Manual 624 102515 A

OPERATION MANUAL
GS 6XX-2
Thermal Plotter
624-102515 Rev. A
December, 2006
~ COPYRIGHT NOTICE ~
This document is copyrighted by OYO Instruments, LP. No part of this publication may be reproduced,
transmitted, transcribed, stored in a retrieval system, or translated into any language or computer language
in any form or by any means, electronic, manual, or otherwise, without written permission of OYO
Instruments, LP, 7007 Pinemont, Texas 77040, U.S.A. Copyright violators may also be subject to civil
penalties.
~ DISCLAIMER ~
OYO Instruments, LP makes no warranties as to the accuracy, validity, or fitness for use of the contents
of this Manual. OYO Instruments, LP reserves the right to revise the information in this Manual at any
time without prior notice.
~ FCC INFORMATION ~
This equipment has been tested and found to comply with FCC 47 CFR Part 15 Emission Requirements for
Class A.
~ CERTIFICATION ~
This device complies with the European EMC Directive 89/336/EEC as amended and with the Standard
for Safety of Information Technology Equipment, including Electrical Business Equipment (UL 1950 and
CAN/CSA C22.2 No. 950).
OYO Instruments, LP
7007 Pinemont
Houston, Texas 77040-3144
U.S.A.
Telephone: 800-747-7651
Telephone: 713-986-4444
Telefax: 713-986-8724
Email: sales@oyo.com
Website: www.oyo.com
EUROPE - OYO Instruments, Europe Ltd.
F3 Enterprise Way,
Luton, Bedfordshire LU3 4BU
England
Telephone: 44 (0) 1582 573980
Telefax: 44 (0) 1582 574945
Email: sales@oyo.co.uk
~ STATEMENT OF LIMITED WARRANTY ~

OYO Instruments, LP (OYO) warrants its imagers (excluding print heads) for twelve (12) months. OYO
warrants its print heads for three (3) months. The purchaser of the imager may extend the print head
warranty to twelve (12) months via the execution of a film supply contract.
This warranty commences on the date of original shipment from OYO. Any part of the imager
manufactured or supplied by OYO and found in reasonable judgment by OYO to be defective in material or
workmanship will be repaired or replaced by an OYO authorized service center without charge for parts and
labor.
To obtain warranty coverage, a Return Material Authorization (RMA) number must be obtained and the
imager, including any defective parts, must be returned to an authorized service center within the warranty
period. Failure to follow the RMA procedure may void the warranty.
This warranty does not cover any imager that has been subject to misuse, neglect, negligence, accident, or
any imager that has been operated in any way contrary to the imager cleaning procedures (as specified in
the OYO Operators Manual). This warranty does not apply to damage resulting from improper
maintenance or from damage caused by imager modifications made by user.
This warranty does not extend to repairs made necessary by (i) normal wear or (ii) by the use of parts,
accessories, or media not distributed by OYO. The use of such uncertified items, especially media, may
adversely affect the imagers operation, performance or durability and therefore void this warranty.
OYO reserves the right to change or improve the design of any imager without assuming any obligation to
modify any product previously manufactured.
ALL IMPLIED WARRANTIES ARE LIMITED IN DURATION TO THE APPLICABLE WARRANTY PERIOD.
ANY SUCH IMPLIED WARRANTIES INCLUDING MERCHANTABILITY, FITNESS FOR A PARTICULAR
PURPOSE, OR OTHERWISE, ARE DISCLAMED IN THEIR ENTIRETY AFTER THE EXPIRATION OF THE
APPLICABLE WARRANTY PERIOD. OYOS OBLIGATION UNDER THIS WARRANTY IS STRICTLY AND
EXCLUSIVELY LIMITED TO THE REPAIR OR REPLACEMENT OF DEFECTIVE PARTS, AND OYO DOES
NOT ASSUME OR AUTHORIZE ANYONE TO ASSUME FOR THEM ANY OTHER OBLIGATION. SOME
STATES AND COUNTRIES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTIY
MAY LAST, SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU.
OYO ASSUMES NO RESPONSIBILITY FOR INCIDENTAL, CONSEQUENTAL OR OTHER DAMAGES
INCLUDING, BUT NOT LIMITED TO, EXPENSE OF RETURNING THE IMAGER TO AN AUTHORIZED
SERVICE CENTER, SERVICE PERSONELS TRAVEL TIME, TELEPHONE AND FASCIMILE CHARGES,
RENTAL OF A LIKE PRODUCT DURING THE TIME WARRANTY SERVICE IS BEING PERFORMED,
TRAVEL, LOSS OR DAMAGE TO PERSONAL PROPERTY, LOSS OF REVENUE, LOSS OF USE OF THE
PRODUCT, LOSS OF TIME, OR INCONVENIENCE. SOME STATES AND COUNTRIES DO NOT ALLOW
THE EXCLUSION OR LIMITATION OF INCEDINTAL OR CONSEQUENTIAL DAMAGES, SO THE ABOVE
LIMITATION MAY NOT APPLY TO YOU.
To locate your nearest OYO service center dial:

(800) 747-7651 or (713) 986-4444 in the United States
(01582) 573980 in the United Kingdom
Or send e-mail to support@oyo.com
~ IMAGER CLEANING PROCEDURES ~
To increase the reliability and useful life of your imager, OYO has designed the following cleaning
procedures. The regular use of these procedures is required to ensure compliance with OYOs warranty
protection for both the imager and the print head. The use of any other procedure may void the warranties
offered by OYO.
The thermal print head, rollers, media conditioner, and interior of the unit should be cleaned after use of
every roll of media, or sooner if required.
Print head Cleaning Instructions:

Wear only latex (non-powder) disposable gloves (part # 540V1106001). When handling and
cleaning the print head, the use of latex gloves is required to keep salts and oils present on the
operators hands from depositing onto the print head surface.
Use only 98% isopropyl alcohol cleaning wipes (part # 160V1106001). A mixture containing a
greater percentage of water may act as a carrier for salts (ions) which may lead to print head
corrosion.
With the cleaning wipe, rub the entire length of the print head.
After cleaning, dispose of all cleaning material. Do not reuse.
Make sure surface of print head is completely dry before closing unit.
Imager Cleaning Instructions:

In order to remove any contaminants and/or residue from the rubber platen roller and metal idler
roller, these components of the imager unit should also be cleaned with 98% isopropyl alcohol
cleaning wipes. All surfaces should be completely dry before closing the unit.
The inside of the imager unit, including the media conditioner, should be vacuumed thoroughly
before loading the next roll of media.
The back and side filters should be checked and vacuumed monthly (or replaced, if necessary) to
ensure adequate airflow across the thermal print head.
Other Precautions:
The print head should never come into direct contact with the platen roller (black drive roller).
Either a piece of Mylar or film should be placed between the print head and the roller if no media is
loaded in the imager.
Do not place media or media hubs directly on the floor or on any other unclean surface. Doing so
may cause contaminants to be picked up and introduced into the imager and cause print head
damage.
Avoid using the first and last wraps of media on the roll. This portion of the media may contain
contaminants due to handling. The manufacturer provides extra media on each roll to compensate
for this procedure.
The front panel of the imager should be opened every three months and shavings from the cutter
removed with a vacuum.
~ RETURN MATERIAL AUTHORIZATION (RMA) PROCEDURES ~

OYO provides warranty support and service through its facilities in Houston, Texas. To obtain warranty
support and service, please take the following steps:
1. To determine the extent of warranty support and service necessary, contact your OYO Technical
Support Department at (800) 747-7651 or (713) 986-4444 between 8:30 AM and 5:30 PM CST,
Monday through Friday, or by facsimile at (713) 986-8724. Or e-mail OYO at support@oyo.com
and indicate your daytime telephone number (including area code) and business address. If the
OYO support technician determines that your imager should be returned to OYO for repair, obtain a
Return Material Authorization (RMA) number from your OYO support technician.
2. Complete a copy of the attached RMA form. Additional copies of RMA forms can be obtained
from OYOs Technical Support Department.
3. Return the imager or appropriate imager component to OYO within 30 days, freight prepaid, in
either its original packaging or packaging affording an equal degree of protection. OYO can
provide approved packaging for a charge.
4. Remove all media from the imager and place a sheet of acetate over the rubber platen roller, also
covering the closed loop wheel in the film path (figure1). Film or media, power cord, hubs, and
cabling do not have to be returned with the imager.
5. Use a plastic sheet large enough to wrap around the entire imager when placing the imager in a box.
When lifting the imager, place lift straps around each end of the imager from the bottom for 2person lift (figures 2 & 3).
6. Enclose in the package a completed copy of the RMA form.
7. Indicate your RMA number on the outside of the package and on any shipping documentation. The
customer is responsible for the cost of shipping and insurance when sending products to OYO for
warranty service or repair.
8. Deliver all packages to:
OYO Instruments, LP
Attn: Service Department
7007 Pinemont
Houston, TX 77040
In the case of repairs covered by OYOs warranty, OYO will pay for shipping costs associated with the
return of the imager or components to the customers site, utilizing any shipping services it deems
appropriate. The customer is responsible for any incidental expenses such as import duties. All repairs will
be warranted for ninety (90) days or the remainder of the original warranty period, whichever is longer.
Failure to follow these procedures may void your warranty coverage or significantly delay warranty
repairs.
~ RETURNED MATERIAL AUTHORIZATION (RMA) FORM ~
CUSTOMER INFORMATION:
YOUR NAME:
COMPANY NAME:
COMPANY ADDRESS:
COMPANY PHONE:
COMPANY E-MAIL:
IMAGER/PLOTTER INFORMATION:
MODEL:
OYO RMA #:
DATE:
SERIAL NUMBER:
DETAILED REASON FOR RETURN:
Provide (i) a printout of print set-up from control panel on imager and (ii) a film sample showing problematic area.
WHAT EVENT LED UP TO THE FAILURE? DESCRIBE HOW TO REPRODUCE THE PROBLEM.
Additional Notes: (OYO Use Only)
Complete and fax this form to OYO at 713-986-8724 for RMA # assignment. OYO will return this RMA
form to you via facsimile, indicating the assigned RMA # and any necessary instructions. When shipping
the imager or parts to OYO, please return a copy of this form in your shipping package.
To be filled out by OYO Technical Support Department:
RMA Number Assigned:
Authorized by:
~ THERMAL MEDIA ~
OYOs thermal imaging products are precisely aligned and adjusted at the factory for proper
operation. The use of OYO certified media and accessories, as well as regular maintenance and
cleaning is essential to ensure the optimum performance of the imager.
Depending on the environment and usage, the imager may require cleaning even after short periods
of operation. Follow the cleaning and maintenance procedure given in Chapter 6.2 of the
Operation Manual.
Changing from paper media to film media requires the user to pay extra attention to the cleaning
process. It is imperative that all paper dust is removed from the imager to ensure optimum
performance.
The following types of thermal media are supplied by OYO for use in the Imager.
1. Report Grade Thermal Paper - This lightweight paper is susceptible to scratching. It
cannot be erased without marring the image. This paper leaves residue, but proper
cleaning, as described in the cleaning procedures, will prevent excessive wear.
2. Presentation Grade Thermal Paper - This heavy top-coated paper is resistant to
scratching. It can be erased without marring the image. This paper leaves residue, but
proper cleaning, as described in the cleaning procedure, will prevent excessive wear.
3. Thermal Film - OYO supplied film has been specially formulated and certified for use
with OYOs imagers. Some film may leave residue, but proper cleaning, as described in
the cleaning procedure, will prevent excessive wear.
4. Thermal Proofing Media - OYO supplied proofing media has been approved for use with
OYOs imagers. Some proofing media may leave residue, but proper cleaning, as
described in the cleaning procedure, will prevent excessive wear.
Contact your OYO sales representative at (800) 747-7651 or (713) 986-4444, or contact us via email at sales@oyo.com to obtain the part number and price of OYOs certified media products for
your imager.
TABLE of CONTENTS
1.0
1.1
1.2
1.3
1.4
INTRODUCTION
General Description............................................................................................................1-1
Functional Description .......................................................................................................1-1
Media Description ..............................................................................................................1-1
Mounting Configurations ...................................................................................................1-2
2.0
2.1
SPECIFICATIONS
Functional/Electrical/Physical/Environmental ..................................................................2-1
3.0
3.1
3.2
3.2.1
3.3
3.3.1
3.3.2
3.3.3
3.3.4
3.4
3.5
3.5.1
3.5.2
3.6
3.7
INSTALLATION
Unpacking...........................................................................................................................3-1
Mounting.............................................................................................................................3-1
Horizontal Mounting ..........................................................................................................3-1
Interfacing...........................................................................................................................3-2
Plot Mode............................................................................................................................3-9
Print Mode ..........................................................................................................................3-9
Driver Considerations.......................................................................................................3-14
Power Switching for 220 VAC ........................................................................................3-15
Installation of Paper Take Up ..........................................................................................3-15
Adjust Paper Supply Reel ................................................................................................3-17
Adjust the Paper Tension .................................................................................................3-17
Installation of Fan Fold Paper Tray .................................................................................3-18
Installation of Fan Fold Paper Guide ...............................................................................3-19
4.0
4.1
4.2
4.3
4.3.1
4.3.2
4.3.3
4.4
4.5
4.5.1
4.6
4.7
4.7.1
4.7.2
4.7.3
OPERATION
Precautions..........................................................................................................................4-1
Power Switch CB1 .............................................................................................................4-1
Control Panel Keypad ........................................................................................................4-1
Keypad Functions...............................................................................................................4-1
Menu and Item Modes........................................................................................................4-2
Parameter Selection ............................................................................................................4-5
Front Panel Indicators ........................................................................................................4-5
Loading Roll Paper.............................................................................................................4-8
Loading Fan Fold Paper .....................................................................................................4-8
Testing ..............................................................................................................................4-10
Error Messages .................................................................................................................4-17
Errors Due to Inappropriate System Configuration ........................................................4-17
Errors Occurred During Plotting Operation ....................................................................4-17
Errors from Electronic Subsystems Interfacing...............................................................4-17
4.8
4.8.1
4.8.2
4.8.3
4.8.4
Remote Escape Sequence Command Control .................................................................4-18

Escape Sequence Commands...........................................................................................4-18
Command Format.............................................................................................................4-18
List of Commands ............................................................................................................4-19
Applying Escape Sequence Command Control ..............................................................4-22
5.0
5.1
5.2
5.3
5.4
5.4.1
5.4.2
5.4.3
5.4.4
5.4.5
5.5
5.5.1
5.6
THEORY OF OPERATION
Introduction.........................................................................................................................5-1
Major Functions and Features of Plotter Controller..........................................................5-2
Parallel Interface.................................................................................................................5-2
Controller Theory of Operation .........................................................................................5-4
Controller Sequencers ........................................................................................................5-4
Input Controller Section Functions....................................................................................5-5
Signal Flow.........................................................................................................................5-6
Output Controller Section Functions .................................................................................5-8
Plotter Control Section Functions ......................................................................................5-8
Thermal Print Head Operation...........................................................................................5-9
Micro-Stepper Control .....................................................................................................5-10
Paper Cutter Circuit..........................................................................................................5-11
6.0
6.1
6.2
6.2.1
6.2.2
6.2.3
6.2.4
6.3
6.3.1
6.3.2
6.3.3
6.3.4
6.3.5
6.3.6
6.4
6.4.1
MAINTENANCE AND REPLACEMENT OF PARTS

Maintenance........................................................................................................................6-1
How to Clean the Print Head .............................................................................................6-1
Other Maintenance .............................................................................................................6-1
Frequency of Cleaning .......................................................................................................6-1
Other Precautions ...............................................................................................................6-2
Trouble Shooting ................................................................................................................6-2
Power Failure......................................................................................................................6-2
Paper Supply Failure ..........................................................................................................6-2
Test Pattern Failure.............................................................................................................6-2
Optical Density Failure ......................................................................................................6-2
Data Transfer Failure..........................................................................................................6-3
Control Panel Failure..........................................................................................................6-3
Unit Access.........................................................................................................................6-3
Entry Routes .......................................................................................................................6-3
Top Cover ...........................................................................................................................6-3
Top Chassis/Print Head Chassis ........................................................................................6-3
End Covers..........................................................................................................................6-4
Front Panel..........................................................................................................................6-4
Power Supply Adjustment..................................................................................................6-6
20V Power Supply..............................................................................................................6-6
5V Power Supply................................................................................................................6-7
Replacement of Parts........................................................................................................6-10
6.5
6.5.1
6.5.2
6.6
ii
6.6.1
6.6.2
6.6.3
6.6.4
6.6.5
6.6.6
6.6.7
6.6.8
6.6.9
6.6.10
6.6.11
6.6.12
6.6.13
6.6.14
6.6.15
6.6.16
6.6.17
6.6.18
Replace PCBA-Plotter Controller....................................................................................6-10

Replace PCBA-Power Switch, Left.................................................................................6-11
Replace PCBA-Power Switch, Right ..............................................................................6-12
Replace Control Panel ......................................................................................................6-12
Replace 5V Power Supply ...............................................................................................6-13
Replace 20V Power Supply .............................................................................................6-14
Replace Print Head ...........................................................................................................6-15
Replace Step Motor-Platen Drive ....................................................................................6-17
Replace Platen Drive Belt ...............................................................................................6-17
Replace Step Motor-Cutter Drive ....................................................................................6-18
Replace Blower- (Fan) .....................................................................................................6-19
Replace Filter-Blower (Fan) ............................................................................................6-20
Replace Drive Cable-paper Cutter ...................................................................................6-21
Replace Cutter Blade Assembly ......................................................................................6-22
Replace Capacitor.............................................................................................................6-23
Replace Switch, Head Engaged .......................................................................................6-24
Assembly of Long Knife ..................................................................................................6-25
Replacement of Long Knife .............................................................................................6-25
7.0
SCHEMATICS/PCBADRWGS/CABLE DRWGS/POWER SUPPLY SPECS
8.0
SPARE PARTS LISTS

Board Level Spares ...............................................................................................................8-1
Component Level Spares ......................................................................................................8-2
iii
LIST OF FIGURES AND TABLES

Fig 1.1
Fig 1.2
Fig 3.1
Table 3.1
Fig 3.2
Table 3.2.a
Fig 3.3
Table 3.2.b
Table 3.2.c
Table 3.2.d
Fig 3.4
Fig 3.5
Fig 3.6
Fig 3.7
Table 3.3
Fig 3.8
Fig 3.9
Fig 3.10
Fig 3.11
Fig 4.1
Table 4.1
Table 4.2
Table 4.3
Table 4.4
Fig 4.2
Fig 4.3.a
Fig 4.3.b
Fig 4.4.a
Fig 4.4.b
Fig 4.5
Fig 4.6.a
Fig 4.6.b
Fig 6.1
Table 6.1.a
Table 6.1.b
Functional Block Diagram ..........................................................................................1-2

Table Top Configuration .............................................................................................1-3
Data Transfer Interface................................................................................................3-2
Interface Connector Pin Assignment ..........................................................................3-4
Interface Connector Pin Assignment ..........................................................................3-5
Interface Signal Description........................................................................................3-5
Driver/Receiver Configuration....................................................................................3-6
Interface Signal Description........................................................................................3-7
Interface Signals-Status ...............................................................................................3-8
Interface Signals-Data Transfer ..................................................................................3-8
Data Transfer Timing ................................................................................................3-10
Control Signal Timing...............................................................................................3-10
ASCII Character Generation .....................................................................................3-11
Character and Code Sets............................................................................................3-12
ASCII Control Codes ................................................................................................3-13
Paper Take Up Installation ........................................................................................3-16
Paper Take Up Adjustment .......................................................................................3-17
Fan Fold Paper Tray ..................................................................................................3-18
Fan Fold Paper Guide................................................................................................3-20
Control Panel Keypad..................................................................................................4-3
MENU Selection..........................................................................................................4-4
Items of System MENU ..............................................................................................4-6
Items of JOB MENU...................................................................................................4-7
Items of PLOT MENU................................................................................................4-7
Fan Fold Paper Loading ............................................................................................4-10
400 dpi Checkerboard Pattern...................................................................................4-11
200 dpi Checkerboard Pattern...................................................................................4-11
400 dpi ASCII Print Pattern ......................................................................................4-12
200 dpi ASCII Print Pattern ......................................................................................4-12
Platen Accuracy Test Pattern ....................................................................................4-13
400 dpi Nib Test Pattern............................................................................................4-14
200 dpi Nib Test Pattern............................................................................................4-15
Trouble Shooting Flow Diagram ................................................................................6-5
Print Head Voltage (Cherokee) Chart.........................................................................6-8
Print Head Voltage (Astec) Chart ...............................................................................6-9
iv
LIST of REVISIONS
Rev
DATE
12/20/06
BRIEF DESCRIPTION of CHANGE

Convert manual to pdf file for CD-ROM version
BY
CT
CHAPTER 1
INTRODUCTION
1.1
GENERAL DESCRIPTION
OYO Instrument's Model GS 6XX-2 (GS 624-2, GS 636-2 and GS 644-2) Thermal
Plotter/Printer is a high-resolution, wide-format and rugged graphics device designed for
field and office use. It utilizes direct thermal printing technology originally developed for
geophysical applications. With few moving parts and no liquid chemicals to contend with,
the GS-6XX-2 operates efficiently, requiring nominal maintenance. The device plots and
prints in both raster and character modes, is easily interfaced to a variety of data sources, and
can be installed on horizontal or (optionally) vertical surfaces.
1.2
FUNCTIONAL DESCRIPTION
The GS 6XX-2 is a raster-scan device that prints and plots information on thermal-sensitive
paper by sequentially addressing an array of nibs (dots) along a fixed thermal print head and
incrementally moving the paper a fraction of the dot length. Fig. 1.1 is a block diagram of
the GS 6XX-2. The components include the (a) thermal print head and its driver circuitry;
(b) micro-stepper motor and its control circuitry; (c) pressure roller (platen) which is driven
by the micro-stepper motor; (d) paper cutter, and (e) interface electronics and power
supplies.
Thermal-sensitive paper from the supply roll is fed between the platen and the thermal print
head. The micro-stepper motor turns the platen, moving the paper past the print head in
steps of 0.3125 mils (0.008 mm). Stepping can be controlled directly by the Plotter/Printer
or indirectly by the data source. As the paper moves, the nibs in the thick-film print head are
addressed through the interface circuitry and heated by applying power to produce an array
of dots representing graphic data and alphanumeric characters. Each dot is 2.5 x 3.0 mils
(0.625 x 0.75 mm). The heated nibs in contact with the thermal-sensitive paper develop
color (black) through a thermo-chemical reaction in the paper's coating. Scanning and
stepping is repeated until the desired image is produced.
1.3
MEDIA DESCRIPTION
The thermal-sensitive paper used in the GS 6XX-2 consists of a base paper and coating of
colorless, non-toxic dye. Some papers with lower sensitivities also employ protective
coatings to improve their handling characteristics. The paper has a bright, smooth surface, is
about 3 mils (0.075 mm) thick and weighs about 0.2 oz/ft2 (60 g/m2). Color (black) is
developed to an optical density of about 0.8 at a temperature of roughly 75 degrees C.
1-1
Thermal Sensitive
Media
Pressure
Roller
Logic
Power Supply
Coated Side
of Media
Interface
& Control
Temperature
Control
Thermal
Print Head
DATA,
STATUS &
CONTROL
Print Head
Power Supplies
Stepper
Control
Fig. 1.1
FUNCTIONAL BLOCK DIAGRAM
1.4
MOUNTING CONFIGURATIONS
The GS 6XX-2 is housed in a rugged, low profile cabinet that is normally mounted on a
horizontal surface. Fig. 1.2 shows the tabletop configuration. The switches and indicators
are accessible and visible.
Paper Take-up equipment is required to automatically wind the printed paper. This is an
available OPTION. Refer to section 3.5.
Fan Fold paper equipment is required for Fan Fold paper. This is an available option for the
GS 624-2 only. Refer to section 3.6.
1-2
33.0 INCHES (GS 624-2)

45.0 INCHES (GS 636-2)
53.0 INCHES (GS 642-2)
83.0 CM (GS 624-2)
114.0 CM (GS 636-2)
134.0 CM (GS 642-2)
21.O INCHES
(52 CM)
TOP VIEW
11.0 INCHES
(28 CM)
FRONT VIEW
Fig 1.2
TABLE TOP CONFIGURATION
1-3
CHAPTER 2
SPECIFICATIONS
Printing Method:................................................................................................................................................ Direct thermal technology
Print Head Configuration: .............................................................................................................................Single Substrate, linear array
Resolution:............................................................................................................................................................................200 or 400 dpi
Paper Drive:...........................................................................................................................................................................Stepper motor
Paper Type:........................................................................................................................................Premium grade or report grade bond
Paper Length: .......................................................................................................................................................................... 500 foot roll
Film Type: .................................................................................................................................................................. Clear or matte finish
Film Length: ............................................................................................................................................................................ 200 foot roll
Nib Size: ............................................................................................................................................... 2.5 x 3.0 mils (0.063 x 0.075 mm)
Optical Density:.......................................................................................................................................................................... 1.0 typical
Stepping Increment: ............................................................................................................................................. 0.3125 mils (0.008 mm)
Stepping Accuracy: ..........................................................................................................................................0.15% or 0.1 in per 72 in
Dot Alignment Error: .......................................................................................................................................................................... 0.1%
Maximum Skew: ................................................................................................................................................................................. 0.1%
Character Set: ............................................................................................................................96 ASCII characters (normal or inverted)
Character Size: ................................................................................................................... 16 x 20 dots (200 dpi), 32 x 40 dots (400 dpi)
Character Density:..............................................................................................................................12.7 characters/in (5 characters/cm)
Configuration: ......................................................................................................................................... Horizontal, table or stand mount
Interface Type: ......................................................................................................................................................Parallel, full scan buffer
Interface Compatibility: ................................................................................................................................................................ Versatec
MODEL NUMBER
GS 624-2
Media Width:
Plot Width:
Dots per Scan:
Bytes per Scan:
Plot Rate: 200 dpi
400 dpi
Printing Speed:
Lines/Minute, 200 dpi
Lines/Minute, 400 dpi
Height:
Width:
Depth:
Net Weight:
Shock:
Half Sine-Wave
Vibration:
5-50 Hz
50-2000 Hz
GS 636-2
GS 644-2
24" (60 cm)

23.6" (60 cm)
9,470
1,184 @ 400 dpi
592 @ 200 dpi
0.125 to 4 ips
0.125 to 2 ips
36" (91 cm)

35.5" (90 cm)
14,206
1,776 @ 400 dpi
888 @ 200 dpi
0.125 to 3 ips
0.125 to 1.5 ips
44" (112 cm)

43.2" (112 cm)
17,278
2,160 @ 400 dpi
1,080 @ 200 dpi
0.125 to 2 ips
0.125 to 1.0 ips
1200
300
11" (28 cm)
33" (83 cm)
21" (52 cm)
120 lb (55 kg)
1200
300
11" (28 cm)
45" (114 cm)
21" (52 cm)
155 lb (70 kg)
1200
300
11" (28 cm)
53" (134 cm)
21" (52 cm)
185 lb (84 kg)
2G
2G
2G
1G
2G
1G
2G
1G
2G
POWER REQUIREMENTS
Voltage:
Frequency:
Power Usage:
Operating Environment:
115 or 220 VAC (auto-switch)

50-60 Hz
90 Watts idle mode, 1000 Watts plot/print mode
Temperature, 0 to 50 degrees C
Humidity, 5 to 95% non-condensing
2-1
CHAPTER 3
INSTALLATION
3.1.1
UNPACKING
When unpacking the GS 6XX-2 Thermal Plotter/Printer, visually inspect the unit for any
damage which may have occurred during shipment. Promptly notify and submit claims
to the carrier for damage to or loss of parts. Check to make sure that the power cord and
paper roll (with hubs) are present.
3.1.2
MOUNTING
3.1.3
HORIZONTAL MOUNTING
The GS 6XX-2 is designed to operate on horizontal surfaces. Plastic feet are provided
on the bottom of the unit for table-top configurations.
Although the GS 6XX-2 is designed for rugged environments, it should not be subjected
to shock or vibration in excess of its specified ratings. Shock-absorbing mounts should
be used where appropriate.
Install the unit in a location where it is not subjected to heat or direct sunlight. Keep
away from large objects that might obstruct ventilation around the unit.
Verify that the AC voltage and frequency match the rating stamped on the plate on the
rear of the cabinet. Plug the power cord into an independent wall outlet. Sharing the
same outlet with other noise-generating equipment should be avoided. If an earth ground
is not provided in the wall outlet, use the rear terminal to connect the unit to a high
conductivity ground path such as a cold water pipe.
Important Notice!
Both power supplies inside the Plotter/Printer are auto-switch.
No changes are required to switch from 110 VAC to 220 VAC or back.
But, if a media take-up is used (see 3.5.1), the media take-up
AC select switch must be set to match the input voltage!
It is essential that the unit be correctly connected to the data source and that the paper
supply roll be properly installed prior to operation. Carefully follow the interfacing and
loading instructions in Sections 3.3 and 4.3. Incorrect interfacing or improper loading
may cause damage to the unit and void the warranty.
3-1
3.3
INTERFACING
3.3.1
GENERAL DESCRIPTION
The GS 6XX-2 can be connected to a variety of data sources using the "Versatec
compatible" interface. Signals from the source transfer byte-parallel data or control
codes to the unit, indicate whether the transfer is Data or Control information, reset the
unit, advance the paper and perform other hand shaking functions. Status signals from
the Plotter/Printer indicate that it is ready to receive a data transfer, whether the unit is
ONLINE and when the paper supply roll is depleted. The unit has two modes of
operation: Plot and Print.
BYTE-PARALLEL DATA
DATA
SOURCE
GS 6XX
PICLK
READY-
Fig 3.1
DATA TRANSFER INTERFACE
3-2
Fig. 3.1 is a simplified diagram of the data transfer interface. Data is transferred to the
unit over an eight-bit parallel data bus. A parallel data input clock pulse (PICLK) must
accompany each byte. The GS 6XX-2 notifies the data source when it is ready to receive
a data byte by changing the state of the READY signal. The bar under or over the
READY mnemonic indicates that the signal is active true at a low level. Thus, when
READY is low, the unit is ready to receive data; when READY is high, the unit is busy
and cannot accept data.
A plot scan or print line is automatically terminated by the unit when the number of bytes
received is sufficient to complete the scan or line, or when the remote line terminate
signal (RLTER ) is asserted. For example, in the absence of a remote line terminate, the
maximum number of 8-bit bytes per plot scan for the GS 624-2 is 1184 and the maximum
number of characters per print line is 296. Note that the number of nibs in the thermal
print head is 9470. This allows 23.6 inches of data to be plotted when inputting 1184
bytes (9470 dots). Plot data transmitted to the GS 624-2 in excess of 1184 bytes are
automatically transferred to the next scan or line. Similarly, print characters of an
unterminated print line beyond 296 characters are automatically transferred to the next
scan or line.
The maximum output data rate is approximately 236.8 kilobytes per second for plot mode
and 5.92 Kilobytes per second for print mode with plot speed at 2 inches per second for
the GS 624-2.
All data, control and status signals connect to the GS 6XX-2 via the male 37-pin D-series
subminiature connector (J1) at the rear of the unit. Table 3.1 and Fig. 3.2 show the pin
assignments of the interface connector. Table 3.2.a thru 3.2.d describes the active levels
and operations of the interface signals.
The interface signals use positive TTL levels. A complemented signal (for example
READY) indicates that the line is active true when it is low. A non-complemented signal
(for example PICLK) indicates that the line is active true when it is high.
Fig. 3.3 shows typical configurations for the interface receivers and drivers. The
interface cable should be limited to a maximum of 50 feet in length and must be made of
24-gauge stranded wire, twisted-pair or ribbon cable.
3-3
SIGNAL PIN
RETURN PIN
SIGNAL NAME
MNEMONIC
20
Input Bit 1 (LSB)
IN01
21
Input Bit 2
IN02
22
Input Bit 3
IN03
23
Input Bit 4
IN04
24
Input Bit 5
IN05
25
Input Bit 6
IN06
26
Input Bit 7
IN07
27
Input Bit 8 (MSB)
IN08
28
Clear
CLEAR
10
29
Parallel Input Clock
PICLK
11
30
Ready
READY
12
31
Print
PRINT
Not Connected
NC
13
14
33
Simultaneous Plot/print
SPP
15
34
Remote Reset
RESET
16
35
Remote Form Feed
RFFED
17
36
Remote End of Transmit
REOTR
18
37
Remote Line
RLTER
19
37
No Paper
NOPAP
32
37
Online
ONLIN
Table 3.1
INTERFACE CONNECTOR PIN ASSIGNMENT
3-4
J1
IN01
IN02
IN03
IN04
IN05
IN06
IN07
IN08
CLEAR-
PICLK
10
READY-
11
PRINT
12
N.C.
13
SPP-
14
RESET-
15
RFFED-
16
REOTR-
17
RLTER-
18
NOPAP
19
DATA
20
21
22
23
24
25
26
27
28
29
30
CONTROL
31
32
ONLIN(STATUS)
33
34
35
36
37
STATUS
Fig. 3.2
INTERFACE CONNECTOR PIN ASSIGNMENTS
SIGNAL
MNEMONIC
PRINT
MODE CONTROL
SIGNAL
ACTIVE
NAME
LEVEL
PRINT
HIGH
This line selects either print or

plot operation. When high,
print operation is selected.
Table 3.2.a
INTERFACE SIGNAL DESCRIPTION
3-5
+5V
7438 SERIES BUFFER

(OPEN COLLECTOR)
1
74 SERIES
GATE
220
Ohms
2
TW PR
330
Ohms
TYPICAL
TYPICAL
RECEIVER
DRIVER
TYPICAL
RECEIVER
TWISTED PAIR NOT TO

EXCEED 50 FEET
TTL
+5V
26LS31 or EQV
10 K
26LS32 or EQV
+
TW PR
120
Ohms
10 K
TWISTED PAIR NOT TO

EXCEED 600 FEET
DIFFERENTIAL
Fig. 3.3
DRIVER/RECEIVER CONFIGURATION
3-6
REMOTE FUNCTIONS* (Interface Signals)

CLEAR
REMOTE
LOW
RESET
REMOTE
LOW
RLTER
REMOTE
LINE
TERMINATE
LOW
RFFED
REMOTE
FORM
FEED
or
REMOTE
END OF
TRANSMIT
LOW
or
REOTR
This command clears the input buffer when READY

is low. READY remains high until the input buffer
has been cleared.
This command resets the unit and reinitiates all logic
as long as this signal is asserted. READY remains
high while RESET is asserted.
This command terminates the buffer currently being
loaded, causes all previously loaded buffers to be
output in sequence, then outputs the buffer just
terminated in sequence. This command is ignored by
the unit if received immediately after a full scan has
been automatically terminated.
This command terminates the buffer currently being
loaded, causes all previously loaded buffers to be
output in sequence, then outputs the buffer just
terminated in sequence. After all data is written on
the paper, it is advanced approximately eight inches.
Table 3.2.b
INTERFACE SIGNAL DESCRIPTION
* Remote functions and data should never be transmitted concurrently or data may be
lost; all remote functions are low going pulses, 300 ns minimum.
3-7
SIGNAL
MNEMONIC
ONLIN
SIGNAL
NAME
ONLINE
ACTIVE
LEVEL
LOW
NOPAP
NO PAPER
HIGH
OPERATION
A low level indicates the unit is
powered on, ONLINE is set to ONLINE, and the interface cable is
connected. A pull-up resistor
must be provided by the user on
this line to maintain a high level
when power is off or the interface
cable is disconnected.
A high level indicates the paper
supply is depleted. During an
out-of-paper condition, the unit
goes busy, outputs the current data
and flashes the LED indicator.
READY then remains busy.
Table 3.2.c
INTERFACE SIGNALS - STATUS
SIGNAL
MNEMONIC
IN01-IN08
BITS 1-8
SIGNAL
NAME
INPUT DATA
ACTIVE
LEVEL
HIGH
PICLK
PARALLEL
INPUT
CLOCK
HIGH
READY
PLOTTER
READY
LOW
OPERATION
These lines enter one byte of
parallel data into the input data
buffer, and must be accompanied by
a PICLK pulse.
This signal strobes a data byte
present on lines IN01-IN08 into the
input buffer. PCLK causes the
plotter to go NOT READY for
approximately 1 s. PICLK must
be a 300 ns minimum pulse.
A low level indicates the unit is ready
to receive the next data byte or
remote command. A high level
indicates the unit is busy and will not
accept data.
Table 3.2.d
INTERFACE SIGNALS - DATA TRANSFER
3-8
3.3.2
PLOT MODE
The GS 6XX-2 uses the raster scan method of plotting. One horizontal line (scan),
consisting of a single row of dots, is written and the paper is incremented. Then another
scan is written, and so forth. The scan is made up of a fixed number of bits. Each bit
within the scan addresses an individual nib in the print head. By programming each scan,
any type of graphic design can be output, including half-tone graphics and alphanumerics
of any size.
Plot patterns are generated one scan at a time. Each scan consists of a horizontal row of
dots. Each dot position corresponds to one particular bit in the data scan stored in the
input buffer. If a bit is a "1", a black dot is printed on the paper in the position
corresponding to the bit position in the buffer. Input bit 8 (IN08) is the most significant
bit (MSB) and addresses to the leftmost writing bit of each byte. Input bit 1 (IN01) is the
least significant bit (LSB). IN08 of the first byte transmitted addresses the first (leftmost) nib. IN01 of the last byte addresses the last nib (rightmost) of the print head.
The Print head interface is equipped with independent input and output buffers, each with
a one scan storage capacity. The contents of the input buffer are transferred to the output
buffer and to the writing circuits. The unit can thus accept a steady stream of data while
simultaneously writing data.
The READY signal is used to supply the data source with an indication as to the unit's
readiness to accept data. When READY is low, the unit can accept one byte of data on
lines IN01-08. This byte must be accompanied by a PICLK pulse. Fig. 3.4 presents the
timing relationship for maximum data transfer. Note that the unit goes busy after receipt
of each byte. The unit goes busy for longer periods during execution of the remote
functions and when the input buffer is full. Fig. 3.5 shows the timing relationships for
the remote functions.
When the input buffer receives the number of bytes necessary to plot a full scan, a write
cycle is automatically initiated, causing the buffer contents to be written.
3.3.3
PRINT MODE
The GS 6XX-2 is equipped with a character generator which converts ASCII-coded
characters to pre-programmed plot patterns. These patterns produce a pre-defined
alphanumeric character set. Each character is formed by a 16 x 20 dot matrix (200 DPI)
and 32 x 40 dot matrix (400 dpi).
Print data is sent to the GS 6XX-2 one ASCII-coded byte at a time. When one complete
print line is received or a print line is properly terminated, the plotter converts the ASCII
coded character into plot patterns (by use of a Character Generator ROM), then
automatically performs twenty plot scans to generate the character line.
3-9
1 uS (Note 2)
BYTE 1
BYTE 2
BYTE 3
DATA (Note 1)
300 nS
Min.
PICLK
BUSY (Note 1)
READY-READY
250 nS
NOTES:
1. Data may change when READY -- goes high.
2. Data entry timing for maximum transfer rate.
Fig. 3.4
DATA TRANSFER TIMING
300 nS
Min.
CLEAR -- or
RESET -300 nS
Min
RFFED -or
REOTR -or
RLTER --
READY --
1 uS
(Note 1)
250
nS
Max
BUSY
250 nS
Max
READY
NOTES:
1. READY -- returns low in 1 microsecond only if the output buffer is empty.
Otherwise, READY -- remains high during the buffer transfer operation (2.0 mS).
2. Pulse rise and fall times not to exceed 100 nanoseconds.
3. The clock pulse (PICLK) must be at least 300 nanoseconds wide, and will
only be accepted when READY is low.
4. Positive logic:
HIGH = +3.5 V to 5 V
LOW = - 0.5 V to +0.5 V
Fig. 3.5
CONTROL SIGNAL TIMING
3-10
1 uS
(Note 1)
As shown in Fig. 3.6, each character is generated by selectively plotting dots within a 16x20 dot
matrix. The character set generates 20 scans per print line. Sixteen scans are used for character
generation and four scans are used to generate a space between each printed line. Each print line
of 20 scans totals approximately 0.10 inches in height.
SCAN 01
SCAN 02
SCAN 03
SCAN 04
SCAN 05
SCAN 06
SCAN 07
SCAN 08
SCAN 09
SCAN 10
SCAN 11
SCAN 12
SCAN 13
SCAN 14
SCAN 15
SCAN 16
SCAN 17
SCAN 18
SCAN 19
SCAN 20
Fig. 3.6
ASCII CHARACTER GENERATION
The normal character set includes 96 ASCII characters, coded as shown in Fig. 3.7.a.
The inverted character set is coded as shown in Fig. 3.7.b. The four control codes are
shown in Fig. 3.7.c.
When in the print mode, the input buffer is used to receive character data. This buffer
has a one print line capacity. After the buffer is filled or terminated, the contents are
output to the writing circuitry.
The READY signal is used to supply the data source with an indication as to the unit's
readiness to accept data. When READY is low, the unit can accept one byte on lines
IN01-IN08. This byte must be accompanied by a PICLK pulse.
Note that the unit goes busy after receipt of each byte. The unit goes busy for longer
periods during execution of remote functions or control characters and when the input
buffer is full.
3-11
B
LS
SB
M
2
3
4
5
6
7
0 1
!
0 1
@A
P Q
' A
P Q
2
"
2
B
R
B
R
3
#
3
C
S
C
S
4
$
4
D
T
D
T
5
%
5
E
U
E
U
6
&
6
F
V
F
V
7
'
7
G
W
G
W
8
(
8
H
X
H
X
9
)
9
I
Y
I
Y
A
*
:
J
Z
J
Z
B
+
;
K
[
K
{
C
,
<
L
\
L
|
D
=
M
]
M
}
E
.
>
N
^
N
~
F
/
?
O
O
G
S
NORMAL CHARACTER SET
O
O
?
/
G
S
~
N
^
N
>
.
}
M
]
M
=
-
|
L
\
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,
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K
[
K
;
+
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J
Z
J
:
*
Y
I
Y
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9
)
X
H
X
H
8
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W
G
W
G
7
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V
F
V
F
6
&
U
E
U
E
5
%
T
D
T
D
4
$
S
C
S
C
3
#
R
B
R
B
2
"
Q
A
Q
A
1
!
P
'
P
@
0
B
LS B
S
M
A
B
C
D
E
F
0 1 2 3 4 5 6 7 8 9 A B C D E F
INVERTED CHARACTER SET
B
LS B
S
M
0 1 2 3 4 5 6 7 8 9 A B C D E F
LF
EOT
FF
CONTROL CODE SET
Fig. 3.7
CHARACTER AND CODE SETS
3-12
CR
When the input buffer receives the number of bytes necessary to print a full line or is
terminated, a write cycle is automatically initiated, causing the buffer contents to be
written. Print transfers are identical to plot transfers except writing times are different
and print transfers can also use ASCII control codes.
ASCII control codes are described in Table 3.3. These codes are functionally identical to
the associated remote functions, which may also be used in the print mode. The print
data transfer sequence is presented in Figs 3.4 and 3.5.
CONTROL
EOT
(End of
Transmission)
HEX
CODE
04
LF
(Line Feed)
OA
FF
(Form Feed)
OC
CR
(Carriage Return)
OD
OPERATION
This control code is functionally identical to REOTR. It
terminates the input buffer and causes its contents to be
OUTPUT. After all data is written on the paper, it is
advanced approximately eight inches.
This control code is functionally identical to RLTER. It
output. This command is ignored by the unit if received
immediately after a full scan has been automatically
terminated. The unit goes busy for a minimum of 1 s
after receipt of this command.
This control code is functionally identical to RFFED. It
output. After all data is written on the paper, it is
advanced approximately eight inches.
This control code performs the same function as the LF
command, except it is honored only when used with a
partially filled buffer. The CR code is ignored if it is
received when the input buffer is full or empty.
Table 3.3
ASCII CONTROL CODES
3-13
3.3.4 DRIVER CONSIDERATIONS

The information presented in the previous sections should provide the user with sufficient
information to design software drivers to operate the three plot/print modes. The
following items are presented as a summary of the most important items to be considered
when preparing a driver program for the GS 6XX-2:
The unit's interface is equipped with one input and one output buffer.
Normal print characters and all plot data are accepted at the fastest possible rate
(maximum 432 kilobytes per second) but control codes embedded in print data
are accepted at about one code per 0.5 to 5.0 milliseconds (depending upon the
control code). Hence, it is vital that all drivers honor the busy status on the
READY signal line on a byte basis to insure correct operation without loss of
data.
In the plot mode, a scan can be terminated at any time by one of several methods.
If termination follows a full scan, it will be ignored since filling the input buffer
automatically generates an internal line terminate. A termination with only a
partial scan will cause the line to be filled with zero bytes. Successive
terminations without intervening data will cause blank scan lines to be generated,
one per termination. Receipt if any termination will generate an interrupt and will
thus require several milliseconds to process, during which the interface will be set
busy. The same is true for remote commands received during plot operations.
In the print mode, a line can be terminated at any time by one of several methods.
If terminations follows a full line, it will be ignored since filling the input buffer
automatically generates an internal line terminate. A termination with only a
partial line will cause that line to be filled with ASCII blank characters.
Successive terminations without intervening data will cause blank lines to be
generated, one per termination.
If a mode change is recognized with PICLK, the data byte that arrived with the
mode change is held up while an interrupt is generated. When the input buffer is
reset and the interface made ready, the data byte that was held up by the interface
is entered and becomes the first data byte processed under the new mode.
If a mode change is recognized with a remote command or ASCII control
character and the input buffer is empty, the mode change will be processed and
then the remote command or ASCII control character will be processed. The
interface is then set ready.
Data should not be sent simultaneously with remote commands. Either the data
or remote command will be lost if sent simultaneously. If several remote
commands are sent simultaneously, they will be processed as follows:
3-14
If RESET occurs, it over-rides all other remote commands. The reset will be
processed and all other remote commands will be cleared.
If CLEAR occurs, the input buffer is cleared, any simultaneous RLTER is
ignored and cleared and any FF or EOT is processed.
If RLTER occurs, the input buffer is completed (if data are present) and the
RLTER is processed. Any FF or EOT is then processed.
If FF occurs, it is processed. Then any EOT is processed.
EOT is the last remote command processed if several occur simultaneously.
3.4
POWER SWITCHING FOR 220 VAC

Both power supplies are Auto-Switch. The GS-6XX-2 operates from both 115 and 220
VAC.
3.5.1
INSTALLATION OF PAPER TAKE UP

Tools Required:
1. Screw Driver - Medium flat blade
2. Hex Wrench 3/32
3. Hex Wrench 5/32, 90 degree
Procedure:
1. Install four (4) 10-32 x .50 long hex washer screws and four (4) keyhole studs as
shown. Do not tighten the screws all the way down. Tighten enough so that the
keyhole studs are secure but slightly loose.
2. Place the Paper Take-Up assembly on the Plotter Floor Stand. Line up the keyhole
cutouts of the Paper Take-Up with the four (4) screws/studs installed per above step.
3. Secure the Paper Take-Up assembly with the remaining two (2) 10-32 x .50 long hex
washer screws as shown.
3-15
FRONT
DETAIL
DETAIL
TYPICAL 2 PLACES
TYPICAL 4 PLACES
Fig. 3.8
PAPER TAKEUP INSTALLATION
3-16
The following steps require that media be installed in the Plotter.

3.5.1
ADJUST PAPER SUPPLY REEL (Side to Side) Refer to Fig. 3.9

Feed the media on to the paper supply reel and check the fit. The gap between the
edges of the media and the flanges should be equal. To adjust, do the following:
Release (untighten) the lever clamp A securing the paper supply reel. Pull the
knob B outward and remove the paper supply core.
Using a 3/32 hex wrench, loosen the 10-32 set screw C securing the left side
drive flange hub to the left side drive shaft. Move the drive flange hub right or
left, as required, to correctly adjust it. Tighten the 10-32 setscrew, place the paper
supply core back in place and re-secure the paper supply reel.
Re-check the media fit. If not equal on both sides, repeat the steps above.
3.5.2
ADJUST THE PAPER TENSION Refer to Fig. 3.9

Loosen (do not remove) the two (2) screws securing the right side cover to the
right side panel. Slide the right side cover forward and off the panel.
Note the tension in the media as it winds on to the paper take up assembly. If the
tension is not equal on both ends, loosen (do not remove) four (4) 10-32 soc cap
screws securing the right side panel to the right side frame. Adjust the 10-32 soc
cap screw D on the bottom flange of the right side cover up or down until the
desired tension is reached. Tighten screws and replace cover when done.
B
Fig. 3-9
PAPER TAKE-UP ADJUSTMENT
3-17
3.6 INSTALLATION OF FAN FOLD PAPER TRAY

The fan fold tray attaches to the bottom of the plotter stand with four (4) screws
(furnished). Refer to Fig. 3.10
Tools Required:
1. Screw driver-medium flat blade or 5/16 inch wrench or nut driver
Procedure:
1. On the bottom side of the top surface of the plotter stand are four (4) threaded holes.
Install the four (4) 10-32 x .50 long screws in the holes leaving approximately 3/16
inch of thread exposed so the tray may be installed on the screws.
2. With the tray oriented as shown, attach it to the plotter stand. Slide the tray backward
on the screws and tighten the screws using either a screwdriver or a 5/16 inch wrench.
The fan fold tray is ready.
FRONT
Fig. 3.10
FAN FOLD PAPER TRAY
3-18
3.7 INSTALLATION OF FAN FOLD PAPER GUIDE

The fan fold paper guide attaches to the back lip of the cutout on the bottom of the
plotter. Refer to Fig. 3.11
Tools Required:
1. Hex Driver-3/32 inch
2. Nut Driver-3/8 inch (or box or open end wrench)
Procedure:
1. Turn the power OFF.
2. Remove the paper roll and core hubs by pulling straight up on the plastic knobs. The
hubs will snap out of the retaining mechanism. Remove the hubs from the old paper
roll core. Insert the hubs into the paper guide furnished with the fan fold option.
3. Install the paper guide mechanism on the bottom of the plotter as shown if Fig. 3.11.
Remove two (2) 10-32 lock nuts (marked A on Fig. 3.11), one at each end of the
power supply chassis where the chassis attaches to the bottom of the plotter (marked
D on Fig. 3.11). Attach the two brackets (marked E), one to each end of the
studs from which the nuts were removed in the previous step. Replace the two nuts to
secure the brackets. Now, attach the fan fold guide mechanism marked C and
tighten the setscrew marked B. The guide mechanism is ready for use.
4. Open a box of fan fold paper. Do not remove the paper from the box. Remove the
top cover (flaps) from the box and place the box in the tray beneath the plotter.
5. Separate the two (2) rods on the fan fold guide mechanism. Feed a few sections of the
paper thru the rods and close the rods with the paper toward the back of the plotter.
Note: The top of form marker on the fan fold paper should be on the left side of the
plotter and facing the platen.
6. Place the paper guide and hubs into the retainer mechanism. Pull the paper out
evenly and smoothly, feeding it behind and over the paper guide and under the paper
cutter. Refer to Fig. 4.3 for more details regarding fan fold paper loading.
3-19
FRONT of PLOTTER
DETAIL
C
B
Fig. 3.11
FAN FOLD PAPER GUIDE
3-20
CHAPTER 4
OPERATION
OYO Thermal Imaging Products are precisely aligned and adjusted at the factory for proper
operation. The use of OYO supplied media and accessories and regular maintenance and
cleaning is essential to ensure optimum Product performance.
Depending on the environment and usage the Product may require cleaning even after short
periods of operation. Follow the cleaning and maintenance procedure given in Chapter 6 of the
Operation Manual.
Changing from using paper media to film media requires that the user to pay extra attention to
the cleaning process. It is imperative to remove all paper dust to ensure optimum film
performance.
The following types of thermal media are supplied by OYO for use in the Product:
1. Report Grade Thermal Paper: This lightweight paper is susceptible to scratching. It
can not be erased without marring the image. This paper leaves residue, but proper
cleaning, as described in the cleaning procedure, will prevent excessive wear.
2. Presentation Grade Thermal Paper: This heavy top-coated paper is resistant to
scratching. It can be erased without marring the image. This paper leaves residue, but
proper cleaning, as described in the cleaning procedure, will prevent excessive wear.
3. Thermal Film: OYO supplied film has been specially formulated for use with OYO
Products. Some film may leave residue, but proper cleaning, as described in the cleaning
procedure, will prevent excessive wear.
4. Thermal Proofing Media: OYO supplied proofing media has been approved for use
with OYO Products. Some proofing media may leave residue, but proper cleaning, as
described in the cleaning procedure, will prevent excessive wear.
Contact your OYO sales representative at 800-747-7561, 713-937-5800 or sales@oyo.com to
obtain the part number and price of OYO supplied media for you Product.
4.1
PRECAUTIONS
Do not turn off the main power or pull the power cord from the wall outlet without first
turning off the POWER switch located on the back of the unit.
The GS 6XX-2 employ only low voltage power supplies. However, hazardous voltages
are present in the motor driver and in the AC input wiring. Reasonable safety
precautions should be used to avoid electrical shock. Turn the unit off before replacing
the paper supply roll or servicing any component.
4-1
Circuits installed on the thermal print head are composed of CMOS ICs. Care must be
taken during operation and service to avoid damage from static electricity. When
replacing the print head, conductive mats and grounding straps should be used to
prevent damage due to electro-static discharges (ESD).
The print head may become dirty even after short periods of operation. Clean the print
head every time a new roll of media is installed. Turn the power off and clean the print
head with the alcohol-saturated pads supplied with the unit. Allow time for the alcohol to
evaporate before turning the power on again.
Never attempt to operate the unit without media moving across the print head! Such a
condition may cause severe damage and void the warranty.
4.2
POWER SWITCH CB1

This switch applies main power to the unit and is located at the back of the unit. The
switch contains an integral circuit breaker (12 amps at 115 VAC).
At Power Up, "GS 6XX-2 ON LINE" will be displayed, and the ONLINE indicator will
be lit green.
4.3
CONTROL PANEL KEYPAD

To access control panel selections, the plotter must be taken off line by toggling the
ONLINE key once. The green ONLINE light will go off, and the "OFF LINE" message
will be displayed.
4.3.1
KEYPAD FUNCTIONS
MENU: This key allows the operator to cycle through the MENU selections during
plotter OFF LINE: SYSTEM menu, JOB menu, PLOT menu or Print the System Setup.
ITEM: This key allows the operator to cycle through all the ITEMs listed under one of
the basic menus.
ON LINE: This key switches the plotter between ON LINE and OFF LINE. The plotter
will be ready to receive data only during ON LINE, with the ONLINE indicator on the
panel lit green.
ENTER: This key allows operator to go from MENU to ITEM selection and also to save
the selected parameter into the plotter's "permanent" memory. Two asterisks "**" will
appear next to the parameter to indicate that it is now the default. As a "permanent"
default, the selection will remain valid even if the plotter is switched OFF, or RESET is
performed.
CUT/PARM+: This key initiates the plotter MEDIA CUT function only when the "GS
6XX-2 OFF LINE" message is on the display. It is also used as a parameter scroll-up key
(PARM+) when the plotter is in the ITEM mode.
FEED/PARM-: This key will move the media 4" long only when the OFF LINE
message is on the display. It is also used as a parameter scroll-down key (PARM-) when
the plotter is in the ITEM mode.
4-2
When parameters are displayed for a selected ITEM, the PARM+ and PARM- keys
allow the operator to cycle up or down through the parameter selections (options) that are
available.
4.3.2
MENU AND ITEM MODES

Table 4.1 shows the menus and menu items available with the basic plotter configuration.
Detailed description of menu items are given below.
After the plotter is powered up, the default state is ON LINE, with the ON LINE
indicator lit green and the message "GS 6XX-2 ON LINE" displayed. Press the ON
LINE key to switch the plotter to the OFF LINE state.
After "GS 6XX-2 OFF LINE" appears on the display, pressing the MENU key causes the
first menu (SYSTEM menu) to appear. Pressing the ITEM or ENTER key enables the
ITEM mode, causing the first item (see Table 4.1) to appear on the display. Pressing the
ITEM key will cycle through all the items under the current menu. When the plotter is
in the ITEM mode, pressing the MENU key will exit the ITEM mode and go back to the
MENU mode.
I MA GER ON L I NE
ON LINE
STATUS
MENU
ON LINE
CUT/PARM+
ITEM
ENTER
FEED/PARM-
Fig. 4.1
CONTROL PANEL KEYPAD
4-3
GS6XX-2
Off Line
SYSTEM
menu
Full/Partial
Line Scan
System
Test
Media
Type
Fan
Control
Low Media
Detection
Luminance
Level
Reset All
Parameters
Total Plot
Footage
Delay Plot
JOB
menu
Plotter
Resolution
Automatic
Media Cut
Hysteresis
Control
Mirror
Image
Negative
Plot
Zig-Zag
Toggling
Remote RESET
Options
PLOT
menu
Contrast Level
Print the
Setup
Plot Speed
Plot Accuracy
Plot Scale
Notes:
1. Arrows " " and " " mean pressing the MENU key.
2. Arrow " " means pressing the ITEM key.
3. The plotter will go from the MENU mode (first row) to the ITEM mode after the ITEM or
the ENTER key is pressed.
4. The plotter will go back to the MENU mode from the ITEM mode by pressing the MENU
key.
Table 4.1
MENU selection
4-4
4.3.3
PARAMETER SELECTION
ITEMs for each of the three menus (SYSTEM, JOB, and PLOT) and their PARAMETER
selections are listed in Table 4.2, 4.3 and 4.4, respectively.
In the ITEM mode, the item along with its default parameter value is on the display.
Pressing the PARM+ or PARM- key will scroll up or down through all the available
parameter values for that specific item.
Any available parameter value can be selected and permanently saved by pressing the
ENTER key when it is displayed. Two asterisks "**" will appear on the display next to
the selected parameter value, indicating its acceptance.
4.4
FRONT PANEL INDICATORS

There are two LED indicators (ON LINE and STATUS) on the panel. Both indicators
are bi-color (green and red).
When the ON LINE indicator is lit green, the plotter is in On Line state and ready to
accept data; when it goes off, the plotter is in OFF LINE state and can go to the MENU
or ITEM mode to change parameters.
If the plotter detects any error, the STATUS indicator will be lit red. An error message
will also be shown on the VF display. See Section 4.7 for detailed error messages.
The plotter will not accept any data when the STATUS LED is lit red with error message
displayed. A flashing red color STATUS indicator means WARNING! The warning
message will be seen on the VF display (such as "Low Media").
The STATUS indicator will be lit green when the plotter performs certain functions, such
as Media Cut and Form Feed.
4-5
ITEM
Full/Partial
Line Scan
System Test
Media Type
Fan Control
Low Media Detection
Luminance Level
Reset All
Parameters
Total Plot Footage
Delay Plot
PARAMETER
- Full Scan
- Fixed Partial Scan
- Checkerboard
- ASCII Print
- Platen Accuracy
- Nib Test
- Contrast Test ...
- Dot Size Test ...
- Roll Premium
- Roll Regular
- Roll Transparency
- Fan-Fold w/offset
(GS624-2 Only)
- Fan-Fold w/o offset
(GS624-2 Only)
- Automatic On/Off
- Always On
- Turn Off Now
- No
- Yes
- Check media Length
25% to 100%
(25% increment)
- No
- Yes
- No
- Yes
DEFINITION
Two choices for
raster line length
- Raster test
- Print test
- Platen test
- Print head Nib Test
- For a range of contrast
- For a range of contrast
Plotter will select correct energy
level for different media
Mode and action of fan control.

(Note 1)
(Note 2)
Display brightness
Reset parameters to factory preset
values except Plot Accuracy (Note 3)
Display the accumulative
footage of use on film and paper
Delay plotting the input raster data
until the on-board memory buffer is
full
Notes:
1. In the Automatic mode, the fan will be turned on whenever the plotter starts, and off after
the plotting is completed and the system cools down. In the Always On mode, the fan
is on all the time and can be turned off when "Turn Off Now" is selected.
2. When "Yes" on Low Media Detection is selected, the STATUS LED will be flashing red
after the plotter detects only about 20 feet of media left in the roll; the warning message
will also be displayed during on line. The "Check Media Length" choice is available
only when the "Yes" choice is selected. Entering "Check Media Length" will give a
rough estimate of media length available in the roll.
3. If the user has ever entered a new value for Plot Accuracy, that value will stay unchanged
(not affected by entering "Reset All Parameters").
Table 4.2
Items of System Menu
4-6
ITEM
PARAMETER
Plotter Resolution
Automatic Media Cut
Hysteresis Control
Mirror Image
Negative Plot
Zig-Zag Toggling
Remote RESET
Options
- 200 DPI
- 400 DPI
- No
- Yes
- No
- Yes
- No
- Yes
- No
- yes
- After EOT/FF
DEFINITION
Low or high
resolution plot
Cut the media after
receiving EOT
Print head control with consideration
of data in the neighboring dots
Mirror image plot of input data
Negative image plot of input data
Every plot will shift 1 bit right after

EOT or FF (Note 1)
- Reset Right Away Plotters response to remote RESET
- Wait for Job Done signal: either reset itself immediately,
or wait until the raster data in the
memory buffer is plotted.
Note:
1. Every plot will shift 1 bit right. The plot will restart from the original beginning after
8 plots at 200 dpi or 16 plots at 400 dpi. The last two (for 200 dpi) or four (for 400
dpi) bytes of the input data shall be blank to ensure that no data will be lost.
Table 4.3
ITEMs of JOB menu
ITEM
Contrast Level
Plot Speed
Plot Accuracy
Plot Scale
PARAMETER
-35% to +20% (paper)
-35% to normal (film)
(both 5% increment)
0.1 to 1.0 ips or
0.125 to 2.0 ips
-0.175" to +0.2" correction
with 72" plot (0.025" increment)
DEFINITION
Adjust plot contrast
- English
- Metric
Control media movement

scale
(Note 1)
Compensate plotter
mechanical error
Note:
1. Ranges of plotting speed for paper:
200 DPI, hysteresis off: 0.125 to 2.0 ips.
400 DPI, hysteresis off: 0.125 to 0.5 ips.
200 DPI, hysteresis on: 0.1 to 1.0 ips.
400 DPI, hysteresis on: 0.1 to 0.4 ips.
For transparencies, the plotting speed is fixed at 0.25 ips and 0.2 ips for hysteresis
control mode off and on, respectively.
Table 4.4
ITEMs of PLOT menu
4-7
4.5
LOADING ROLL PAPER

1. Turn off the power switch (CB1).
2. Lift the two latches on both sides of the plotter (front) and hinge up the top section.
3. Remove the paper roll and core hubs by pulling straight up on the plastic hubs. The
hubs will snap out of the retainer mechanism. Remove the hubs from the old paper
roll core.
4. Insert the hubs into a new roll of paper. Orient the paper so that the emulsion side of
the paper will be UP when it is fed under the paper cutter. This will assure that the
print head on the hinged section above come in contact with the emulsion side of the
paper when it is latched back into place. The emulsion side may be determined by
scratching the paper with a sharp fingernail. If it turns black, that side is the
emulsion side.
5. Replace the paper roll by firmly pressing the hubs straight down into the retainer
mechanism. The hubs will snap into place. Make sure that the emulsion side is
properly oriented, as discussed above.
6. Pull the paper out evenly and smoothly, and feed it UNDER the paper cutter
mechanism.
7. Now gently lower the hinged top section onto the paper and latch the top section
down.
8. Turn on the power. Verify that paper is feeding properly by pushing the paper FEED
key on the front panel. The paper should move evenly across the head.
9. Press the paper CUT key on the front panel. If the paper cutter moves across the
paper area without cutting the paper, the operator has failed to feed the paper
UNDER the cutting mechanism when loading the new roll.
4.5.1
LOADING FAN-FOLD PAPER (GS-624-2 ONLY)

Note: When the fan-fold paper tray is used, the plotter should be configured
appropriately. (SYSTEM menu: ITEM= Media Type; Parameter = Fan-Fold
with Offset or without Offset)
1. Turn off the power switch (CB1).
2. Lift the two latches on both sides of the plotter (front) and hinge up the top section.
3. Remove the paper roll and core hubs by pulling straight up on the plastic hubs. The
hubs will snap out of the retainer mechanism.
4. Install the fan-fold paper tray in the same retainer mechanism used by the paper hubs.
4-8
5. Install the Paper Feed Guide. The Guide will hinge up to allow loading a supply of
fan-fold paper, or the paper may be installed in the paper tray before putting the Paper
Feed Guide in place.
6. Load the fan-fold paper.
Caution!
Make sure that the black Top Of Form marker is on the bottom left of the paper
as viewed from the front of the unit when the paper is loaded. This assures that the
thermal coating will be next to the print head.
See Fig. 4.1 for the routing of the fan-fold paper through the paper guide. The paper is
fed from the back of the tray over the paper guide center bar, over the fan-fold guide
tube, under the idler shaft, over the platen, and out under the cutter at the front of the unit.
Now gently lower the hinged top section onto the paper and latch the top section down.
Turn on the power switch. Verify that paper is feeding properly by pressing the PAPER
FEED switch.
4-9
NOT TO SCALE !
PRINT HEAD
PLATEN
IDLER
CUTTER
PAPER
GUIDE TUBE
(OPTION)
FAN FOLD MEDIA SUPPLY
Fig. 4.2
FAN FOLD PAPER LOADING
4.6
TESTING
The GS 6XX-2 features built-in plotting/printing tests to verify that the unit is operating
normally. The self-test functions should be used after initial installation and in case of
trouble-shooting. The test pattern is intended for maintenance and troubleshooting only,
and should not be used as a performance standard.
1. Make sure that the paper is loaded as described in Section 4.5. Turn on the power
switch.
2. Press the ON LINE key to switch the plotter to OFF LINE. This status will be
seen on the Front Panel VF Display. Then select the SYSTEM menu and the
System Test item. The PARM+ or PARM- key may be used to select the
desired test: Checkerboard, ASCII Print, Platen Accuracy, Nib Test,
Contrast Test, or Dot Size Test. Press ENTER to initiate the test.
CHECKERBOARD: At 400 dpi, this test pattern displays approximately 6
checkerboard squares per inch across the width of the paper for 4 inches. At 200
dpi, the test pattern displays approximately 3 checkerboard squares across the
width of the paper for about 4 inches. Sample patterns are shown in Fig. 4.3.a
and 4.3.b.
4-10
Fig. 4.3.a
400 DPI CHECKERBOARD PATTERN
Fig. 4.3.b
200 DPI CHECKERBOARD PATTERN
4-11
ASCII PRINT: This test pattern prints 40 lines of 96 ASCII characters across the paper.
The resolution of the plot (200/400 dpi) is indicated on the left side of the printout.
Sample patterns are shown in Fig. 4.4.a and 4.4.b.
***
***
***
***
***
***
***
***
***
***
***
***
***
***
***
***
***
***
***
***
***
400 dpi ***

400 dpi ***
400 dpi ***
400 dpi ***
400 dpi ***
400 dpi ***
400 dpi ***
400 dpi ***
400 dpi ***
400 dpi ***
400 dpi ***
400 dpi ***
400 dpi ***
400 dpi ***
400 dpi ***
400 dpi ***
400 dpi ***
400 dpi ***
400 dpi ***
400 dpi ***
400 dpi ***
!#$%( )*+,-./0123456789:;< + >?@ABCDEFGHIJKLMNOPQRTSUVWXYZ[ \

Fig. 4.4.a
400 DPI ASCII PRINT PATTERN
***
***
***
***
***
***
***
***
***
***
***
***
***
***
***
***
***
***
***
***
***
200 dpi ***

200 dpi ***
200 dpi ***
200 dpi ***
200 dpi ***
200 dpi ***
200 dpi ***
200 dpi ***
200 dpi ***
200 dpi ***
200 dpi ***
200 dpi ***
200 dpi ***
200 dpi ***
200 dpi ***
200 dpi ***
200 dpi ***
200 dpi ***
200 dpi ***
200 dpi ***
200 dpi ***

Fig. 4.4.b
200 DPI ASCII PRINT PATTERN
4-12
PLATEN ACCURACY: This test checks the stepping accuracy of the plotter and allows an
adjustment to be made on a record 72 inches long. The test prints the nominal distance lines
across the paper with annotations from 1 to 72 inches. Sample patterns are shown in Fig. 4.5.
This 72-inch plot may be measured with an accurate scale to determine the platen accuracy. As
shown in Table 4.4, the PLOT menu, the Plotter Accuracy may be corrected from -0.175" (short)
to +0.2" (long) in increments of 0.025". After determining the amount of correction desired,
choose the correction parameter value and key in ENTER. A second test and measurement
should confirm the results. Note that selections of different lengths ranging from one to eight
feet and of different patterns (normal grid, dark filled, or blank interiors) are available.
Fig. 4.5
PLATEN ACCURACY TEST PATTERN
(400 DPI and 200 DPI are the same)
4-13
NIB TEST: This test checks whether any failed nib of the print head exists. In addition to the
leading and tail mark lines, a vertical line of one-half inch is plotted for every 8th nib, and at the
end of each line, the next adjacent nib will continue the plot. This pattern repeats until all the
nibs have completed the plotting. Sample patterns are shown in Fig. 4.6.a and 4.6.b.
Fig. 4.6.a
400 DPI NIB TEST PATTERN
4-14
Fig. 4.6.b
200 DPI NIB TEST PATTERN
3. Examine the stability of the plotting/printing operation, the image quality and the
media feeding accuracy. Observe the status of the indicator lights. If an abnormal
condition or malfunction occurs, please refer to Sections 6.1 (Adjustments) and 6.2
(Troubleshooting).
4-15
The following tests allow the user to run a sequence of fixed pattern plots for a range of
contrast settings. The plot result may help the user choose the appropriate contrast
setting for the application plot.
CONTRAST TEST: After entering this test mode, the PARM+ or PARM- key
can be used to adjust the maximum or minimal contrast settings for the range to
be tested. To run the test, press ENTER again. For each contrast setting, there
are two rows of checkerboard squares, of which the size are the same
(0.32"x0.32") in either 200 dpi or 400 dpi.
***
Energy Level Test:

(Media: Paper: Resolution: H: 300 dpi V: 300 dpi: Hysteresis control : Yes)
= = Contrast : -35% = =
= = Contrast : -30% = =
= = Contrast : -25% = =
= = Contrast : -20% = =
DOT SIZE TEST: This test is similar to the Contrast Test, except that the plot is
of mesh pattern, with each square representing a 200x200dpi dot.
***
Dot Size Test: Size ; 2x2

= = Contrast : -35% = =
= = Contrast : -30% = =
= = Contrast : -25% = =
4-16
4.7
ERROR MESSAGES
The following Error Messages may appear on the VF Display. There are three categories
of error messages. The error messages along with their cause and remedy are listed
below.
4.7.1
ERRORS DUE TO INAPPROPRIATE SYSTEM CONFIGURATION

"No plotter connector"
Cause:
The print head connector is not plugged in.
Remedy:
Turn off the plotter and plug in the connector.
"The lid is open!"
Cause:
The top section is not completely latched.
Remedy:
Close and latch the top section. Then reset the system by
Either pressing the reset button or turning the system off
and on.
"Wrong media - Reselect" (GS 624-2 Only)
Cause:
"Fan-fold paper" parameter is selected while the
actual loaded media is NOT fan-fold paper.
Remedy:
Select the correct media parameter and continue.
4.7.2
ERRORS OCCURRED DURING PLOTTING OPERATION

"Out of media!"
Cause:
Media runs out.
Remedy:
Load a new roll of media.
"Thermohead overheat!"
Cause:
The print head is overheated.
Remedy:
Turn off the plotter immediately. Wait for the print head
to cool down before restarting. If the overheating problem
persists, please consult the technical support.
4.7.3
ERRORS FROM ELECTRONIC SUBSYSTEMS INTERFACING

"TE Interface error!"
"Unknown TE error"
"TEIF Comm error!"
"TEIF Recv error!"
"TEIF Timeout error!"
"Unknown TEIF error!"
Cause:
Remedy:
Unknown TEIF (Thermal Engine Interface) error or bad

communication between the TE controller and the system
processor.
Reset the system. If the problem still persists, please
consult the technical support.
4-17
4.8
REMOTE ESCAPE SEQUENCE COMMAND CONTROL
4.8.1
ESCAPE SEQUENCE COMMANDS

In the past, OYO plotters have been controlled through the Versatec Green Sheet
interface without remote functions. Newer plotters, with the multitude of commands,
require a new scheme to allow users to access new features without modifying the
existing hardware.
A special ASCII character string will be used to send commands to the plotter in PRINT
mode. The command string starts with the escape character (9B hex) and must be an
even number of bytes. In some cases an extra byte is used to pad out the command
string. Escape command characters will not be printed by the plotter.
Usually all the command functions are only active until a Form Feed (FF) or End-ofTransmission (EOT) is issued. At that point, the function enabled by the command will
be disabled. The other condition causing the function to be disabled is when a remote
RESET is issued. In these cases (after FF, EOT, or RESET), the plotter will use the
previous parameters (before those escape sequence commands are issued) for new plots.
In case that the functions enabled by escape sequence commands are required to stay in
effect after the current plot, a special escape command (Disable FF & EOT Reset) needs
to be issued.
4.8.2
COMMAND FORMAT
The escape character with the high bit (bit 8) set will cause the plotter to look at the
character immediately following the escape character as a command byte, specifying the
operation to be performed. The next two bytes following the command byte will be used
as a byte count. The sequence is as follows:
[ESC] [M] [NN] [PP...]
where
ESC = Escape character with bit 8 set (9B hex)
M = Command byte (ASCII code)
NN = Byte count (2 bytes, not ASCII coded)
PP... = Parameter or Data, always even number of bytes
4-18
COMMAND BYTE
ASCII Command Byte
Function
D
F
H
I
J
L
M
S
Z
>
<
Diagnosis
200/400 dpi Selection
Hysteresis Control
Inverse Image Setting
English/Metric Selection
Scan Line Length
Mirror Image Setting
Speed Control
Zig-Zag Toggling
Disable FF & EOT Reset
Enable FF & EOT Reset (default)
RESERVED COMMAND CHARACTERS

Character
Function
A
C
E
G
N
P
R
T
W
4.8.3
Invert Alpha Mode

Clear Buffer
Line Enhance
Gray Shade Control
Color Header Preamble
100/200 dpi Selection
Select Plot Mode
Rewind (color plot)
LIST of COMMANDS
REMOTE DIAGNOSIS (D)
This command enables the plotter to enter the self-test mode in which a diagnostic
checkerboard or an ASCII print pattern is plotted without operator intervention.
During remote self-test, the BUSY signal on the interface will be active (i.e., the
READY- line will be asserted high) and the plotter will not accept data. The plotter
signals TEST FAILURE back to the host by deasserting the ONLINE- line (TTL) or
asserting INOP (Inoperative) line (Differential) on the interface upon failing the time-out
specification. (Manual diagnosis on the plotter front panel will also be provide to detect
cabling problems.) Note that this command is a one-shot command, i.e., the diagnosis
plot won't be repeated even when an escape command of "Disable FF & EOT Reset" is
issued. The calling sequence is:
[ESC] [D] [02] [PP]
where
PP = 00
PP = 01
Checkerboard plot
ASCII print
4-19
200/400 DPI SELECTION (F)

The command sets the plotter to low resolution (200 dpi) or high resolution (400 dpi).
The calling sequence is:
[ESC] [F] [02] [PP]
where
PP = 00
PP = 01
200 dpi
400 dpi
HYSTERESIS CONTROL SELECTION (H)

This command enables or disables the hysteresis control. The calling sequence is:
[ESC] [H] [02] [PP]
where
PP = 00
PP = 01
Disable hysteresis control

Enable hysteresis control
INVERSE IMAGE PLOTTING (I)

This command causes the output to be printed or plotted in reverse (negative) image:
every bit that is a one will be a zero and vice versa. The calling sequence is:
[ESC] [I] [00]
ENGLISH/METRIC SCALE SELECTION (J)
This command selects English or metric scaling. The calling sequence is:
[ESC] [J] [02] [PP]
where
PP = 00
PP = 01
English scale
Metric scale
SCAN LINE LENGTH SELECTION (L)

This command selects the raster line length. The calling sequence is:
[ESC] [L] [02] [PP]
where
PP = 00
PP = 01
FULL line length

FIXED PARTIAL line length
4-20
MIRROR IMAGE PLOTTING (M)

This command causes a mirror image of the output to be plotted/printed. The calling
sequence is:
[ESC] [M] [00]
SPEED CONTROL (S)
This command selects the output speed of the plotter. The calling sequence is:
[ESC] [S] [02] [PP]
where the correspondence between PP and the speed, in ips (inches per second), is as
follows:
PP
speed
00 = 0.125 ips
01 = 0.250 ips
02 = 0.375 ips
03 = 0.500 ips
04 = 0.750 ips
05 = 1.000 ips
06 = 1.250 ips
07 = 1.500 ips
08 = 1.750 ips
09 = 2.000 ips
ff = Maximum valid speed
Note that an invalid speed selection will be ignored and the speed selected by the plotter
will be the maximum valid speed, which is dependent on the plot resolution and the
media.
ZIG-ZAG TOGGLING (Z)
This command enables the Zigzag toggling feature, which would extend the life of the
print head generating grid-lines. This command is provided to ensure compatibility with
software that needs the full plotting width of the head. Enabling this command will
automatically lose one data byte for each raster line. The calling sequence is:
[ESC] [Z] [02] [PP]
where
PP = 00
PP = 01
PP = 02
Disable zigzag toggling

Zigzag toggling after EOT only
Zigzag toggling after EOT or Form Feed
4-21
Disable FF & EOT Reset (>)

This command causes the plotter not to reset escape sequence command functions if a
form-feed (FF) or an end-of-transmission (EOT) is issued. The calling sequence is:
[ESC] [>] [00]
Care must be taken when using this function. If the user forgets to re-enable the reset
function, the next user will have those functions enabled for his/her output. The system
default state (either after power-up or after receiving a remote reset command) is "Enable
FF & EOT Reset".
Enable FF & EOT Reset (<)
This command enables the plotter to reset escape sequence command functions upon
receiving an ASCII form-feed (FF), end-of-transmission (EOT), remote FF, or EOT
signal. The calling sequence is:
[ESC] [<] [00]
A remote RESET or a system boot (either power-up or pressing the reset button) will also
cause the plotter to be in the reset enabled condition.
4.8.4
APPLYING ESCAPE SEQUENCE COMMAND CONTROL

The following remarks are to be observed when applying remote escape sequence
command control.
1. Escape sequence commands are to be sent in the PRINT mode. The functions to
be enabled by the commands won't take effect until the current PRINT mode job
is done. Following this PRINT mode job, any of remote form feed signal
(RFFED), remote end of transmission signal (REOTR), ASCII FF or ASCII EOT
should not be sent to the plotter before starting the next PLOT mode job, in which
the functions enabled by remote escape commands will stay in effect.
2. For the sake of leaving the plotter's onboard configuration intact, it is a good
practice to attach an Enable FF & EOT Reset command to the end of main escape
commands. This would guarantee that the plotter be returned to the original
configuration (before the change caused by those escape commands) after the
PLOT mode job of desirable functions is completed.
3. The following is an example on how a user does a 400 DPI plot on a plotter of
unknown resolution setting (i.e., the onboard configuration could be either 200
DPI or 400 DPI):
Set the plotter in PRINT mode (asserting PRINT signal high)
Send the byte sequence (in hex)
9B 46 00 02 00 01 9B 3C 00 00
(10 bytes in total; 46h=ASCII F, 3Ch=ASCII code of <)
Set the plotter in PLOT mode (deasserting PRINT signal, i.e., pulling it
low)
Send data file to be plotted
Assert RFFED or REOTR signal
4-22
CHAPTER 5
THEORY OF OPERATION
5.1
INTRODUCTION
The GS 6XX-2 Wide Format Plotter Controller Assembly is composed of one Printed
Circuit Board Assembly (PCBA) containing the Input Controller circuitry and the Plotter
Controller circuitry. The Input Controller circuitry contains the Differential Line Receiver
for long-line parallel input data and command signals from the Versatec interface, and TTL
compatible input circuitry. The Input Controller section of the PCBA, under control of a
AM29200 32-bit RISC Processor, contains all circuitry required to store the data, decode the
commands, convert the Plot/Print data to a serial bit stream format and send it via the Raster
Data parallel interface to the Plotter Controller section and, through a 96 pin connector and
Adapter Board, to the print head.
The Plotter Controller section of the PCBA utilizes a 87C196 16-bit Micro-Controller to
manage the print head data and control logic, and control the stepper motor and paper cutter
interface. By selecting the appropriate Print head Adapter Board, the GS 624-2/GS 6362/GS 644-2 Wide Format Plotter Controller PCBA provides all necessary logic for the
operation and control of Models GS 624-2, GS 636-2 or GS 644-2 Thermal Plotter/Printer.
At present, the input interface may be used only with "Versatec-compatible" data sources.
(See chapter 3). The Controller Assembly provides:
A standard parallel interface for the transfer of commands and data
High speed micro-processor programmed control
Appropriate preventive interlocks
Local/remote operation
Diagnostic test for functional verification
An internal and external RS232 serial port
5-1
5.2
MAJOR FUNCTIONS AND FEATURES OF PLOTTER CONTROLLER

The GS 6XX-2 Interface Controller:
Emulates a Versatec 24"/36"/44" Plotter/Printer with hardware and software
compatibility.
Features a Versatec Parallel Interface with the ability to plot data or print
annotations.
Provides a standard ASCII 96-character set with normal and inverted orientations.
ASCII control characters are recognized in the print mode.
Provides automatic line feed for contiguous input data stream having 1184 (24"),
1776 (36") or 2160 (44") bytes per line (400 DPI).
Has a maximum input data rate of 1 Mbyte/second, while plotting at one inch per
second.
Provides simultaneous and overlapped controller operations for data input, print
head loading, and plot control to achieve maximum operating speed.
Provides manual TEST function to verify complete and proper operation of the
Controller and attached Plotter.
Has safety interlocks for STALLED or OUT-OF-PAPER status and HEAD
DISENGAGED (OPEN) status to prevent possible damage to the print head.
Provides remote ON-OFF control of print head voltage to prevent possible damage
to print head and voltage switching for 400 dots/inch feature.
Allows micro-step line advance adjustment to achieve line advance accuracy of
better than + 0.15%.
5.3
PARALLEL INTERFACE
The Controller interface is compatible with the Versatec Parallel Interface protocol and
includes the ability for Plot, Print, and Simultaneous Print with Plot. A detailed description
of the Versatec interface is described in chapter 3 of this manual. Following is a brief,
simplified summary of the interface signals.
5-2
IN(1-8)
Eight data input lines which transmit data bytes for PLOT functions or
ASCII character bytes for PRINT functions. Data is received when a PICLK
signal is asserted coincidentally with the data.
PRINT
Identifies the input data byte as Print ASCII data when PRINT is true (high),
or as Plot data bytes when not true (low: PRINT).
SPP
Identifies the mode of operation as Simultaneous Print with Plot.

RESET Remote Reset function when asserted. It causes the Controller to be
initialized to the initial POWER-UP state.
REOTR
Remote End of Transmission when asserted. It causes the current input line
of rasterized dots to be terminated, followed by a paper advance of two
inches.
CLEAR
Clears the Input Buffer when asserted.
PICLK
Parallel Input Clock. A data strobe pulse used to signal when an input byte of
data is available. If the Controller is NOT BUSY when this signal is
asserted, the input byte is received into the Input Buffer, the Controller
becomes NOT Ready (READY), or BUSY; the byte received is processed,
and the Controller returns to the READY (= NOT BUSY) state.
RLTER
Remote Line Terminate pulse. Causes the partial input line of dots to be
terminated and the remainder of the input line to be filled with zero data or
blank characters.
RFFED
Remote Form Feed pulse causes the remainder of the input line to be
terminated, followed by a paper advance of two inches.
READY
A STATUS signal from the Controller indicating that the Controller is

Ready to receive data or commands.
ONLIN
A STATUS signal from the Controller indicating that the Controller is

ONLINE and ready to receive data.
NOPAP
A STATUS signal from the Controller indicating that the Plotter/Printer has
sensed an OUT-OF-PAPER condition or the transport lid is OPEN.
5-3
5.4
CONTROLLER THEORY OF OPERATION

The Controller is designed and programmed to implement the functions and features
described above. The Controller uses:
Three separate Programmable Logic controller sequencers slaved to a 32-bit 29200
RISC Processor and a 87C196 Micro-Controller. A slow (8-bit) and fast (32-bit)
Program Memory are used.
A non-volatile Parameter Memory (Battery back-up)
A 32-bit, 4-MB DRAM System Data Memory. (8 and 16 MB optional)
A Character Generator ROM (ASCII to raster) for up to 96 alphanumeric characters
for the PRINT mode.
Microprocessor control of print/step functions.
Logic to support the control and operational requirements
5.4.1
CONTROLLER SEQUENCERS
See GS 6XX-2 Controller Schematics 624-102265, sheets 1-13, Adapter Board Schematics
624-102280, 636-102283, and 644-102286; and Plotter control panel Schematic 644102172 in chapter 7 of this manual)
The Control Sequencers provide the micro-programmed control for the following
sequences:
Data Input Control Sequence
Memory Cycle Control Sequence
Output Control Sequence
Load Control Sequence
Plot Control Sequence
Stepper (Paper Move) Control Sequence
Paper Cut Sequence
5-4
5.4.2
INPUT CONTROLLER SECTION FUNCTIONS

DATA and COMMAND signals are brought in via rear panel connector J1. TTL inputs are
connected internally to the Controller PCBA connector TTL I/P, J14. Differential (LongLine) signals are connected to Controller PCBA connector DIFF I/P, J15. The cable from
rear panel J1 will be connected to either J14 or J15 on the Controller Board. (Sheet 1 of 13)
The TTL input COMMANDS from J14 go directly to buffer U58 and are terminated by
resistor RP9. COMMANDS from the Differential Input connector J15 are terminated by
RP6, RP7 and go to Differential Line Receivers U61, U62. The differential command
inputs are then output as single-ended lines to be connected in parallel with the TTL
command outputs from U58. The enable signals DIFF and TTLIN-, generated by the input
connector keying, control the selected source of the commands which go to the
Programmable Logic chip U48 (Sheet 2 of 13). Plotter OUTPUT STATUS like READY,
NO PAPER and ON LINE are routed through U52 for DIFF operation and through U53A
for TTL operation.
The TTL DATA interface uses a 74LS244N Buffer/Line Driver (U57), with terminating
resistor R18 on the 8 Data Input lines.
The Differential DATA interface uses two DS3486N Differential Line Receivers (U59,
U60) with terminating resistors RP10, RP11 on the Data Input lines.
DATA signals (TTL or DIFF) are output to the system data bus as D (0..7). The data are
latched in, one 8-bit byte at the time, by Latch U56 and are stored temporarily in a 4K x 8
FIFO, U49. (Sheet 2 of 13). The 8-bit PLOT data are then converted to 32-bit packed
RASTER data by programmable U48, and U50, U54 and U55, and are output to the 32-bit
data bus, ID (0..31).
The 32-bit raster data are then sent through DMA to the 1 MB X 32 DRAM System Data
Memory U40 (Sheet 4 of 13). Note that U39 is an optional 4 MB Memory for expanding
the System Data Memory capacity to 8 MB. (For optional 16 MB, one 16 MB module is
installed as U40. For optional 32 MB, another 16 MB module is added as U39).
PRINT 8-bit ASCII data received by latch U56 and stored in FIFO U49 are not rasterized at
this point but are transferred byte-by-byte from U48 to the AM29200 RISC Processor, U43,
where it is decoded. The 8-bit ASCII data are then transferred to System Data Memory,
U40, via the 32-bit System Data bus ID (0..31). When one line of ASCII data has been
stored in System Data Memory, it is then transferred to FIFO U14 for processing. (See
CHARACTER GENERATOR following).
ADDRESSES on 24 Address lines [A(0..23)] are generated by the RISC Processor, U43,
which contains an Address Decoder, and are sent out on the Address Bus to the System Data
Memory (U40), the 2-MBit (256K x 8 EPROM) Slow Program Memory, U44; the nonvolatile SRAM Parameter Memory, U46, (both on Sheet 4 of 13); the RS232 serial port
circuit (Sheet 5 of 13), and the 32-bit SRAM Fast Program Memory composed of U34, U35,
U37, and U38 (Sheet 6 of 13). PROGRAM instructions are downloaded from the 8-bit
5-5
Slow Program Memory to the 32-bit Fast Program Memory to speed up the program runtime.
The data handling sequence is controlled by software associated with the PLOT, PRINT or
SIMULTANEOUS PLOT/PRINT modes.
The CHARACTER GENERATOR IC (AM27C512-95DC), U11, receives Hex ASCII code
bits ASC0-7 from the 4K x 8 FIFO, U14, for a maximum of 296 characters (GS-624-2), 444
characters (GS-636-2, or 540 characters (GS-644-2) per line (scan). The entire line of
characters are encoded from PRINT (ASCII) data held in System Data Memory and
transferred to FIFO U14. After printing one line the FIFO is empty and must be refilled
from System Data Memory for the next line of characters.
The CHARACTER GENERATOR ROM contains the bit-mapped ASCII character set
(ASCII to Raster Look-up Table) for printable alphanumerics. (Sheet 5 of 13) PRINT
Raster Data are latched by U28, U31, U32 and U33 and are put on the 32-bit system Data
Bus ID (0..31) to be stored through DMA into the System Data Memory, U40.
5.4.3 SIGNAL FLOW

Input COMMANDS are received as discussed in Section 5.4.2 above and are sent to
Programmable Logic chip EPM7128LC84-15, U48 (Sheet 2 of 13). These and other
commands are processed by this IC (U48), which functions as an Input Controller. These
Logic Arrays are programmed to respond to the input commands issued by the computer
and control panel selections, and to handle the processing of these commands in response to
the RISC Processor, U43 (Sheet 3 of 13), and 16-bit Micro-Controller, U9 (Sheet 10 of 13).
PLOT DATA and PRINT character bytes received by the Differential Line Receiver or TTL
inputs (see Section 5.4.2 above) are latched into U56, converted to 32-bit data (U48, U50,
U54, U55) as shown on Sheet 2 of 13, and stored in the System Data Memory (4 MB
DRAM x 32) via the 32-bit Data Bus ID (0..31). This DRAM Memory is organized as an
input and output memory buffer, under control of the RISC Processor, U43, and the
Programmable Logic array, U48. Input and output memory cycle requests are processed in
concert with logic functions handled by the 16-bit 87C196 micro-controller, U9 (Sheet 10 of
13) which features a built-in program memory, and the Programmable Logic array, U8
(Sheet 12 of 13).
INSTRUCTIONS from the 8-bit Slow Program Memory, U44 (Sheet 4 of 13) are
downloaded to the Fast Program Memory composed of four CY7C199 Memory chips, U34,
U35, U37 and U38 (Sheet 6 of 13). The 32-bit instruction words are transferred via the 32bit Data Bus to the 16-MHz RISC Processor for very rapid processing.
Sheets 7, 8 and 9 of 13 show the circuitry for converting the RASTER data to THERMAL
PLOTTER data. When a line of PRINT data from the CHARACTER GENERATOR, or
seismic PLOT data held in Memory, is ready to be PLOTTED, these data are input as 32-bit
5-6
data to the RISC Processor, U43, and are converted to a serial bit stream, VDAT (Video
Data). These 1-bit serial data are sent to a Serial-to-Parallel circuit: first to U29, U27 for bitby-bit storage [32 KByte], (Sheet 7 of 13) and as VD (0..2) to Programmable Logic chip
U16 (Sheet 8 of 13). (VD0 = current line of data; VD1 = previous line of data; VD2 = 2nd
previous line of data. These data are stored in the 32 KB buffer, U27. VD0, VD1 and VD2
provide hysteresis control for the GS624-2, GS636-2, and GS644-2 plotter).
From U6, the serial bit stream becomes DOUT, going to U21, U25 and U26 (Sheet 7 of 13)
where it is converted to 18-bit packed parallel data (RAD0-RAD17) and output to the 18-bit
RAD (0..17) data bus. A second output from U16, PADR (0..9), is input to 2nd stage
memory U20 and U24 (8K x 18) and output to the same RAD (0..17) bus. Data bit DOUT
is accompanied by clock bit DCLK that clocks the data into the serial-to-parallel circuit.
Sheet 8 of 13 shows the RAD0-17 data going to 3rd stage memory U12 and U15, 2 FIFOs
(4K x 18), which can store 4 lines of data. Here it is converted to the print head Data format
under control of Programmable Logic array, U16. The 18-bit data are output as TD(0..17)
to buffers U17, U18 and U22 (Sheet 9 of 13) and are sent via 96 pin connector J8 (THAD)
and Adapter Board to the print head.
STROBE signals SB0 - SB8 are generated in Programmable Logic chip U16 and are sent as
SB (0..8) to U22 and U13 (Sheet 9 of 13). Along with bit-clock TDCLK and latch signal
LATCH, these signals are also sent to the Print head Assembly via 96-pin Connector J8
(THAD) and Adapter Board. Signal PRON- (U13) is used to disable the Print head output
for power-up protection of the heads (Sheet 9 of 13). Signals PT0 and PT1 come from the
connector (J8) index pins. They go to the RISC Processor, U43, and Programmable Logic
chip U16 to indicate the type of plotter that is connected: GS624-2, GS636-2 or GS644-2.
By plugging the correct Print head Adapter Board into J8 on the motherboard, and
connecting the output to the print head, the Wide Format Plotter Controller circuitry will
accommodate either one of these plotters.
The RS232 Serial Port (Sheet 5 of 13) utilizes Connector J11, Driver/Receiver U42, and
Serial Port Controller U47 to communicate with the 32-bit System Data Bus. U47/U42 can
control two serial ports: an external one (J11) and one built into the 87C196 MicroController, U9 (Sheet 10 of 13).
RESET circuitry (Sheet 6 of 13) accepts remote command RIN-, manual push-button reset
SRIN or power-up reset (U41).
Control (switch) panel connector J13 (Sheet 6 of 13) and transceiver U51 connects
AM29200 RISC Processor with the Plotter control panel Circuit shown on Schematic 644102172, Sheet 1 of 1. This circuitry is located on a separate Printed Circuit Board mounted
just under the control panel. Connector J1 on this board interfaces with connector J13 on the
motherboard.
The control panel has a vacuum florescent external display, which is connected to the
bottom of 16 I/O pins associated with the Key Pad Decoder/Debounce chip, U1. The
5-7
control panel has six keypads for encoding commands to the Plotter Controller. (The circuit
has accommodations for two more keypads, for future expansion). U4 generates a scan-rate
clock SLOCLK that constantly checks all the keys to determine if one is depressed or not. If
U1 detects some key depressed, it will generate an interrupt sequence to the 29200 RISC
Processor. The RISC Processor will then read back data from the control panel indicating
which key has been pushed.
IC U2 generates some signals to communicate between the 29200 RISC Processor and the
control panel, and florescent display. Latch U3 latches data from the 29200 RISC Processor
to turn on a red (Warning!) LED if something is wrong, or a green LED if everything is
OK.
5.4.4
OUTPUT CONTROLLER SECTION FUNCTIONS

Beginning on Sheet 10 of 13, the circuitry shown controls functions managed by the
87C196 16-bit Micro-Controller, U9. This Micro-Controller monitors print head
temperature by the thermistor voltage inputs on lines TH0-TH7, controlled by the
resister/capacitor network shown on Sheet 10 of 13. These analog voltage inputs go to an
A/D converter in the 87C196 Micro-Controller to control the print head operation. PRONfrom the Controller U9 turns the fan on by Relay K1 (Sheet 13 of 13).
Controller U9 and Programmable Logic chip U8 (Sheet 12 of 13) work together to control
the print head read/write cycles, and the transfer of data from the external source to, and
from, the System Data Memory, and the rasterization of one scan of data at the time for print
head plotting. IC's U6 and U10 (Sheet 10 of 13) control the TURN-ON time (strobe) for the
print head nibs. Power-control logic (PWRA, PWRB) and the LATCH command originate
in the Micro-Controller, U9.
The selection of PRINT, PLOT or SPP controls the operation. Data is accessed from the
System Data Memory, converted to serial 1-bit data, then packed into 18-bit parallel data
words, having a raster scan image format for PLOT, PRINT or Simultaneous PLOT/PRINT
mode operation.
5.4.5 PLOTTER CONTROL SECTION FUNCTIONS

The print head has built-in electronics to receive the 18-bit parallel data and store it into a
register as a serial bit stream of 9470 (GS 624-2), 14,206 (GS 636-2) or 17278 (GS644-2)
bits maximum for each raster line. (EXAMPLE: GS 636-2: 1,776 bytes x 8 bits = 14,208
bits maximum. NOTE that there are actually 14,208 -2 = 14,206 nibs in the Print head).
STROBE signals STRB0 - STRB8, a bit CLOCK (THDCK), and a LATCH signal also go
out to the print head interface. The DATA bits (THD0 - THD17) for each line (scan) are
clocked into the print head holding register, then loaded into the print head latches and
strobed out to the print head drivers in groups, as described in Section 5.5 below.
5-8
System STATUS Buffer U7 (Sheet 9 of 13) transfers system status signals coming from left
and right sensor connectors J3 and J6 (Sheet 13 of 13) to Programmable Logic Array U8
(Sheet 12 of 13). These signals indicate the physical plotter status such as low paper, left cut
enable, right cut enable, lid open, top of form, etc., conditions that affect the system
operation. Signals TP and LPS have adjustable pots to control the signal. The other signals
are pulled up to VCC through resistors RP2. Logic signals PWA and PWB going through
U7 to J6 control phase A and B print head voltages for plotting 400/200 dots per inch.
INTERRUPTS INTR0-, INTR1-, and INTR2- originating from U48, U47 and the control
panel are input to the RISC Processor U43. INTR2- is the high priority interrupt to shut the
system down if the STATUS input so dictates.
5.5
THERMAL PRINT HEAD OPERATION

The system will transfer a maximum of 1,184 bytes (9,470 dots), 1,776 bytes (14,206 dots),
or 2,160 bytes (17,278 dots) per line at 400 dots/inch for the GS 624-2, GS 636-2 or GS
644-2, respectively. At 200 dots/inch resolution, these figures are divided by 2. The input
register for the print head is designed to address groups of 512 dots per group. The last
group may be less than 512 dots to provide the correct number of dots per line. EXAMPLE:
GS 636-2 @ 200 dots/inch: Designed to address 13 groups of 512 bits and one group of 448
bits (512 x 13 + 448 = 7,104).
The system is designed for dual action: 400 dots/inch and 200 dots/inch. At 400 dots/inch
resolution the power supply switching circuit supplies two independent switched voltages to
the nib circuit to produce two separate dots at that point. The input data is printed twice. In
the 200 dots/inch mode the power is applied without switching to both nibs to produce one
single dot that has 1/2 the resolution. Because each dot is printed by two nibs the full line of
data is printed across the paper at 200 or 400 dots/inch.
PLOT MODE
GS 624-2:
(Raster Data)
FULL position:
PARTIAL position:
GS 636-2:
FULL position:
PARTIAL position:
GS 644-2:
FULL position:
PARTIAL position:
5-9
1184 bytes/line at 400 DPI

PRINT MODE
(ASCII Mode)
GS 624-2:
FULL position:
PARTIAL position:
296 bytes/line at 400/200 DPI

GS 636-2:
FULL position:
PARTIAL position:

GS 644-2:
FULL position:
PARTIAL position:

The LATCH signal is used to transfer the data from the serial registers to the print head data
latches.
Each GROUP has a separate STROBE (STRB0 to STRB8) to gate the data bits from the
latch circuit to the individual transistors which drive the heater elements in the thermal print
head. Voltage A and B (+20V) will be switched or applied simultaneously to enable the
driver transistors.
This procedure is micro-program controlled by the Micro-Controller U9, with U10, U6
(Sheet 10 of 13), and Programmable Logic array U16 (Sheet 8 of 13). The PRINT/PLOT
data are transferred to the print head Input Register, the contents are strobed by the LATCH
signal to the Output Latch Register (on the print head) and are then gated to the individual
transistors to be imaged by strobing the print head in separate line segments.
The overlapped controller operations described above for data input, data output and print
head control provides a high speed printing/plotting rate limited only by the time required to
cause thermal imaging of the media.
5.5.1
MICRO-STEPPER CONTROL
The micro-step motor that drives the recording paper in increments of 0.3125 mils operates
from 36 VDC. Logic signals to control the step functions are supplied by the plotter stepcontrol logic found on Sheets 11 of 13 and 12 of 13.
The 16-bit Micro-Controller, U9, and the Programmable Logic Array U8, generate the Step
Count logic CN (0..7) going to Step Count Memory U3 on Sheet 11 of 13. The step motor
control logic is supplied with a 16 MHz clock (MCLKS) coming from the RISC Processor.
Stepping speed is selected from the control panel switch as SPD1-, SPD2-, and SPD3- (LO,
MED, HI). The selected speed is applied to U8 (Sheet 12 of 13) and is output as Step Count
Logic CN (0..7) to U3. STP0-STP7 from U3 goes to Stepper Controller, U2, along with
SRST.
5-10
The Stepper Controller output is applied to step-motor drivers U1 and U5 (PBL3770A)

and is sent out to the step motor via J2 (Paper Move) as signals MA1, MA2, MB1, MB2
on AWG 22 wire, identified as follows:
MA1 = Green (Pin 2)
MA2 = Blue (Pin 4)
MB1 = Black (Pin 1)
MB2 = Red (Pin 3)
These wire colors match the step-motor wiring harness.
5.6
PAPER CUTTER CIRCUIT

The GS-624-2/636-2/644-2 Plotter/Printers employ a motor-driven paper cutter to cut the
rolled paper automatically at the end of a record or manually as desired. The control panel
has a paper cut (CUT/PARM) switch that is pressed for manual operation. The automatic
function may be enabled or disabled by a parameter setting on the control panel. (See
Chapter 4, OPERATION)
Sheet 11 of 13 shows the paper cut circuitry. The logic signal PN (0..5) is input to U19 and
is output to U23 as PST0-PST7. The paper cut drive motor is driven by drivers U30 and
U36 (PBL3770A). Step Count Memory U19 and micro-step Controller U23 supply the step
logic for the drivers, very similar to the paper move circuitry.
The motor drive output goes from U30 and U36 as PCB1, PCA1, PCB2, PCA2, going to
pins 1, 2, 3, 4 respectively on J7, and thus to the paper cut drive motor.
The cutter motor will drive the cutting blade across the paper in one direction, then stop.
The next drive command will move the cutter in the opposite direction and then stop. Thus
the cutter operates in either direction across the paper.
5-11
CHAPTER 6
MAINTENANCE & REPLACEMENT OF PARTS
6.1
GENERAL DESCRIPTION
The Imager is precisely aligned and adjusted at the factory for proper operation. No
mechanical or electrical adjustments are required during routine use.
Do not loosen screws marked with red lacquer. Components secured with marked
screws have been precisely aligned at the factory using special fixtures. Loosening
the screws may cause misalignment of the components!
6.2
MAINTENANCE
To increase the reliability of the print head, the following cleaning procedure is
recommended. The use of this procedure is required to ensure continued warranty
coverage of the print head and the Imager.
6.2.1
How to Clean the Print Head

1.
2.
3.
4.
5.
6.2.2
Wear latex (non-powder) disposable gloves (part # 540V1106001).

Open 98% isopropyl alcohol cleaning wipes (part # 160V1106001).
With the cleaning wipe, rub the entire length of the print head.
After cleaning, dispose of all cleaning material. Do not reuse.
Make sure surface of print head is completely dry before closing unit.
Other Maintenance
1. The rubber platen roller and metal idler roller should be cleaned with 98% isopropyl
alcohol cleaning wipes to remove any contaminants and/or residue. All surfaces
should be completely dry before closing the unit.
2. The inside of the unit should be vacuumed and the media conditioner, if installed,
should be cleaned thoroughly before loading the next roll of media.
3. The back and side filters should be checked and cleaned if necessary to ensure good
airflow across the thermal print head.
6.2.3
Frequency of Cleaning
The thermal print head, rollers, media conditioner, and interior of the unit should be
cleaned at the end of every roll of media or sooner if required.
The back and side filters should be vacuumed or replaced monthly or sooner if
necessary.
6-1
6.2.4
Other Precautions
The print head should never come into direct contact with the platen roller (black
drive roller). Either film or Mylar should be placed between the head and the roller if
no media is loaded in the imager.
The filters on the back and side of the imager should be checked and cleaned monthly
(more often if necessary) to ensure good airflow over the print head.
Do not place media or media hubs directly on floor or other unclean surface. Doing
so may cause contaminants to be picked up and introduced into the machine, which
can ultimately cause print head damage.
Avoid using the first and last wraps of media on the roll. This portion of the media
may contain contaminants due to handling. The manufacturer supplies extra media on
each roll to compensate for this procedure.
The front panel of the imager should be opened every 3 months and shavings from
the cutter removed with a vacuum.
6.3
TROUBLE SHOOTING
6.3.1
Power Failure
The power switch CB1 serves as the AC power on switch as well as circuit breaker for AC
overloads protection. The individual power supplies are also fused for additional protection
on each unit.
6.3.2
Paper Supply Failure

If the paper fails to feed properly, check for paper jams at the supply roll and in the transport
assembly. Also, check to make sure that the stepper motor is operating by pressing the
"PAPER FEED" key when the system is off line and observing the rotation of the platen.
6.3.3
Test Pattern Failure

If the built-in test failure occurs in generating the test patterns shown in Figs. 4.2 or 4.3, refer
to the TROUBLESHOOTING FLOW DIAGRAM Fig.6.1.
6.3.4
Optical Density Failure

Clean the print head as described in Sec. 6.2. Check the adjustment of power supply
voltages as described in the Sec. 6.5. If no plotted or printed image is present during
execution of the self-test function the PLOTTER CONTROLLER PCBA may be
inoperative. If only a portion of the image is missing, one or more of the print head nibs may
be inoperative or damaged.
6-2
6.3.5
Data Transfer Failure

If the unit operates properly during execution of the self-test function, but does not plot or
print incoming data, check the interconnections between the unit and the data source.
6.3.6
Control Panel Failure

Consult OYO Instruments Technical Support Group.
6.4
UNIT ACCESS
This section describes how to open or remove various covers and panels to permit access to
the interior of the unit to add media or perform maintenance.
6.4.1
Entry Routes - Parts are accessible as follows:

Top Cover - Open the top cover (door) by moving the two (2) latches on top of the unit
inward and lifting the cover upward.
TO OPEN TOP COVER, MOVE
LATCHES IN-WARD AND LIFT UP.
TO OPEN PLOTTER,
LIFT LATCHES.
Top Chassis/Print Head Chassis - Open the chassis by pulling the two (2) levers on the
front of the unit upward and lifting the chassis upward.
6-3
To separate the upper chassis from the

print head chassis, * pull both of these
pins (one at each end) outward and the
chassis will separate.
Caution: Hold the print head chassis
while pulling the pins outward so that
the chassis will not fall.
PRINT HEAD CHASSIS
PIN
* The pins will remain in the"outward"

(unlocked) position if they are rotated
approx half a turn when pulled out.
UPPER CHASSIS
End Covers - Remove the end covers

(right or left) by removing two (2) pan head screws securing the cover(s) to the rear of
the chassis. Gently pull the back of the end cover outward and then slightly forward.
This should disengage the cover from the end cover lock located in the front of the unit.
End Cover Entry
Front Panel Entry
REMOVE THESE SCREWS
REMOVE THESE SCREWS
Front Panel - Remove the front panel by first removing the two end covers (see above)
and then removing four (4) pan head screws (2 each side) securing the front panel to the
chassis.
6-4
NO
SELF TEST FAILURE
PRESS "ONLINE" SWITCH
YES
NO
MEDIA ADVANCES
1. CHECK INTERLOCK, HEAD OPEN &

PAPER OUT SENSORS.
2. CHECK STEP PULSED FROM U1 & U5,
PINS 1 & 15.
3. CHECK STEP MOTOR BELT.
4. CHECK U9, PINS 22 & 23. (RDYLH &
HDRDY).
5. CHECK 36V POWER SUPPLY
YES
CHECK THE 20V POWER SUPPLY
NO
MEDIA O.K.
YES
1. CHECK AC POWER
2. SET THE 20V POWER SUPPLY
VOLTAGE TO MATCH THE PRINT
HEAD VOLTAGE SETTING.
1. CHECK HEAD CONNECTORS

2. VERIFY MEDIA IS INSTALLED
CORRECTLY.
HEAD O.K.
MEDIA O.K.
NO
YES
1. CHECK STRB0 PULSE ON THE
PLOTTER CONTROLLER U22.
2. CHECK CLOCK U13 (THDCK).
3. CHECK LATCH PULSE U13.
4. CHECK SERIAL DATA U29 (VDAT).
1. INSTALL HEAD CONNECTOR.

2. INSTALL MEDIA WITH MEDIA
COATING NEXT TO PRINT HEAD.
3. MAKE SURE THE PRINT HEAD IS IN
CONTACT WITH THE MEDIA.
NO
STROBES O.K.
YES
1. CHECK ASSOCIATED CIRCUITRY
ON CONTROLLER SCHEMATIC 1,
624-102265-1, SHEETS 8,9,10.
REPLACE PRINT HEAD
Fig. 6.1
TROUBLE SHOOTING FLOW DIAGRAM
6-5
6.5
6.5.1
POWER SUPPLY ADJUSTMENT

20V Power Supply
There are two types of 20V power supply in this imagesetter. Find out which power supply
in your plotter and follow the instruction to the adjustment.
Cherokee Power Supply (Black color)

The print head voltage is set to match the 20V power supply voltage at the factory. If either
the print head or the 20V power supply is changed, the voltage (V1) must be reset as follows:
Tools Required:
1. Screw driver-medium flat blade
2. Screw driver-small flat blade (for 20V power supply adjustment)
3. Digital multimeter (+/- 0.1% accuracy)
Procedure:
1. Press the ON LINE switch to off-line (LED is OFF).
2. Press MENU to access SYSTEM MENU.
3. Press ITEM to FAN CONTROL.
4. Press PARM+ or PARM- to ALWAYS ON .
5. Press ENTER.
6. Press ON LINE, power supply will now come on.
7. Remove left end cover screws in rear of plotter, remove left end cover.
8. Connect the red lead of the multimeter to the V1 positive (+) lead of the power
supply. Connect the black lead of the multimeter to the V1 negative (-) lead of the
power supply.
9. Set the voltmeter to a higher voltage range than the voltage being set.
10. Using the PRINT HEAD
VOLTAGE table, select the
voltage which corresponds to the
print head resistance (marked on
the print head label).
11. Use a small screw driver to turn
the V1 potentiometer on the
power supply. Turn clockwise
(CW) to increase and counterclockwise (CCW) to decrease.
12. Repeat steps 1 - 3.
Adjust at V1
13. Select AUTOMATIC ON/OFF
6-6
Astec Power Supply (Gold color)

The print head voltage is set to match the 20V power supply voltage at the factory. Is done as
follows: If either the print head or the 20V power supply is changed, the voltage (V1 + V2)
must be reset as follows:
Tools Required:
1.
2.
3.
4.
Screw Driver-Medium size flat tip

Alignment Tool (for 20V power supply adjustment)
Digital Multimeter (+/- 0.1% accuracy)
Electrostatic Wrist Band and Anti-Foam Pad
Procedure:
1.
2.
3.
4.
5.
6.
7.
8.
Press the ON LINE switch to off-line (LED is OFF).

Press MENU to access SYSTEM MENU.
Press ITEM to FAN CONTROL.
Press CUT/PARM+ or FEED/PARM- to ALWAYS ON .
Press ENTER.
Press ON LINE; Power supply will now come on.
Remove left end cover screws in rear of plotter, remove left end cover.
Connect the RED lead of the multimeter to the V1 positive (+) lead of the power
supply. Connect the BLK lead of the multimeter to the V1 negative (-) lead of the
power supply.
9. Set the volt meter to a higher voltage range than the voltage being set.
10. Using the PRINT HEAD VOLTAGE table, select the voltage which corresponds
to the print head resistance (marked on the print head).
11. Use a small screwdriver to turn the V1 potentiometer on the power supply. Turn
clockwise (CW) to increase and counter-clockwise (CCW) to decrease.
12. Repeat steps 8 - 11 to adjust V2.
13. Repeat steps 1 - 2.
V2
14. 14. Select AUTOMATIC

ON/OFF
V1
ADJUST HERE
* NOTE *
Nominal V1
Nominal V2
13.3V
6.7V
6-7
Cherokee Power Supply Voltage Chart

RESISTANCE
(OHMS)
1270
1280
1290
1300
1310
1320
1330
1340
1350
1360
1370
1380
1390
1400
1410
1420
1430
1440
1450
1460
1470
1480
1490
1500
VOLTAGE
RESISTANCE
(OHMS)
18.54
18.60
18.66
18.72
18.78
18.84
18.90
18.96
19.02
19.08
19.14
19.20
19.26
19.31
19.37
19.43
19.49
19.55
19.60
19.66
19.72
19.77
19.83
19.89
VOLTAGE
1510
1520
1530
1540
1550
1560
1570
1580
1590
1600
1610
1620
1630
1640
1650
1660
1670
1680
1690
1700
1710
1720
1730
1740
19.94
20.00
20.05
20.11
20.17
20.22
20.28
20.33
20.39
20.44
20.49
20.55
20.60
20.66
20.71
20.76
20.82
20.87
20.92
20.98
21.03
21.08
21.13
21.19
The Print Head voltage may be obtained in two ways:

1. Find the resistance printed on the print head label in the plotter.
Refer to the chart above and find the voltage corresponding to
the resistance on the label.
2. Or, use the following formula:
HV = 3.0 + 0.436 *
HR
HV = Head Voltage
HR = Head Resistance
Table 6.1.a
Print Head Voltage (Cherokee) Chart
6-8
Astec Power Supply Voltage Chart

Resistance
(Ohms)
Voltage
V1
Voltage
V2
Resistance
(Ohms)
Voltage
V1
Voltage
V2
Resistance
(Ohms)
Voltage
V1
Voltage
V2
1800
1810
1820
1830
1840
1850
1860
1870
1880
1890
1900
1910
1920
1930
1940
1950
1960
1970
1980
1990
2000
2010
2020
2030
2040
2050
2060
2070
2080
2090
2100
2110
2120
2130
2140
12.87
12.90
12.93
12.97
13.00
13.03
13.07
13.10
13.13
13.17
13.20
13.23
13.27
13.30
13.33
13.36
13.40
13.43
13.46
13.49
13.52
13.56
13.59
13.62
13.65
13.68
13.71
13.75
13.78
13.81
13.84
13.87
13.90
13.93
13.96
6.43
6.45
6.47
6.48
6.50
6.52
6.53
6.55
6.57
6.58
6.60
6.62
6.63
6.65
6.67
6.68
6.70
6.71
6.73
6.75
6.76
6.78
6.79
6.81
6.83
6.84
6.86
6.87
6.89
6.90
6.92
6.94
6.95
6.97
6.98
2150
2160
2170
2180
2190
2200
2210
2700
2710
2720
2730
2740
2750
2760
2770
2780
2790
2800
2810
2820
2830
2840
2850
2860
2870
2880
2890
2900
2910
2920
2930
2940
2950
2960
2970
14.00
14.03
14.06
14.09
14.12
14.15
14.18
12.89
12.91
12.94
12.96
12.98
13.00
13.03
13.05
13.07
13.09
13.12
13.14
13.16
13.18
13.20
13.23
13.25
13.27
13.29
13.31
13.33
13.36
13.38
13.40
13.42
13.44
13.46
13.49
7.00
7.01
7.03
7.04
7.06
7.07
7.09
6.45
6.46
6.47
6.48
6.49
6.50
6.51
6.52
6.54
6.55
6.56
6.57
6.58
6.59
6.60
6.61
6.62
6.63
6.65
6.66
6.67
6.68
6.69
6.70
6.71
6.72
6.73
6.74
2980
2990
3000
3010
3020
3030
3040
3050
3060
3070
3080
3090
3100
3110
3120
3130
3140
3150
3160
3170
3180
3190
3200
3210
3220
3230
3240
3250
3260
3270
3280
3290
3300
3310
13.51
13.53
13.55
13.57
13.59
13.61
13.64
13.66
13.68
13.70
13.72
13.74
13.76
13.78
13.80
13.82
13.85
13.87
13.89
13.91
13.93
13.95
13.97
14.00
14.01
14.03
14.05
14.07
14.09
14.11
14.13
14.16
14.18
14.20
6.75
6.76
6.77
6.79
6.80
6.81
6.82
6.83
6.84
6.85
6.86
6.87
6.88
6.89
6.90
6.91
6.92
6.93
6.94
6.95
6.96
6.97
6.99
7.00
7.01
7.02
7.03
7.04
7.05
7.06
7.07
7.08
7.09
7.10
Find the resistance printed on the print head label in the plotter. Refer to the
chart above and find the voltage corresponding to the resistance on the label.
Table 6.1.b
PRINT HEAD VOLTAGE (ASTEC) CHART
6-9
6.5.2
5V Power Supply
Tools Required:
2. Screw driver-small flat blade
3. Digital multimeter (+/- 0.1% accuracy)
Procedure:
1. Remove the right end cover.
2. Open the top cover.
3. Connect the red lead of the multimeter to the POS (+) lead of the 5V power
source connector located on the PCBA. (See Fig. 1 and 2)
4. Connect the black lead of the multimeter to the NEG (-) lead of the 5V power source
connector located on the PCBA. (See Fig. 1 and 2)
5. Set the voltmeter to a higher voltage level than the voltage being used. (Approx. 10V
DC or more)
6. Turn on the power.
7. Use a small screw driver to turn the blue potentiometer on the power supply. Turn
clockwise (CW) to increase and counter-clockwise (CCW) to decrease. (See Fig. 3)
8. Set voltage to 5.1V.
POS (+)
NEG (-)
FIG. 1
FIG. 2
FIG. 3
Adjust here
6-10
6.6
REPLACEMENT OF PARTS
6.6.1
Replace PCBA-Plotter Controller

Tools required:
1. Hex driver, 1/4
Procedure:
1.
2.
3.
4.
5.
6.
Open the top cover. (Refer to 6.4)

Disconnect all connectors connected to the PCBA.
Remove the Print Head Adapter Board.
Remove all nylon standoffs securing the PCBA.
Lift the PCBA off and install the replacement unit.
All ITEM PARAMETERS are factory default. If necessary, reset the parameters as per
4.2.4.
REMOVE ALL STANDOFFS,

WIRING HARNESSES AND
RIBBON CABLES
REMOVE THIS BOARD FIRST!
6-11
6.6.2
Replace PCBA-Power Switch (left side)

Tools Required:
2. Wrench-5/16 inch (box / open end wrench)
3. Hex driver, 1/4
Procedure:
1. Open the top chassis / print head chassis.
2. Separate the top chassis from the print head chassis by pulling the pins at each end of the
chassis.
3. Disconnect the wires connected to the terminal strip on the PCBA.
4. Remove (4) nuts securing the PCBA to the chassis.
5. Pull the PCBA outward far enough to disconnect the connector connected to it.
6. Install the replacement PCBA.
REMOVE CONNECTOR
REMOVE NUTS
REMOVE WIRES
6-12
6.6.3
Replace PCBA-Power Switch (right side)

Refer to 6.6.2
6.6.4
REPLACE CONTROL PANEL

Tools Required:
Procedure:
2.
3.
4.
5.
Open the top cover.

Remove screws (4) securing the panel.
Disconnect cable (connector) connected to the panel.
Install the replacement panel.
Note: Shims under right side of panel
REMOVE SCREWS
REMOVE CABLE
6-13
6.6.5
Replace 5V Power Supply

Tools Required:
1. Hex driver-7/64 inch (or allen wrench)
Procedure:
2. Remove the 4-40 socket head screws securing the power supply cover and
lift the cover off.
3. Remove four (4) screws securing the power supply.
4. Lift the power supply out and disconnect the connectors connected to it.
5. Install the replacement power supply.
REMOVE
SCREWS
6-14
6.6.6
Replace 20V Power Supply

Tools Required:
1.
2.
3.
4.
5.
6.
Hex driver-7/64 inch (or allen wrench)

Nut driver-3/8 inch (or box / open end wrench)
Screw driver-large flat blade
Allen wrench-5/32 inch
Procedure:
2. Remove 4-40 socket head screws securing the cover over the power supplies and
lift the cover off.
3. Remove both end covers.
4. Remove (5) nuts securing the power supply chassis to the bottom of the plotter.
5. Remove (4) 8-32 socket head screws (2 each end) securing the power supply
chassis to the sides of the plotter.
6. Remove (4) 10-32 socket head screws securing the power supply to the power
supply chassis.
7. Remove wires from power supply.
8. Install the replacement power supply.
9. Replace wires to newly installed power supply.
10. Set the power supply voltage to match the print head voltage per 6.5.
REMOVE COVER
REMOVE HARDWARE
6-15
6.6.7
Replace Print Head

Tools Required:
1.
2.
3.
4.
5.
6.
Screw driver-medium flat blade

Screw driver-small flat blade
Hex driver-5/32
Nut driver-3/8
Nut driver-5/32
Digital multimeter-(+/- 0.1% accuracy)
Procedure:
(See illustrations on next page)
1. Separate print head chassis from top chassis. Refer to 6.4.

2. Disconnect wires at both POWER SWITCH PCBAs. (Only #1 and #3)
3. Remove two (2) screws and nuts from the head actuator switches. (Left and right
ends) Carefully place the switch towards the rear of the plotter. (This keeps the
switch out of the way during removal and installation of the print head).
4. Remove wires connected to the negative ( ) terminal of big capacitors.
5. Remove ribbon cables from print head.
6. Remove four (4) nuts/washers (2 each end) securing the print head to the print head
chassis. Note how the grounding cable is installed onto the print head.
Caution: Hold the print head securely to prevent it from falling out of the print
head chassis!
7. To reinstall new print head, reverse steps 2 - 6. Leave nuts loose for adjustment
procedure.
Adjustment: (See illustrations on next page)
1.
2.
3.
4.
Close and latch both latches of the upper chassis.

Open the top cover.
Tighten the rear mounting nuts of the print head.
Separate the print head chassis from the upper chassis and tighten the two remaining
nuts that secure the print head to the print head chassis. Loosen these nuts 1/4 - 1/2 a
turn to allow for thermal expansion. Set the 20V power supply voltage to match the
print head voltage per 6.5.
6-16
REMOVE
SCREWS
REMOVE # 1and 3
TIGHTEN, THEN
LOOSEN 1/4-1/2TURN.
REMOVE WIRES FROM

NEGATIVE TERMINAL.
TIGHTEN WITH UPPER

CHASSIS CLOSED AND
LATCHED.
TIGHTEN THESE NUTS WHEN UPPER

CHASSIS IS CLOSED AND LATCHED.
6-17
6.6.8
Replace Step Motor-Platen Drive (illustration next page)

Tools Required:
1.
2.
3.
4.
5.
6.

Pliers-small cutter
Nut driver-3/8
Hex driver-3/32
Hex driver-7/64
Hex driver-5/32
Procedure:
1.
2.
3.
4.
5.
Remove the left end cover. Refer to 6.4.

Cut the cable tie wrap and disconnect motor connector.
Loosen the (4) 10-32 nuts that secure the motor/motor plate and remove the belt.
Remove nuts and motor assembly from plotter.
Remove the (4) 6-32 socket head screws that assemble the motor plate to the
motor. Install motor plate onto the new motor.
6. To replace the new motor, follow steps 1-5 in reverse order.
Adjustment:
1. Tighten the platen drive belt, by pressing firmly down onto motor pulley and tighten
motor assembly.
6.6.9
Replacement of Platen Drive Belt

LOOSEN NUTS
Tools Required:
1. Screw driver-large flat blade
2. Nut driver-3/8 inch (open end wrench)
Procedure:
1.
2.
3.
4.
5.
6.
Remove the left end cover.

Loosen four (4) nuts securing the motor bracket.
Slide the motor / bracket upward.
Remove the belt.
Install the replacement belt.
For adjustment, refer to 6.6.8.
6-18
6.6.10 Replace Step Motor-Cutter Drive

Tools Required:
1.
2.
3.
4.
5.
6.
Screw driver-large flat blade

Wrench-11/32 inch open end
Procedure:
1.
2.
3.
4.
5.
6.
7.
8.
Remove both end covers.

Remove the front cover.
Loosen screw securing the left end cutter drive belt pulley.
Remove the cutter drive belt from the motor pulley.
Remove four (4) nuts securing the motor bracket. Take the motor / bracket out.
Remove four (4) screws / nuts securing the motor to the motor bracket.
Remove the pulley from the motor shaft.
Install the replacement motor.
REMOVE NUTS
LOOSEN
6-19
6.6.11 Replace Blower-(Fan)

Tools Required:
1. Allen wrench-3/32 inch
Procedure:
2. Remove four (4) screws (2 each end) securing the blower air guide assembly to he print
head chassis. Remove the air guide assembly and set it aside.
3. Disconnect the power connector connected to the blower to be changed.
4. Remove four (4) screws securing the blower to be changed.
5. Lift the blower out and install the replacement blower.
CONNECTOR
AIR
GUIDE
REMOVE
SCREWS
6-20
REMOVE
SCREWS
6.6.12 Replace Filter-Fan (Blower)

Tools Required:
1. Hex driver-3/32 (or allen wrench)
Procedure:
2. Remove all screws securing the filter bracket to the back of the plotter.
3. Install replacement filter.
REMOVE SCREWS
6-21
6.6.13 Replace Drive Cable-Paper Cutter

Tools Required:
1. Screw driver-large flat blade
2. Hex driver-1/8 inch (or allen wrench)
3. Wrench-11/32 inch box or open end
Procedure:
1.
2.
3.
4.
5.
Remove both side covers.

Remove front cover.
Loosen (do not remove) the left end cutter cable pulley. Take the cable off.
Remove the nut securing the cable to the cutter assembly.
Install the replacement cable.
FRONT
COVER
REMOVE CABLE
LOOSEN SCREW
6-22
6.6.14 Replace Cutter Blade Assembly

Tools Required:
Procedure:
2.
3.
4.
5.
Remove both end covers.

Remove the front cover.
Remove the two (2) screws securing the cutter assembly to the bearing housing.
Install the replacement cutter blade assembly.
USE THE EDGE OF THE CUTTER

ASSEMBLY AND THE HOUSING TO
HELP ALIGN CUTTER DURING
INSTALLATION.
6-23
6.6.15 Replace Capacitor

Tools Required:
2. Pliers-cutter
Procedure:
1.
2.
3.
4.
Open the top chassis / print head chassis.

Cut the tie wrap securing the capacitor to the print head chassis.
Remove two (2) screws securing the wires to the capacitor.
Install the replacement capacitor. Refer to Ch 8 for Wiring Diagram.
REMOVE WIRES
6-24
6.6.16 Replace Switch-Head Engaged

Tools Required:
1.
2.
3.
4.

Nut driver-5/32 inch small size
Hex driver-3/32 inch
Soldering iron / solder
Procedure:
1.
2.
3.
4.
5.
6.
Open the top chassis / print head chassis.

Remove (de-solder) the two (2) wires connected to the switch.
Separate the print head chassis from the top chassis
Remove the two (2) screws / nuts securing the switch to the chassis.
Install the replacement switch and re-solder the wires.
These switches (there are two) control the "HEAD OPEN" indicator mounted on the
switch panel on top of the unit. When the print head is closed (engaged), the indicator
light should be off (un-lighted). To set the switch actuator so that the indicator functions
properly (un-lighted when print head is closed), do as follows:
a. Locate the access holes through which the hex driver is inserted to adjust the screw
controlling the switch actuator. There are two switches and two holes, one at each
end of the unit. The top cover must be open for access to the holes. Insert the hex
driver and turn the screw CCW (counter clockwise) several turns or enough so that
the screw does not make any contact with the switch actuator. Visually check to see
that there is no contact.
b. Close the top chassis / print head chassis.
c. Turn power ON. The "HEAD OPEN" indicator should be on (lighted).
d. With the 3/32 inch hex driver inserted into the screw, turn the screw CW (clockwise)
slowly until the "HEAD OPEN" indicator turns off. The switch actuator is now set
correctly.
REMOVE SCREWS
ADJUST HERE
6-25
6.6.17
Assembly of Long Knife

Tools Required:
1.
2.
3.
4.
5.

Hex driver-5/16
Allen wrench-5/64
Allen wrench-5/32
Open end wrench-5/16
Procedure:
1. Remove the left and right end covers by removing the 10-32 screws, located on
the rear of the plotter. (2 ea. side)
2. Open upper chassis. (Refer to 6.4)
3. Remove Remove the 10-32 hex hd. screws (1 ea. side) that hold the long knife
assembly into the plotter.
4. Remove the 6-32 flat hd. cap screws that hold the long knife blade onto the
stiffener.
5. Important! Do not rotate blade end for end. Rotate blade front to back or back
to front and reassemble onto the stiffener. Note the proper operating angle in the
end view illustration below.
6. Reinstall long knife blade assembly into the plotter. Center the assembly by it
about 1/2 from the inside surface of the plotter ends as shown in the illustration
below.
6.6.18
Replacement of Long Knife

Tools and Procedure (Refer to 6.6.17)
Parts Required:
Long Knife Replacement Kit P/N
6-26
618-103646,624-103647,
628-103648, 636-103649,
644-103650
CHAPTER 7
SCHEMATIC DIAGRAMS, CABLE ASSEMBLY DRAWINGS
AND POWER SUPPLIES
7.1
SCHEMATIC DIAGRAMS
There are total 26 pages for this section and include:
Wide Format Plotter Controller board
Component Layout: 624-102267-3,
Schematic Diagrams: 624-102265-3,
1 page
13 pages
Print Head Adapter,624

Component Layout: 624-102282,
Schematic Diagrams: 624-102280,
1 page
1 page

1 page
1 page

1 page
1 page
Pot Adapter, Controller

1 page
1 page
Switch Panel board

Component Layout:
Schematic Diagram:
644-102174,
644-102172,
1 page
1 page
Power Switch board, 400DPI

Schematic Diagram: 624-103289,
1 page
1 page
7-1
7.2
CABLE ASSEMBLY DRAWINGS

There are total 60 pages for this section and include:
Wiring Diagram:
Wiring Diagram-Paper Take Up:
Cable Diagram-Imagesetter/400dpi:
List of Cable Assembly, 400DPI:
Cable Assy-6XX Head Power, Right:
Cable Assy-624 PR HD Data:
Cable Assy-636/642 CTRL/Step Motor:
Cable Assy-6XX Data in:
Cable Assy-642 Data in:
Cable Assy-636 PS1/RHT LRG CAP:
Cable Assy-6XX PS1/LRG CAP POS/NEG:
Cable Assy-6XX Sensors, Left:
Cable Assy-6XX Sensors, Right:
Cable Assy-6XX Fan, Normal SPD:
Cable Assy-636 CTRL/Cut Motor:
Cable Assy-6XX Head Engaged Switch, Left:
Cable Assy-636/644 PR HD Data (#1):
Cable Assy-636 Print Head (2):
Cable Assy-6XX CTRL/Fan Power:
Cable Assy-624 CTRL/Fan Power:
Cable Assy-624 Data in:
Cable Assy-624.V2 RHT CAP to 20V PS:
Cable Assy-624 CTRL/Fan Control:
Cable Assy-624 Fan, Lo SPD:
Cable Assy-636 CTRL/Fan Control:
Cable Assy-636 Fan, LO SPD:
Cable Assy-644 PS1/RHT Large CAP:
Cable Assy-636 CTRL/Cut Motor:
Cable Assy-644.CTRL/Fan Control:
Cable Assy-6XX Motor, Stepper/Cutter:
Cable Assy-644 PR HD data (#2):
Cable Assy-6XX CTRL/SW Panel:
Cable Assy-6XX CTRL/Cut Motor:
Cable Assy-6XX Platen GND:
Cable Assy-624 RHT CAP to 20V PS:
Cable Assy-644 Right Cap to 20V PS:
Cable Assy-644 CTRL/SW Panel:
Cable Assy-6XX Fan, High Speed:
Cable Assy-6XX Head Power, Right:
Cable Assy-6XX Head Engaged Switch, Right:
Cable Assy-624 CTRL/LFT Sensor:
Cable Assy-624 CTRL/RHT Sensor:
Cable Assy-636/644 CTRL/Left Sensor:
7-2
600-103599,
624-100267,
600-104711,
1 page
1 page
1 page
1 page
624-100376, 1 page
624-100768, 3 pages
636-100811, 1 page
636-100815, 3 pages
636-100815-1, 3 pages
636-100816, 1 page
636-100817, 1 page
636-100819, 1 page
636-100820, 1 page
636-100821, 1 page
636-100822, 1 page
636-100823, 1 page
636-100824, 4 pages
636-100825, 2 pages
624-100991-1, 1 page
624-100992, 1 page
624-100996, 3 pages
624-100997, 1 page
636-101204-1, 1 page
624-101487, 1 page
624-101488, 1 page
636-101490, 1 page
636-101497, 1 page
644-101916, 1 page
644-101917, 1 page
644-101919-1, 2 pages
644-101957, 1 page
636-101996, 1 page
644-102547, 1 page
624-102548, 1 page
624-102862, 1 page
624-103023, 1 page
624-103093, 1 page
644-103094, 1 page
644-104263, 1 page
600-104732, 1 page
600-104804, 1 page
600-104805, 1 page
624-105077, 1 page
624-105078, 1 page
600-105079, 1 page
636-105080, 1 page

7.3
644-105081,
POWER SUPPLIES
It contains two types of power supplies:
Logic Power Supply
IPD SRW65-2005 (400V1006011),
IPD SRW115-4002 (400V1006042),
Head Power Supply:
Cherokee (discontinued),
Astec VS1-K4-A8-00-474-CE-N40CP (400V1006038),
Convert Cherokee to Astec PS Document (600-105347)
7-3
1 page
5 pages
5 pages
2 pages
8 pages
6 pages
CHAPTER 8
SPARE PARTS
Board Level, Plotter/Printer, GS 6XX-2
Rev K
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
PART NUMBER
624-102267-3
624-102282
636-102285
644-102288
624-103291
644-102174
170V1036060
170V1036062
313V1056098
624-104126
400V1006031
245V1026001
624-103028-1
636-103030-1
644-103031-1
644-102979-2
0600021
250V1206002
250V1206003
250V1206004
270V1056006
430V1056006
250V2046007
636-100892
636-100819
636-100820
636-101996
636-100821
636-100823
600-104805
600-104732
Notes:
NAME-DESCRIPTION
PCBA-Wide Format Plotter Controller, 400 DPI
PCBA -Print Head Adapter, 624 (See Note 2)
PCBA -Power Switch, 400 DPI (2/Unit)
PCBA -Front Panel (Control Panel)
SRAM-32Kx8 20 NS DIP (U34, 35, 37, 38)
DRAM-4Mx36 60NS SIMM (U40)
IC-MEM, DS1220AB-200 (U46)
Power Supply-400V1006042 with Fan
Power Supply-QD6L1R-1A
Display-VF, CU20025SCPB-T20A
Print Head Assembly -24 (See Note 2)
Media Supply Hub AssemblyConnector-EAC 305 Switchcraft
Spring-Gas, C16-09723 Suspa (See Note 1)
Filter-RF, 6EQ8 Corcom
Circuit Breaker-MB2-B-34-615-1-A12-BC
Belt-Timing, A6R23M132090
Paper Cutter AssemblyCable Assembly-Left Sensors, Media Low/Paper Cut/TOF
Cable Assembly-Right Sensors, Platen/Paper Cut
Cable Assembly-Step Motor/Media Cut Motor
Cable Assembly-Normal Speed Blower with Connector
Cable Assembly-Head Engaged Switch, Left Side
Cable Assembly-Head Engaged Switch, Right Side
Cable Assembly-High Speed Blower with Connector
1. For GS 624 only

2. For GS 636 only
3. For GS 644 only
8-1
QTY
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
2
2
2
1
1
1
1
1
1
1
1
1
1
1

Manual 624 102515 A

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OPERATION MANUAL

~ STATEMENT OF LIMITED WARRANTY ~

To locate your nearest OYO service center dial:

~ IMAGER CLEANING PROCEDURES ~

Print head Cleaning Instructions:

Imager Cleaning Instructions:

~ RETURN MATERIAL AUTHORIZATION (RMA) PROCEDURES ~

~ RETURNED MATERIAL AUTHORIZATION (RMA) FORM ~

DETAILED REASON FOR RETURN:

Additional Notes: (OYO Use Only)

Remote Escape Sequence Command Control .................................................................4-18

MAINTENANCE AND REPLACEMENT OF PARTS

Replace PCBA-Plotter Controller....................................................................................6-10

SCHEMATICS/PCBADRWGS/CABLE DRWGS/POWER SUPPLY SPECS

SPARE PARTS LISTS

LIST OF FIGURES AND TABLES

Functional Block Diagram ..........................................................................................1-2

BRIEF DESCRIPTION of CHANGE

33.0 INCHES (GS 624-2)

24" (60 cm)

36" (91 cm)

44" (112 cm)

115 or 220 VAC (auto-switch)

Input Bit 1 (LSB)

Input Bit 8 (MSB)

Parallel Input Clock

Remote Form Feed

Remote End of Transmit

This line selects either print or

7438 SERIES BUFFER

TWISTED PAIR NOT TO

TWISTED PAIR NOT TO

REMOTE FUNCTIONS* (Interface Signals)

This command clears the input buffer when READY

NORMAL CHARACTER SET

INVERTED CHARACTER SET

CONTROL CODE SET

3.3.4 DRIVER CONSIDERATIONS

POWER SWITCHING FOR 220 VAC

INSTALLATION OF PAPER TAKE UP

The following steps require that media be installed in the Plotter.

ADJUST PAPER SUPPLY REEL (Side to Side) Refer to Fig. 3.9

ADJUST THE PAPER TENSION Refer to Fig. 3.9

3.6 INSTALLATION OF FAN FOLD PAPER TRAY

3.7 INSTALLATION OF FAN FOLD PAPER GUIDE

POWER SWITCH CB1

CONTROL PANEL KEYPAD

MENU AND ITEM MODES

FRONT PANEL INDICATORS

Mode and action of fan control.

Every plot will shift 1 bit right after

Control media movement

LOADING ROLL PAPER

LOADING FAN-FOLD PAPER (GS-624-2 ONLY)

FAN FOLD MEDIA SUPPLY

400 dpi ***

!#$%( )*+,-./0123456789:;< + >?@ABCDEFGHIJKLMNOPQRTSUVWXYZ[ \

200 dpi ***

!#$%( )*+,-./0123456789:;< + >?@ABCDEFGHIJKLMNOPQRTSUVWXYZ[ \

Energy Level Test:

Dot Size Test: Size ; 2x2

ERRORS DUE TO INAPPROPRIATE SYSTEM CONFIGURATION

ERRORS OCCURRED DURING PLOTTING OPERATION