Proportional Model 3460 Intercharacter spacing n/60 n/72 n/120 n/144 n/216 n/720 Model 3480/80+ n/120 n/180 n/360 n/720
General
### CHARACTER FORMATION DPC= dots per character Model 3460 H S Draft (text 10 cpi): Draft (text 12 cpi): Draft (text 15 cpi): Draft (graphic char): LQ (text 10 cpi): 12 LQ (text 12 cpi): 12 LQ (text 15 cpi): 12 LQ (proportional): LQ (graphic char): 5 5 5 7 2 1 1 18 14 2 1 1 0 1/144" 1/144" 1/144" 0 0 Model 3480/80+ H S H Res (V) 9 7 7 12 5 3 3 42 36 3 3 1 0 1/360" 1/360" 1/360" 0 0 1/120" 1/120" 1/120" 1/120" (24) (24) (24) 1/360" 1/360" (24) (24) (16) (30)
H Res (V) 1/72" (9) 1/72" (9) 1/72" (9) 1/72" (9) (18) 31 (18) 27 (18) 21 1/144" (18) 1/144" (18)
(24) (30)
### VERTICAL SPACING LPI= Basic: lines per inch 2, 3, 4, 6, 8, 12 Model 3460 Incremental n/72 n/144 n/216 n/720 Model 3480/80+ n/60 n/72 n/180 n/216 n/360
### BIT IMAGE (DOT GRAPHICS) Model 3460 Horizontal: Model 3480/80+
60, 72, 120, 144 60, 80, 90, 120, 216, 240, 288 180, 240, 360 60, 72, 144, 216 60, 72, 144, 180 1.16 GEK-89537
Vertical: GENICOM 3460 / 3480 / 3480+
General
GENICOM 3460 / 3480 / 3480+
1.17
GEK-89537
Maintenance Manual Overview ### CHARACTER SETS CS1, CS2, EPSON Italic. EPSON National Character Sets. ANSI National Character Sets. ISO Character Sets with all national variations. PC437, PC850, PC851, PC852, PC853, PC855, PC860, PC863, PC864, PC865, PC866, PC867, Mazowia, Turkish, Greek
General
RESIDENT FONTS Draft, Courier, OCRA-Ext, OCRB-Ext., Gothic, Prestige, Script, Orator
OPTIONAL FONTS Possibility to add other fonts through optional Fonts cartridge up to 256 KB support according to PCMCIA Standard.
PRINTING ATTRIBUTES Compressed Double Height Double Width Sub/Superscript Slanted Double Strike Emphasized Underline
BAR-CODES 12 BAR-CODE types: UPC-A, UPC-E, EAN8, EAN 13, 2/5 INTERLEAVED CODE 3 of 9, CODE 93, CODABAR, CODE 128, POSTNET, CODE 11, MSI
Height, Check Digit, Horizontal Print density programmable. Human Readable Characters available.
GENICOM 3460 / 3480 / 3480+
1.18
GEK-89537
Maintenance Manual Overview ### MEDIA HANDLING BACKWARD PAPER MOVEMENT The reverse paper movement is always allowed with the following limitations: - Fanfold Form - Cut Sheet Form Until the paper is parked (max. 20"). up to 76.2 mm, (3").
General
### MEDIA CHARACTERISTIC The basic printers can manage a manual single sheet front insertion and up to 3 fanfold modules formats in 4 different paths. SINGLE SHEET Front insertion and straight path The printer can accept these formats: ### A5, A4, A3, portrait and landscape ### A2 portrait LETTER, LEGAL and EXECUTIVE WIDTH LENGTH THICKNESS COPIES minimum 114.3mm maximum 444.5 minimum 101.6 maximum 558.8 maximum 0.635 1+7 minimum maximum minimum maximum minimum maximum minimum maximum 4.5" mm mm mm mm
17.5" 4" 22" 0.025"
WEIGHT (original) WEIGHT (Multicopy) first sheet other carbon
50 gr/M 120 gr/M 55 gr/M 75 gr/M 45 gr/M 75 gr/M 14 gr/M 35 gr/M
12.5 lbs 30.0 lbs
18.75 lbs 11.25 lbs 18.75 lbs 3.5 lbs 8.75 lbs
FRONT PUSH FANFOLD Frontal push fanfold feeding and straigh path WIDTH LENGTH THICKNESS COPIES minimum 76.2 mm 3.0" maximum 431.8 mm minimum 76.2 mm maximum 609.6 mm maximum 0.635mm 1+7 minimum maximum minimum maximum maximum 55 gr/M 150 gr/M 45 gr/M 75 gr/M 35 gr/M
17.0" 3.0" 24" 0.025"
WEIGHT (original) WEIGHT (Multicopy) copies carbon
GENICOM 3460 / 3480 / 3480+
1.19
GEK-89537
General
REAR PULL FANFOLD Frontal pull fanfold feeding and straight path Same as Front Push Fanfold
GENICOM 3460 / 3480 / 3480+
1.20
GEK-89537
Maintenance Manual Overview REAR PULL FANFOLD Bottom pull fanfold feeding and straight path Same as Front Push Fanfold, except for the maximum WIDTH up to 381 mm (15") .
General
REAR PUSH FANFOLD Rear push fanfold feeding WIDTH LENGTH THICKNESS COPIES minimum 76.2 mm 3.0" maximum 431.8 mm minimum 76.2 mm maximum 609.6 mm maximum 0.35mm 1+3 minimum maximum minimum maximum maximum 55 gr/M 80 gr/M 45 gr/M 75 gr/M 35 gr/M
17.0" 3.0" 24" 0.0138"
WEIGHT (original) WEIGHT (Multicopy) copies carbon
13.75 lbs 20 lbs 11.25 lbs 18.75 lbs 8.75 lbs
The printer can accept also the Automatic Sheet Feeder option with these paper limitations: ASF ALL BINS Capacity Bin of 120 sheets LENGTH maximum THICKNESS maximum COPIES 1+2 WIDTH minimum maximum WEIGHT (original) minimum maximum
355 mm 0.35mm 88.9 mm 304.8 mm 60 gr/M 150 gr/M
14" 0.0138" 6" 12" 15 lbs 37.5 lbs
WEIGHT (Multicopy with carbon) first/last sheet minimum maximum other minimum maximum carbon approx. WEIGHT (Multicopy sensitive) first/last sheet minimum maximum other minimum maximum
70 gr/M 80 gr/M 35 gr/M 40 gr/M 25 gr/M
70 gr/M 80 gr/M 40 gr/M 60 gr/M
17.5 lbs 20.0 lbs 10.0 lbs 15.0 lbs
ENVELOPES Capacity of 30 envelopes max., Size US 6, US 10 ASF 1 BIN LENGTH ASF 2 BIN GENICOM 3460 / 3480 / 3480+ 1.21 GEK-89537
minimum
114 mm
4.5"
Maintenance Manual Overview LENGTH ASF 3 BIN LENGTH ### INTERFACES minimum 216 mm 8.5"
General
minimum
267 mm
10.5"
There are two interfaces with automatic protocol and I/F switching on SW commands. - Parallel interface IBM-EPSON and CENTRONICS compatible MENU SELECTABLE 7/8 DATA BITS Transfer speed up to 200 KB Buffer up to 64 KB - Serial interface RS232/C for remote and local connection, RS422A for local connection 300/600/1200/2400/4800/9600/19200/38400 BAUD 7/8 DATA BITS DTR / XON - XOFF flow control Break function Buffer up to 64 KB
### DEVICE PROTOCOLS Model 3460 Emulation: EPSON IBM ANSI Printer Names FX1000 Proprinter XLIII GENICOM 3410, 3840 LQ1050 Proprinter X24/XL24 GENICOM 1220 Model 3480/80+
### ELECTRICAL CHARACTERISTICS JA/US Specification : EU/UK Specification : AC Consumption : 120 V 220/240 V Idle Printing +10% -15%, 50/60Hz 2Hz +10% -15%, 50/60Hz 2Hz less than 80 VA less than 200 VA
### ENVIRONMENTAL CONDITIONS The storage and transit environment (1 year) of the device and the related expansion module and supplies is: Temperature Range Humidity Range - 20 C to + 60 C (-4 F to 140 F) 5% RH to 90% RH (not condensing)
The operating environment is : Temperature Range Humidity Range + 10 C to + 40 C (41 F to 104 F) 20% RH to 80% RH (not condensing)
GENICOM 3460 / 3480 / 3480+
1.22
GEK-89537
Maintenance Manual Overview Additional resctrictions are introduced by the paper. The ECMA standard suggestions are : Temperature Range Humidity Range + 16 C to + 24 C 40% RH to 60% RH (not condensing)
General
GENICOM 3460 / 3480 / 3480+
1.23
GEK-89537
Maintenance Manual Overview ### NOISE Sound Pressure level bystander position according to ISO 7779: 58 dBA in Draft mode 53 dBA in Quiet mode (without A.S.F.) (without A.S.F.)
General
### CONFORMITY TO STANDARDS The product technical approach, materials and implementation will be consistent with the latest issue of the following requirements herafter distinguished by market area: For mains voltage 115 V : Electromagnetic Compatibility Safety Regulations For mains voltage 220 - 240 V : Electromagnetic Compatibility Safety Regulations GS SIGN Cispr 22 Class B EN60950 IEC 801-2, 3, 4 FCC Class B UL1950,CSA 950
### MAINTAINING PARAMETERS Next maintaining parameters are valid under the following conditions: Standard temperature and humidity (23 2 C, 50 5 RH) MTTR The MTTR is the estimated time to repair the printer at Optimum Replaceable Unit (ORU) level is 15 minutes. It includes: - Identifying the faulty ORU - Changing the ORU - Cleaning paper paths - Testing locally MTBF/RELIABILITY MTBF depends on duty cycle rate (D.C.). For these printers it is 10.000 HRS @ 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
GENICOM 3460 / 3480 / 3480+
1.24
GEK-89537
Maintenance Manual Overview 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/week.
General
GENICOM 3460 / 3480 / 3480+
1.25
GEK-89537
Maintenance Manual Overview LIFE - UNIT - RIBBON 5 years 9 Mcharacters Draft (standard black type) 15 MCharacters Draft (extended black type) 2 MCharacters Draft each band (color type) 400 M Characters Draft
General
- PRINT HEAD
### USER INTERFACE The Operator Panel of this printer has the overall appearance of a plane surface as shown in the next figure 1.4 with the following: - 1 LCD Display with 16 alpha-numeric digit - 9 Push Buttons - 8 LED indicators (3 for status and 5 for paper paths)
Fig. 1.4 Operator Panel Overview
GENICOM 3460 / 3480 / 3480+
1.26
GEK-89537
Paper Handling
Chapter 2 Paper Handling Overview
GENICOM 3460 / 3480 / 3480+
2.1
GEK-89537
Paper Handling
2.1 Introduction
These printers are designed to be extremely flexible in paper handling. Moreover, the mechanism has been designed to be, first of all, ergonomic for a better and easier end-user operation.
2.1.1 Paper Handling Architecture

All the paper paths described below can co-exist and can be selectable via MENU and SW commands. The printer automatically switches from one path to the other except for the rear pull tractor positions. Via operator panel menu it is possible to select one format per each path (up to 6) or a single format (equal for all paths). The basic configuration provides these ways to manage the paper formats: (In the next figure the paths for continuous modules are indicated as <#########> , while the paths for single sheet forms are indicated as ---> ; each path is identified with a number).
### SINGLE SHEET A semi-automatic frontal single sheet insertion (PATH 1). The single sheet forms are manually loaded in this path. When a sheet is inserted, the sensors detect its presence and the printer loads the paper automatically without any other action. ### CONTINUOUS MODULE (FANFOLD) Through a user installable/removable tractor unit the fanfold module can be fed through the following positions: FRONT PUSH mode (PATH 2) with tractor group in position A, also overlapped with single sheet (PATH 1). REAR PUSH mode (PATH 3) with tractor group in position B, also overlapped with single sheet (PATH 1). REAR PULL mode with frontal insertion (PATH 4) with tractor group in position C, also overlapped with single sheet (PATH 1), exclusive with fanfold in PATH 3. REAR PULL mode (PATH 4) with tractor group in position C, with input from the bottom (PATH 5), also overlapped with single sheet (PATH 1) exclusive with fanfold in PATH 3. For the first two paths, the continuous module exits from PATH 10.
GENICOM 3460 / 3480 / 3480+
2.2
GEK-89537
Paper Handling
### DOUBLE FANFOLDS Through the optional second user installable/removable tractor unit the following feeding positions for continuous module are available : DUAL PUSH fanfolds mode. The first fanfold from the front in push mode with basic tractor group in position A (PATH 2), the second from the rear in push mode with optional tractor group in position B (PATH 3), both overlapped with a single sheet (PATH 1). For this path, the fanfolds exit (once at a time) from PATH 10. PUSH&PULL fanfolds mode in which the fanfold can be fed from the front in push mode with the basic tractor group in position A (PATH 2) and at the same time is pulled from the second tractor group in position C (PATH 4). Also this configuration can be overlapped with a single sheet (PATH 1).
### AUTOMATIC SHEET FEEDER (ASF) Through the optional Automatic Sheet Feeder the following feeding positions for single sheets are available : REAR in the first bin (PATH 6). REAR in the second bin (PATH 7). REAR in the third bin (PATH 8). Inside the paper output stacker, a mechanical switch allows the alternance between the output single sheets, which are collected to the output stacker (PATH 9), and the fanfold using this exit (PATH 10).
On the next figure 2.1 it is possible to see the internal architecture of this printer in which the different paper paths handled by the new design of the mechanical assembly are put in evidence. On the table 2.1 it is possible to find the Paper Path Types that can be selected according to the printer Path Configurations.
GENICOM 3460 / 3480 / 3480+
2.3
GEK-89537
Paper Handling
Fig. 2.1 Paper Handling Architecture
PAPER PATH TYPES A A A A A A A A A B B B B B B B B B B B C C C C C C D E F F F F F F G G G G
PAPER PATH CONFIGURATIONS FRONT PUSH PATH REAR PUSH PATH REAR PULL PATH FRONT+REAR PUSH PUSH PULL PATH FRONT PUSH+ASF1 FRONT PUSH+ASF2 FRONT PUSH+ASF3 FRONT & REAR PUSH+ASF1 FRONT & REAR PUSH+ASF2 FRONT & REAR PUSH+ASF3
A= FRONT PUSH PATH B= MANUAL PUSH PATH C= REAR PUSH PATH D= REAR PULL PATH E= PUSH-PULL PATH F= ASF 1 G= ASF 2&3 GENICOM 3460 / 3480 / 3480+ 2.4 GEK-89537
Paper Handling
Table 2.1 Printer Path Configurations
2.1.2 Paper Feeder Movements

The next figures 2.2, 2.3 show how the feeder movements are done in this printer. RIGHT SIDE On the right side of the printer, the paper motor (1) drives a series of gears and feeder assy through the main paper belt (5) . Directly connected through the paper motor gear, there is an idle gear (2) which gives the motion to the front push-pull tractor assy idle gear (4). The tractor gear (3) is engaged-disengaged on the tractor idle gear (4) through a linear movement done by the push-pull tractor assy motor. The main paper motor belt also drives the platen assy pulley gear (9) and the lower feeder assy gear (7). A movable idle (5) is present to give the proper belt tension. A second belt called platen belt (10), takes the motion from the platen assy internal gear and drives the upper feeder assy gear (11). The support spring rollers (8) and the pinch rollers of the bail assy (12) assure the correct paper feeding from the manual front path and the out of platen area respectively. See chapter 2.2 for the manual actions for opening the pinch rollers.
LEFT SIDE On the left side the upper feeder assy gear (11) gives the motion to the rear push-pull tractor assy through a couple of gears and to the paper stacker gear (15). A manual lever engages the tractor idle gear (4) in two possible modes: - through the movable gear (14A) for the rear push path action. - through the idle gear (13) the movable gear (14B) for the rear pull action. Chapter 2.2 shows the rear tractor push-pull lever action. The tractor gear (3) is engaged-disengaged on the tractor idle gear (4) through a linear movement done by the push-pull tractor assy motor. A specific motorized roller (18) is present on each ASF to feed the paper sheet up to the friction rollers (17).
On this side there is also the mechanism which automatically opens and closes the friction rollers located below the platen assy (17) when the rear push path is choosen. This action is done through a combined movement of the carriage motor and the paper motor. When the friction rollers must be moved, according with the selected paper path, the carriage motor moves the carriage unit to the left-most position, causing the movement of the friction lever assy and the engagement of the open gear (9) to the sector gear (16). At this point, a paper movement slides the the friction bar assy with the sector gear splined to its shaft (16) to the proper open or closed position. GENICOM 3460 / 3480 / 3480+ 2.5 GEK-89537
Paper Handling
GENICOM 3460 / 3480 / 3480+
2.6
GEK-89537
Paper Handling
Figure 2.2 Paper Feeder Parts on Right Side
GENICOM 3460 / 3480 / 3480+
2.7
GEK-89537
Paper Handling
Figure 2.3 Paper Feeder Parts on Left Side The figure below shows the mechanical parts related to the automatical movement of the friction rollers. Carriage assy (1) Friction Lever assy (2) Friction Bar assy (3) with Sector gear (4) Open Gear (5) Friction Rollers (6)
At manufacturing site, the mechanical assy is mounted and the tests and diagnostic are done to store the proper rear fanfold sensor values in the NVM according to the proper friction rollers position (the rear fanfold sensor tuning values stored in NVM are different if the friction rollers are opened or closed). It is important not to move the carriage and paper advance knob manually to change the friction bar position because this would cause the loss of the correspondance between mechanism position and the sensor tuning . If any intervention of this kind has been done, it is indispensable to run the T&D to assure the correct correspondance.
Figure 2.4 Automatic Movement of Friction Rollers
GENICOM 3460 / 3480 / 3480+
2.8
GEK-89537
Paper Handling
2.1.3 Paper Path Configurations 2.1.3.1 Basic Configuration

The next figures 2.5, 2.6 and 2.7 show the alternative positions of the standard pushpull tractor unit, and related paper paths. The figure 2.5 shows the Front Load Push-Mode of the fanfold. The figure 2.6 shows the Rear Load Push-Mode of the fanfold. The figure 2.7 shows the Rear Load Pull-Mode of the fanfold (alternatively the paper can enter in the bottom feed slot). For all these paper paths, it is possible to overlap a single sheet.
IMPORTANT REMARK ### For the REAR PUSH mode, the fanfold must have a maximum thickness of 0.35 mm instead of 0.635 mm of the other paths. ### For the REAR PULL mode, a manual intervention is necessary. The bail assy must be lifted (upper position) and the selection slider located on the left side of the printer must be in its up position to assure the correct rotation of the rear tractor (see chapter 2.2.5 or user manual for major details).
GENICOM 3460 / 3480 / 3480+
2.9
GEK-89537
Paper Handling
Figure 2.5 Front Load Push-Mode
Figure 2.6 Rear Load Push-Mode GENICOM 3460 / 3480 / 3480+ 2.10 GEK-89537
Paper Handling
Figure 2.7 Rear (Bottom) Load Pull-Mode
2.1.3.2 Dual Fanfold Configurations

The next figures 2.8, 2.9 show the dual tractor units configuration allowing the alternance between two fanfolds, and related paper paths. The figure 2.8 shows the Front Load Push-Mode and the Rear Load Push-Mode of the fanfolds. The figure 2.9 shows the Front Load Push-Pull Mode of the fanfold. For all these paper paths, it is possible to overlap a single sheet.
IMPORTANT REMARK ### For the REAR PUSH mode, the fanfold must have a maximum thickness of 0.35 mm instead of 0.635 mm of the other paths. ### For the REAR PULL mode, a manual intervention is necessary. The bail assy must be lifted (upper position) and the selection slider located on the left side of the printer must be in its up position to assure the correct rotation of the rear tractor.
GENICOM 3460 / 3480 / 3480+
2.11
GEK-89537
Paper Handling
Figure 2.8 Front Load Push-Mode and Rear Load Push-Mode with two tractors
GENICOM 3460 / 3480 / 3480+
2.12
GEK-89537
Paper Handling
Figure 2.9 Front Load Push-Pull Mode with two tractors
GENICOM 3460 / 3480 / 3480+
2.13
GEK-89537
Paper Handling
2.1.3.3 ASF Configuration

The figure 2.10 on next page shows the positions of the Automatic Sheet Feeder and related paper paths. The ASF can co-exists with both the push-pull tractor units (front and rear) installed. The 1st BIN can accept also envelopes.
Figure 2.10 Automatic Sheet Feeder GENICOM 3460 / 3480 / 3480+ 2.14 GEK-89537
Paper Handling
2.2 Actions to put the Rear Tractor in Pull Mode

The figure 2.11 shows the manual actions that must be done to put the rear tractor unit in PULL mode instead of push. ### Check that the plastic slider is in "PULL" mode selection (up position). ### Open the top cover and gently lift the paper bail assy.
GENICOM 3460 / 3480 / 3480+
2.15
GEK-89537
Paper Handling
Figure 2.11 Actions to do to put the Rear Tractor in Pull mode
GENICOM 3460 / 3480 / 3480+
2.16
GEK-89537
Maintenance Manual Replacement
Removal and
Chapter 3 Removal and Replacement for 3460 (A2) / 3480 (A2)
GENICOM 3460 / 3480 / 3480+
3.1
GEK-89537
Removal and
3.1 Overview
This section describes the removal and replacement procedures for the basic printer. Before starting any of these procedures, turn the power switch OFF, and take off the plug from the wall socket. Before disassembling the printer, remove the paper in the printer and the inked ribbon cartridge. After the covers removal, the power supply cover tool must be installed to prevent any accidental contact of technician hand with the main heat-sink of the power supply itself if the printer is powered-on without covers. REMARK Caution and Warning in this section highlight specific information. A CAUTION provides information intended to prevent equipment damage. A WARNING provides information intended to prevent personal injury. You must observe anti-static precautions when maintaining this printer. Disassembly procedure must to be executed from the front side of the printer.
3.2 Recommended Hand Tools and Equipment

The following items should be available for the technicians performing corrective maintenance on printers: ### ### ### ### ### ### ### ### ### ### Assortment of Philips head and common screwdrivers Set of spanners for M3 and M5 nut Extractor for chip Pliers Soldering iron (and soldering wire with flux core) A Multimeter for resistance and voltage measurements Feeler gauge for print head gap adjustment Dynamometer for carriage and motor belts adjustment Slender spring hook Set of fastener loop self-lock P.N. 78399165-001
### Power Supply cover tool
### Test & Diagnostic Tools T&D Card P.N. 78399178-001 Serial 232 Loop-Back Connector P.N. 78403675-001 Serial 422 Loop-Back Connector P.N. 78403676-001 Parallel Loop-Back Connector P.N. 78401829-001 Mechanical Option Loop-Back Connector P.N. 78403674-001 ### Antistatic Tools (on-site) Antistatic Tools (repair bech) P.N. 76166990-209 P.N. 76957474-002
GENICOM 3460 / 3480 / 3480+
3.2
GEK-89537
Removal and
3.3 O.R.U. ORDER OF ACCESS

Table 4.1 shows the accessibility of EACH ORU (Optimum Replaceable Unit), and the procedure necessary to access to each one.
Remove ORU: 1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 11) 12) 13) 14) 15) 16) 17) 18) 19) 20) 21) 22) Push-Pull Tractor Group 1 Operator Panel Boards Print Head Front Cover Parts Rear Cover Parts Serial Interface Board Main Board Power Supply Board Ribbon Motor AGA Motor AGA Support and T/F lever Carriage Motor and Fan Bail Assy Cut Sheet Assy Upper Feeder Assy Platen Assy Lower Feeder Assy Carriage Assy Sensor Cable Assy Mechanical Assy Paper Motor Friction Bar Assy
Requires these procedures in the order shown: (section 3.3.1) 2 (section 3.3.2) 3 (section 3.3.3) 1,2,4 (section 3.3.4) 5 (section 3.3.5) 5,6 (section 3.3.6) 5,6,7 (section 3.3.7) 5,6,8 (section 3.3.8) 1,2,4,5,9 (section 3.3.9) 1,2,4,5,10 (section 3.3.10) 1,2,4,5,11 (section 3.3.11) 1,2,4,5,12 (section 3.3.12) 13 (section 3.3.13) 1,2,4,14 (section 3.3.14) 1,2,4,5,15 (section 3.3.15) 1,2,4,5,16 (section 3.3.16) 1,2,4,5,17 (section 3.3.17) 1,2,4,5,18 (section 3.3.18) 1,2,4,5,19 (section 3.3.19) 1,2,4,5,20 (section 3.3.20) 1,2,4,5,20,21 (section 3.3.21) 1,2,4,5,20,22 (section 3.3.22)
(*)
(*) (*) (*) (*) (*)
Table 3-1 ORU ORDER OF ACCESS
NOTE : Procedure with an asterisk require ADJUSTMENT PROCEDURE (see chapter 5)
All the spare parts available on logistic are reported in the specific Illustrated Parts Catalog at chapter 11.
GENICOM 3460 / 3480 / 3480+
3.3
GEK-89537
Removal and
3.3.1 Push-Pull Front Tractor Group

CAUTION Do not remove and install the push-pull tractor group with the printer at power-on. 1) Open the front antinoise cover. 2) Close the single sheet support cover, if open, by pulling it upward until it is fastened with the magnetic lock. 3) Disengage the tractor group from the mechanical assy by acting on the two small levers (located on plastic tractor sides) that block the tractor group on it. 4) Remove the push-pull tractor unit by pulling it downward. Replace the tractor group following the above instructions in reverse order. The same operations are required for the optional rear push-pull tractor group.
GENICOM 3460 / 3480 / 3480+
3.4
GEK-89537
Maintenance Manual Replacement Figure 3.1 Push-Pull Front Tractor Group removal
Removal and
GENICOM 3460 / 3480 / 3480+
3.5
GEK-89537
Removal and
3.3.2 Operator Panel Boards

CAUTION Don't attempt this operation without taking all recommended anti-static precautions. 1) Open the operator panel group by acting on its middle top side to disengage it from the cover. 2) Open the top cover group by acting on the two push-buttons (located on the front side of the cover). 3) Unscrew the screw securing the operator panel shield to the mechanical assy (in new printers this action will be not necessary anymore). 4) Unplug the operator panel connector from the operator panel board. 5) Rotate the operator panel group of 90 and at the same time extract it from the front cover. 6) Unscrew the six screws securing the operator panel boards to the cover and remove them. 7) Remove the operator panel board from the LCD display board by acting on the two plastic spacers catches that retain the boards together. Replace the operator panel boards group following the above instructions in reverse order.
GENICOM 3460 / 3480 / 3480+
3.6
GEK-89537
Removal and
Figure 3.2 Operator Panel Parts removal
GENICOM 3460 / 3480 / 3480+
3.7
GEK-89537
Removal and
3.3.3 Print Head

WARNING The print head may have hot surface after a certain time of printing. Wait for it to cool down. 1) Open the top cover group by acting on the two push-buttons (located on the front side of the cover). 2) Place the print head to the rightmost carriage position and remove the inked ribbon cartridge and bail assy. 3) Unscrew the screw securing the print head cable to the carriage assy. 4) Unscrew the two screws securing the print head. 5) Open the printhead cable zif-connectors and unplug these connectors and the color motor connector (if present) by manually acting on their bends. 6) Remove the printhead. Replace the Print Head following the above instructions in reverse order.
NOTICE : Before securing the screw, push the P.H. to its inside stop position. No adjustment is required.
GENICOM 3460 / 3480 / 3480+
3.8
GEK-89537
Maintenance Manual Replacement Figure 3.3 Printhead Removal
Removal and
GENICOM 3460 / 3480 / 3480+
3.9
GEK-89537
Removal and
3.3.4 Front Cover Parts

1) Remove the front tractor group (refer to chapter 3.3.1) 2) Remove the operator panel group (refer to chapter 3.3.2) 3) Unscrew the four screws securing the main front group (two on left and right printer side, the other two on the front side). 4) Remove the main front cover by extracting it and, at the same time, rotating it towards its front side. 5) Open the top cover and extract it from the main front cover by acting on its pins (located on both sides). 6) Extract the magnet interlock from the front cover by simply pulling it out of the cover. Replace the Main Front Cover Parts following the above instructions in reverse order.
Figure 3.4 Main Front Cover Parts GENICOM 3460 / 3480 / 3480+ 3.10 GEK-89537
Removal and
3.3.5 Rear Cover Parts

1) Remove the ASF cover by simply extracting it from the main rear cover. 2) Unscrew the four screws securing the main rear group (two on left and right printer side, the other two on the rear side under the ASF cover). 3) Remove the main rear cover by extracting it from the rear side. 4) Extract the rear tractor cover with the interlock board by simply extracting them from the main rear cover. 5) Remove the paper deflector cover by simply unhooking it from the cover. 6) Extract the paper stacker covers by simply unhooking them from the main rear cover. 7) Extract the interface cover by simply unhooking them from the main rear cover. 8) Extract the paper knob by simply pulling it out from the platen axis. Replace the Main Rear Cover Parts following the above instructions in reverse order.
Figure 3.5 Main Rear Cover Parts GENICOM 3460 / 3480 / 3480+ 3.11 GEK-89537
Removal and
3.3.6 Serial Interface Board

CAUTION Do not attempt this operation without taking all recommended anti-static precautions. 1) Remove the rear cover group (refer chapter 3.3.5) 2) Unscrew the two screws securing the serial interface board to the base assy. 3) Remove the the Serial Interface Board by simply extracting it from the main board connector.
Figure 3.6 Serial Interface Board
GENICOM 3460 / 3480 / 3480+
3.12
GEK-89537
Removal and
3.3.7 Main Board

CAUTION Do not attempt this operation without taking all recommended anti- static precautions. Remember to remove the eproms from the main board and install them on the new one in the corresponding position. 1) Remove the main rear cover (refer to chapter 3.3.5) 2) Unscrew the six screws securing the main board to the base unit. 3) Unscrew the three screws securing the interface connector metal support to the lower shield (two are located on the rear side, one is located on the left side of the printer). 4) Unplug all the connectors from the main board by acting on their bends. Note: cables) 5) Unhook the upper part of the rear connector bracket from the base assy. 6) Extract the main board from the printer. 7) Unscrew the two screws fixing the metal plate on the parallel connector and remove it. Replace the Main Rear Cover Parts following the above instructions in reverse order paying attention to the rear horizontal guides and to its bottom shield. Open the print head cable zif-connector before extracting the cable. Open the metal retaining clip with a screwdriver (installed only on the flat
GENICOM 3460 / 3480 / 3480+
3.13
GEK-89537
Removal and
Figure 3.7 Main Board
GENICOM 3460 / 3480 / 3480+
3.14
GEK-89537
Removal and
3.3.8 Power Supply Board

CAUTION Do not attempt this operation without taking all recommended anti-static precautions. 1) Remove the main rear cover (refer to chapter 3.3.5) 2) Unscrew the screw securing the inlet bracket and remove it. 3) Unscrew the screw securing the ground cable on the metal shield. 4) Unscrew the screws securing the power supply cover to the lower shield and remove it. 5) Unscrew the six screws securing the power supply board to the base unit. 6) Unplug the connector from the main board and gently extract the power supply board from the printer.
Replace the power supply board following the above instructions in reverse order paying attention to the rear horizontal guides.
GENICOM 3460 / 3480 / 3480+
3.15
GEK-89537
Removal and
Figure 3.8 Power Supply Board
GENICOM 3460 / 3480 / 3480+
3.16
GEK-89537
Removal and
3.3.9 Ribbon Motor

1) Remove the Main Rear and Front Covers (refer to chapter 3.3.4 and 3.3.5) 2) Remove the circlip retains the pivot assy to the left ribbon cartridge support. 3) Unscrew the four screws securing the left ribbon cartridge support on the left side of the mechanical assy. 4) Extract the ribbon motor from the plastic support. 5) Remove the plastic support and the pivot assy from the mechanical assy. 6) Unplug the ribbon motor connector from the main board and extract the cable from its cable retainers located in the rear part of the mechanical assy. 7) Remove the pivot assy.
Replace the ribbon motor assy and the left support parts following above instructions in reverse order.
GENICOM 3460 / 3480 / 3480+
3.17
GEK-89537
Removal and
Figure 3.9 Ribbon Motor and left cartridge support
GENICOM 3460 / 3480 / 3480+
3.18
GEK-89537
Removal and
3.3.10 AGA Motor

1) Remove the Main Rear and Front Covers (refer to chapter 3.3.4 and 3.3.5) 2) Unscrew the two screws securing the AGA motor on the mechanical assy. 3) Unplug the AGA motor connector from the main board and extract the cable from its cable retainers located on the rear part of the mechanical assy. 4) Remove the AGA motor assy. Replace the AGA motor following the above instructions in reverse order. NOTICE : Before tighteing the motor screws, verify the correct and free movement of the AGA gears. Run the AGA calibration procedure to verify the correct AGA marker position.
GENICOM 3460 / 3480 / 3480+
3.19
GEK-89537
Removal and
Figure 3.10 AGA Motor
GENICOM 3460 / 3480 / 3480+
3.20
GEK-89537
Removal and
3.3.11 AGA Support and T/F Lever

1) Remove the Main Rear and Front Covers (refer chapter 3.3.4 and 3.3.5) 2) Unscrew the two screws securing the AGA support on the left side of the mechanical assy and remove it. 3) Remove the AGA support. 4) Remove the retainer circlip by a proper tool from the platen axis. 5) Remove the friction washer, the open gear and the spring by simply extracting them from the platen axis. 6) Remove the tractor friction lever by simply extracting upward from the left side of the mechanism. Replace the AGA support and T/F lever following the above instructions in reverse order. NOTICE: Put the AGA marker position in the same previous position. Run the AGA calibration procedure to verify the correct AGA marker position.
GENICOM 3460 / 3480 / 3480+
3.21
GEK-89537
Maintenance Manual Replacement Figure 3.11 Aga Support and T/F Lever
Removal and
GENICOM 3460 / 3480 / 3480+
3.22
GEK-89537
Removal and
3.3.12 Carriage Motor

1) Remove the Main Rear and Front Covers (refer to chapter 3.3.4 and 3.3.5) 2) Cut the self-lock plastic strips retaining the cables on the carriage motor bracket. 3) Unscrew the two screws securing the motor bracket on the right side of the mechanical assy and to the ground shield. 4) Remove the M3 nut securing the motor bracket on the front tractor connector support. 5) Remove the rear motor bracket by extracting it from the rear. 6) Unplug the carriage motor connector from the main board and extract the cable from its cable retainers located in the rear part of the mechanical assy. 7) Unscrew the four screws securing the front carriage motor bracket to the mechanism. 8) Remove the front carriage motor bracket. 9) Unscrew the two screws securing the carriage motor assy to the mechanism. 10) Drive off the carriage belt from the carriage motor gear. 11) Unscrews the three studs securing the carriage motor to its support. 12) Remove the carriage motor assy. Replace the carriage motor assy following the above instructions in reverse order. NOTICE : The carriage motor replacement requires an appropriate carriage belt adjustment (refer to chapter 5).
GENICOM 3460 / 3480 / 3480+
3.23
GEK-89537
Removal and
Figure 3.12 Carriage Motor
GENICOM 3460 / 3480 / 3480+
3.24
GEK-89537
Removal and
3.3.13 Bail Assy

1) Open the top cover group by acting on the two push-buttons (located on the front side of the cover). 2) Put the carriage unit in the rightmost position. 3) Rotate the bail assy toward its front side to unhook it from the left and right mechanical frames. 4) Remove the bail assy. Replace the bail assy following the above instructions in reverse order.
Figure 3.13 Bail Assembly GENICOM 3460 / 3480 / 3480+ 3.25 GEK-89537
Removal and
3.3.14 Cut Sheet Assy

1) Remove the Main Rear and Front Covers (refer to chapter 3.3.4 and 3.3.5) 2) Unscrew the screw securing the cut sheet assy on the right side of the mechanical assy. 3) Gently remove the cut sheet assy by simply extracting it from the mechanical assy from the left side. Replace the cut sheet assy following the above instructions in reverse order.
Figure 3.14 Cut Sheet Assembly GENICOM 3460 / 3480 / 3480+ 3.26 GEK-89537
Removal and
3.3.15 Upper Feeder Assy

1) Remove the Main Rear and Front Covers (refer to chapter 3.3.4 and 3.3.5) 2) Remove the bail assy (refer to chapter 3.3.16). 3) Remove the circlip retaining the upper feeder axis on the left side of the mechanical assy and shift the bushing on the the feeder assy axis right. 4) Remove the right bushing. 5) Drive off the platen belt from the upper feeder assy gear. 6) Put the rear tractor plastic slider push-pull selector in its rear position. 7) Remove the upper feeder assy by extracting it from the left side of the mechanical assy rotating the feeder assy on the left side slightly to the front. Replace the upper feeder assy following the above instructions in reverse order.
Figure 3.15 Upper Feeder Assy GENICOM 3460 / 3480 / 3480+ 3.27 GEK-89537
Removal and
3.3.16 Platen Assy

1) Remove the Main Rear and Front Covers (refer chapter to 3.3.4 and 3.3.5). 2) Remove the upper feeder assy (refer to chapter 3.3.15). 3) Remove the Aga support and the T/F lever (refer to chapter 3.3.13). 4) Remove the circlip retaining the platen assy to the pulley gear. 5) Unscrew the two screws securing the bearing bracket to the left side of the mechanism and remove it. 6) Remove the bearing and the special washer from the platen axis. 7) Put the print head to its maximum distance from the platen assy. 8) Gently shift the platen assy left from its position and then extract it from the left side of the mechanical assy. Replace the platen assy following the above instructions in reverse order. NOTICE: the platen assy replacement requires an appropriate print head gap adjustment procedure (refer to chapter 5).
GENICOM 3460 / 3480 / 3480+
3.28
GEK-89537
Removal and
Figure 3.16
Platen Assy
GENICOM 3460 / 3480 / 3480+
3.29
GEK-89537
Removal and
3.3.17 Lower Feeder Assy

1) Remove the Main Rear and Front Covers (refer chapter to 3.3.4 and 3.3.5). 2) Remove the AGA motor (refer to chapter 3.3.13). 3) Remove the AGA support (refer to chapter 3.3.14). 4) Remove the cut sheet assy (refer to chapter 3.3.17) 5) Remove the circlip retaining the AGA gear to its pivot and remove the gear. 6) Unscrew the screw securing the AGA sector to the main shaft and remove it. 7) Remove the carriage motor assy (refer to chapter 3.3.15). 8) Loosen the paper belt tensioning lever screw and remove the paper belt from the lower feeder assy gear and the gear from its axis. 9) Remove the circlip retaining the lower feeder gear to the axis. 10) Unscrew the four screws securing the cut sheet profile to the mechanical assy. 11) Remove the cut sheet profile by simply extracting it from the front. 12) Remove the circlip retaining the lower feeder axis on the right side of the mechanical assy and shift the feeder assy from its location. 13) Remove the lower feeder assy by simply extracting it from the mechanism. Replace the lower feeder assy following the above instructions in reverse order. NOTICE : the lower feeder assy replacement requires an appropriate carriage and paper belts adjustment procedure (refer to chapter 5).
GENICOM 3460 / 3480 / 3480+
3.30
GEK-89537
Removal and
Figure 3.17
Lower Feeder Assy
GENICOM 3460 / 3480 / 3480+
3.31
GEK-89537
Removal and
3.3.18 Carriage Assy

CAUTION : Before starting with this procedure, put the carriage assy in the maximum distance from the platen assy to avoid any print head mask damage. 1) Remove the Main Rear and Front Covers (refer to chapter 3.3.4 and 3.3.5). 2) Remove the print head (refer to chapter 3.3.3). 3) Remove the carriage motor assy (refer to chapter 3.4.15). 4) Remove the AGA support and the AGA sector on the left side part. 5) Unscrew the screw securing the carriage belt to the carriage assy. 6) Unscrew the two screws securing the main shaft retainer to the left side of the mechanism. 7) Unscrew the two screws securing the main shaft retainer to the right side of the mechanism. 8) Gently rotate the carriage assy with the front bar upward and extract it from the rear bar. Replace the carriage assy following the above instructions in reverse order. NOTICE: the carriage assy replacement requires the appropriate print head gap and carriage belt adjustment procedures (refer to chapter 5). Slowly introduce the front bar into the carriage holes paying attention to the oil-felt inside it.
Figure 3.18 Carriage Assy GENICOM 3460 / 3480 / 3480+ 3.32 GEK-89537
Removal and
3.3.19 Sensor Assy

1) Remove the Main Rear and Front Covers (refer to chapter 3.3.4 and 3.3.5). 2) Remove the AGA support and the T/F lever on the left side part (refer to chapter 3.3.14). 3) Remove the ribbon motor and support (refer to chapter 3.4.12). 4) Remove the platen assy (refer to chapter 3.3.19). 5) Remove the two left-most friction assemblies. 6) Unscrew the screw securing the rear fanfold sensor support to the frame and remove it by simply extracting it from the left side. 7) Unscrew the screw securing the front fanfold sensor to its support. 8) Unscrew the screws securing the ribbon fault and home position sensors to the plastic support. 9) Unscrew the single sheet sensor from its metal support and extract it from the left side of the mechanical assy. 10) Unplug the connector from the main board and extract the cable from its cable retainers located in the rear part of the mechanical assy. Replace the sensor assy following the above instructions in reverse order.
GENICOM 3460 / 3480 / 3480+
3.33
GEK-89537
Removal and
Figure 3.19 Sensor Assy
GENICOM 3460 / 3480 / 3480+
3.34
GEK-89537
Removal and
3.3.20 Mechanical Assy

1) Remove the Main Rear and Front Covers (refer to chapter 3.3.4 and 3.3.5). 2) Unscrew the screws securing the ground strips on the lower shield on both sides of the printer. 3) Unplug all the connector from the main board. 4) Unscrew the two screws retaining the mechanical block to the base assy. 5) Cut the two plastic self-locked strips retaining the mechanical blocks on the base assy and remove the mechanical assy. 6) Pay attention to the paper position mylar on the base assy. Replace the mechanical assy following the above instructions in reverse order.
GENICOM 3460 / 3480 / 3480+
3.35
GEK-89537
Maintenance Manual Replacement Figure 3.20 Mechanical Assy
Removal and
GENICOM 3460 / 3480 / 3480+
3.36
GEK-89537
Removal and
3.3.21 Paper Motor

1) Remove the Main Rear and Front Covers (refer to chapter 3.3.4 and 3.3.5). 2) Remove the mechanical assy (refer to chapter 3.3.23). 3) Loose the paper belt tensioning lever screw and remove the paper belt from the paper motor gear. 4) Unscrew the three screws securing the paper motor to the right side of the mechanical assy and remove it. Replace the paper motor following the above instructions in reverse order. NOTICE: the paper motor replacement requires an appropriate paper belt adjustment procedure (refer to chapter 5).
Figure 3.21 Paper Motor GENICOM 3460 / 3480 / 3480+ 3.37 GEK-89537
Removal and
3.3.22 Friction Bar Assy

1) Before proceeding, assure that the friction rollers are open; the flat part of the friction bar assy must be upward (see chapter 2 for more details). 2) Remove the Main Rear and Front Covers (refer to chapter 3.3.4 and 3.3.5). 3) Remove the platen assy (refer to chapter 3.3.20). 4) Extract the friction supports by simply pulling them upward from their location. 5) Remove the mechanical assy (refer to chapter 3.3.23). 6) Remove the circlip retaining the friction bar assy to the mechanism. 7) Remove the friction bar assy by simply extracting it from the left side.
Replace the friction bar assy following the above instructions in reverse order.
NOTICE: the friction bar assy must have a proper position coherently with the sensor tuning values stored in NVM. See chapter 6.4 for more details.
Figure 3.22 Friction Bar Assy
GENICOM 3460 / 3480 / 3480+
3.38
GEK-89537
Removal and
Chapter 4
Removal and Replacement for 3460 (A3) / 3480 (A3) / 3480+
GENICOM 3460 / 3480 / 3480+
4.1
GEK-89537
Removal and
4.1 Overview
See the same section of the chapter 3.
4.2 Recommended Hand Tools and Equipment

4.3 O.R.U. ORDER OF ACCESS

Table 4.1 shows the accessibility of EACH ORU (Optimum Replaceable Unit), and the procedure necessary to access to each one.
Remove ORU: 1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 11) 12) 13) 14) 15) 16) 17) 18) 19) 20) 21) 22) 23) Push-Pull Tractor Group 1 Operator Panel Boards Print Head Front Cover Parts Rear Cover Parts Main Board Power Supply Board Ribbon Motor AGA Motor AGA Support and T/F lever Carriage Motor and Fan Bail Assy Cut Sheet Assy Upper Feeder Assy Platen Assy Lower Feeder Assy Carriage Assy Sensor Cable Assy Mechanical Assy Paper Motor Friction Bar Assy Ribbon Mask Lower Mylar
Requires these procedures in the order shown: (section 4.3.1) 2 (section 4.3.2) 3 (section 4.3.3) 1,2,4 (section 4.3.4) 5 (section 4.3.5) 5,6 (section 4.3.6) 5,6,7 (section 4.3.7) 1,2,4,5,8 (section 4.3.8) 1,2,4,5,9 (section 4.3.9) 1,2,4,5,10 (section 4.3.10) 1,2,4,5,11 (section 4.3.11) 12 (section 4.3.12) 1,2,4,13 (section 4.3.13) 1,2,4,5,14 (section 4.3.14) 1,2,4,5,15 (section 4.3.15) 1,2,4,5,16 (section 4.3.16) 1,2,4,5,17 (section 4.3.17) 1,2,4,5,18 (section 4.3.18) 1,2,4,5,19 (section 4.3.19) 1,2,4,5,19,20 (section 4.3.20) 1,2,4,5,19,21 (section 4.3.21) 22 (section 4.3.22) 23 (section 4.3.23)
(*)
(*) (*) (*) (*) (*)
Table 4-1 ORU ORDER OF ACCESS
NOTE : Procedure with an asterisk require ADJUSTMENT PROCEDURE (see next chapter)
All the spare parts available on logistic are reported in the specific Illustrated Parts Catalog.
GENICOM 3460 / 3480 / 3480+
4.2
GEK-89537
Removal and
4.3.1 Push-Pull Front Tractor Group

4.3.2 Operator Panel Board

4.3.3 Print Head

To remove the print head please refere to the same section of chapter 3. NOTICE : Before securing the screw, push the P.H. to its inside stop position. Securing the right screw and then the left one with a force = 25Kg. Run the AGA calibration procedure (T&D 12) to verify a correct AGA value.
4.3.4 Front Cover Parts

4.3.5 Rear Cover Parts

GENICOM 3460 / 3480 / 3480+
4.3
GEK-89537
Removal and
4.3.6 Main Board

See the related sectiont of the chapter 3.
MAIN BOARD
J28 J22 J24
S1
S2
S3
Figure 4.2 Main board and firmware location
PWA 2V4C24 / 2V4C09 J22= Serial interface connector (to plug serial inerface board). J24= Serial interface connector for cable. J28= Parallel interface connector. S1= Controller firmware location. S2= T&D firmware location. S3= Generator firmware location.
MODEL 3480+
RELEASE TBD TBD TBD TBD TBD TBD TBD TBD TBD
CODE XXXX (controller) XXXX (T&D) XXXX (generator) XXXX (controller) XXXX (T&D) XXXX (generator) XXXX (controller) XXXX (T&D) XXXX (generator)
I.C. TYPE
LOCATION S1 S2 S3 S1 S2 S3 S1 S2 S3
CHECKSUM
3480 (A3)
3460 (A3)
GENICOM 3460 / 3480 / 3480+
4.4
GEK-89537
Removal and
4.3.7 Power Supply Board

See the related section of the chapter 3. NOTICE On 3480+ unplug also the fan connector cable before removal and replacement the power supply.
4.3.8 Ribbon Motor

See the related section of the chapter 3.
4.3.9 AGA Motor

4.3.10 AGA Support and T/F Lever

4.3.11 Carriage Motor

4.3.12 Bail Assy

4.3.13 Cut Sheet Assy

4.3.14 Upper Feeder Assy

4.3.15 Platen Assy

GENICOM 3460 / 3480 / 3480+
4.5
GEK-89537
Removal and
Figure 4.3 Force for fixing platen and main shaft of carriage assy
GENICOM 3460 / 3480 / 3480+
4.6
GEK-89537
Removal and
4.3.16 Carriage Assy

CAUTION : Before starting with this procedure, put the carriage assy in the maximum distance from the platen assy. 1) Remove the Main Rear and Front Covers (refer to chapter 4.3.4 and 4.3.5). 2) Remove the print head (refer to chapter 4.3.3). 3) Unscrew the two screws securing the ribbon mask and remove it. 4) Remove the AGA support and the AGA sector on the left side part. 5) Unscrew the screw securing the carriage belt to the carriage assy. 6) Unscrew the two screws securing the main shaft retainer to the left side of the mechanism. 7) Gently pull-up a little the front bar in its right side and in the meantime moves it left in order to exctract it from the right side. Be carefull to do not damage the little spring (item 137 of fig.4.16B) located in each side between the front bar and the frame. Before reassembly of the printer it is mandatory to apply in this point a silicon grease (molikote type). 8) Gently rotate the carriage assy with the front bar upward and extract it from the rear bar. Replace the carriage assy. a- Insert the black flange on the main bar. b- Insert the carriage on the main bar. c- Insert the other black flange on the main bar and assembly the carriage with its flanges. d- Gently insert oil felt in proper locate under the periferal area of the flanges. Continue the reassembly of the printer following the above instructions in reverse order. ATTENTION: before tight the front bar retainer screws, push-down the retainers indicate in figure 4.15B (force F2), then secure in sequence the screws C and D. Check for the correct tighten of the belt clamp screw securing the carriage belt. NOTICE: the carriage assy replacement requires the appropriate print head gap and carriage belt adjustment procedures.
GENICOM 3460 / 3480 / 3480+
4.7
GEK-89537
Removal and
Figure 4.4 Carriage Assy
GENICOM 3460 / 3480 / 3480+
4.8
GEK-89537
Maintenance Manual Replacement Figure 4.5 Particular of little spring and main shaft
Removal and
4.3.17 Lower Feeder Assy

4.3.18 Sensor Assy

4.3.19 Mechanical Assy

4.3.20 Paper Motor

4.3.21 Friction Bar Assy

4.3.22 Ribbon Mask

1) Open the top cover. 2) Remove the inked ribbon. 3) Unscrew the two screws A and B. 4) Gently remove the ribbon mask. Replace the ribbon mask following the above instructions in reverse order.
rib. mask ---> screw A --->
/ O O
\ <--- screw B
print head
Figure 4.6 Ribbon mask removal (top view)
GENICOM 3460 / 3480 / 3480+
4.9
GEK-89537
Removal and
4.3.23 Lower Mylar

1) Remove the top cover. 2) Remove the inked ribbon. 3) Unscrew the two screws. 4) Gently remove the lower mylar. Replace the lower mylar following the above instructions in reverse order.
Figure 4.7 Support spring with lower mylar
1- Support spring 2- Lower mylar 3- Screws fixing lower mylar with the support spring
GENICOM 3460 / 3480 / 3480+
4.10
GEK-89537
Maintenance Adjustments
Manual
Chapter 5 Adjustments
GENICOM 3460 / 3480 / 3480+
5.1
GEK-89537
Manual
5.1 Overview
This section describes the adjustment procedures for the basic printer.
5.1.1 Carriage Belt

This adjustment is required only if the carriage belt or parts related to the replacement of it are removed (pulley assy, carriage motor assy, etc.). Standard Value : 700 gr 5% Tools : Push-Force type Dynamometer 1) Put the carriage assy in the rightmost position in the printer. 2) Loosen the M5 nut securing the loose pivot to its support. 3) Put the carriage belt under tension through a counter-clockwise rotation of the screw located on the loose pivot. 4) Apply the specified load in the middle of the carriage belt through a dynamometer with the indicated force to obtain the contact between the upper and the lower side of it. Repeat the step 3, if necessary. 5) Keep the screw fixed and, at the same time, tighten the nut. After this adjustment it is necessary to run the bidirectional printing adjustment to assure the best performances of the printer.
GENICOM 3460 / 3480 / 3480+
5.2
GEK-89537
Manual
F=0.7Kg
Figure 5.1 Carriage Assy Belt Adjustment
GENICOM 3460 / 3480 / 3480+
5.3
GEK-89537
Manual
5.1.2 Paper Belt

This adjustment is required when the paper motor or the paper belt are removed. Standard Value : 1000gr 10% Tools : Push-Force type Dynamometer 1) Unscrew the two screws securing the adjustment lever to the right side of the mechanism. 2) Apply the specified load on the hob of the lever with inward orientation as figure 5.2 and securing the screws to stretch the paper belt. First tighten the screw indicated as A). An hole on the base assy is provided for this purpose. After this adjustment it is necessary to run the T&D procedures to verify the correct forward - backward paper advancing in fanfold and single sheet paper.
GENICOM 3460 / 3480 / 3480+
5.4
GEK-89537
Manual
Figure 5.2 Paper Belt Adjustment
GENICOM 3460 / 3480 / 3480+
5.5
GEK-89537
Manual
5.1.3 Print Head Gap

This adjustment is required only if one of these parts are removed: - Platen Assy - Carriage Assy - Rear Bar. Two little white spots are painted on the left-side metal platen axe and on the spring support assy. These spots are the locations for the manufacturing adjustment and indicate the maximum platen eccentricity and the platen/carriage eccentricity points (i.e.: the minimum print head gap is with carriage assy located over the spring support white spot and with the platen rotation for the white spot aligned with the print head). Their position and meaning are indicated as follow and they can use as a reference points in the procedure after described when these parts are not replaced. 1) Support spring assy. A white dot is painted on the support spring assy. It indicates (joint to the white dots reported in item 2a) the position in the carriage assy axial movement in which there is the maximium drum eccentricity. 2) Platen assy. 2a) Two white dots are painted on the left metal axe of the platen assy and its relative bearing. Matchingof these dots (joint to the white dot reported in item 1) indicates the position for the platen assy rotation in which there is the maximum drum eccentricity. i.e.: the minimum distance from the print head needles to the platen is with the combination of item 1) and 2a). 2b) A red dot is painted on the left metal axe of the platen. The matching of this dot with the white dot on the bearing indicates the position for the platen assy rotation in which there is the maximum drum eccentricityin the area where the AGA routine is running during T&D. 3) Rear bar. side minimum Two white dots are painted on the eccentric bushing and on the right located in the right ide of the rear bar. They ndicate the position of the eccentric bushing to obtain the value for the platen drum and peint head alignment parallelism.
Procedure
For the complete print head gap adjustment procedure follow all the steps (1 to 12). For the simplified procedure follow all the the steps without 7b, 7c,7d and 7e.
If only the carriage assy has been replaced with a new one, it is possible readjust the print head gap with the reduced procedure by the helping of the painted dots of the current parts. If only the support spring assy has been replaced with a new one, before install it paint a white dot in the same location of the replaced one and readjust the print head gap with the reduced procedure by the helping
of the painted dots . If only the platen assy has been replaced with a new one, it is possible GENICOM 3460 / 3480 / 3480+ 5.6
GEK-89537
Maintenance Adjustments readjust the print head gap following the complete procedure. If only the rear bar has been removed, it is possible readjust the print head gap with the reduced procedure by the helping of the painted dots of the current parts for new ptinters (with the eccentric bushing installed), otherwise the complete procedure must be done. Standard Value : 0.25 mm to 0.30 mm (0.01 to 0.012 inch) Tools : Feeler Gauge To assure the correct printhead gap for all the carriage movements, follow these steps: 1) Remove paper, the ribbon cartridge and the bail assy. 2) Moves the print head in its farmost position from the platen and then remove the AGA marker. 3) Moves the carriage assy until the print head nose is in front of the white dot painted on the support spring assy and, at the same time, rotates the platen assy until the white dots on its left axe and bearing matching. 4) Insert a feeler gauge between the print head needles and the platen drum and assure for its ortogonally position. Remark: inch) measure the feeler gauge end does not enter more than 20mm (0.78 from the print head mask top edge to avoid an incorrect due to the spring support mylar presence.
Manual
5) Gently move the print head towards the platen utilizing the AGA gear until the feeler gauge is frictioned. 6) If the printers has not the reference colored points, verify with the feeler gauge that in any carriage position the distance between the print head and the platen is between 0.25 - 0.3mm (item 2 of figure 5.3). 7) Furthermore, the platen ends must be aligned with the print head by 0.08mm (0.003 inch).
Example :
------------------------------------------------------- platen A B C ###### ###### ######
printhead needles
Possible Values:
A B C --------------------------------0.25 0.25 0.25 0.3 0.3 0.3 0.22 0.27 0.3 0.3 0.27 0.22
In case the alignment is not correct (>0.08mm) follows these steps: If the white dot is painted on the eccentric bushing: 7a) Verify if the white dot on the rear bar eccentric bushing matches with the one located on the right side.
GENICOM 3460 / 3480 / 3480+
5.7
GEK-89537
Maintenance Adjustments If they are not matching, unscrew the right side screw securing the smaller bar, gently rotate the eccentric bushing with a plier for its alignment with the white dot. While holding the eccentric bushing, firmly tighten the right side screw. 7b) Tighten the left side rear bar screw. 7c) Loosen the right side rear bar screw (item 1). 7d) Gently rotate the eccentric bushing with a plier (item 2) and verify the alignment in its best condition. 7e) After the adjustment, while holding the eccentric bushing with the plier, firmly tighten the right side screw. For older printer without eccentric bushing, the best parallelism can be obtined in a similar procedure by the movement of the rear bar in the right side hole. 8) Mount the AGA marker by slightly tightening the right side screw indicated on figure 5.4(item A). Set the AGA wheel on reference 1. 9) Hold the AGA wheel on reference 1 and slowly dropit to its normal position. If during the gears engagement, two teeth are touching, put the AGA marker gear in the first free tooth and tighten both the screw (item A and B of figure 5.4). The AGA marker should be on reference 0.9. Check for its complete and free rotation. 10) Put the AGA marker in the farmost position from the platen. Manually insert a 80 gr/m2 single sheet paper between the platen and the print head. It must be free to slide up and down. Slowly move the AGA wheel inward. The paper must lightly frictioned when the AGA reference is on 1. 11) Power on the printer and run the T&D 12 routine for AGA setting. Select the single sheet insertion. Load a 80gr/m2 single sheet paper. The AGA proceure must be run when the red dot painted on the left axe of the platen matches with the white dot on the bearing. Use the paper advance knob to reach this point and run the T&D AGA routine until the AGA marker is on reference 1-1.3. If the platen assy has not the red dot painted, the procedure must be repeated at least three times on different point along the diameter of the platen and select the point in which the AGA marker has the minimum value and paints the red dot on its left axe for future use. 12) Store the correct AGA value and power off the printer.
Manual
GENICOM 3460 / 3480 / 3480+
5.8
GEK-89537
Manual
Figure 5.3 Print Head Adjustment
Figure 5.4 AGA Marker Adjustment
5.1.4 AGA Calibrate

GENICOM 3460 / 3480 / 3480+ 5.9 GEK-89537
Manual
This test is usefull to check the AGA marker position located on the left side of the mechanism. After the print head gap adjustment, the AGA marker position must be coherent with the paper sheet thickness loaded. If one copy of paper is loaded (80 gr/m2), the marker must be in position 1. If it is not correct please follow the below adjustment procedures. The procedure can be executed in two modes: ### At FIELD level, the test is executed in the T&D 12 test. ### At USER level in the OPERATIONAL Menu under the FORM THICKNESS item.
FIELD LEVEL MODE Herein below the T&D 12 AGA procedures included in the T&D test are described. There are two AGA setting procedures related to the Automatic Gap Adjustment method and to the Fixed Gap Adjustment method.
Automatic Gap When the T&D 12 test is running, the display shows "AGA CALIBRATE " by the message "SS PATH FF".
followed
At this point, it is possible to choose the paper path for which the AGA calibration (automatic gap method) has to be performed. SS means single sheet (the LOAD/FF key must be pressed). FF means fanfold (the PAPER key must be pressed). If the fanfold paper is choosen, the printer automatically loads the paper engaged on the front tractor, otherwise the display will show "LOAD PAPER" and the LOAD/FF key must be pressed. If the single sheet is choosen, the display will show "INSERT CUT SHEET". If a sheet is put in this path, the printer automatically loads it. After the paper loading, the display shows "+ YES NO AGA n -" and then "YES<- STORE ->NO".
means the store in NVM of the selected value (LOAD/FF key) and skip to next fixed gap procedure. means that this test will be repeated (PAPER key).
again + AGA n -
If the PAPER key is pressed, the AGA calibration procedure is executed and the display shows "+ AGA n -". means a positive change of the AGA value (LOAD/FF key) means the execution of the AGA calibration test (LF key) displays the AGA value. means a negative change of the AGA value (PAPER key)
The range of the variation is from -8 to +8 (every unit changes the gap of 0.03 mm).
GENICOM 3460 / 3480 / 3480+
5.10
GEK-89537
Maintenance Adjustments Fixed Gap After the previous procedure, the display shows "AGA FIX ADJUST" followed by the messages "+ AGA n -" and then "YES<- STORE ->NO". YES NO means the store in NVM of the selected value (LOAD/FF key) and skip to next T&D 14 test. means that this test must be repeated (PAPER key).
Manual
If the PAPER key is pressed, the AGA fixed gap calibration procedure is executed again and the display shows "+ AGA n -". + AGA n means a positive change of the AGA value (LOAD/FF key) means the execution of the AGA calibration test (LF key) displays the AGA value. means a negative change of the AGA value (PAPER key)
The range of the variation is from -26 to +26 (every unit changes the gap of 0.03 mm).
USER LEVEL MODE Herein below the FORM THICKNESS item changing under the OPERATIONAL Menu are described. There are two AGA setting procedures related to the Automatic Gap Adjustment method and to the Fixed Gap Adjustment method. To enter in the Automatic Gap Adjustment method proceed as follow: - Press the ON LINE key to disable the printer. - Hold the MENU key to enter the OPERATIONAL Menu. - Press the key until the display shows: FORM THICKNESS - Press the ENTER key to change the thickness adjustment method and press the key until the display shows: FORM: AUTO - Press ENTER key, the display shows: FORM: AUTO>0 - Use the key to select the proper value in the range between -3 to +5. - Press ENTER key to save selection.
To enter in the Fixed Gap Adjustment method proceed as follow: - Press the ON LINE key to disable the printer. - Hold the MENU key to enter the OPERATIONAL Menu. - Press the key until the display shows: FORM THICKNESS - Press the ENTER key to change the thickness adjustment method and press the key until the display shows: FORM: FIXED - Press ENTER key, the display shows: FORM: FIXED>0.6 - Use the key to select the proper value in the range between 0.3 to 8.6. - Press ENTER key to save selection.
GENICOM 3460 / 3480 / 3480+
5.11
GEK-89537
Manual
The Automatic or the Fixed Gap Adjustment value will be stored as a "path" parameter or as a "format" parameter based upon the GAP ASSIGN selection in the SYSTEM MENU.
5.1.5 First Printing Line

This adjustment is required only if the paper sensor is removed. The procedure can be executed in two modes: ### At FIELD level, the test is executed in the T&D 15 test. ### At USER level in the OPERATIONAL Menu under the PAGE SETUP item.
FIELD LEVEL MODE Herein below the T&D 15 procedures included in the T&D test are described. After the execution of the T&D 14 test, a tear-off of the standard T&D fanfold module must be done by the operator. The display will show "TEAR & PUSH KEY" to advise the operator about this action. After aving pressed the TEAR key, the operator can press any key to start this procedure. The printer automatically parks the paper. The display shows the message "YES F.FR ADJ? NO". YES NO means that the front fanfold first line printing adjustment to be choosen (LOAD/FF key). means that this test will be skipped (PAPER key).
If NO is choosen, the display will show "YES F.RE ADJ? NO". YES choosen NO 16 means that the rear fanfold first line printing adjustment has been (LOAD/FF key). means that this test will be skipped (PAPER key) and the next T&D test is executed.
If YES is choosen on one of the previous tests, the procedure runs. The display shows "FRONT CALIBRATE " or "REAR CALIBRATE" according to the selected paper path. The printer parks the paper automatically and reloads the selected paper positioning it at the first line. A printout of eight "EEEEEEEE" is done. The paper is automatically advanced to show the result to the operator above the top cover. The display shows "PUSH A KEY" for a few seconds. After that, the paper is automatically move backward to the first line, and the display shows : "+ F.FR n -" or "+ F.RE n -". + F.FR or F.RE n means a positive change of the FRONT or REAR value (LOAD/FF key) means the execution of the FRONT or REAR calibration test (LF key) displays the FRONT or REAR value. means a negative change of the FRONT or REAR value (PAPER key)
The range of the variation is from -128 to +127 (every unit is the minimum paper motor movement = 1/144" for 9 needles model and 1/180" for 24 needles model). GENICOM 3460 / 3480 / 3480+ 5.12 GEK-89537
Manual
If the LF key is pressed, the FRONT or REAR calibration procedure is executed again (a printout of eight "EEEEEEEE" shifted on the right side of the previous one is done) and the display shows "YES<- STORE ->NO".
GENICOM 3460 / 3480 / 3480+
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Manual
YES
means the store in NVM of the selected value (LOAD/FF key) and skip to next REAR CALIBRATE test. The display will show "YES F.RE ADJ? NO". YES means the rear fanfold first line printing adjustment to be choosen (LOAD/FF key). NO means that this test will be skipped (PAPER key) and the next T&D 16 test is executed. NO means that this test will be repeated (PAPER key). USER LEVEL MODE Herein below the PAGE SETUP item changing under the OPERATIONAL Menu are described. To enter in the Page Setup function proceed as follow: - Press the ON LINE key to disable the printer. - Hold the MENU key to enter the OPERATIONAL Menu. - Press the key until the display shows: PAGE SETUP - Press the ENTER key twice to select this function. The display shows: PAGE: TREF>0 - Use the key to select the proper value. - Press ENTER key to save selection. The range is between -90/90 to +180/90 inch or -1 to -2 inches for 3480 model or between 72/72 to +144/72 inch for 3460 model depending upon the SYSTEM MENU (PROGRAM UNITS).
5.1.6 Vertical (bidirectional printing)

This adjustment is required only if some parts related to the carriage assy movement are removed. The procedure can be executed in two modes: ### At FIELD level, the test is executed in the T&D 16 test. ### At USER level in the INITIAL SET-UP Menu under the ALIGNMENT item. (see User manual for details).
FIELD LEVEL MODE Herein below the T&D 16 procedures included in the T&D test are described. After the execution of the previous T&D15 test, the display will shows the message "YES VERT ADJ? NO". YES NO means the vertical (bidirectional printing) adjustment has been choosen (LOAD/FF key). means that this test will be skipped (PAPER key) and the next T&D 17 test is executed. 5.14 GEK-89537
GENICOM 3460 / 3480 / 3480+
Manual
If YES is choosen for one of the previous tests, the procedure runs. The display will show "VERTICAL ADJUST".
GENICOM 3460 / 3480 / 3480+
5.15
GEK-89537
Maintenance Adjustments A printout of two patterns composed each by 3 lines of 30 "H" characters follow by a line of "H" characters printed from left to right and "I" characters printed in opposite way is performed as indicated in next figure (the value (N) between the patterns is the selected vertical value). The paper is automatically advanced to show the result to the operator above the top cover. The display shows "PUSH A KEY" for a few seconds. After that, the paper is automatically moved backward to the first line, and the display shows : "+ VERT n -". + VERT n means a positive change of the VERTICAL value (LOAD/FF key) means the execution of the VERTICAL calibration test (LF key) display the VERTICAL value means a negative change of the VERTICAL value (PAPER key)
Manual
The range of the variation is from -6 to +6 (every unit is the minimum carriage motor movement = 1/120"). If the LF key is pressed, the VERTICAL calibration procedure is executed again and the display shows "YES<- STORE ->NO". YES NO means the store in NVM of the selected value (LOAD/FF key) and skip to next test (T&D 17). The printer parks automatically the front fanfold paper. means that this test will be repeated (PAPER key).
USER LEVEL MODE Herein below the ALIGNMENT item changing under the INITIAL SET-UP Menu are described. To enter in the Alignment function proceed as follow: - Turn off the printer's power. - Press and hold the LINE FEED and FF/LOAD keys. - While holding these keys, turn on the printer's power. - Release the keys. - Press the key until the display shows: - Press the ENTER key to select this function. The display shows: - Use the key to select the proper value. - Press ENTER key to save selection.
ALIGNMENT ALIGN>0
The range is between -6 to +6. If the currently displayed value is changed, then the alignment setting changes. If you press the FORMAT key then 3 rows of "H" are printed as indicated below.
HHHHHHHHHH HHHHHHHHHH HHHHHHHHHH HHHHHHHHHH HHHHHHHHHH HHHHHHHHHH HHHHHHHHHH HHHHHHHHHH HHHHHHHHHH HHHHHHHHHH HHHHHHHHHH HHHHHHHHHH H HHHHHHHHH HHHHHHHHHH HHHHHHHHHH N HHHHHHHHHH HHHHHHHHHH HHHHHHHHHH HHHHHHHHHH HHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHH
HHHHHHHHHH HHHHHHHHHH HHHHHHHHHH HHHHHHHHHH HHHHHHHHHH HHHHHHHHHH HHHHHHHHHH HHHHHHHHHH HHHHHHHHHH HHHHHHHHHH HHHHHHHHHH HHHHHHHHHH H HHHHHHHHH HHHHHHHHHH HHHHHHHHHH N HHHHHHHHHH HHHHHHHHHH HHHHHHHHHH HHHHHHHHHH HHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHH
GENICOM 3460 / 3480 / 3480+
5.16
GEK-89537
Manual
Figure 5.5 Vertical Adjustment Test
5.1.7 Tear-off Line

This adjustment is required only if the tear-off quote must has changed if the top cover or one of the two fanfold sensors have been removed. The procedure can be executed in two modes: ### At FIELD level, the test is executed in the T&D 17 test. ### At USER level in the TEAR-OFF MODE.
FIELD LEVEL MODE Herein below the T&D 17 procedures included in the T&D test are described. After the execution of the previous T&D16 test, the display will show the message "YES TEAR ADJ? NO". YES NO means the tear adjustment will be choosen (LOAD/FF key). means that this test will be skipped (PAPER key) and the next T&D 18 test is executed.
If YES is choosen on one of the previous tests, the procedure runs. The display will show "TEAR ADJUST" and then "YES T.FRONT NO". YES NO means the rear fanfold tear-off test will be run (LOAD/FF key). means that this test will be skipped (PAPER key).
If YES is choosen, the display will show "FRONT CALIBRATE", if NO is choosen the display will show "REAR CALIBRATE". A printout of 1 lines of 60 "X" characters is done at the first printable line. The paper is automatically advanced to a fixed value (the distance between the print-head and the tear-off quote) to show the result to the operator above the top cover. The tear-off position of the paper must be aligned to the cutter line of the top cover. The display shows "+ TEAR n -". + TEAR n means a positive change of the TEAR value (LOAD/FF key) means the execution of the TEAR calibration test (LF key) and the paper is automatically moved backward to the first line. displays the TEAR value means a negative change of the TEAR value (PAPER key)
The range of the variation is from -128 to +127 (every unit is the minimum paper motor movement = 1/144" for 9 needles model or 1/180" for 24 needles model). If the LF key is pressed, the TEAR calibration procedure is executed again (no further printout is done) and the display shows "YES <- STORE-> NO". YES means the store in NVM of the selected value (LOAD/FF key) and skip to next test (T&D 18). 5.17 GEK-89537
GENICOM 3460 / 3480 / 3480+
Maintenance Adjustments NO means that this test will be repeated (PAPER key).
Manual
GENICOM 3460 / 3480 / 3480+
5.18
GEK-89537
Manual
USER LEVEL MODE Herein below the TEAR-OFF item changing under the TEAR-OFF Mode are described. To enter in the Tear-Off alignment function proceed as follow: - With the printer powered on and the fanfold paper inserted paper. - Press TEAR key. - The display shows: PLEASE TEAR OFF - Press the or the keys to select the proper value The display shows: TEAR OFF VALUE xxx - Press TEAR key to save selection. The range of the variation is from -128 to +127 (every unit is the minimum paper motor movement = 1/144" for 9 needles model or 1/180" for 24 needles model).
5.1.8 Sensor Tuning

This adjustment is suggested when the main board is changed or if some problems appear in the paper detection. The paper sensors are reflecting type. They are driven by the main board in a dynamic mode. This means that the input led is driven by the + 5 Voltage with an impulse wave to increase its life. The output signal enters in an analog multiplexer and then to the analog to digital converter port of the microprocessor (see figure 3.12). The sensors are adjusted at manufacturing site with a proper T&D tool which stores these output voltage levels of the three sensors detected with NO PAPER installed. This value is stored in NVM on main board. If the main board or if some parameters of these sensors are changed (due to their lifeparameters degradation or simply a different shining printer location), this level may not be correct anymore for the normal operation of the printer. Also if the mechanical assy has been disassembled in the friction bar assy part, check the coherence between the position of this part and the values stored in NVM (see chapter 6.4). Check all these aspects and, enventually, readjust and memorize these values. The procedure can be executed in two modes:
ALWAYS WITHOUT ANY PAPER INSERTED IN ALL PATHS. ### At FIELD level, the test is automatically executed in the T&D 11 test (this is the first test of the mechanism). ### At USER level in the INITIAL SET-UP Menu. GENICOM 3460 / 3480 / 3480+ 5.19 GEK-89537
Manual
GENICOM 3460 / 3480 / 3480+
5.20
GEK-89537
Manual
FIELD LEVEL MODE This test is executed automatically in the T&D11 test.
USER LEVEL MODE Herein below the SENSOR TUNE item changing under the INITIAL SET-UP Menu are described. To enter in the Sensor Tune function proceed as follow: - Turn off the printer's power. - Press and hold the LINE FEED and FF/LOAD keys. - While holding these keys, turn on the printer's power. - Release the keys. - Press the key until the display shows: - Press the ENTER key to select this function. The display shows: - Use the key to select YES value. - Press ENTER key to save selection.
SENSOR TUNE TUNE>N TUNE>Y
GENICOM 3460 / 3480 / 3480+
5.21
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Maintenance Manual Maintenance
Service
Chapter 6 Service Maintenance
GENICOM 3460 / 3480 / 3480+ 89537
6.1
GEK-
Service
6.1 Overview
This section describes how to maintain the printer in order to obtain from it always the best performances. In this chapter it is possible to find also some helps to test printer and to identify defective components using the Test & Diagnostic facilities. For all other aspects regarding the printers setting and printer programming, please refer to the following manuals: Model 3460/3480 User's manual (P.N. GEK-89170) Model 3460 Programmer's manuals (P.N. GEK-89212) Model 3480 Programmer's manuals (P.N. GEK-89213)
First-level maintenance is based on F.R.U. (field replaceable unit).
GENERAL REMARK Pay attention to turn the printer off, unplug the power cord and wait for at least 5 minutes before starting with the cleaning operations due to the high temperature on some mechanical parts when the printer is on normal operation from a long time (print head, carriage motor, paper motor). Install the power supply cover tool if a printer maintenance is done when the printer is powered on (see chapter 6.3.3).
6.2 Initial Ispection

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.
6.2.1 Set-Up
Check for the following items to make sure they are fullfilled. ### 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 ? GENICOM 3460 / 3480 / 3480+ 6.2 89537
GEK-
Service
In the OPERATIONAL MENU under the PRINT STATUS item it is possible find three different menu listings : SYSTEM, CONFIG and FORMAT. Please refer to the user manual for more details on all these items.
6.2.2 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: ### 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 thay may cause discoloration and scratching. ### Do not LUBRICATE the main and rear shaft, but only clean dirt. ### Be especially carefull 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.
6.2.3 Paper Specifications

Also the paper is important to have high performances. Check for the correct paper specifications. See chapter 1.3 and the USER manual for more details.
6.2.4 Consumables
Genicom reccomends 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 typical 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 concering: ### no cancerous materials ### no inflammability of the plastic materials GENICOM 3460 / 3480 / 3480+ 89537 6.3 GEK-
Maintenance Manual Maintenance ### other standard
Service
GENICOM 3460 / 3480 / 3480+ 89537
6.4
GEK-
Service
6.3 Troubleshooting Guide

The recommended sequences for the printer fault detection are: ### To observe initializing procedure and Operator Panel messages. ### To check power malfunctions. ### To run the SELF-TEST procedure. ### To run the T&D (Test and Diagnostic) procedure. ### If necessary, run the HEXADECIMAL dump procedure. At any stage where appropriate, refer to the troubleshooting guide.
6.3.1 Initializing Phase

When the printer is powered on, before starting the normal operations, it performs an initializing phase (BOOSTRAP). During this phase the Software of the printer initializes the hardware resources of the printer for the correct function. ### The display will show: STARTING UP
and then performs a full-matrix display check from leftmost to rightmost position. ### The display will show : ################################################ After a successfull initialization phase, the printer enters in the normal operation phase, moves the carriage assy on the left most position to check the home position sensor and goes in READY or WAIT state, depending on if the paper is already installed or not. If the printer does not initialize correctly see next chapter to see the possible error messages displayed on the LCD.
6.3.2 Printer Errors

Some errors can be displayed by the printer. These errors can be divided into three main groups: ### Status errors ### Recoverable errors ### Not recoverable errors
6.3.2.1 Status Errors

GENICOM 3460 / 3480 / 3480+ 89537 6.5 GEK-
Maintenance Manual Maintenance When an error of this kind occurs, the printer shows some messages to the User with the action to do to fix or by-pass the error condition. See 3460 and 3480 Models User manuals for major details.
Service
GENICOM 3460 / 3480 / 3480+ 89537
6.6
GEK-
Service
6.3.2.2 Recoverable Errors

When an error of this kind occurs, the printer enters in WAIT state and the display will show the first message indicating the error then, in some cases, another second message will be displayed giving more specific information about the error condition. The buzzer sounds an intermittent sound. All these errors can be reset pressing the ON LINE key or through specific actions. ### The display shows: COVER OPEN with a continuous buzzer sound. Cause: Action: Cause: Action: The top cover is open during the initializing phase. Close the cover, check for magnet installed on cover. The operator panel board may be faulty. Install a new one.
### The display shows: CLOSE COVER. Cause: The top cover has been opened during operation. Action: close the cover. ### The display shows a first message PAPER JAM followed by CHECK ALL PATHS Cause: A paper jam error condition occurs in a paper path during a parking or an ejecting procedure. Action: Check if the paper is correctly installed and remove it if it is jammed. Press the ON LINE key to reset the error condition. ### The display shows a first message RIBBON BLOCKED followed by CHECK RIBBON Cause: The inked ribbon of the cartrdige is blocked and the relative sensors detect this fault (the problem appears with some characters printed with poor ink density). Action: Check if the ribbon is correctly inserted. Remove the ribbon and turn the tension knob to make sure that the ribbon is not jammed. Press the ON LINE key to reset the error condition. ### The display shows: PRINT INTEGRITY . Cause: An anomalous blocking of the carriage assy has been happened and the relative home position sensor detects this fault (the problem appears with the printout shifted on the left or right side). Action: Check if the carriage assy movement is free. Press the ON LINE key to reset the error condition. ### The display shows a first message BUFFER OVERFLOW followed by CHARACTER LOST Cause: An overflow condition occurs in the buffer (if the serial interface is selected). The host is sending data to the printer even if it has been required to stop transmission. Action: Check the connection between the printer and the host. Press the ON LINE key to reset the error condition. Turn the printer off if the buffer must be cleared.
GENICOM 3460 / 3480 / 3480+ 89537
6.7
GEK-
Maintenance Manual Maintenance ### The display shows: OVERRUN ERROR followed by CHARACTER LOST. Cause: An error on the serial transmission occurs. The printer did not recognize a bit. Action: Check the serial parameter of the printer and of the host. Press the ON LINE key to reset the error condition. Turn the printer off if the buffer must be cleared. ### The display shows: FRAMING ERROR followed by WRONG CHARACTER. Cause: An error on the serial transmission occurs. The printer recognized a wrong bit. Action: Check the serial parameter of the printer and of the host. Press the ON LINE key to reset the error condition. Turn the printer off if the buffer must be cleared. ### The display shows: PARITY ERROR followed by WRONG CHARACTER. Cause: An error on the serial transmission occurs. The printer recognized a wrong parity bit. Action: Check the serial parameter of the printer and of the host. Press ON LINE key to reset the error condition. Turn the printer off if the buffer must be cleared. ### The display shows: DATA SET OFF.
Service
Cause: The DSR signal is not connected to the printer and is not ready for data transfer (if the serial interface and remote connection are selected). Action: Check the connection between the printer and the host. Press ON LINE key to reset the error condition. ### The display shows: INTERLOCK ERROR with a buzzer sound. Cause: The rear tractor cover has been removed and the push-pull tractor is not installed in the rear position. Action: Put the rear tractor cover in its correct position or insert the push-pull tractor in its rear position. Press ON LINE key to reset the error condition. ### The display shows: NVM CHANGE followed by NVM CHANGED. Cause: The eprom of the basic FW on the main board has been changed (for FW updating) or the main board has been replaced with a new one. Action: Push any key to Initialize. All the Menu Items are set to their default values.
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6.3.2.3 Unrecoverable Errors

When an error of this kind occurs, the printer is halted and enters in error state. All these errors cannot be reset through specific actions and require the powering-off of the printer. Typically all these problems appear if an internal error in the BOOSTRAP or NORMAL operation phases is detected. If after powering-on the printer the problem appears again, run the T&D test as described in chapter 6.4 , to check the faulty O.R.U.. If the message appears again, contact your nearest Technical Support. In the BOOSTRAP phase the following messages can be displayed. If one of these messages appears, the BOOSTRAP phase is not positively ended and, consequently, the hardware resources of the printer are not initialized. For all these messages, the fault mainly depends on the EPROMs or on the microcontroller or on the data bus problems (Eproms or Main Board F.R.U.).
MESSAGE STARTING UP (fixed) # SOFTWARE ERROR # ENGINE DRIVER # PM SET-UP ERR # VOID EXEC LIST # MFILE CHECKSUM # UNK MFILE TYPE # TOO MANY FILES # CARD 0 REMOVED # NVRAM DRIVER # MFLIST MEM ERR
MEANING Printer not inizialized Internal unrecoverable error Engine driver attach/open error Print Manager process setup error Executable file not found Memory File Check-sum error Unknown Memory File Type Memory File List Overflow Cartridge Broken or Removed NVM Driver attach/open error Memory Allocation error
Table 6.1A Unrecoverable Error Display Messages (Boostrap Phase)
In the normal operation phase a unrecoverable message with a combination of the following parameters can be displayed. DEVICE (SPV, INT, P_M, ENG) SERVO (n1) CODE (n2) GENICOM 3460 / 3480 / 3480+ 6.9 89537
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Maintenance Manual Maintenance COMMAND Example: (n3) ENG FLT 4 3 0 Means an Engine Device Initialization failure error.
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Maintenance Manual Maintenance If one of these messages appears, the BOOSTRAP phase is positively ended but some problems arised in the handshaking between the various modules of the SW PLATFORM layer. The possible combinations can be: DEVICE SPV FLT SPV FLT SPV FLT SPV FLT SPV FLT SPV FLT SPV FLT INT FLT P_M FLT P_M FLT P_M FLT P_M FLT P_M FLT P_M FLT P_M FLT P_M FLT ENG FLT ENG FLT ENG FLT ENG FLT ENG FLT ENG FLT ENG FLT ENG FLT ENG FLT ENG FLT ENG FLT ENG FLT ENG FLT SERVO 0 0 0 0 1 1 1 0 0 0 0 0 0 0 0 0 2 2 2 2 2 2 2 3 3 3 3 4 4 CODE 1 2 3 4 5 6 7 0 6 6 6 6 6 6 6 6 2 2 2 2 2 2 2 2 2 3 3 0 3 COMMAND 0 0 0 0 0 0 0 0 1 2 3 4 5 6 7 8 64 65 66 67 68 70 71 16 18 16 18 0 0 ERROR DESCRIPTION
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Supervisor error (interpreter process answer error) As above (Font files not found error) As above (NVM device read error) As above (NVM device write error) As above (I/F line driver open error) As above (I/F line driver attach error) As above (Memory Allocation error) Interpreter errors Print Manager Error (Graphic memory Block not found error) As above (unbalanced graphics list counter error) As above (unbalanced cache counter errror) As above (unbalanced printing plane counters error) As above (unknown drawing law error) As above (bad graphics descriptor error) As above (drawing list overflow error) As above (unrecoverable internal error) Engine error (Paper load value out of range) Engine error (Paper eject value out of range) Engine error (Paper park value out of range) Engine error (Paper step value out of range) Engine error (Paper LF,FF value out of range) Engine error (Paper tear-off value out of range) Engine error (Paper recovery tear-off value out of range) Engine error (Print Density value out of range) As above (Print Position value out of Range) As above (Carriage Home position not reached error) As above (Carriage Position check Failure error) As above (Engine Device Initialization failure error on ribbon movement sensor) As above (Engine Device Initialization failure error on Carriage Home position sensor)
Table 6.1B Unrecoverable Error Display Messages (Normal Phase)
For all the messages described above except for the ENG type with SERVO=4, the fault mainly depends by the EPROMs or by the microcontroller or by the data bus problems (Eproms or Main Board F.R.U.). For the last two ENGINE errors see the faulty probability guide in chapter 6.3.6.
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6.3.3 Power Malfunctions

If the printer does not power on, it is essential to check the power supply condition. WARNING: The power supply is a switching-type with some parts (fuses and primary filter parts) under high tension even if the switch is off and other (main heat-sink) under high tension with the printer powered-on. Install the power supply cover tool before starting any operations after the rear cover removal as indicated in the figure 6.1 below. 1) Insert the hole present in the rear part of the Power Suppy cover tool into the plastic pin located on the base assy. 2) Hook the front part of the cover to the base assy.
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Figure 6.1 Power Supply Cover Tool Installation
6.3.3.1 P.S. Troubleshooting Guide

This little guide can be usefull to find a fault on the power supply F.R.U.. ### The printer is not powered on. Cause: Actions: No AC voltage reaches the printer. Check power cord insertion. Press power switch. Check voltage at wall outlet. Replace power supply board.
### The DC voltages are not present on the main board. Cause: Actions: The power supply may be faulty. Remove the power supply cable from the main board (refer to chapter 4.3.5). Put a load on the + 5 voltage pin of 300 mA minimum (a resistor of 15 ### of 3 W). This load is indispensable to run the power supply correctly, otherwise the feed-back reaction is not present and the not activated. Check for the voltages on the power supply connector and on board as indicated in the figure 6.2. All voltages are protected for short-circuit. If the voltages are corrected, check for electromechanical parts impedance (refer to chapter 7). Replace the defective electromechanical part. If the impedances are correct, replace the main board. ### The AC printer fuse blown. Cause: Actions: An overcurrent on primary circuit is occurred. Replace the FUSES with new ones. For 230 VAC the value must be 3.15 A (2 fuses). For 120 VAC the value must be 5 A (1 fuse). Unplug the connector from the main board and apply the load on +5v. If the fuses blown again, replace the power supply board. ### The printer is powered off after a short time power on. Cause: GENICOM 3460 / 3480 / 3480+ 89537 An overload is present on secondary voltages. 6.13 GEK-
regulation is
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Maintenance Manual Maintenance Actions: If the voltages are corrected, check for electromechanical parts impedance (refer to chapter 7). Replace the defective electromechanical part. If the impedances are correct, replace the main board.
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### The printer initializes correctly but it does not display anything. Cause: The operator panel board is faulty or with bad connection to main board. Actions: Check for the proper connection of the operator panel to the main board. Replace the operator panel board or the operator panel cable or the main board.
CONNECTOR TEST POINT
DESCRIPTION
CONNECTOR PIN 1 + 5 V DC CONNECTOR PIN 2 + 5 V DC CONNECTOR PIN 3 GROUND CONNECTOR PIN 4 GROUND CONNECTOR PIN 5 GROUND CONNECTOR PIN 6 GROUND CONNECTOR PIN 7 GROUND CONNECTOR PIN 8 + 38 V DC CONNECTOR PIN 9 + 38 V DC CONNECTOR PIN 10 + 38 V DC CONNECTOR PIN 11 (a) + 79 V DC CONNECTOR PIN 12 FAN CONTROL (not used)
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Figure 6.2 Power Supply Test Points
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6.3.4 SELF TEST

Self-Test is an internal test to check the logic and electromechanical performances at User level. To execute this test it is necessary to load the fanfold paper into the printer. Press the ON-LINE key to disable the printer. Press the MENU key to enter the OPERATIONAL Menu. Press the key until the display shows: TEST MODE. Press the ENTER key, the display shows : TEST: PAPER WIDHT Press the the ENTER key twice. The display shows: TEST:START TEST Press the ENTER key. The display shows: TEST: START>NO Use the key to select YES. Press the ENTER key, to start the test.
The printer can be left in connection with the host line. The printer prints until the MENU (paused and restarted) or ON-LINE (exit) key is pressed. The format is as indicated in next figure. The Self-Test is printed with a number of columns depending on the RIGHT MARGIN selection. The print sample is formed by: ### ### The firmware code and release for both the Eproms (controller and characters generator) The Font, CPI and Emulation current parameters. A continuous ASCII pattern of complete lines of characters sequentially shifted.
Inspect the print sample for: ### ### ### ### ### ### ### ### Equal density of the character Equal darkness Character sharpness No missing part of character Underline character and descenders No smudges or strikes Equal density of lines Compose character correctly formed (graphic)
Refer to the faulty probability table to correct any printing problem.
GENICOM 3480 Matrix Advantage CONTROLLER GENERATOR FONT CPI EMULATION : 78404534 : 78403830 :COURIER :10 :EPSON LQ Rel: Rel: 2.06 1.03 44A513937-G20 44A513937-G50
!"#$%&'()*+,-./0123456789:;<=>?@ABCDEFGHIJKLMNOPQRSTUVWXYZ[\]^_ab !"#$%&'()*+,-./0123456789:;<=>?@ABCDEFGHIJKLMNOPQRSTUVWXYZ[\]^_abc GENICOM 3460 / 3480 / 3480+ 89537 6.16 GEK-
Maintenance Manual Maintenance "#$%&'()*+,-./0123456789:;<=>?@ABCDEFGHIJKLMNOPQRSTUVWXYZ[\]^_abcd Figure 6.3 Self-Test Printout
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6.3.5 HEX DUMP

This test is necessary when a protocol line error is detected but no error appears by the other internal tests of the printer. This procedure allows to see all the characters i.e. also the control characters sent by the host to the printer (example: ESC, DC4, CR, LF, etc.) in a readable printout. To execute this test is necessary to load the fanfold paper into the printer. Press the ON-LINE key to disable the printer. Press the MENU key to enter the Operational Menu. Press the key until the display shows: TEST MODE Press the ENTER key. Press the until the display shows: TEST:HEX DUMP Press the ENTER key. Press the key, the display shows: TEST: HEX DUMP>NO Use the key to select YES. Press the ENTER key, to start the test.
The printer can be left in connection with the host line. The display shows: HEXADECIMAL DUMP. The printer prints until the ON-LINE key is pressed again. This status is reset with the power-off of the printer. The format is as indicated in next figure. After the selection any character sent to the printer will be printed in its hexadecimal value on the left side associated with its ASCII character on the right side of the printout.
Example: Text in normal mode: ASCII: ESC C H HEX: 1B 43 48 BASIC: CHR$(27);CHR$(67);CHR$(72)
The same text in hex-dump mode:
HEXADECIMAL DUMP MODE 0000 0001 0002 0003 0004 41 53 48 45 0A 42 3B 43 32 29 43 49 49 58 20 20 41 53 49 48 52 24 0D 0A 3A 20 45 3A 20 31 43 3A 20 28 36 37 53 43 20 42 20 34 43 48 52 29 3B 43 43 33 24 48 20 20 28 52 48 34 32 24 0D 0A 38 0D 37 29 28 37 ASCII: ESC C HW HEX: 1B 43 48W BASIC: CHR$(27) ;CHR$(67);CHR$(7 2)W
Figure 6.4
Hex-Dump Printout
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6.3.6 Fault Probability Guide

Please use this guide whenever a fault is detected but no special display configuration is displayed. Usually, if a fault regards an electromechanical part and if no feed-back is arised, no error is detected by the firmware of the printer. In fact, except for the home postition and ribbon sensors, (that have a feed-back circuit to return the status condition), the other mechanical parts do not have a return feed-back because they are in open-loop circuit. So, for example, if the paper does not advance, the fault regards these parts: (paper motor, driver circuit and logic H/W). For this fault, only the paper movement can be verified with a T&D printout.
SYMPTOM:
Inconsistent character printing (some dark, some light, gaps or spaces or incomplete. The ribbon may not be correctly mounted. Re-install the ribbon cartridge. The ribbon cartridge may be faulty. Install a new one. The ribbon does not work correctly (RIBBON BLOCKED) message. Check if the carriage unit movement allows a correct ribbon cartridge movement. Replace the left support group pivot assy. The printhead cable may be incorrectly installed. Check for the P.H. cables to be correctly mounted. Replace printhead cable. The printhead may be faulty. Install a new one. The AGA function does not work. Check for the AGA motor impedance, connection and gears movement. Replace defective components. The main board may be faulty. Install a new one. Run T&D procedure to verify. The power supply board may be faulty. Check the voltages. Install a new one. The gap between P.H. and platen is not correct. Check for the platen adjustment procedure.
CAUSE: ACTION: CAUSE: ACTION: CAUSE: ACTION:
CAUSE: ACTION:
CAUSE: ACTION: CAUSE: ACTION:
CAUSE: ACTION: CAUSE: ACTION: CAUSE: ACTION:
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Maintenance Manual Maintenance SYMPTOM: CAUSE: ACTION: The printer stops printing (slowly printing). The thermal sensor in the P.H. is broken. Check for thermal sensor impedance (see chapter 8). Replace print head. The connection of the P.H. and DOE board is defective. Verify the connection. Replace P.H. cable. The main board may be faulty. Install a new one.
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CAUSE: ACTION:
CAUSE: ACTION:
Note: This operation must be done at room temperature.
SYMPTOM: CAUSE: ACTION: CAUSE: ACTION:
Color printing is not performed correctly. The ribbon is not correctly installed. Re-install the color ribbon. The color motor is not correctly mounted or faulty. Check for color motor impedance (see chapter 8). Replace the color motor. The connection of the P.H. and main board is defective. Verify the connection. Replace P.H. cable. The main board may be faulty. Install a new one. Run T&D procedure to verify.
CAUSE: ACTION:
CAUSE: ACTION:
SYMPTOM: CAUSE: ACTION: CAUSE: ACTION:
The character printing is vertically disaligned. The printer may not be correctly adjusted. Run T&D adjustments to check vertical adjustments. The carriage belt is not correctly adjusted. Check for correct carriage belt tension. Refer to adjustment procedures.
SYMPTOM: CAUSE: ACTION:
The tractor/friction motor does not work. The tractor/friction (alternance) motor may be faulty. Check for its impedance (see chapter 7) Replace t/f motor. The connection of the motor and main board is defective. Verify the connection. Replace the cable. The main board may be faulty. Install a new one. Run T&D procedure to verify. 6.20 GEK-
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Maintenance Manual Maintenance SYMPTOM: CAUSE: ACTION: CAUSE: ACTION: The paper does not advance correctly. The paper motor cable is not correctly mounted. Check for paper motor connection on main board. The paper motor may be faulty. Check for paper motor impedance or connection on main board. Replace the paper motor. The paper movement has not equal line spacing. Check for paper belt tension to be correct. Check for the paper belt adjustment. The main board may be faulty. Install a new one. Run T&D procedure to verify. The paper holes of fanfold are torn. Remove torn paper and replace with incoming proper sheet. Check the tension of the paper between left and right tractors. Paper is not correctly aligned on sprocket wheels. Load paper again, ensuring that corresponding holes at each side of the paper are correctly aligned on the tractors (see tractor assy
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CAUSE: ACTION:
CAUSE: ACTION: CAUSE: ACTION:
CAUSE: ACTION: removal).
SYMPTOM:
The printer initialized, but the display and Leds are off. O.P. keys are working. The connection of the operator panel board and main board is defective. Verify the connection. Replace the cable or the o.p. board or the display.
CAUSE: ACTION:
SYMPTOM:
The printer initialized, but only the display is off. O.P. key are not working. The connection of the operator panel board and main board is defective. Verify the connection. Replace the cable or the o.p. board or the display. The ribbon sensor is faulty. Check for the ribbon sensor action through the pivot assy. Replace the pivot assy. Replace the sensor cable group. Replace the ribbon motor assy.
CAUSE: ACTION:
CAUSE: ACTION:
SYMPTOM:
The printer initialized, but the carriage assy moves 1 inch to the right. The connections of the home position sensor or the carriage motor are defective. Verify the connections of the sensors cable group and carriage motor on main board. 6.21 GEK-
CAUSE: ACTION:
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Maintenance Manual Maintenance CAUSE: ACTION: The home position sensor or the carriage motor assy are faulty. Check for the sensor action through the carriage assy and the motor impedance. Replace the sensors cable group or the carriage motor assy.
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Maintenance Manual Maintenance SYMPTOM: CAUSE: ACTION: The printer not initialized, the buzzer sound continuously. The Controller eprom or the main board may be faulty. Run the T&D to verify these parts. Replace the controller eprom or the main board.
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The printer initialized but the paper is not loaded. The paper optical reflective sensors may be faulty. Check if the sensor cable is correctly inserted on the main board. Check if the sensors cable is correctly installed in the mechanical without short circuit. Check for the correct optical sensors diode impedance (about 1 K Refer to chapter 7.
### )
The printer not initialized with message ENG FLT 4 0 0. The ribbon sensor detects a inked ribbon stop. First check the inked ribbon cartridge for proper working. Check the sensors cable proper connection to the main board. Check the main board. The printer not initialized with message ENG FLT 4 3 0. The home position sensor detects a carriage stop. First check the carriage for its proper free movement. Check the carriage belt correct mounting. Check the sensors cable proper connection to the main board. Check the main board
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6.4 Test & Diagnostic

6.4.1 Introduction
The TEST & DIAGNOSTIC program, abridged in "T&D", is adopted to check the various functional parts composing the printer, and to diagnose possible operating defects which might occur during this phase. The T&D program can also be considered as a software tool to support the production activities. It has been realized in order to avoid the shipment of printers not perfectly operating.
6.4.2 T&D Structure

The software architecture of this printer is composed of one layer called as "PLATFORM", which has the task to manage the interfaces towards the existing H/W resources, and an "APPLICATION" layer which contains modules for emulations management. The T&D provision is an application module and uses the PLATFORM to accede the H/W resources (engine, operator panel, nvm, etc.). Under diagnostic conditions the whole RAM is checked to assure that there are no errors in the area in which the Operating System will be allocated. For this purpose, it has been stated that the portion of diagnostic procedure carrying out these tests, should be executed at system's BOOTSTRAP. If, and only if bootstrap tests give positive result, the PLATFORM module and the diagnostic application will then be initialized. At this point, subsequent tests will be executed (NVM, plugs, printouts, etc...).
6.4.3 T&D Kit

A specific card of T&D card is issued with P.N. 78399178-001. The FW of the T&D card includes: ### ### ### complete code for all the tests described in the next chapter module for standard printout adjustment for 1st line, tear-off, vertical printing
Together with this card three loop-back must be installed: The 232 serial loop-back connector The 422 serial loop-back connector The mechanical options loop-back connector The parallel loop-back connector P.N. 78403675-001 P.N. 78403676-001 P.N. 78403674-001 P.N. 78401829-001
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6.4.4 Execution of User T&D

The USER T&D is the T&D procedure for the field level maintenance. It requires the following: ### ### ### The T&D card plugged onto the right side slot provided in the cover. MFG jumper on operator panel board must be absent as default setting. The serial interface 232 and parallel interface loop-back connectors must be installed in the serial and in the parallel interface connectors. The mechanical options loop-back connector must be installed in the paper stacker connector. Insertion, before starting test, of some forms (136 characters, 72 lines) of fanfold module on the front tractor path. Press simultaneoulsy ON LINE and PAPER keys at power on for at least 2 seconds.
###
###
###
All tests indicated in the table 6.1 are one-shot or automatically sequential executed depending by the first choice after the initialization phases (see chapter 6.4.6 ). At the end, sample forms are printed out for all electromechanical checking and mechanical adjustments. During the execution of each test, the display will show some messages to show to the technician the activity in progress or the action the operator has to do in that moment.
NOTICE : ### It is indispensable that no paper modules are present in any paper paths when the T&D procedure is executed (the sensors must be not covered by the paper). In fact, the T&D automatically adjusts, whitout any intervention, all the reflective sensors of the printer (single sheet, front fanfold, rear fanfold). ### The cover must be closed, otherwise a message "# COVER OPEN " displayed. will be
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6.4.5 Loop-Back Connectors

The T&D can check also the functionalities of various I/F's existing on the printer. A proper loop-back connector must be used to have the correct feed-back. Three connectors are used for the following intefaces: ### Serial Interface loop-backs. They are composed by some wires that connect the output signals with the input signals of these interfaces, one for the RS232 and the other for RS422 type. See figure 6.5A and 6.5B for diagrams. ### Parallel Interface loop-back. It is composed by some wires that connect the output signals with the input signals of this interface plus an intergrated circuit (parallel latch) that provides the correct handling of the bidirectionality of the data input/output lines. See figure 6.6 for diagram. ### Mechanical Options loop-back. This loop-back must be inserted in the connector located in the upper right side of the mechanical assy in which the paper stacker assy must be inserted. It is composed by an integrated circuit (serial latch) that provides the correct handling of the the data input/output lines. The insertion key of this loop-back provides the pin 1 at the top-right position (with the printer in frontal view). See figure 6.7 for diagram. NOTICE: Insert the parallel interface and the mechanical options loop-backs only when the printer is powered off.
6.4.5.1 Loop-Back Connector Diagrams

The next three figures show the diagrams of these loop-backs. 232/C SERIAL INTERFACE LOOP-BACK DTR RTS SRTS TXD 232 (20) ( 4) (11) ( 2) --------------------------------------------------------------------( 6) DSR ( 5) CTS ( 8) DCD ( 3) RXD 232
Figure 6.5A 232/C Serial I/F Loop-Back Diagram
422/A SERIAL INTERFACE LOOP-BACK DTR RTS SRTS GENICOM 3460 / 3480 / 3480+ 89537 (20) ( 4) (11) ---------------------------------------------------( 6) DSR ( 5) CTS ( 8) DCD 6.26 GEK-
Maintenance Manual Maintenance TX-A 422 (13) TX-B 422 (14) ----------------------------------(16) RX-A 422 (19) RX-B 422
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Figure 6.5B 422/A Serial I/F Loop-Back Diagram
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Maintenance Manual Maintenance PARALLEL INTERFACE LOOP-BACK
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Figure 6.6 Parallel I/F Loop-Back Diagrams
MECHANICAL OPTIONS LOOP-BACK
Figure 6.7 Mechanical Option Loop-Back Diagrams
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6.4.6 Diagnostic Program Management

After the T&D launch, in the T&D 0 phase, the display shows "BOOT RAM TEST US". Then, after the boostrap phase, the hardware is initializing and the display shows "STARTING UP " with the led of the FRONT PUSH PATH lit. After the hardware initialization, the diagnostic procedure enters in the other tests, and the display shows: "T&D START UP " that means the correct opening of the T&D driver. Then the display will show :
"YES SINGLE? NO"

If the LOAD/FF key is pressed, the one-shot test procedure is put under execution. At every running test, the display will show:
"T&D(n) YES NO END "

- If the PAPER key is pressed the T&D procedure is stopped. - If the PAPER key is pressed the displayed test is skipped with a buzzer "beep" sound. Hold down this key to automatically skip the T&D tests. - If the LF key is pressed the displayed test is put under execution; at the end the next test is displayed. At every running test, the message "T&D (n) USER" in which (n) represents the number of the test as indicated in the next table is displayed. If the PAPER key is pressed the automatic sequential execution procedure is put under execution. At every running test, the message "T&D (n) USER" in which (n) represents the number of the test as indicated in the next table is displayed.
The next table 6.2 shows the flowchart of the T&D procedure The T&D gives some interaction messages. An indication inside a border means a certain key pressure.
KEY
An indication between double brackets as below, means a display message.
"LCD MESSAGE "
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6.4.6.1 Diagnostic Flow Chart

Power on with ON LINE + PAPER starts the USER T&D procedure. A fanfold module of 72 lines form must be installed in the front path tractor. The T&D procedure is interactive and shows at every time the action that must be done. This is a schematic flow-chart of the whole T&D USER procedure in automatic sequential mode.
RUNNING TEST
LCD MESSAGE
PUSHED KEY
KEY's ACTION
Initialization phases
"BOOT RAM TEST US" "STARTING UP" "T&D START UP" "YES SINGLE? NO" LOAD/FF PAPER Runs single shot test choice Runs automatic complete test choice
T&D Choice
Hw/Sw mismatch test Main Eprom test Card Eprom test Font Eprom test Operator Panel test
"T&D01 USER" "T&D 2 CRC ROM *" "T&D 3 CRC CARD *" "T&D 4 CRC FONT *" "T&D 5 USER" "PUSH KEY 1 --->" through "PUSH KEY 9 --->" "T&D 6 USER" "T&D 8 USER" "T&D 9 USER" "INSERT 422 LOOP" ANY KEY Starts test for 232/C Insert 422 loop-Back Starts test for 422/A
ON LINE through PATH
Key 1 test through Key 9 test
Parallel Interface test NVM test Serial Interface test
Mechanical Option test Ribbon & color test
"T&D 10 USER" "T&D 11 USER" "FRICTION OPEN" "Y CHANGE IT? N"
LOAD/FF LOAD/FF PAPER LOAD/FF PAPER ###
Changes NVM status and store it Skips this control Starts ribbon & motor color test Stops test ### GEK-
"<--- START & RUN" "STOPPING ---> ### GENICOM 3460 / 3480 / 3480+ 89537 ### 6.30
Maintenance Manual Maintenance Table 6.2 T&D USER Flow Chart (I)
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### Aga Calibrate test
### "T&D 12 USER" "AGA CALIBRATE" "SS PATH FF" "+ AGA n -" "YES <-STORE ->NO" "+ AGA n -"
###
###
LOAD/FF PAPER LOAD/FF PAPER LOAD/FF LF PAPER
Single sheet choice Fanfold front choice Stores AGA in NVM Repeats the test Increments AGA value Executes AGA Decrements AGA value
"AGA FIX ADJUST" "+ AGA n -" "YES <-STORE ->NO" "+ AGA n -"
LOAD/FF PAPER LOAD/FF LF PAPER Any key LOAD/FF PAPER
Fanfold Printout test
"T&D 14 USER" "TEAR & PUSH KEY" "YES F.FR. ADJ? NO" "T&D 15 USER" "FRONT CALIBRATE" "+ F.FR n -" "PUSH A KEY" "YES <-STORE ->NO" "YES F.RE. ADJ? NO"
1st line on front f. test
Stores AGA in NVM Repeats the test Increments AGA value Executes AGA Decrements AGA value Prints the Fanfold pattern Position the printout module to tear-off Front fanfold choice Skips to 1st line r.f. test
LOAD/FF LF PAPER LOAD/FF PAPER LOAD/FF PAPER
Increments the 1st line f.f. value Executes the 1st line f.f. test Decrement the 1st line f.f. value Stores 1st line f.f. in NVM Repeats the test Rear fanfold choice Skips to next test
1st line on rear f. test
"REAR CALIBRATE" "+ F.RE n -" "WAITING ...." "YES <-STORE ->NO"
LOAD/FF LF PAPER LOAD/FF PAPER
Increments the 1st line r.f. value Executes the 1st line r.f. test Decrement the 1st line r.f. value Stores 1st line r.f. in NVM Skips to next test
Vertical (bidirect.) test
"T&D 16 USER" "YES VERT ADJ? NO" "VERTICAL ADJUST" "+ VERT n -" "PUSH A KEY" "YES <-STORE ->NO"
LOAD/FF PAPER LOAD/FF LF PAPER LOAD/FF PAPER
Vertical adj. choice Skips to next test Increments the vertical adj. value Executes the vertical adj. test Decrements the vertical adj. value Stores vertical adj. value in NVM Skips to next test GEK-
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###
###
###
###
Table 6.2 T&D USER Flow Chart cont'd (II)
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### Tear-off adj. test
### "T&D 17 USER" "YES TEAR ADJ? NO" "TEAR ADJUST" "YES T.FRONT NO" "FRONT CALIBRATE" "+ TEAR n -"
###
###
LOAD/FF PAPER LOAD/FF PAPER LOAD/FF LF PAPER LOAD/FF PAPER LOAD/FF PAPER LOAD/FF LF PAPER LOAD/FF PAPER
Tear-off adj. choice Skips to next test Choice of front fanfold test Skips to rear fanfold test Increments the tear-off value Executes the tear-off test Decrements the tear-off value Stores front tear-off value in NVM Repeats the test Choice of front fanfold test Skips to next test Increments the tear-off value Executes the tear-off test Decrements the tear-off value Stores rear tear-off value in NVM Repeats the test
1st line on front fanfold
"YES <-STORE ->NO" 1st line on rear fanfold "TEAR ADJUST" "YES T.REAR NO" "REAR CALIBRATE" "+ TEAR n -"
"YES <-STORE ->NO" Single Sheet Test Interlock test "INSERT CUT SHEET" "T&D 18 USER" "T&D 19 USER" "OPEN COVER" "CLOSE COVER" "FRICTION OPEN" or "FRICTION CLOSED" "END T&D ...."
Friction NVM recall
ANY KEY
Table 6.2 T&D USER Flow Chart cont'd (III)
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On 3480+ and 3460 / 3480 A3 profile is also available the following T&D.
Paper Sensors Test
T&D 20 USER Y SENSOR TUNE N Y PATH STATUS N C:F F:F R:F P:OP C:B F:B R:B P:CL
LOAD/FF LOAD/FF Visual check for change F (free) to B (busy) after insert or remove paper for each path. C= cut sheet F= Front tractor path R= rear tractor path (or ASF) P= Pinch position (Open or CLose) ANY KEY LOAD/FF ANY KEY
Y THRESHOLD N C27 F0f R5e (92)
These are the threshold values. stored in the NVM of the main board. R have two possible values, with friction close and parenthetical with friction open Visual check for indicative values: -without paper - with paper present.
Y SENSOR LEVEL N C:1d C:8f Y F:02 F:76 R:38 R:ee N
LOAD/FF
REPEAT TEST
ANY KEY PAPER LOAD/FF
For not repete the test If you want repete the test
Table 6.2 T&D USER Flow Chart cont'd (IV)
6.4.6.2 Diagnostic Error Management

In case the test detects an error, the diagnostic program is interrupted and the following message is displayed:
"KO(n1) ORU(n2) [n3]"

In which the n1, n2 and n3 means respectively: n1: n2: n3: the number of failed test (indicated as TEST N. in table 6.1) the O.R.U. interested by the fault (indicated as ORU in table 6.2) the diagnostic error code (indicated as ERROR CODE in table 6.3)
At this point a pressure on any key allows the error handling. The display shows:
"REPT SKIP INIT "

The three choices can be performed by the operators: ### REPT means the same test can be repeated (LOAD/FF key). 6.35 GEK-
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### ###
SKIP means the failed test can be skipped (LF key). INIT means the T&D restarts from the beginning except the BOOT test (PAPER key).
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6.4.7 T&D Tests List

The executed tests are 19, or 20 for printers with new profile. The table below shows the complete list of tests with description and the O.R.U. (Optimum Replaceable Unit) under test.
TEST CODE TEST DESCRIPTION O.R.U. ----------------------------------------------------------------------------------------------------------------------T&D 0 BOOT RAM TEST MAIN BOARD T&D 1 HW/SW CHECK TEST EPROM/MAIN BOARD T&D 2 CONTROLLER EPROM CRC CNTRL EPROM T&D 3 OPTIONAL CARD EPROM CRC OPT. CARD T&D 4 GENERATOR EPROM CRC GEN. EPROM T&D 5 OPERATOR PANEL TEST O.P. BOARD T&D 6 PARALLEL INTERFACE TEST MAIN BOARD T&D 7 Not used T&D 8 NVM TEST MAIN BOARD T&D 9 SERIAL INTERFACE TEST SERIAL I/F BOARD T&D 10 MECHANICAL OPTION TEST PAPER STACKER/ASF T&D 11 RIBBON, COLOR MOTOR MAIN BOARD/RIBBON WELD RIBBON WELD TEST BOARD/MOTORs REAR FRICTION STATUS T&D 12 AGA CALIBRATE TEST MAIN BOARD/MOTOR T&D 13 Not used T&D 14 FANFOLD MODULE PRINTOUT MAIN BOARD/PRINT HEAD MECHANISM T&D 15 1ST LINE ADJUSTMENT TEST MECHANISM/MAIN BOARD T&D 16 VERTICAL ADJUSTMENT TEST MECHANISM/MAIN BOARD T&D 17 TEAR-OFF ADJUSTMENT TEST MECHANISM/MAIN BOARD T&D 18 SINGLE SHEET PRINTOUT MAIN BOARD/PRINT HEAD MECHANISM T&D 19 INTERLOCK TEST MECHANISM/O.P. BOARD T&D 20 SENSOR TUNE MECHANISM/MAIN BOARD
Table 6.3 T&D Tests List Table
6.4.8 O.R.U. List

The table below shows the list of O.R.U (optimum replaceable unt) involved in the diagnostic phase. O.R.U. DESCRIPTION -----------------------------------------------------------------------0 Main Board 1 Operator Panel Board 2 Diagnostic Card 3 Mechanical Parts 4 Supervisor SW 5 Eproms GENICOM 3460 / 3480 / 3480+ 89537 6.37 GEK-
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Table 6.4 ORU List Table
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6.4.9 Diagnostic Errors Table

TEST N. ORU ERROR CODE DESCRIPTION ---------------------------------------------------------------------------------------------------------------------------------0 0 1 MAIN BOARD (ram error) 1 5 1 CONTROLLER EPROM (Hw/Sw error) 1 5 2 GENERATOR EPROM (Hw/Sw error) 2 5 1 CONTROLLER EPROM (crc error) 3 2 2 CARD EPROM (crc error) 4 5 3 GENERATOR EPROM (crc error) 5 1 1 O.P. BOARD (key 1 error) 5 1 2 O.P. BOARD (key 2 error) 5 1 3 O.P. BOARD (key 3 error) 5 1 4 O.P. BOARD (key 4 error) 5 1 5 O.P. BOARD (key 5 error) 5 1 6 O.P. BOARD (key 6 error) 5 1 7 O.P. BOARD (key 7 error) 5 1 8 O.P. BOARD (key 8 error) 5 1 9 O.P. BOARD (key 9 error) 5 1 10 O.P. BOARD (general error) 6 0 1 PARALLEL I/F (strobe-busy error) 6 0 2 PARALLEL I/F (slct-init error) 6 0 3 PARALLEL I/F (ack-autofdxt error) 6 0 4 PARALLEL I/F (flt-sctin error) 6 0 5 PARALLEL I/F (data rx-tx error) 7 not used 8 0 1 MAIN BOARD (nvm data error) 8 0 2 MAIN BOARD (nvm crc error) 9 0 1 SERIAL I/F (data rx-tx error) 9 0 2 SERIAL I/F (dtr-dsr error) 9 0 3 SERIAL I/F (rts - cts error) 9 0 4 SERIAL I/F (srts-dcd error) 10 0 1 PAPER STACKER BOARD error 12 0 16 MECHANICAL (aga error) 12 0 17 MAIN BOARD (nvm aga value error) 13 not used 14 0 20 PRINT HEAD THERMAL SENSOR error 19 1 1 O.P. BOARD (interlock close error) 19 1 0 O.P. BOARD (interlock open error) 21 0 1 MAIN BOARD (watch-dog min. error) 21 0 2 MAIN BOARD (watch-dog max. error) 20 3 11 MECHANICAL (paper sensor error) n (*) 3 12 MECHANICAL (ribbon sensor error) n (*) 3 13 MECHANICAL (carriage sensor error) n (*) 3 14 MECHANICAL (aga error) n (*) 3 15 MECHANICAL (aga adjust value in nvm error) 20 20 n Note: (*) 3 (*) 3 (*) 3 4 (**) 16 17 27 20### 41 MECHANICAL (front tractor sensor error) MECHANICAL (rear tractor sensor error) MECHANICAL (carriage movement error) T&D Internal error
(*) n means that this error can appear in all the tests in which a mechanical movement (carriage motor, paper motor) is requested (T&D 11, T&D 12, T&D 14, T&D 15, T&D 16, T&D 17, T&D 18). 6.39 GEK-
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(**) If an ORU 4 appears with an associated error values from 20 to 41, a T&D internal error has been detected (Supervisor SW error). Power off the printer and restart the T&D procedure. If it appears again, contact the nearest Compuprint support. Table 6.5 T&D Error Codes
6.4.10 Tests Description

T&D 0 - RAM MEMORY TEST This test is executed during system bootstrap if diagnostic condition is present. The whole ram which is used by the Operating System module is checked. If this test fails, the T&D is halted with no possibility to go ahead.
T&D 1 - HARDWARE / SOFTWARE MATCH TEST This test checks if the eproms present on the main board are of the proper type with respect to the respective board (for 9 or 24 needles).
T&D 2 - CONTROLLER EPROM MEMORY TEST This test executes the CRC with 31-degree polynomial, which involves the whole memory addressing (512 KB x 8 = 4 Mb). For a positive test issue, the computation must be 0. During the test the display shows "T&D 2 CRC ROM *". A flushing asterisk indicates the correct running of the test.
T&D 3 - FONT/EMULATION EPROM MEMORY TEST This test executes the CRC with 31-degree polynomial, which involves the whole memory addressing (256 KB x 8 = 2 Mb). For a positive test issue, the computation must be 0. During the test the display shows "T&D 3 CRC CARD *". A flushing asterisk indicates the correct running of the test.
T&D 4 - GENERATOR EPROM MEMORY TEST This test executes the CRC with 31-degree polynomial, which involves the whole memory addressing (512 KB x 8 = 4 Mb). For a positive test issue, the computation must be 0. During the test the display shows "T&D 3 CRC FONT *". A flushing asterisk indicates the correct running of the test.
T&D 5 - OPERATOR PANEL BOARD TEST This test consists of a first reading, which checks for 9 keys to be opened. If one key is damaged (short circuit), an error message is displayed and the T&D is halted. After that, the test checks all the 8 leds of the printer. All these leds are lit and then off, then sequentially from right to left one led is lit for about 0.5 second with an associated buzzer sound. GENICOM 3460 / 3480 / 3480+ 89537 6.40 GEK-
Maintenance Manual Maintenance Then the test continues with a request to push sequentially the 9 keys from right to left. The display shows the message "PUSH KEY 1 --->" to indicate that the rightmost key should be pressed. Then, at every step the display shows the message "PUSH KEY (n)". If the wrong key is pressed, the buzzer sounds twice to advise the error. In case that the requested key is not activated within a few seconds, an error code is displayed.
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T&D 6 - PARALLEL INTERFACE TEST This test checks by means of loop-back plug closing, for the correct operation of control, status and data signals of the bi-directional interface (see loop-back diagram at chapter 6.4.5).
T&D 8 - EEPROM MEMORY TEST (NVM) This test controls the check-sum of the non-volatile memory (eeprom or nvm).
T&D 9 - SERIAL INTERFACE TEST This test checks by means of loop-back plug closing, for the correct operation of control, status and data signals of the serial RS232 and RS422 interfaces (see loop-back diagram at chapter 6.4.5).
T&D 10 - MECHANICAL OPTIONS TEST This test checks the mechanical option connector signals by means of a special loopback. For further details, refer to the Section dedicated to the diagrams of the loopback plugs in this chapter.
T&D 11 - SENSOR TUNE RIBBON, COLOR MOTOR, RIBBON WELD and REAR FRICTION STATUS TESTs SENSOR TUNE This test is executed just before any mechanical movement (T&D 11 to T&D18 and eventually T&D20), so the T&D11 is the first impacted test. If one of these tests is skipped, the rear friction status check appear in the next one. This test is automatically done by the T&D program without any manual intervention. REMARK! Before running this test remove, if present, the paper from any paths.
FRICTION STATUS This test is executed just before any mechanical movement (T&D 11 to T&D18 and eventually T&D20), so the T&D11 is the first impacted test. If one of these tests is skipped, the friction status check appear in the next one. The last test is to verify and change, if necessary, the coherence between the internal NVM data for the Friction Bar Position and the relative mechanical position of the bar itself. As described in chapter 2, in this printer there is an automatical movement of the friction GENICOM 3460 / 3480 / 3480+ 89537 6.41 GEK-
Maintenance Manual Maintenance rollers for the rear fanfold path. In case of any change (main board of disassembly/riassembly of the mechanical assy) it is important to check this coherence. The display will show: "FRICTION CLOSE " or "FRICTION OPEN " depending on the reading value stored in NVM on the main board. After having pressed the LOAD/FF key, the message "Y CHANGE IT? N" will be displayed. The choice can be Y (LOAD/FF key) to change this data and stored it or N (PAPER key) to skip this test.
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Maintenance Manual Maintenance It is possible to find 4 conditions, and these are the actions to be done. FRICTION BAR ASSY DISPLAY MESSAGE ACTIONS POSITION (see figure below) ----------------------------------------------------------------------------------------------------------------------------CLOSED FRICTION CLOSED Push the PITCH key to skip the test. No other action. OPEN FRICTION OPEN Push the PITCH key to skip the test. The printer closes the friction bar assy and stores CLOSED in the NVM data. Open the friction bar assy by manually sliding on on the carriage to its left-most position while rotating the paper knob. Then push the PITCH key to skip the test. Push LOAD/FF key. The printer stores OPEN in NVM data and then closes the friction bar assy and stores CLOSED in the NVM data.
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CLOSED
FRICTION OPEN
OPEN
FRICTION CLOSED
Figure 6.8 Friction Bar Assy Position
RIBBON and COLOR MOTOR This test checks the correct movement of the ribbon and the color motors. The display shows "<START & RUN". If the LOAD/FF key is pressed, the test is executed and the ribbon motor is activated together with a motor color activation and the display shows "STOPPING ->". If the PAPER key is pressed, the test will be stopped.
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Maintenance Manual Maintenance T&D 12 - AGA CALIBRATE TEST This test allows to check the correct functioning of the AGA if some mechanical parts related to the printing area are removed (carriage assy, aga motor, platen assy, ect) with a consequent out-of-tolerance of the mechanism with respect to the Manufacturing setting. See chapter 5.1.4 for more details.
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T&D 14 - FANFOLD STANDARD PRINTOUT TEST This test consists in printing a standard module (136 characters, 72 lines) having defined dimensions containing a set of tests checking the parts involved in print, such as printhead, needles, carriage, etc. See specific chapter 6.4.11.1 for its analysis. After this test a tear-off of the printed module is requested by the operator to have the correct printout of next test T&D15. The display will show "TEAR & PUSH KEY".
T&D 15 - FIRST LINE CALIBRATE TEST This test allows to calibrate the first printing line on both the fanfold paths. It is useful to personalize the printout with a specifical user application. See chapter 5.1.5 for more details.
T&D 16 - VERTICAL CALIBRATE TEST This test allows to calibrate the bidirectional printing. If some mechanical parts related to the carriage assy movement area are removed (carriage assy, carriage motor, carriage belt, ect) with a consequent out-of-tolerance of the mechanism with respect to the Manufacturing setting, it is useful to set the printout for best performance. See chapter 5.1.6 for more details.
T&D 17 - TEAR OFF CALIBRATE TEST This test allows to calibrate the tear-off quote. It is useful to personalize the printout with the specifical user application. See chapter 5.1.7 for more details.
T&D 18 - SINGLE SHEET STANDARD PRINTOUT TEST This test consists in printing a standard module (A3 format) having defined dimensions containing a set of tests checking the parts involved in print, printhead, needles, carriage, etc. The display will show "LOAD CUT SHEET" and a manual paper loading is requested. The printer automatically will load the paper without any key pressure. See specific chapter 6.4.11.2 for its analysis.
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Maintenance Manual Maintenance T&D 19 - INTERLOCK SWITCH TEST
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This test checks the correct functioning of the microswitch installed on the operator panel board. If the T&D detects the cover in open status before starting this test, the display will show "COVER IS OPEN..." and "PLEASE CLOSE IT!" alternatively. During the test, the display shows the message "OPEN COVER " and an action on the top cover is requested. After that the display shows "CLOSE COVER". If the actions are not executed in a certain time, the diagnostic stops and displays the error. T&D 20 - SENSOR TUNE In the new models also the T&D 20 execute the sensor tune. This T&D shows the path status, the threshold values stored in NVM and the sensor level. In this way it is possible verify the correct functionment of the paper sensors and their margin.
T&D 21 - T&D END DUMMY TEST This test is a dummy test indicating if the T&D ended successfully. At this time the display will show: "FRICTION CLOSED" or "FRICTION OPEN" depending on the reading value stored in NVM on the main board. A pressure on any key is necessary to skip the test. At the end of the T&D, the display will show "END T&D ....". The printer must be powered-off.
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6.4.11 Analisys of Standard Modules 6.4.11.1 Fanfold Printout

Please use this standard printout module as a reference when checking all printing quality problems and the tractor movement. The following are the explanations of the various tests performed in this module reported in the next figures 6.9 and 6.10. 1. check module. 2. Two pattern of 6 "E" characters in draft mode on the left and right margins are printed in the first print line together with a continuous underscore line to the horizontal printing skew of the paper at the top margin of the
The same pattern containing also the heading of the test is printed in quality mode in the second line. The complete Eproms codes and releases are listed in the third line (controller, generator and diagnostic). A complete pattern which checks all the 9 or 24 needles depending of the printer type follows. A paper movement test (with forward and backward movements) is performed: A) First the printer prints the first and third chopped-lines. B) After the point 12. a backward movement is made and the central line is printed. This line must be between the two previous chopped-lines.
3.
4.
5.
chopped-
6.
A "H" character pattern is printed to check the bidirectional vertical alignment in normal text printout. A bit image pattern is printed to check the bidirectional vertical alignment in graphic printout.
7.
8.
Three lines of characters set with different printing types and with the composed color (first line at 10 CPI draft orange color, second line at 17.14 CPI draft violet color and the third at 10 CPI quality green color) are then printed. 9. 10. 11. 12. 13. A special pattern of "H" character shows the carriage movement. A color graphic pattern checks the printing of color graphic test. A continuous line is printed in the 50th position. See step B) of item 5. A forward paper movement is performed to reach the 72th position and a pattern as described at point 1 is printed.
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Figure 6.9
3460 T&D Standard Fanfold Printout (reduced)
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Maintenance Manual Maintenance Figure 6.10 3480 T&D Standard Fanfold Printout (reduced)
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6.4.11.2 Single Sheet Printout

Please use this standard printout module as a reference when checking all printing quality problems and the single sheet movement. Following are the explanations of the various tests performed in this module reported in the next figure 6.11. 1. Two pattern of 6 "E" characters in draft mode on the left and right margins are printed in the first print line together with the heading of the test and a continuous underscore line to check the horizontal printing skew of the paper at the top margin of the module. 2. inch 3. The paper forward movement is tested printing seven "_____" lines at 1 distance.
The last line is similar to the first line without the heading and printers model and is printed at a distance of 1 inch from the preceeding print line. The paper backward movement is tested printing seven lines as described at point 2 in reverse order. The position of these lines should match the lines printed with the forward movement. A final form feed to paper eject is done. A mismatch of max. 1 mm is accepteptable.
4.
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Figure 6.11 3460/3480 T&D Standard Single Sheet Printout (reduced) 6.52
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Electromechanical
Chapter 7 Electromechanical Devices
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7.1 Overview
This chapter describes all the electromechanical parts of the printer with their main electrical and mechanical requirements to allow the field service technicians to check the correct functioning.
7.1.1 Print Head

The print head installed on this printer is an electromagnetic non-ballistic type. There are three different types, one for 3460 (9 needles), one for 3480 (24 needles) and another one for 3480+ (24 needles). For the 9 pins print head, the needles have diameter of 0.3 mm (0.012") and they are positioned in a single row with vertical pitch of 0.353 mm (1/72"). Needle 1 is the top most. For the 24 pins print head, the needles have diameter of 0.2 mm (0.0087") and they are positioned in a diamond layout in which the odd pins (1### 23) are positioned in the right row with the vertical pitch of each row of 0.282 mm (1/90"). Needle 1 is the top most of right row, needle 2 is the top most of the left row. The new print head for 3480+ can have a speed printing of 450cps. ELECTRICAL REQUIREMENTS Coil resistance Thermal sensor (see table below) 5.0 ### 10% measured at 25 1000 ### 6% measured at 25
Temperature (C) 10 20 25 30 40 50 60 70 80 90 100 110 120 130 140 150
Resistance (### ) 887 961 1000 1039 1121 1206 1295 1387 1483 1583 1687 1794 1905 2020 2138 2260
Table 7.1
Print Head Resistance/Temperature Characteristics
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Electromechanical
The print head overview and its pin connector assignment are shown in next figure 7.1 and table 7.2 for 9 needles model and figure 7.2 and table 7.3 for 24 needles model respectively.
CONNECTOR P1 Pin Pin Pin3 Pin Pin Pin Pin Pin Pin Pin10 Pin Pin 1 Non connected 2 Non connected Non connected 4 Non connected 5 + 38 Volt 6 + 38 Volt 7 GND (thermal sensor) 8 Needle N. 5 9 Thermal Sensor Needle N. 7 11 + 38 Volt 12 + 38 Volt Pin13 + 38 Volt Pin14 Needle N. 9 Needle N. 8 Pin16 Needle N. 6 Pin17 Needle N. 4 Pin18 Needle N. 2 Pin19 Needle N. 1 Pin20 Needle N. 3 Pin21 Connector P2 Pin 2 Connector P2 Pin 1 Pin23 Connector P2 Pin 4 Pin24 Connector P2 Pin 3
Pin15
Pin22
Table 7.1 9 Needles print head pin assignment
Figure 7.1 9 Needles print head pinout
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Maintenance Manual Devices CONNECTOR P1 Pin Pin Pin3 Pin Pin Pin Pin Pin Pin Pin10 Pin Pin 1 Connector P4 Pin 1 2 Connector P4 Pin 2 Connector P4 Pin 3 4 Connector P4 Pin 4 5 + 38 Volt 6 + 38 Volt 7 GND (thermal sensor) 8 Needle N. 8 9 Thermal Sensor Needle N. 10 11 + 38 Volt 12 + 38 Volt
Electromechanical
Pin15
Pin22
Pin13 + 38 Volt Pin14 Needle N. 12 Needle N. 14 Pin16 Needle N. 16 Pin17 Needle N. 18 Pin18 Needle N. 20 Pin19 Needle N. 22 Pin20 Needle N. 24 Pin21 Connector P3 Pin 2 Connector P3 Pin 1 Pin23 Connector P3 Pin 4 Pin24 Connector P3 Pin 3
CONNECTOR P2 Pin Pin Pin3 Pin Pin Pin Pin Pin Pin Pin10 Pin 1 + 38 Volt 2 Needle N. 2 + 38 Volt 4 Needle N. 4 5 Needle N. 6 6 Needle N. 23 7 + 38 Volt 8 Needle N. 21 9 + 38 Volt Needle N. 19 11 Needle N. 17 Pin12 Needle N. 15 Pin13 + 38 Volt Needle N. 13 Pin15 + 38 Volt Pin16 Needle N. 11 Pin17 Needle N. 9 Pin18 Needle N. 7 Pin19 Needle N. 5 Pin20 Needle N. 3 + 38 Volt Pin22 Needle N. 1
Pin14
Pin21
Table 7.3 24 Needles print head pin assignment
Figure 7.2 24 Needles print head pinout
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7.1.2 Motors 7.1.2.1 Carriage Motor

The carriage motor is a 1.8 hybrid bipolar stepper motor. ELECTRICAL REQUIREMENTS Phase resistance 0.84 ### 15% Measured at 25 between pin 1-2 and 3-4 Phase inductance 2 mH 20% Measured at 1 Khz 100 mV with energized coil. Rated motor voltage 2.1 V With rated voltage applied to both phases (parallel). Rated phase current 2.5 A With rated current applied to both phases (series). Back electromotive force 20 Vpeak 20% With motor shaft at the constant speed of 1000 RPM MECHANICAL REQUIREMENTS Step angle 1.8
The pin connector assignment is shown in fig. 7.3
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Fig 7.3 Carriage motor pin connector assignment
7.1.2.2 Paper Motor

The paper motor is a 1.8 hybrid bipolar stepper motor identical for both the printer models. There are two different paper motor groups having different gears on the motor shaft.
ELECTRICAL REQUIREMENTS Phase resistance 2.4 ### 10% Measured at 25 between pin 1-2 and 3-4 Phase inductance 36 mH 20% Measured at 1 Khz 100 mV. Rated motor voltage 4.4 V With rated voltage applied to both phases (parallel). Rated phase current 1.4 A With rated current applied to both phases (series). Back electromotive force 29 Vpeak 20% With motor shaft at the constant speed of 1000 RPM MECHANICAL REQUIREMENTS Step angle 1.8
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Electromechanical
Fig 7.4 Paper motor pin connector assignment
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7.1.2.3 AGA Motor

The aga motor is a 3.6 permanent magnet bipolar stepper motor. ELECTRICAL REQUIREMENTS Phase resistance 19 ### 10% Measured at 25 between pin 1-2 and 3-4 Phase inductance 18 mH 20% Measured at 1 Khz 100 mV. Rated motor voltage 7.7 V With rated voltage applied to both phases (parallel). Rated phase current 0.31 A With rated current applied to both phases (series). Back electromotive force 15.5 Vpeak 20% With motor shaft at the constant speed of 1000 RPM MECHANICAL REQUIREMENTS Step angle 3.6
Fig 7.5 AGA motor pin connector assignment GENICOM 3460 / 3480 / 3480+ 7.8 GEK-89537
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7.1.2.4 Ribbon Motor

The ribbon motor is a 7.5 permanent magnet bipolar stepper motor. ELECTRICAL REQUIREMENTS Phase resistance 24 ### 10% Measured at 25 between pin 1-2 and 5-6 Phase inductance 33 mH 20% Measured at 1 Khz 100 mV. Rated motor voltage 7.3 V With rated voltage applied to both phases (parallel). Rated phase current 0.35 A With rated current applied to both phases (series). Back electromotive force 21 Vpeak 20% With motor shaft at the constant speed of 1000 RPM MECHANICAL REQUIREMENTS Step angle 7.5
Fig 7.6 Ribbon motor pin connector assignment
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7.1.2.5 Alternance Motor

The alternance motor is a direct current motor. ELECTRICAL REQUIREMENTS Terminal resistance 46.15 ### 10% The terminal resistance is calculated as the rated motor voltage divided by stall current. Terminal inductance Measured at 1 Khz. Rated motor voltage 24.5 mH 20%
24 V
Rated motor current 0.215 A The rated motor is the current supplied to the motor at rated torque (0.51 Ncm), rated voltage and constant speed of 100 RPM. Stall current 0.52 A 10% The Stall current is the armature current when the rated motor voltage is applied to the motor with locked rotor. No load current 0.035 A 40% The No load current is the motor armature supply current at no load speed. Back Electromotive Force 1.7 V 10% The back electromotive force is the voltage measured across the terminal, carrying the motor shaft to a constant speed of 1000 rpm.
7.1.2.6 ASF Motor

The automatic sheet feeder motor is a direct current motor. ELECTRICAL REQUIREMENTS Terminal resistance 37.56 ### 10% The terminal resistance is calculated as the rated motor voltage divided by stall current. Terminal inductance Measured at 1 Khz. Rated motor voltage 20 mH 20%
24 V
Rated motor current 0.15 A The rated motor is the current supplied to the motor at rated torque (0.51 Ncm), rated voltage and constant speed of 100 RPM. Stall current 0.62 A 10% The Stall current is the armature current when the rated motor voltage is applied to the motor with locked rotor. No load current 0.038 A 40% The No load current is the motor armature supply current at no load speed.
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Electromechanical
Back Electromotive Force 1.7 V 10% The back electromotive force is the voltage measured across the terminal, carrying the motor shaft to a constant speed of 1000 rpm.
7.1.2.7 Color Motor

The ribbon motor is a linear actuator stepper motor. ELECTRICAL REQUIREMENTS Phase resistance 150 ### 10% Measured at 25 between pin 1-2 and 3-4 Phase inductance 106 mH 20% Measured at 1 Khz 100 mV. Rated motor voltage 12 V With rated voltage applied to both phases (parallel). Rated phase current 0.07 A With rated current applied to both phases (series). MECHANICAL REQUIREMENTS Travel Incremental unit 18 mm 0.0846 mm 10%
Fig 7.7 Color motor pin connector assignment GENICOM 3460 / 3480 / 3480+ 7.11 GEK-89537
Electromechanical
7.1.2.8 Stacker Motor

The ribbon motor is a 15 permanent magnet bipolar stepper motor. ELECTRICAL REQUIREMENTS Phase resistance 200 ### 10% Measured at 25 between pin 1-2 and 3-4 Phase inductance 170 mH 20% Measured at 1 Khz 100 mV. Rated motor voltage 12 V With rated voltage applied to both phases (parallel). Rated phase current 0.06 A With rated current applied to both phases (series). Back electromotive force 17.5 Vpeak 20% With motor shaft at the constant speed of 1000 RPM MECHANICAL REQUIREMENTS Step angle 15
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Maintenance Manual Devices Fig 7.8 Stacker motor pin connector assignment
Electromechanical
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Electromechanical
7.1.3 Cables 7.1.3.1 Sensors Cable

This cable is composed of five optical sensors (two interrupter and three reflective ones). The figure below shows the electrical connections of this cable.
Fig. 7.9 Sensors Cable
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Electromechanical
7.1.3.2 Alternance Cable

The figure below shows the electrical connections of this cable.
Fig. 7.10 Alternance Cable
7.1.3.3 Paper Stacker Cable

Fig. 7.11 Paper Stacker Cable
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Electromechanical
7.1.3.4 Operator Panel Cable

Fig. 7.12 Operator Panel Cable
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Maintenance Interfaces
Manual
Chapter 8 Interfaces
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8.1
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Manual
8.1 Overview
This chapter refers to the interfaces used on the printer. Information passing through the interface can be described in three separate aspects (levels): 1- Physical and electrical characteristics which enable the transferred signals to be recognized by both devices that are talking each other. 2- Link protocol signals and rules enabling and maintaining the connection and the transfer of data to be recognized and interpreted by both devices. 3- Device protocol the "language" which allows different products to give the same meaning to the transferred information. Refer to the USER MANUAL for all the recognized commands.
8.1.1 Hot Interfaces

All physically available interfaces are simultaneously connected to systems. When one is operating, the other interface(s) are busy unless the input memory reserved for that interface has space enough to receive characters. To each interface an emulation is associated (by the operator) changing the interface parameters also the emulation environment. If there is not enough memory to store the complete environment, changing the interface in case of different emulations will reset the printer, including DLL data. The interface is reserved as soon as a first character is received, and until 10 sec. are passed after the end of any printing activity without receiving any characters (any type, including service, commands etc).
8.2 IEEE 1284 Parallel Interface

The hardware of the parallel interface implemented in this printer is able to support the IEEE 1284 interface, even if the actual level of FW is not able to manage it. This interface is a bi-directional extension of the existing personal computer parallel interface (commonly known as the CENTRONICS interface). The bi-directional communication occurs using the signals of the currently interface. This new interface has been issued due to the limitation of the actual standard parallel interface with respect to the new PC environment. The serial port provides bi-directionality but does not offer enough bandwidth. The Standard parallel interface (Centronics) offers a higher but limited bandwidth and no bidirectionality. Centronics also requires a lot of assistance from the host CPU making it inadeguate for environments like Windows where multiple applications are running simultaneously. FEATURES 1) This interface provides the capability to send data from the host to the peripheral device at higher speed than it was possible before. This is accomplished by shortening the signal timing values where possible. 2) This interface provides a path for data to be sent from the peripheral device to the host using existing and future parallel port hardware. 3) The reverse channel capability reduces the amount of user interaction needed to operate the peripheral device. GENICOM 3460 / 3480 / 3480+ 8.2 GEK-89537
Maintenance Interfaces For example, application program can ask a printer for a list of fonts currently available. The application can then decide if new fonts must be downloaded, rather than asking the user to do it.
Manual
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Manual
8.2.1 Communication Modes

The IEEE1284 interface supports a number of distinct communication modes, and the interpretation of interface signals depends on the current mode.
### Compatibility mode (Centronics)
This is the lower level mode which provides an asynchronous, byte-wide forward (hostto-peripheral) channel with data and status lines used according to their original definitions. In this mode, the host sends 8-bit bytes to the peripheral device over the interface data signal D1 ... D8.
### Nibble Mode
This mode provides an asynchronous, reverse (peripheral-to-host) channel, under control of the host. In this mode, peripheral device to host data bytes are sent as two sequential, four-bit nibbles using the four peripheral-to-host status lines. This mode is used with Compatibility mode to implement a bi-directional channel. These two modes cannot be active simultaneously.
### Byte Mode
This is the higher mode supported by the printer. It provides an asynchronous, bytewide reverse (peripheral-to-host) channel using the eight data lines of the interface for data and the control/status lines for handshaking. This mode is used with Compatibility mode to implement a bi-directional channel with transfer direction controlled by the host, when the host and the peripheral both support bi-directional use of the data lines. These two modes cannot be active simultaneously.
The highest interface mode can be selected via Menu: in this way the interface can be limited to: Centronics, Bidirectional Nibble, Bidirectional Byte.
8.2.2 Operating Phases

Interface operation is divided into different interface phases. Each communication mode consists of one or more phases. Additional phases are defined toward initialization and transitions between communication modes. The names and interpretations of the interface signals may vary between phases, but are consistent within each phase. Compatibility Mode Phases Compatibility Mode Forward Data Transfer phase. This phase begins when the host asserts nStrobe and ends following data hold time and nStrobe de-assertion (the host is not free to send the next data until the device acknowledges the transfer using nAck). The host may not initiate negotiation to a new operating mode until the interface returns to Compatibility Mode Forward Idle Phase. Compatibility Mode Forward Idle Phase The interface is in Compatibility mode with no data transfer in progress. The host may initiate a data transfer in Compatibility mode, or may initiate negotiation to a new operating mode. GENICOM 3460 / 3480 / 3480+ 8.4
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Manual
GENICOM 3460 / 3480 / 3480+
8.5
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Maintenance Interfaces Nibble and Byte Mode Phases Reverse Data Transfer phase. Data transfer from peripheral to host. Reverse Host Busy Data Available phase. The peripheral has data to transmit. Reverse Host Data Not Available phase The peripheral has no more data to trasmit. Reverse Idle phase No data transfer in progress, the host is waiting for device data. When data is available, the peripheral will cause the interface to go to the Reverse Interrupt phase. Reverse Interrupt phase This phase provides the mechanism for the peripheral to alert the host that it has data to transfer. While in this phase, the host may cause the interface to go to the Termination Phase.
Manual
Additional Phases Initialization phase This phase includes both power-on initialization and host-driven interface reset. Negotiation phase Signal handshaking to change the signaling method from Compatibility Mode to Nibble or Byte. Termination phase A host-initiated transition phase in which the interface is changed from Nibble or Byte to Compatibility.
8.2.3 Negotiation
This interface is self adapting to the same mode as the system to which it is connected, also if it is not IEEE 1284 compliant. This means that a IEEE 1284 compliant host negotiates with the peripheral device to determine whether or not the device is 1284 compliant by checking its status lines to include PError and nFault both at logic high levels for a particular host stimulus. (n Selectin set high in conjunction with host busy being set low to request a 1284 mode). Together with this stimulus, the IEEE 1284 interface protocol has been designed to allow the host to request that the peripheral device uses various communication modes. This is accomplished by the host placing an extensibility request value on the data bus during the negotiation phase. The value 00h means Nibble Mode, while the value 01h means Byte Mode The printer answer on Xflag signal to this value. The Xflag affermative response is LOW for Nibble Mode, HIGH for Byte Mode.
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Manual
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Manual
8.2.4 Parallel Interface Signals

1284 Mode signal names are shown with their Compatibility mode (Centronics) names in paretheses ( ).
PIN N. for PIN N. for SIGNAL SIGNAL RETURN SOURCE NAME WIRE WIRE --------------------------------------------------------------------------------------------------------------------------------------HostClk (nStrobe ) 1 19 HOST AD1 AD2 AD3 AD4 AD5 AD6 AD7 AD8 (Data (Data (Data (Data (Data (Data (Data (Data 1) 2) 3) 4) 5) 6) 7) 8) 2 3 4 5 6 7 8 9 10 11 12 13 14 31 32 36 16, 33 17 18 35 PRINTER (max. 250mA) PRINTER (3.3 K pull-up) 20 21 22 23 24 25 26 27 28 29 28 HOST in Compatibility mode and negotiation phase NOT USED in Nibble mode BIDIRECTIONAL in Byte mode
PrtClk (nAck) PrtBusy (Busy) AckDataReq (PError) Xflag (Select) HostBusy (nAutofd) n.a. (nInit) nDataAvail (NFault) 1284 Active (NSelectIn) Common Logic Ground Chassis Ground Optional output voltage (+ 5V DC) Pulled up signal (+ 5V DC)
PRINTER PRINTER PRINTER PRINTER HOST HOST PRINTER
Table 8.1 Parallel Interface Pin Assignment
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Manual
8.2.4.1 Parallel Interface Signals Behaviour

HostClk / nWrite (nStrobe ) Compatibility Mode: Negotiation phase: printer input latch. Reverse Data Transfer phase:
Set active low to transfer data into printer input latch. Data is vaild while nStrobe is low. Set active low to transfer extensibility request value into Data is valid on the falling edge of HostClk. Set high during Nibble Mode transfer to avoid latching data into printer. Pulsed low during Byte Mode transfers to acknowledge transfer of data from the printer. The printer shall ensure that this pulse does not transfer a new data into the printer input latch.
AD1..AD8 (Data 1...Data 8) Compatibility Mode: Negotiation phase: Reverse Data Transfer phase:
Forward channel Data Extensibility request value. Nibble Mode: NOT USED Byte Mode : Reverse channel Data
PrtClk (nAck) Compatibility Mode: Negotiation phase:
Reverse Data Transfer phase: Reverse Idle phase :
Pulsed low by the printer to acknowledge the transfer of a data from the host. Set low to acknowledge 1284 support, then set high to indicate that the Xflag (Select) and data available flags may be read. Used in both Nibble and Byte Modes to qualify data being sent to the host. Set low then high by printer to cause an interrupt indicating to host that data is available.
PrtBusy (Busy) Compatibility Mode: Negotiation phase: Reverse Data Transfer phase:
Reverse Idle phase : AckDataReq (PError) Compatibility Mode:
Driven high to indicate that the printer is not ready to receive data. Reflects the present state of the printer's forward channel. Nibble Mode: Data bits 3 then 7, then forward channel busy status. Byte Mode : Forward channel busy status. Forward channel busy status.
Negotiation phase: Reverse Data Transfer phase: Reverse Idle phase:
Driven high to indicate that the printer has encountered an error in the paper path. The printer shall set nFault low whenever it sets PError high. Set high to indicate 1284 support, then follows nDataAvail (nFault). Nibble Mode: Data bits 2 then 6. Byte Mode : Same as nDataAvail (nFault) Set high until host requests data transfer, then follows nDataAvail (nFault).
GENICOM 3460 / 3480 / 3480+
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Maintenance Interfaces Xflag (Select) Compatibility Mode: Negotiation phase:
Manual
Reverse Data Transfer phase: Reverse idle phase:
Set high to indicate that the printer in on-line. The name Xflag refers to extensibility flag. Used by the printer to reply to the requested extensibility byte sent by the host during the negotiation phase. The signal level is low for Nibble Mode, high for Byte Mode. Nibble Mode: Data bits 1 then 5. Byte Mode : Same as negotiation phase. Same as negotiation phase.
HostBusy (nAutofd) Compatibility Mode: Negotiation phase:
Reverse Data Transfer phase:
Reverse Idle phase:
Set low by host to put the printer into auto-line feed mode. Set low in conjunction with 1284 Active (NSelectIn) being set high to request a 1284 mode. Then set high after printer sets PtrClk (nAck) low. Nibble Mode: Set low to indicate that host can receive printer-to-host data, then set high to acknowledge receipts of that nibble. Byte Mode: Same as Nibble Mode to request and acknowledge bytes. Following a reverse channel transfer the interface transitions to idle phase when HostBusy (nAutoFd) is set low and printer has no data available. Set high in response to PtrClk (nAck) low pulse to re-enter reverse data transfer phase. Is set high with 1284 Active (nSelectIn) being set low, the 1284 idle phase is being aborted and the interface returns to Compatibility Mode.
Peripheral Logic High (+ 5V ) Set high to indicate that all other signals sourced by the printer are in valid state. Set low to indicate the printer is off.
n.a. (nInit) Compatibility Mode:
Negotiation phase: Reverse Data Transfer phase:
Pulsed low in conjunction with 1284 Active low to reset the interface and force to return to Compatibility Mode idle phase. Set HIGH Set HIGH
nDataAvail (NFault) Compatibility Mode: Negotiation phase:
Reverse Data Transfer phase:
Reverse Idle phase : GENICOM 3460 / 3480 / 3480+
Set low to indicate that an internal printer error has occurred. Set high to acknowledge 1284 compatibility. In Nibble or Byte Mode it is then set low to indicate printerto-host data is available following host setting HostBusy (nAutoFd) high. Nibble Mode: Set low to indicate that printer is ready to send to host. Then used to send data bits 0 then 4. Byte Mode : Used to indicate that data is available. Used to indicate that data is available. 8.10 GEK-89537
Manual
1284 Active (NSelectIn) Compatibility Mode: Negotiation phase: Reverse Data Transfer phase:
Reverse Idle phase :
Set low by host to select printer. Set high in conjunction with Host Busy being set low to request a 1284 mode. Set high to indicate that bus direction is printer to host. Set low to terminate 1284 mode and set bus direction host to printer. Same as Reverse Data Transfer phase.
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Figure 8.1 Compatibility, Nibble and Byte Mode phase transitions.
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8.2.5 Electrical and Physical Characteristics

Physical Interface (Centronics and IEEE) The standard parallel interface is available on a specific 36 pin connector type AMPHENOL 57-40360-12-D56 or equivalent; it corresponds with IEEE 1284 connector type B. Electrical Interface Compliant with IEEE 1284 level 2 . It is accepted that until the proper integrated components are not available, the IEEE 1284 level 1 will be used. Standard Centronics requests OUTPUT 0.0V < Low Level (OFF) < 0.5V 2.4V < High Level (ON) < 5.0V 0.0V < Low Level (OFF) < 0.8V 2.4V < High Level (ON) < 5.0V FAN-OUT < 5UL
INPUT
FAN-IN < 5UL
UL = TTL Normalized Input Unit Load = 40 /uA High,1.6 mA Low CENTRONICS DRIVE CAPABILITY Up to 15 feet (5m), AWG 26 min. Twisted conductors on TTL receiver. The max. reacheable distance is conditioned by the Host drive capability and by the noise level along the interface cable path.
Standard IEEE 1284 requests Level 1 Drivers (circuits with TTL levels) Open circ. High level <= 5.5V Low level >= -0.5V Steady High level >=2.4V @ 0.32mA Low level <=0.4V @ 12 mA Pull up resistors >=1.8Kohm (cntrl & status) >=1.0 Kohm (data) Capacitance <= 50pF no damage/improper operation transients -2.0 to +7.0 V threshold High level <=2.0V sink curr.: <= 0.32 mA Low level >=0.8V <= 12 mA pull up resistors <=470ohm (cntrl & status) <=1000 ohm (data) capacitance <= 50 pF Rise/fall time (0.8Vto2.0V) <=120 ns (circuits with AC symmetric impedences) Open circ. High level <= 5.5V Low level >= -0.5V Steady High level >=2.4V @ 12mA Low level <=0.4V @ 12 mA Slew rate 0.05-0.4 V/ns no damage/improper operation transients -2.0 to +7.0 V threshold High level <=2.0V sink curr.: <= 20 uA 8.13 GEK-89537
Receivers
Level 2 Drivers
Receivers GENICOM 3460 / 3480 / 3480+
Maintenance Interfaces Low level >=0.8V minimum 0.2V maximum 1.2 V capacitance <= 25 pF histeresis <= 20 mA
Manual
8.2.6 Interface Timing
CENTRONICS mode
Figure 8.2 Centronics Timing
IEEE 1284 mode
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1284 active
AckDataReq
Manual
Data
byte
byte
HostBusy
Host clk
Prt clk PrtBusy
nDataAvail
Host to printer
Printer to host
FORWARD
REVERSE
Figure 8.3 IEEE 1284 Timing
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8.3 Serial Interface

The printers can optionally provide an additional board with a 25 pin connector with both RS-232/C and RS-422/A electrical interfaces. Selection is done by Configuration Menu. These interfaces support full-duplex connections only (no Line Turn Around procedure is available). When the Reduced (LOCAL) Connection is selected, it is possible to exchange data on either the RS-232/C or RS-422/A interface, according to selected type of interface. When the RS-232/C interface is selected, the Full Connection can be used, with all its control signals. For remote connections, RS 232 C is required. Since the RS-422/A interface does not support any control signal, the printers assume all control signals of the EIA RS-232/C interface as being internally asserted to a positive level.
8.3.1 RS-232/C Full Duplex Connection 8.3.1.1 Serial Interface RS-232/C Signals
Pin N. RS-232/C Signal source circuit local remote conn. conn. --------------------------------------------------------------------------------------------------------------------------------------1 FRAME GND 101 AA 7 2 3 SIGNAL GND 102 AB BA BB PRT HOST PRT DATA SET Signal Name ISO/CCITT circuit
TRANSMITTED DATA (TXD) 103 RECEIVED DATA (RXD) 104
4 5 6 8
REQUEST TO SEND (RTS) CLEAR TO SEND (CTS) DATA SET READY (DSR) DATA CARRIER DETECTOR (DCD) 2ND REQUEST TO SEND TO SEND (2nd RTS) DATA TERMINAL READY (DTR)
105 106 107 109
CA CB CC CF
PRT
PRT DATA SET DATA SET DATA SET
11
120
SCA
PRT
20
108
CD
PRT
PRT
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Table 8.2 RS-232/C Serial Interface Pin Assignment
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8.3.1.2 RS-232/C Signals Behaviour

These notes use the pin number for reference. 1 Frame GND (Shield) Shield can be optionally disconnected from the frame ground by means of a customer accessible jumper. The printer is shipped with pin 1 connected to the frame ground (protective ground). 7 Signal ground This pin is the common 0 Volt of the power supply. 2 Transmitted data signal (an output from printer) A MARK condition is held during IDLE communication state. An indeterminate state is present when printer is powered off. 3 Received data signal (input) No fail safe circuit is present on this input signal. The receive data selection feature must select this input to provide to the printer.
data
4 Request to Send Signal (output) An ON condition is provided as long as Data Set Ready signal is found ON (DSR is assumed always ON in Reduced Connection). It is held ON until printer is disconnected. An indeterminate output is present when printer is powered off. 5 Clear to Send (input) Full_Connection: Remote connection: When ON this signal enables the data transmission to the Host (e.g. status, flow control characters etc.). Direct connection to Host: Normally it is provided by the printer generated Request To Send signal via crossed wire connection in the cable. Reduced_Connection: Printer assumes an ON condition for this signal. 6 Data Set Ready (input) Printer enables its reception and its transmission only if the ON condition is found on this signal. Full_Connection: Remote connection: An ON condition indicates that Data Set is connected to the line. This does not always mean that the link is actually established, because it depends on the used type of data sets and network. Printer considers the ON condition as an actualized connection with the Host. Normally, when a Data Set is used on a switched or leased line, this signal going ON is an answer, after a certain time, to the printer Data Terminal Ready turned ON and viceversa. It is responsibility of the Host to make decisions GENICOM 3460 / 3480 / 3480+ 8.18 GEK-89537
Maintenance Interfaces about the call establishment and printer availability. Hence, the printer will simply suspend its connection phase until Data Set Ready will turn ON after DTR is turned ON.
Manual
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Maintenance Interfaces Direct connection to Host: Normally it is provided by the Host generated Data Terminal Ready signal via crossed wire connection in the cable. Reduced_Connection: Printer assumes an ON condition for this signal. 8 Data Carrier Detector (input) Full_Connection: Remote connection: An ON condition on this signal indicates that Host modem is sending the data carrier frequence (Host has turned ON its Request To Send). An OFF condition indicates either the Host is not sending its carrier or the link line has been interrupted. Direct connection to Host: Normally it is provided by the Host generated Request To Send signal by crossing the wire in the connection cable. Reduced Connection: Printer assumes as ON condition for this signal. 11 2nd Request to Send Signal (output) Functionally equivalent to Data Terminal Ready 20 Data Terminal Ready (output) Remote connection: An ON condition of this signal indicates that printer is ready to initiate a connection. Printer turns or confirms the ON condition on this signal every time is initialized. In turn, an ON condition is expected on the Data Set Ready signal. Normally it is wired to the Host Data Set Ready signal by crossing the wire in the connection cable. An indeterminate condition is present on this output signal when printer is powered OFF.
Manual
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8.3.1.3 RS-232/C Electrical and Physical Characteristics
SIGNAL STATE ELECTRICAL LOGICAL CATEGORY LEVEL LEVEL -------------------------------------------------------------------------------------------------------MARK (Stop) DATA SPACE (Start) In the range from +3V to +25V "0" In the range from -3V to -25V "1"
ON CONTRL OFF
In the range from +3V to +5V In the range from -3V to -5V
"1"
"0"
Signals between -3V and +3V must not be used since receivers assume an indeterminate output state. Drive capability: In accordance with RS-232/C Standard and CCITT-V28 Recommendation: the maximum assured distance is 50 feet (15m) for all supported data rates.
8.3.2 RS-422/A Interface

This interface is provided together with the full RS 232C on the same optional board and uses the same 25 pin connector: some of the pins are dedicated to each type of interface. If the printer provides both RS-232/C and RS-422/A interfaces, when it is personalized for local connection it must be able to exchange data on either the RS-232C or RS-422/A interface with no distiction about which type of interface is used. Since the RS-422/A interface does not support any control signal, the printer assumes all control signals of the EIA RS-232/C interface as being internally asserted to a positive level. This interface is intended as a subset of standard RS 422 providing its basic signals and allowing the connection of printers at the same conditions as the competition. This interface supports full-duplex local connections. Only data signals are provided in this interface. Pin assignments refer to the same 25 pin connector also used for the RS 232-C interface.
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8.3.2.1 RS-422/A Interface Signals

Pin N. ISO/CCITT Signal source circuit ---------------------------------------------------------------------------------------------------1 FRAME GND 7 13 14 16 19 SIGNAL GND TRASMIT TRASMIT RETURN RECEIVE RECEIVE RETURN T (A) T (A) R (A) R (B) PRINTER HOST Signal Name
Table 8.3 RS-422/A Serial Interface Pin Assignment
8.3.2.2 RS-422/A Signals Behaviour

These notes use the pin number for reference. 1 Frame GND (Shield) Shield can be optionally disconnected from the frame ground by means of a customer accessible jumper. The printer is shipped with pin 1 connected to the frame ground (protective ground). 7 Signal ground This pin is the common 0 Volt of the power supply. 13 Transmit Indeterminate level is output when printer is powered off. Mark signal is present when printer is not sending data. 16 Receive A mark state fail safe circuitry is present on this input in order to prevent spurious receptions when the cable is disconnected or the driver is powered off at the host side. A mark level is expected when sender is in idle state.
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8.3.2.3 RS-422/A Electrical and Physical Characteristics

SIGNAL STATE ELECTRICAL LOGICAL CATEGORY LEVEL LEVEL -------------------------------------------------------------------------------------------------------MARK (Stop) TRANSMIT SPACE (Start) T(A) more positive than T(B) "0" T(A) more negative than T(B) "1"
MARK (Stop) RECEIVE SPACE (Start)
R(A) more negative than R(B) R(A) more positive than R(B)
"1"
"0"
Drive capability: Using a proper twisted pair shielded cable, a maximum distance of 4000 feet (1200 m) is expected when standard driver and receiver circuits are used on both sides
8.3.3 Other Characteristics of RS-232/C & RS-422/A

### ###
Transmission type: Data char. format:
Asynchronous (start/stop) with serial bit data 1 Start bit + 8 Data bit + 1 Parity bit + 1 Stop bit. data bits is selectable. The framing error reported on is link and device protocol dependent. The least significant bit is sent first, parity bit follows data bits. Start and stop bits are character framing bits.
Number of paper
###
Bit trasmission :
the
###
Parity & P.check:
NO reporting
The parity check is ODD/EVEN or MARK/SPACE or PARITY accordin to the selection. The parity error on paper is link and device protocol dependent. Parallel bit: The ability to avoid the presence of the parity bit both in reception and trasmission is device dependent. <2% of the bit time (i.e.printer sends the stop distorsion bit which edges can be shifted + 2% degrees with respect to their
###
Trasmitting gross: Start/Stop at maximum nominal position).

###
receive margin: Better than 37% (i.e. printer samples the last bit of a 10 bit character in the range of + 13% around the nominal bit center of the received character) Data Bit Rate: 300/600/1200/2400/4800/9600/19200/38400 Bps. The bit rates actually provided are device dependent. 8.23 GEK-89537
###
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Manual
8.4 Link Protocols

8.4.1 DTR & 2nd RTS Data Flow Control
The data flow is controlled by the 2nd RTS interface signal on pin 11 of RS-232/C interface (25 pin connector) Signal levels Low (negative) : if buffer is in HGL condition High (positive) : if buffer is in LGL condition The DTR signal (pin 20) of this interface is driven with the same procedure of the pin 11. When input buffer condition goes in the Medium Guard Level (MGL), DTR/2nd RTS is set OFF until the buffer condition recovers to Low Guard Level (LGL) again (see next figure).
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Maintenance Interfaces Figure 8.4 DTR/2nd RTS Timing
Manual
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Manual
8.4.2 Xon/Xoff Data Flow Control

The data flow is controlled via TX line. The XON code (HEX. 11) is used to indicate that the printer is able to receive data. (It is sent also at Power-on after completion of initialization) The XOFF code (HEX. 13) is used to indicate that the printer is unable to receive data. The XOFF code is sent when input Buffer is in the Medium Guard level (MGL) condition. The XOFF code is sent on every received character when input buffer is in the High Guard Level (HGL). The XON code is sent when the buffer is in the Low Guard Level (LGL) condition. The XON code is repeated every two (2) sec when no data are sent to the printer.
Figure 8.5 XON/XOFF Timing GENICOM 3460 / 3480 / 3480+ 8.26 GEK-89537
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8.4.3 Buffer Management

The data transmission is conditioned by the buffer status. Rx buffer is managed in a two guards mode and its state is reported through DATA FLOW CONTROL message. A Medium Guard Level and a Low Guard Level can be defined in order to respectively stop and allow start of character transmission. MGL (stop) condition is maintained valid until the buffer is emptied (by printing) up to the LGL, which in turn is maintained valid until the MGL is reached; i.e. a buffer filled with characters in number between MGL and LGL is declared MGL or LGL according to its preceeding condition. The value of LGL is the buffer size minus 528 characters (or the buffer size if it is lower than that value). The value of LGL is defined taking into consideration some customer applications where a pack of 512 characters is sent to the printer without any intermediate check. When Rx buffer overrides Medium-Guard-Level (64 byte less than Max buffer capacity), Interface enters BUSY State. When Rx buffer, after printing, goes down to the Low-Guard-Level, Interface resumes READY State.
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Figure 8.6 Buffer Management
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Chapter 9 Options
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Maintenance Options
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9.1 Overview
This section describes the options available for this printer with their characteristics and installation procedure.
9.1.1 Automatic Sheet Feeder

The Automatic Sheet Feeder consists of a motorized input feeder that can handle up to 120 single sheet paper forms (see chapter 1.4 for more details). The ASF can coexist also with the Rear tractor unit. This option is USER installable and a MENU personalization is required. In the figure 9.1 it is possible to see the various components of the 1st ASF, which are: 1) First Bin Feeder Assembly 2) Output Paper Stacker Assembly 3) Antinoise Cover 4) Paper Support for input paper 5) Paper Support for output paper 6) Metal hooks for ASF installation on basic mechanism 7) Electrical finger-board for ASF electrical connection 8) Output Stacker metal supports 9) Cable connection ASF-Output Stacker
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Figure 9.1 1st ASF Components
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Maintenance Options ASF BLOCKS DIAGRAM The ASF hardware is composed of two separate boards: Paper Stacker Board ASF Board.
Manual
and up to five motors (with 3 ASF installed): Paper Stacker stepper motor which switches a metal plate to allow the correct loading of the single sheet or the fanfold through it. ASF DC motor inside each ASF which loads the single sheet into the printer.
The first board is included in the STACKER assembly and connects, through its finger-type edge and the stacker cable, the main board. The second board is integrated in the ASF1 assembly and allows the connection of the DC motors As described in chapter 3, the ASIC integrated circuit drives the mechanical option connector lines via its internal serial synchronous interface. The blocks diagram of the STACKER/ASF option isa shown below.
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Figure 9.2 ASF and Stacker Blocks Diagram
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Maintenance Options ASF INSTALLATION 1) Remove the ASF rear cover by simply extracting it from the main rear cover. 2) Remove the upper antinoise cover by simply extracting it from the main rear cover and install the new one in the same position (item 3 of fig. 9.1). 3) Remove the two slot covers with the paper deflector for output stacker installation by simply unooking them from the top cover. 4) Locate the two grooves on the metal base frame of the mechanical assy. In these grooves you have to insert the two metal hooks of the ASF support (item 6 of fig. 9.1).
Manual
OUTPUT STACKER INSTALLATION 5) Locate the connector which provides the connection of Output Stacker board with the Main Board through the Paper Stacker Cable on the right side of the top cover. - Install the output stacker inserting the grooves (item 8 of fig. 9.1) in the dedicated pins present on the basic mechanism. - Slowly insert the board edge (item 7 of fig. 9.1) in the connector until the stacker clicks. - Connect the bin cable (item 9 of fig. 9.1) in the proper connector present in the right side of output stacker. To remove the output stacker, open the two metal supports of the Output Stacker (item 8 of fig. 9.1) by acting on the two proper black levers and extracting it.
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Figure 9.3 ASF Installation (rear view)
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Maintenance Options SECOND (and THIRD) BIN INSTALLATION The second and the third bin are also installable by the USER. 1) First of all, remove the plastic cover plates located on both rear sides of the first bin by simply extracting them. 2/3) Slide the second bin into the first bin until the two support arms snap in place. (The pin located in the bottom part of in the first bin must be inserted into the hole present in the hook lever (item 3) located on the front part of the second bin (both sides). 4) Remove the ASF board cover by simply extracting it from the metal frame. 5) Install the second BIN cable in the proper connector of the board shown inside the circle in the figure below. Follow the same procedure for the installation of the third BIN on the second one. To remove the BINs, is necessary to start from the first one. Remove the two plastic caps (item 6) by simply extracting them from the first bin case. Locate the hook lever and related pin (item 2 and 3) through the front hole remaining after the plastic caps removal. Put a flat screwdriver between these parts to un-hook them and, at the same time, extract the second BIN from the first one. Follow the same procedure for the removal of the second bin from the third one.
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Figure 9.4 Second Bin ASF Installation GENICOM 3460 / 3480 / 3480+ 9.8 GEK-89537
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9.1.2 Color Motor

The color option consist in a linear actuator (step motor) installed on the carriage assy. The linear movement of this motor causes the up-and-down movement of the metal bar present in front of the color inked ribbon cartridge. This cartridge has only two fixing points in its rear part, therefore it is free to up and down in its front part where the four color band inked ribbon is installed. This option is USER installable and no MENU personalization is required. COLOR MOTOR INSTALLATION Before proceeding to color motor installation remove, if present, the inked ribbon cartridge. 1) Insert the color motor connector in the plug present on the left side of print head support. 2) Insert the color motor assy in its position on the carriage assy. 3) Tighten the two screws.
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Maintenance Options Figure 9.5 Color Motor Installation
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Maintenance Options COLOR RIBBON INSTALLATION Before proceeding to color ribbon installation power on the printer to initialize hte color motor (the actuator will be in its maximum inner position). 1) Install the color ribbon cartridge on its left and right supports. 2) Insert the plastic bracket present on the color ribbon over the ribbon color plastic side.
Manual
3) Gently push down the ribbon plastic bracket over the motor plastic braket guide until it "clicks" into place. 4) To remove the color ribbon a slightly pree on the lever before extracting the ribbon plastic bracket.
Figure 9.6 Color Ribbon Installation GENICOM 3460 / 3480 / 3480+ 9.11 GEK-89537

Genicom 3460 Maint Manual

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GENICOM

MODEL 3460/3480/3480+ MAINTENANCE MANUAL GEK-89537

GENICOM 3460 / 3480 / 3480+

Table of Contents cont'd

GENICOM 3460 / 3480 / 3480+

Table of Contents cont'd

GENICOM 3460 / 3480 / 3480+

Table of Contents cont'd

GENICOM 3460 / 3480 / 3480+

Table of Contents cont'd

Page 9.2 9.2 9.6 GEK-89537

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GENICOM 3460 / 3480 / 3480+

GENICOM 3460 / 3480 / 3480+

GENICOM 3460 / 3480 / 3480+

GENICOM 3460 / 3480 / 3480+

COPYRIGHT 1998 - GENICOM CORPORATION Printed in Italy All Rights Reserved

GENICOM 3460 3480

Canadian D.O.C. Radio Interference Regulation

GENICOM 3460 3480

Maintenance Manual Overview

Chapter 1 General Overview

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Maintenance Manual Overview

Difference about 3460/3480 (A2), 3460/3480 (A3) and 3480+

1.1.1 Scope of the Products

1.1.2 Printers Features Summary

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Maintenance Manual Overview

1.2 General Description

Fig. 1.1 Basic Printer Parts Location (front view)

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Maintenance Manual Overview

1. Interface Cover 2. Rear Tractor Unit Cover 3. Paper Stacker Covers

4. ASF Location Cover 5. AC Power Inlet 6. Paper Deflector

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Maintenance Manual Overview

1.2.2 Physical Dimension

1.2.3 Printer Structure

Maintenance Manual Overview

1.2.3.1 Mechanical Assy

1.2.3.1.1 Tractor Unit Assy

1.2.3.2 Print Head

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Maintenance Manual Overview

1.2.3.4 Electronic Hardware

1.2.3.5 Inked Ribbon Cartridge

1.2.3.6 Mechanical Options

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Maintenance Manual Overview

1.3 Product Components

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Product Name: Marketing Identifier: The product is composed of:

GENICOM 3460 / 3480 / 3480+

Maintenance Manual Overview

Product Name: Marketing Identifier: The product is composed of:

Product Name: Marketing Identifier: The product is composed of:

Product Name: Marketing Identifier: The product is composed of:

Product Name: Marketing Identifier: The product is composed of:

Product Name: Marketing Identifier: The product is composed of: