JUKI 6100 Bedienungsanleitung

CONTENTS

^3 EMER/\ L•*•••1

1Bssic SpGcif icstions ,1

2. Main Component Units 1

2.1 Print unit 1

212 ntrolunit •••*•*••*•* 1

2.3 Cover unit 1

3. Block Diagrams 2

3.1 Block diagram of all component units 2

3.2 Block diagram of control boards 2

4. Operation of Print Unit Mechanisms 3

4.1 Carriage feed mechanism 3

4.2 Character selection mechansism 6

4.3 Hammer mechanism 6

4.4 Ribbon feed mechanism 7

4.5 Form feed mechanism 7

5. Removal and Replacement 8

5.1 Maintenance tools 8

5.2 Disassembly and assembly 9

6. Adjustment 31

6.1 Carriage unit and linear motor unit adjustment 31

6.2 Ribbon mechanism adjustment 42

6.3 Platen drive mechanism adjustment 46

6.4 Paper bail adjustment 47

7. Theory of Operation 48

7.1 Power supply 48

7.2 MCU and SCU operations 54

7.3 Daisy motor and linear motor home position sensor circuit 61

7.4 Control panel 62

8. Lubrication 65

8.1 Lubricating the carriage unit 66

8.2 Lubricating the frame unit 67

8.3 Lubricating the parts 68

9. Configuration 70

10. Troubleshooting 71

10.1 General desciption 71

10.2 Troubleshooting 71

GENERAL

This Technical Manual describes the maintenance, troubleshooting, and operating

principle of the daisy wheel printer.

1. Basic Specifications

Print speed

Print system

Print wheel

Character spacing

Line spacing

Form feed

Max. form width

Copies

Ribbon

Interface

Environmental requirements

Weight

18characters/second (Max.)

Daisy wheel

1OO-characters/wheel

110 characters under 10 pitch.

132 characters under 12 pitch.

165 characters under 15 pitch.

82 to 220 characters under proportional spacing mode.

1/48 inch (1 /96 inch possible by ESC sequence)

Friction feed

13 inches (printing line 1 1 inches)

Original copy +3copies

IBM 82 compatible multi strike or single strike ribbon

(selectric II ribbon)

Centronics parallel interface

RS232C Serial Interface (Option)

Temperature 41°F ~95°F(5 ~35°C)

Humidity 30% ~85% (no dew condensation)

About 27.5 lbs. (about 12.5 kg)

2. Main Component Units

This printer consists of the following three major units.

2.1 Print unit

The print unit is comprised of the frame assembly, carriage and linear motor unit

and the form feed mechanism. Occupying the largest part of the print unit, the

carriage performs lateral feed, character selection, printing and ribbon feed. Use

of aliner motor makes the carriage simple in design for easy maintenance.

2.2 Control unit

This unit provides all the controls for the printer and consists of apower supply

and two CPU boards. One of the CPU circuit boards serves as the slave CPU

circuit board for controlling the print unit mechanisms, and the other is the master

CPU circuit baord for controlling the slave CPU circuit board and for the commu-

nication with the host CPU.

2.3 Cover unit

The cover unit consists of abottom cover, center cover, top cover, and acoustic

cover. Except for two screws, snap-latches are used for connection between the

covers.

3. Block Diagrams

3.1 Block diagram of all component units

Interface >'

Operation

panel

Power supply

Control

board

Carriage

PF motor

Status SW

Fig. 3.1

3.2 Block diagram of control boards

Serial interface

connector

Buffer Buffer

8251

UART

Serial interface

board (option)

Parallel interface

connector

Operation panel

connector

Buffer

ABuffer

RAM 2k byte

(MAY 8k byte)

ROM

8k byte

256 byte RAM

8155

Timer I/O port

8051 Master CPU

AMaster CPU board

8051 Slave CPU

Driver circuit

Carriage, PF Motor,

status SW connector

Slave CPU board

Fig. 3.2

-2-

As previously described in Section 2"Main Component Units", all communications to

the host CPU and all printing functions are performed by the control unit. Two sepa-

rate circuit boards, the Master CPU and the Slave CPU, comprise the Control Unit. The

standard printer comes with aCentronics compatible Parallel Interface. An optional

serial interface board is also available which attaches directly to the master CPU board.

Installation of the serial interface over-rides the parallel interface, in effect, making the

two interfaces mutually exclusive.

oMaster CPU

Data from the host CPU received via parallel interface is latched at the I/O port of

the 8155. The 8051 master CPU retrieves this data and stores it into RAM. The

master CPU then reads data from RAM, performs computations and transfers the

data necessary for printing to the slave CPU. All data retrieved from RAM is checked

for embeded escape sequences or special control codes.

oSlave CPU

In response to the commands received from the master CPU, the slave CPU will

energize the appropriate driver circuits to perform the printing function. Among the

components under control of the slave CPU are the linear motor, selection motor,

ribbon motor, clutch magnet and the line feed motor. The 805 1on the slave CPU

board has two timers which aid the CPU in controlling two of the control compo-

nents in an overlap mode. An example would be during the print operation when

after acharacter has been printed, the CPU operates the linear motor to move to the

next print position while it is operating the selection motor to align the next charac-

ter to print. The operation of all the necessary components for printing being

controlled by asignle slave CPU is seen as one of this printers strongest features.

4. Operation of Print Unit Mechanisms

The print unit mechanism may be divided into the following five mechanisms:

(1) Carriage feed mechanism

(2) Character selection

(3) Hammer mechanism

(4) Ribbon feed mechanism

(5) Form feed mechanism

4.1 Carriage feed mechanism

The carriage feed mechanism is directly driven by alinear stepping motor. It is

controlled by the CPU according to the driving timing which has been stored

beforehand, and is driven by constant-current based on frequency modulation.

Further, this carriage feed mechanism is designed to reduce the driving current

while not in use, thereby avoiding waste of power. The resolution of the lateral

feed is 1/120 inch.

-3-

The positional detection is done at the leftmost point. This positional detection

is done to detect the home position, and no positional detection will be done

during printing. In other words, since open-loop control is used, no out-of-position

prints caused by erroneous feed made by external force during printing will be

corrected. In the following cases, however, the printer will move its carriage to the

left end to detect the home position and then indicate the error or correct the

position:

*The home position is detected using the form feed code. If, at this time, any

feed error caused by an external force already exists, an error indication will be

given.

*With the printer stopped by operating the pause switch, if you inadvertently

move the carriage while doing ribbon replacement or the like, operate the

check switch to restart the printer. Then the printer will detect the home

position to correct the position for normal printing.

The carriage will perform high-speed skipping for higher effective printing speed.

The skipping comes in long skipping and short skipping, each having different

skipping speed. The linear motor uses apermanent magnet and is driven by the

interaction with the driving current.

Permanent magnet

Rail

Fig. 4.1

When currents are allowed to flow through the coils as shown in Fig. 4.1, the

magnetic fluxes produced by the coils and those produced by the permanent

magnet will flow through the poles of the coil 01 and coil 03. In the coils 02 and

04, the direction of the fluxes produced by the coils is opposite from that of the

fluxes produced by the permanent magnet and therefore the both fluxes will

cancel each other. As aresult, the magnetic poles of the coils 01 and 03 are

attracted to the poles of the rail, causing the motor to stop as shown in Fig. 4.1

Fig. 4.2

When currents are allowed to flow through only the coil 03 as shown in Fig. 4.2,

the magnetic fluxes produced by the coil and the permanent magnet will flow

through the poles of the coil 03, causing the motor to move the right and then

stop in the position indicated in Fig. 4.2.

Fig. 4.3

Further, when currents are let flow through the coils 01 and 02 in the opposite

direction from the above, the magnetic fluxes produced by the coils and those

produced by the permanent magnet will cancel each other at the poles of the coil

01 because of their opposite direction. The magnetic fluxes generated by the coils

and the permanent magnet will go through the poles of the coil 02. Consequently,

the poles of the coils 02 and 03 will be attracted to the poles of the rail, and the

motor will further move to the right before it stops at the point indicated in Fig.

4.3.

Thus, the motor is moved by successively changing the direction of the currents

flowing through the coils.

-5-

4.2 Character selection mechanism

The character selection mechanism is directly driven by astepping motor. It is

controlled by the CPU according to the driving timing which has been stored

beforehand, and is driven by constant-current. Large currents flow through the

mechanism during acceleration but the currents grow smaller as the speed in-

creases. Further, it is designed to reduce the driving current wile not in use in

order to avoid waste of power. The rotational resolution is 3.6°, i.e., there are 100

stop positions per revolution, which correspond to the number of printable chara-

cters on the daisy wheel. The daisy wheel is to be dropped in for setting. To

perform the initial setting, move the carriage to the left end and run the motor to

position the daisy wheel.

The daisy wheel is positioned by the following mechanism.

Arm

Fig. 4.4

When the carriage is moved to the left end, the arm on the frame depresses the

case lever. When the daisy motor runs and the pin of the case lever enters the hole

in the daisy wheel, the daisy wheel stops rotating. As the motor further runs until

the positioning pin enters the positioning hole in the daisy wheel, the rotation of

the daisy wheel will be synchronized with the motor running.

4.3 Hammer mechanism

The Hammer mechanism consists of along-stroke plunger magnet. It is driven by

aconstant-current chopper circuit which is controlled by the slave CPU. Impact

pressure is determined by the length of time that the driver circuit is energized

and can be varied according to the size of the character to be printed.

-6-

4.4 Ribbon feed mechanism

Awide ribbon which can be vertically shifted in three stages is used. Either a

single-strike ribbon or multi-strike ribbon is used. In the multi-strike ribbon, the

same part is hammered afew times while in the single-strike ribbon the same part

is struck only once.

The drive gear ratio, which determines the amount of ribbon movement, is auto-

matically set according to the type of ribbon cartridge being installed.

1, Single-strike ribbon 2. Multi-strike ribbon

The lift and fall, and winding of the ribbon are done by the dc motor, spring

clutches and clutch magnet through the cams. The spring clutch is used for the

ribbon lift cam and ribbon down cam. When the ribbon motor runs to put the

clutch magnet into operation, aspring clutch works to cause the ribbon lift cam

to turn 1/3. At this time, the ribbon lift cam makes the ribbon move up and down,

and the pawl of the ribbon lift cam kicks the ratchet arm to feed the ribbon.

As the motor runs in the operate the ribbon down cam, making the ribbon go

down to the lowest position. The ribbon down cam is activated at the end of a

print operation to allow easy visual inspection of the last print line.

4.5 Form feed mechanism

The platen is driven by astepping motor through an intermediate gear to accom-

plish form feed. When moving the platen in reverse, the stepper motor will move

the platen past the point where printing is to be done, then the platen will be

moved forward to the print line and stopped. This is down to help compensate for

backlash between the gears of the form feed mechanism.

/7TT\

/Ttv\

/Tm

Fig. 4.5

-7-

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