Documation_M 200_Card_Reader_Technical_Manual_Aug1973 Documation M 200 Card Reader Technical Manual Aug1973
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TECHNICAL MANUAL
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AUGUST
1973
I
,~:
DOCUMATlON, INCORPORATED, 1971
Contents of this manual may not be reproduced in whole or in part without written
permission of Documation, Incorporated.
II
I I
DO'CUMATION
INCORPORATED
I
POST OFFICE BOX 1240
MELBOURNE, FLORIOA 32901
7485
IMPOR~NT
NOTICE
THIS TECHNICAL MANUAL IS SUPPLIED
WITH DOCUMATION CARD RFADER SERIAL
NUMBER 'I" .-:
THIS MANUAL SHOULD REMAIN WITH THAT
CARD RFADER.
Technical ?vIa mw 1 Change Hecore!
This Technic31 ;'Imllwl 118:3 been upd3tcd to re~Lect Customer Specific8tions. T\Iinor cllOnges
to text or schematics arc mark8d on the p3r'·.:s affected. M3jor cbanges to text or schemDtics
arc cOl.-rected by direct replacement of paGes affected, or are contained in an Addendum.
REGNACENTRALEN
Customer:
230
Frequency
50
Voltage
M 200
Model:
/
CS
No.
:
Option<;·.
129 C
~n0.4,,-,8,,--_
Addendums:
-,"n-4/~8",-_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Text Gl181jges:
.:.:n:l..7.::a:...-_______._______________________.
Schem'1tic Changes:
Drawing No. or
Modification
Title
Wiring Diagram,
\Viril1g Diag:tam,
Card Cage, P. C.
Wiring Diagram,
AC Power Distribution, 115 VAC, GO Hz
j\ C POViCi' Dist:::ibtition, 230 VA C, 50 Hz
Card Location
Card Cage . • . • . •
1142000·
5V Power Supply, 115 V!~C, 60 Hz
5V Power Supply, 230 VAC, :30 lIz
Solenoid Driver, US VAC, 60 Hz •••
Solenoic! Driver, :~30 VAC, 50 Hz •
.;""11 _ ,...,1_
/""'I __
........ .Lv;".,I·..
......, .... ~ .... ...A. .......
~_l
,\
_ _ _ _ ",1,,'1 __
~
.. j.:..;..I..1~.Jl.j
of
•••••••
Schern3tic, (sheet 1 of 3) .
SchematiC, (sheet 2 of 3) •••
Schemotic, (sheet 3 of 3) •••
Error Card Assembly •..•••••
Schematic, (sheet 1 of 2) •.•
Sc11emotic, (sheet 2 of 2) .••
Sync Card Assembly . . . . . • . • ;. ".••
Schematic, (sheet 1 of 3) •
Schematic, {sheet 2 of 3) ••
SchematiC, (sheet 3 of 3) •••
Control Carel Assen:b)y ..• , .• ,
SchematiC, (sheet 1 of 2) .•.
Scr:enlatic, (sheet 2 of 2) •••
t10DIFIED PER CS
_--1:10DIFIED PER CS
1241715
1241715
\
Special Cards:
Doc., No.
M 2408
A
TABLE OF CONTENTS
SECTION 1
INTRODUCTION
Page
Paragraph
1.1
1.2
1.3
General
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1- 1
1- 1
1- 1
SECTION 2
UNPACKING AND INITIAL CHECKOUT
2.1
2.2
Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Initial Checkout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2- 1
2- 1
SECTION 3
OPERATION
3.1
3.2
3.3
3.4
3.5
Loading the Input Hopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unloading Stacker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control and Indicator Description . . . . . . . . . . . . . . . . . . . . . . . .
Operational Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operational Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.
.
.
.
.
3333-
1
1
1
3
3.. 4
SECTION 4
THEORY OF OPERATION
4.1
4.2
4.3
Card Feeding Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Data Recovery . . . • . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2.1
Reader Control . . . . . . . . . . . . . . . • . . . . . . . . . . . . . . .
4. 2. 2
Data Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4. 2. 3
Data Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Detail Operational Description . . . . . . . . . . . . . . . . . . . . . . . . . . .
4. 3.1
Reader Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.1.1 4.8 MHz Oscillator and Four-Phase Generator .. .
4.3.1. 2 Control Logic . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.1. 3 Pick Logic . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.1.4 Column Counter . . . . . . . . . . . . . . . . . . . . . . . .
4.3.1.5 Error Logic . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.2
Data Detection. . . . . . . . . . . . . . . . . . . . . . . . . . . • . • . .
4.3.2.1 Data Amplifiers and Inverters . . . . . • . • . . . . . .
4.3.2.2 One Dark and One Light. . . . . . . . . . . . . . . . . . .
4. 3. 3 . Data Storage . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . . . .
4. 3. 3.1 Data Control and Sync Logic. . . . . . . . . . . . . . . .
4.3.3.2 Data Amplifiers and Inverters • . . . . . . . • . . . . •
i
4- 1
4- 2
4- 2
4- 2
4- 4
4- 4
4- 5
4- 5
4- 5
4- 7
4- 9
4-12
4-13
4-13
4-13
4-15
4-15
4-19
SECTION 5
INTERFACE
Page
Paragraph
5.1
5.2
5.3
5.4
5.5
General
Timing
5.2.1
Pick Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.2
Data Readout. . . . . . . . . . . . . . .'. . . " . . • . . . . . . . . . . .
Alarms
5.2.3
5.2.3.1 Hopper Check . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.3.2 Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.3.3 Motion Check . . . . . . . . . . . . .'. . . . . . . . . . . .
Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Signal Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5- 1
5- 1
.
.
.
.
.
.
.
.
5- 1
55555555-
3
3
3
4
4
4
6
6
SECTION 6
ADJUSTMENT PROCEDURES
6.1
6.2
6.3
6.4
6.5
6.6
6.7
6.8
6.9
General • • • • ••••
Tension on the Main Drive Motor Belt • • • • • • • • • • • • • • • •
Magnetic Pickup Adjustment • • • • • •
• • • • • • • •
Adjustment of Stack Photocell • • •
• •
• • • • • • • • • • •
Roller Shaft Bearing Preload. • • • • • • • • •
• ••••••••••
Hopper Empty Switch Adjustment • • • • • • • • • • • • • • • • •
Stacker Full Switch Adjustment. • • • • • • • •
• • • •
Picker Sector Adjustment. •
• • • • • • • •
Stacker Adjustment • • • • • • •
• • • • • • • •
6- 1
6- 1
6- 3
6-'4
6- 5
6- 6
6- 6
6- 9
6-11
SECTION 7
PREVENTIVE MAINTENANCE
7.1
7.2
7.3
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7. 2. 1
Picker Sector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2.2
Casting Assemblies . . . . . . . . . . . . . . . . • . . . . . . . . . . . .
7.2.3
Cooling Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . .
7. 2. 4
Exte,rior Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7- 1
7- 1
7- 1
7- 1
7- 2
7- 2
7- 2
SECTION 8
TROUBLESHOOTING
8.1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fault Isolation Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ii
8- 1
8- 1
SECTION 9
REPAIR PROCEDURES
9.1
9.2
9.3
9.4
9.5
9.6
9.7
9.8
9.9
9.10
9.11
9.12
9.13
9.14
9.15
9.16
General. • • . • • • • • •
Required Tools • • • • • •
Main Drive Motor Belt ••
Magnetic Pickup • . • • •
Solenoid . . . . . . . . . . . .
Stacker Casting • • • • •
Stacker Roller Bearing Assemblies • • • • • •
Read Head Assembly • • • • • • • • • • •
Light Station Assembly. • • • • • • •
Stacker Shaft Support Bearings
Vacuum Pump Motor Assembly Belt ••
Stacker Full Switch. •
• • • • •
Hopper Empty Switch. • •
Pick:er. . . . . . . . . .
Indicator Lamps • • •
Picker Roller Bearings
SECTION 10
DRAWINGS
SECTION 11
SIGNAL MNEMONICS AND ABBREVIATIONS
SECTION 12
ILLUSTRATED PARTS BREAKDOWN
iii
99999-
1
4
6
6
8
9-11
9-14
9-14
9-16
9-16
9-17
9-19
9-20
9-21
9-22
9-23
LIST
OF
ILLUSTRATIONS
Page
Figure
1-1
1-2
2-1
3-1
3-2
4-1
4-2
4-3
4-4
4-5
4-6
4-7
4-8
4-9
4-10
4-11
4-12
5-1
5-2
6-1
6-2
6-3
6-4
6-5
6-6
6-7
6-8
6-9
6-10
6-11
6-12
7-1
9-1
9-2
9-3
9-4
9-5
9-6
9-7
9-8
9-9
9-10
Card Reader, Three-Quarter Front View (Typical) ••
Card Reader, Three-Quarter Rear View (Typical)
• • • • • •
U npa.cking. . . • . . • . • . .
. . . . . . . • .
Switch and Indicator Location
• • • • • •
Operational Flow Chart ••••
• • • • •
• • • • • • • • •
Card Feeding Air Flow. • • •
• • • • •
Block Diagram, M Series Card Reader
• • • •
• • • • • •
Timing Relationship for Standard Punched Card ••••••
Block and Timing Diagram, 4.8 MHz Oscillator and Four-Phase
Generator . . . . • . . . . . . . . . . . . . .
Block and Timing Diagram, Control Logic • • • • • • • • • •
Block and Timing Diagram, Pick Logic • • •
• • • •
Block and Timing Diagram, Column Counter
• • •
Block and Timing Diagram, Error Logic • • • • • • • • •
Block and Timing Diagram, Data Amplifiers and Inverters.
Block and Timing Diagram, One Dark and One Light • • • • • • • •
Block and Timing Diagram, Data Control and Sync Logic Drivers •
Block and Timing Diagram, Data Register and Data Drivers • •
Interface Timing Diagram • • •
• •
• • •
Circuit Characteristics. •
• • • • • • • • • • • • • •
Top Cover Removal • • • • • • •
• • •
• • • • •
Rear Panel Removal • • • • • •
• • • • • •
Drive Motor Belt Tension Adjustment • • • • •
• • • • • • • • •
Magnetic Pickup Adjustment • • • • • • • • • • • • • • • • •
Location of Stack Photocell and Photocell Set Screw
Roller Shaft Bearing Preload Adjustment
• • • • •
• • • • •
Hopper Empty Switch Adjustment • • • •
• • • •
• • • •
Stacker Panel Removal • • • • • • • • • • • • • • • • • • • • •
Picker Sector Adjustment, Rear View •
• • • •
Picker Sector Adjustment, Front View • • •
• • • • • • • • • •
Removal of Vacuum Tube Adapter • • • • • • • • • • • • •
• • •
Stacker Spring Adjustment •
• ••••••••••••••••••
Solenoid Lubrication • • • • • • • • • • • • • • • • • • • • • • • • •
Top Cover Removal
Rear Panel Removal
Rear View ,Cover Removed
• • • • • •
• • •
Front View, Main Mounting Plate Removal • • • • • •
Partial Front View, Cover Removed
••••
Bottom View, Main Mounting Plate • • • • • • • • • • •
Partial Top Left View, Cover Removed • • • • • • • • • • • • •
Solenoid Replacement and Adjustment • • • • • • • • • • •
Side View, Main Mounting Plate • • • •
• • • • •
• • • •
Rear View, Cover and Rea.r Connector Panel Removed ••
. .. ..... . .. ..
.... . . .....
iv
....
.....
1- 0
1- 0
2- 2
3- 2
3- 5
4- 1
4- 3
4- 4
4- 5
4- 6
4- 8
4-10
4-11
4-14
4-15
4-17
4-18
5- 2
5- 6
6- 2
6- 2
66666-
3
3
4
5
6
6- 7
6- 7
6- 8
6- 8
6-12
7- 2
9- 2
9- 2
9- 5
9- 5
9- 7
9- 7
9- 9
9-10
9-12
9-12
9-11
9-12
9-13
9-14
9-15
9-16
10-1
10-IA
10-2
10-3
10-4
10-5
10-5A
10-6
10-6A
10-7
10-8
10-9
10-10
10-11
10-12
10-13
10-14
10-15
10-16
10-17
10-18
10-19
10-20
Stacker Casting Removal and Bearing Replacement •
Front View, Main Wiring Connections •
• • • • •
Vacuum Pump Belt Adjustment • • • • • • •
Stacker Panel Removal • • • • • • • • • • • • • • •
Stacker Full Switch Replacement
• •
Top View Casting Assembly •••
Wiring Diagram, AC Power Distribution, 115V, 60 Hz •
Wiring Diagram, AC Power Distribution, 230V, 50 Hz ••
Card Cage, P. C. Card Location.
Wiring Diagram, Card Cage • • • • • • • • • • • • • •
Wiring Diagram, Control Panel • • • • • • • • • • •
Schematic Diagram, 5V Power Supply, 115V, 60 Hz • • • • • • • •
Schematic Diagram, 5V Power Supply, 230V, 50 Hz
Schematic Diagram, Solenoid Driver, 115V, 60 Hz •
Schematic Diagram, Solenoid Driver, 230V, 50 Hz •
Assembly Diagram, Clock Card • • • • • • • • • • • • •
Schematic Diagram, Clock Card (sheet 1 of 3)
Schematic Diagram, Clock Card (sheet 2 of 3) • • • • • • • • •
Schematic Diagram, Clock Card (sheet 3 of 3)
Assembly Diagram, Error Card • • • • • • • • • • • • • • • • •
Schematic Diagram, Error Card (sheet 1 of 2)
Schematic Diagram, Error Card (sheet 2 of 2)
Assembly Diagram, Sync Card • • • • • • • •
Schematic Diagram, Sync Card (sheet 1 of 3) • • • • • • • • • •
Schematic Diagram, Sync Card (sheet 2 of 3)
Schematic Diagram, Sync Card (sheet 3 of 3)
Assembly Diagram, Control Card • • • • • • • • •
Schematic Diagram, Control Card (sheet 1 of 2) • • • • • • • • • •
Schematic Diagram, Control Card (sheet 2 of 2) • • • • • • • • • •
....
. ...
..
. ....
v
9-15
9-18
9-18
9-19
9-20
9-22
10- 1
10- 1A
10- 2
10- 3
10- 4
10- 5
10- 5A
10- 6
10- 6A
10- 7
10- 8
10- 9
10-10
10-11
10-12
10-13
10-14
10-15
10-16
10-17
10-18
10-19
10-20
Figure 1-1.
Figure 1-2.
Card Reader, Three-Quarter Front View (Typical)
Card Reader, Three-Quarter Rear View (Typical)
1-0
SECTION 1
INTRODUCTION
1.1 GENERAL
This teclmical manual contains operation, maintenance, interface, and repair information
to properly set up, operate, and maintain the Doeurnation Model M200 Card Reader. An
Illustrated Parts Breakdown is included in Section 12 to aid in locating and identifyin.g
parts if replacement becomes necessary.
The M200 Card Reader shown infigures 1-1 and 1-2 is designed to read standard 12-row,
80 column plmched cards. The hopper capacity is adequate to hold approximately 550
cards of .007" thickness. These are separated from the stack sequentially and moved
past a phototransistor read station where the data is recognized in a serial, column-bycolumn manner. The cards arc then stacked into the output hopper in the same order as
they were originally put into the reader. The reading cycle is externally controlled for
single card selection or continuous run. In the continuous mode, the reader will read
285 cards per minute.
1.2 DESCRIPTION
The entire reader is constructed around a mainframe, figure 1-1. Mounted within the
mainframe are the input hopper and output stacker, card track mechanism and control and
indicator panel and printed circuit card cage. All logic ci:.:cuitry is contained on printed
circuit boards within the card cage. Located on the underside of the mainplate assembly
are the drive motor, drive train, and a portion of the card pick mechanism. The bottom
area of the mainframe contains the vacuum pump motor assembly and the remainder of
the electronics.
Located on the rear of the reader, figure 1-2, are three controls, a circuit breaker, the
power input, the I/O connector, and a cooling fan.
1.3 SPECIFICATIONS
READING SPEED:
285 cards per minute maximum in continuous run.
Single Card Cycle: 200 milliseconds.
CARD TYPE:
Standard 80 column cards.
CONTROL:
Demand feed, one card-at-a-time under external
program control. Reader will continuous run as
long as the Pick Command remains TRUE.
INPUT:
Pick Command (PC)
Logic True for l~sec
-15 MaDC @ 0.8 VDC Max.
1-1
OUTPUT:
Data Lines and
Interface Signals
TTL Type 7404 or Equivalent.
I Source 2.2 MaDC
I Sink -15 MaDC @ O. 4 VDC Max.
HOPPER SIZE:
4.0 inches (apprOximately 550 cards of 7 mil
thiclmess).
STACKER SIZE:
4.0 inches (apprOximately 550 cards of 7 mil
thiclmess).
POWER REQUIREMENTS:
Voltage:
115 VAC ± 10%, Bingle phase, 60 Hz (standard model).
230 VAC ± 10%. Bingle phase. 50 Hz (export model).
Power:
1650 VA (MAX) starting load for 3 sec
570 VA (MAX) running load
Height:
11 inches
27.9 cm
Width:
19-1/4 inches
48.9 cm
Depth:
14 inches
35.5 cm
60 pounds
27.3 Kg
SIZE:
WEIGHT:
OPERATING ENVIRONMENT:
Dry Bulb Temperature
Relative Humidity
Wet Bulb Temperature
Thermal Shock
Altitude
50 to 100°F.
30 to 90% non-condensing
80 0 F. maximum
150 F. per hour
1000 feet below to 6000 feet above sea level
STORAGE ENVIRONMENT:
Dry Bulb Temperature
Relative Humidity
Altitude
-25 to +135 0 F.
5 to 95% non-condensing
1000 feet below to 12,000 feet above sea level
CARD STOCK
The card must meet American National Standard's specification ANSI X3.11-1969,
Specification for General Purpose Paper Cards for Information Processing.
PUNCH DATA
Punch data must meet American National Standard ANSI X3. 21-1967 specifications.
1-2
SECTION 2
UNPACKING AND INITIAL CHECKOUT
2.1 UNPACKING
The M Series Card Readers are packed in a cardboard container, figure 2-1, with
cushioning and padding to protect the equipment from damage during shipment. Inspect
the outside of the container and report any physical damage to the carrier immediately.
Included in the container are the power cord and technical manual. After removing these
items, lift the card reader straight up and place on a flat, sturdy, support area. Inspect
the reader for any physical damage and report any damage to Documation Incorporated.
Locate a Phillips screwdriver and with the reader tilted in an upright position, remove
the two red 8 x 32 screws in the bottom plate. These screws lock the blower motor plate
in a solid position to prevent damage to the motor plate vibration isolators during shipment. If the reader is reshipped, these screws must be installed.
2.2 INITIAL CHECKOUT
Use the following instructions to test reader readiness.
a.
Make sure input voltage and frequency are correct. Plug in the A C power
cord.
b.
Set the MODE switch (rear panel) to LOCAL.
c.
Set the SHUTDOWN switch (rear panel) to AUTO.
d.
Place the AC power (rear panel, top left) to ON to energize the reader.
The POWER indicator illuminates and, after approximately a 3-second
delay, the STOP and HOPPER CHECK indicators illuminate.
e.
Depress and hold momentarily the LAMP TEST switch (rear panel) and
observe that all front panel indicators illuminate. Release switch.
f.
Pull the hopper follower back with one hand and load approximately 3
inches of unpunched cards into the hopper area.
g.
Depress the RESET switch. The RESET indicator will illuminate and the
STOP indicator will extinguish. The drive motor and vacuum/blower
should come on and, after approximately a 3-second delay, the cards
should be picked and stacked. The drive motor and vacuum/blower will
then shut off and the STOP and HOPPER CHECK indicators illuminate.
h.
Place the AC power to OFF. All indicators are extinguished.
i.
Pull the stacker plate down with one hand and remove the cards.
j.
This completes the initial off-line test.
2-1
Figure 2-1. Unpacking
2-2
SECTION 3
OPERATION
3.1 LOADING THE INPUT HOPPER
Load the input hopper with punched cards to be read as follows:
a.
Remove the hopper follower and load the card deck into the hopper area;
the first card to be read must be placed at the front with the 9" edge down,
column "1" to the left. Continue placing cards into the hopper until it is
loosely filled (approximately 550 cards). Replace follower.
CAUTION
00 NOT PACK THE INPUT HOPPER
SO FULL THAT THE RIFFLE ACTION
AT THE AIR RIFFLE CAP IS INHIBITED
b.
The hopper may be loaded while cards are being read if the operator is careful to keep tension on the front portion of the deck while loading additional
cards at the rear. This is accomplished with the input hopper approximately
one-half to one-third full. Use just enough pressure to maintain the riffle
action.
c.
Unloading the input hopper is the reverse of the loading procedure. Normally
all cards are processed through the reader; however, if it is necessary to
unload the hopper, remove the follower and remove the card deck. If the
cards are arranged in a particular order, exercise care in repacking them in
their storage container so that the order is maintained.
3.2 UNLOADING STACKER
To unload the stacker, perform the following steps:
a.
Pull stacker follower down and remove the front or rear portion of the card
deck from the stacker area, being careful that deck order is maintained.
b.
To unload stacker during operation, pull stacker down and remove portion
of deck taking care to allow stacker plate to return to its normal position
gradually.
3.3 CONTROL AND INDICATOR DESCRIPTION
Reader controls and indicators, figure 3-1, are located on the front control panel, the
rear of the card cage, and the rear subframe. Control and indicator descriptions are as
follows:
3-1
EJ
powu
r·············r·············r···········~·············:
I
I
I
•
:
:
:
:
t
!
READ
~ PICK i STACK [HOPPER 1
CHECK : CHECK i CHECK : CHECK :
:
:
i
:
:
:L..............................:'..... ___ ..... _____ O''''!_______ .......... ..1-! ................. _ .. __ A;
i:
I
STOP
o
II
RESET
0
r.. __.~L-r"-1-. :::-r.-"-"]
.- . "
:I
::" ·'1
L ....J: .... _. ~
' 1 - ' ..
L... .. _ J
FRONT CONTROL PANEL
AC POWER
LAMP TEST ~
~
SHUTDOWN
MA~AUTO
M~
REMOTe(~LOCAL
REAR PANEL
Figure 3-1. Switch and Indicator Location
3.3.1
FRONT PANEL CONTROLS AND INDICATORS
Located on the front panel are two pushbutton type switches; STOP and RESET.
3-2
'I
Located above these switches are lighted indicators showing reader status; they
are RESET (green), and STOP (red).
Five other indicators are located on the front panel.
POWER
READ CHECK
PICK CHECK
STACK CHECK
HOPPER CHECK
3.3.2
REAR READER CONTROLS
Located on the rear of the reader are two mode switches, a LAMP TEST switch
and the main AC power circuit breaker. The two mode switches are:
SHUTDOWN - MAN/AUTO
MODE - REMOTE/LOCAL
3.4 OPERATIONAL PROCEDURES
The following procedures explain both the operational sequence and some of the theory
associated with the controls and indicators.
a.
Select the mode of operation, MANUAL or AUTO. When the MANUAL mode
is selected, the drive motor and vacuum/blower will run continuously when
AC power is applied. When the AUTO mode of operation is selected, all
motors will turn off after the last card is read.
b.
The second mode switch is used to select either REMOTE or LOCAL operation. When LOCAL operation is selected, card reader operations are controlled from the operator's control panel. In normal operation the card
reader is connected to the appropriate interface logic and the switches
should be in AUTO and REMOTE positions.
c.
With the LOCAL mode of operation established, place the AC power circuit
breaker on the rear panel to ON to apply primary power to the reader. The
dri ve motor and vacuum/blower will not come on at this time due to the
input hopper being empty and AUTO shutdown selection. The POWER indicator illuminates.
d.
Depress the LAMP TEST switch and check that all front panel indicators are
lighted.
3-3
e.
Load the input hopper and depress the RESET switch. The RESET switch is
a momentary action pushbutton switch used to clear any error conditions
and establish the card reader "ready" condition. When the "ready" condition
is established, the RESET indicator will light green. All motors will start
and riffling action begins on the first half inch of cards.
f.
As the cards are being read, the PICK CHECK indicator will light if a card
has failed to reach the read head after a pick command has been given. Inspect the cards in the input hopper for excessive leading edge damage.
interlocked webs or cards stapled together. If no apparent card damage is
present, check for excessive card warpage.
g.
The READ CHECK indicator will light and the "stop" condition will be
established when any of the following conditions are detected.
1.
2.
3.
4.
3.5
Failure of leading or trailing edge dark check.
Failure of trailing edge light check.
Card slippage.
Control logic failure.
h.
The STACK CHECK will light if the previous card read has not reached the
output stacker. Check the card track to make sure it is clear and check the
output stacker for incorrectly stacked cards.
i.
The HOPPER CHECK indicator will light when the input hopper is empty
or when the output stacker is full. This is normal operation.
j.
The STOP switch is a momentary action pushbutton switch used to terminate
card reader operation at the end of a read cycle. The STOP indicator will
light red when the "stop" condition is established.
OPERATIONAL FLOW CHART
Figure 3-2 shows a flow chart of the sequence of events which may be encountered in
operating the reader. If trouble is experienced, refer to this check list before calling
for maintenance.
3-4
NOTE'
--;O;-ER CORD CONNECTED TO PROPER
VOLTAGE 6 FREOUENCY AVAILABLE
BEFORE POwER SWITCH IS DEPRESSED
CHECK THAT
CIRCUIT BREAKER IS ON
SET SWITCHES TO
DESIRED MODE
DEPRESS ~AMP TEST
SWITCH TO ASSURE' PROPER
OPERATION ON INDICATORS
HOPPER CHECK A~ARM
REMA IN 5 ON WITH HOPPER
PROPERLY LOADED
PICK CHECK ALARM
IS RAISED
CHECK FIRST CARD IN
HOPPER FOR STAPLES
OR SEVERE MUTILATION
INSPECT LAST CARD
IN STACKER FOR
TORN LEADING OR
TRAILING EDGE
CH ECK PICK SHOE
FOR INK BUILD UP
SCRUB WITH ALCOHOL
INSPECT LAST CARD
FOR SEVERE DAMAGE
OR STACKER BLOCKAGE
HOPP~R IS EMPTY
OR STACKER IS FULL
UNLOAD STACKER
RELOAD HOPPER
DEPRESS RESET SWITCH
NOTE·
STOP INDICATOR WILL LIGHT AND
BLOWER WILL SHUTDOWN WHEN IN
REMOTE I AUTO MODE.
Figure 3- 2 - Operational Flow Chart
3-5
SECTION 4
THEORY OF OPERATION
4.1 CARD FEEDING MECHANISM
The card feeding mechanism, figure 4-1, is designed around an air flow system that uses
air pressure to separate the cards and a vacuum to pick the cards. Pressurized air riffles
the first half inch of cards in the input hopper so that they stand apart, individually "air
cushioned" from the rest of the card deck and each other. This prevents the cards from
sticking together in case of static electricity, hole locking, or torn webs and eliminates
frictional forces between the cards. The vacuum picker pulls the bottom card in and holds
it against the picker's rubber surface. When a pick command is received, the reader's
electronics drives a rotary solenoid coupled to the picker sector causing it to rotate. As
the solenoid moves the picker sector, the card is accelerated due to the friction forces
caused by the vacuum between the picker's rubber surface and the card. The picker sector
rotates pulling the card toward and into the drive rollers. When the leading edge of the
card reaches the drive rollers, the rollers pull the card into the card track. The picker
is now returned to its rest position by spring tension. As the card in the track clears the
picker's surface, the next card is sucked down ready for the next pick command.
AIR RIFFLE CAP
~~~
AIR VACUUM IN PICKER
SECTOR HOLES PULLS CARDS
IN AGAINST SECTOR AND
CARD MOVES TOWARD PINCH
WHEN SECTOR TURNS
FANS PRODUCE AIR
PRESSURE AND VACUUM
-
AIR FLOW
Figure 4-1. Card Feeding Air Flow
4-1
4.2 DATA RECOVERY
The logic block diagram for the M Series Card Reader is shown in Figure 4-2.
Data recovery is accomplished by the functions of Reader Control, Data Detection and
Data Storage. Reader Control synchronizes the electronic scanning of the card with the
mechanical actions of the reader. This provides card picking, card movement through
the read station, data flow control and card stacldng. Data Detection converts the light/
dark conditions of the read station into usable digital signals for Data Storage. Data
Storage provides the data synchronization, buffering and retainment required for data
transfer from the reader.
4.2.1
READER CONTROL
Primary control timing is established by the 4. 8 MHz Crystal Oscillator and the
Four-Phase Generator. These are used to shift, store and control other logic
operations.
When a PICK COMMAND is received from the controlling device, card processing
will begin provided no alarm conditions exist. The Pick Logic produces a PICK
signal to the Solenoid Driver, a PCLK signal, and a pick-command reset (PCR) to
the Control Logic. These actions initialize the various control circuits and energize
the solenoid to pick a card from the input hopper. If a card does not reach the read
station, the PICK eHE CK alarm is raised.
The Read Station and Stacker utilize phototransistor sensors to read the card's
hole pattern and to monitor the card's movement. When a card is picked and
moved into the card track, the leading edge interrupts the light to the Read Station.
This produces a ONE DARK signal that is used by the Control Logic to generate a
Good Pick Reset (GPR) which initializes the synchronization of the card's movement through the Read Station. The Column Counter then counts columns via the
Data Control and Sync Logic as the card moves past the Read Station, thus synchronizing the mechanical card movement with the electronic circuits. The Column
Counter generates a DARK CHECK at Column 0 and 81 and a Light Check at Column
84. Figure 4-3, Timing Relationship for Standard Card, shows these check positions. These checks provide a quality check on both the Read Station and the
mechanical card movement.
4.2.2
DATA DETECTION
As the card passes between the Light Emitting Diodes (LEDs) of the Light Station
and the Phototransistors of the Read Station the light and dark conditions are
sensed and amplified by the Read Station's phototransistors. The light (punched
hole) and dark conditions are converted to electronic signals atthe Phototransistor's
4-2
READER FUNCTIONAL AREAS
r-----------'r-----I
DATA DETECTION
DATA STORAGE
READER CONTROL
I
r+l
- z:
8
..,
.....
«
I-
C> Vl
-' .....
:I:
t
C.:I
-
~
-'
ONE DARK}
/
"'lVl
~ b
b~
~-~
f--.
DATA
AMPLIFIERS
AND
INVERTERS
:J ~
INVERTER
L.tONE
I
I
I
I
ONE DARK
I
I
ONE LIGHT
I
I
112.......
1/
lIGHT~
CONTROL
SWITCHES
DATA
REGISTER
~
i
i
'"
a:
« ..,
>->
«
ca:
STIlC
TSH
DATA
i
HAG
PICK UP
r:
CSDS
!
I~
DATA
CONTROL &
SYNC LOGIC
I
5TI'C
STI'D
a:
u
1"0
HOPPER CHECK
HOlION CHECK
ERROR
r
f
Vl
u _
""5
:I: .....
_
..,
12/
READY ISTOP INDICATORS
2,
a\
,
r
""~ ~
00
DATA
PSET '
+
""u+
I
I
,4L~
'-.../
u c
z:
0
u
I
I~
-
ERROR I NO I CATORS
ERROR
LOGIC
I
c
CONTROL
LOGlr
'-.../
READY
PCR + PCLK
INDEX
HARKS ..
I
0
1
I
r
GPR
.... I
i'lCR
TIMING
STROBE
LOGIC
----.;
I
f+
~
I
I
I
-
HOPPER EMPTY
ISTACKER fUll
STACK
STATION
I
I
I
12",
-:~
~~
««
I
I
I
:
BICR
I
a:-'
wO
I
30:::
0
1-
Ie:::
<>.
-', 0
z
"
'"
I
I
r
COLUMN
COUNTER
u
I
I
I
I
,~
-
f=fn
OS>.
BLOWER
SOLID STATE
RELAY
PICK
.... COMI1AND
r
4.BMHZ
OSCILLATOR
AND FOUR
PHASE GEIl.
Figure 4-2. Block Diagram, M Series Card Reader
~
.......
PICK
LOGIC
I
PICK
f-
PICK
SOLENOID
DRIVER
BUSY
INTERfACE
SIGNALS
TO & FROM
CONTROlLING
DEVICE
emitters and used to drive the Data amplifiers and inverters. Outputs of the Data
Amplifiers and Inverters pass through the One Light/One Dark inverters and provide detected data to the Data Register.
4.2.3
DAT A STORAGE
To accomplish Data Storage, the Data Control and Sync Logic sends Synchronized
Data Strobes (CSDS) to the Data Register at predetermined punched column positions. Synchronization is accomplished by a notched ferrous timing disc attached
to one of the drive roller shafts. As the timing disc rotates, a reluctance pickup
senses the movement of the disc's notches past the pickup producing timing signals.
These signals are used by the Data Control and Sync Logic to generate Data Strobes
(CSDS) for each of the 80 columns. Data Storage includes Data Drivers that provide buffering between the Data Register and the interface lines.
4.3 DETAIL OPERATIONAL DESCRIPTION
The following gives a detailed description of each block shown in Figure 4-2, Block
Diagram - M Series Card Reader. The description is designed to give the reader an indepth understanding of how the card reader works without the usual logic gate-by-gate
description.
The reader should familiarize himself with the signal mnemonics used in the text description and contained in Section 11 since it will aid in interpreting both the description that
follows and the logic schematics in Section 10.
NOTES:
(!)
(2)
(3)
Ir'I Ir"I
I II
I
LJ
LJ
o
01
DASHED LINES INDICATE PSEUDO HOLES IN CARD.
DC = DARK CHECK
LC = LIGHT CHECK
GPR = GOOD PICK RESET
HOLE SIZE EXAGGERATED fOR EXPLANATION.
a) HOLE SIZE = .055 IN.
b) WEB SIZE = .032 IN.
i
i
0--··----··
_ _ . ________ .
,
I
, "L.J
I
L.J
r.,I r.,
.,I Ir..,I
I I
I
I
I
I
I
I
I
I
I
I
I
I
I
12
'"
.J Lj
184
n
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
:
I
,
,,I
DC
LC
I
,
GPII
··-0
.._
10 II'
I
I
.-
I
I
,
oc
I
I
CARD MOTION
Figure 4-3 - Timing Relationship for Standard Punched Card
4-4
4.3. 1
READER CONTROL
The following is a detailed description of each block shown under Reader Control
in Figure 4-2,. Block Diagram, M Series Card Reader.
4.3.1.1
4.8 MHz Oscillator and Four-Phase Generator
The block diagram and timing diagram for the 4. 8 MHz Oscillator and
Four-Phase Generator is shown in Figure 4-4. The oscillator is crystal
controlled and provides a TTL compatible 4. 8 MHz squarewave as an output. The 4. 8 MHz output is divided by ten in a decade counter and the
counter's 480 KHz output used to drive the Four-Phase Generator. The
Generator then divides the 480 KHz by four, generating signals QJA, QJB,
QJc, QJD and Cl as shown by the timing diagram of Figure 4-4.
QJA, QJB, QJc, QJD and Cl are used throughout the reader as a timing
source.
4. 3. 1. 2
Control Logic
The Control Logic (Figure 4-5) contains the Ready/Stop Logic, Power On
Reset, Blower Control, Reset Control and Good Pick Sync Control. At
reader power turn on, a three-second Power On Reset (POR) is initiated.
See timing of Figure 4-5. The long POR allows the blower to come up to
speed before the controlling device or an operator can initiate a reader
0A
0B
4.BMHZ
CRYSTAL
OSCILLATOR
.....I
.:... 10 1480KHZ ..
.
I
...
FOUR
PHASE
GENERATOR
---
TO PICK LOGIC, CONTROL LOGIC AND
DATA CONTROL AND SYNC LOGIC
0C
00 _
ff
--
/
TO PICK LOGIC
480KHZ
~8.33
I
--i
0A
I--~
r1l
I
---i
0B
I
t--~
~
I
I
U 5----1
1 uS
I
I
nL-__~J
1 u 5
n'---JJ
0c~s------~r1~------------~~
0Drs--------~rl'-----------_Jf
ffj;-----...,
J
Figure 4-4 - Block and Timing Diagram, 4. 8 MHz Oscillator
and Four-Phase Generator
4-5
FROM STOP.
_ _ _ _ _ _.::..:..:;.;..._ _~_ _ _...,
SWITCH
-
FRJ ~.------:========-----+t
ERROR LOGIC
FROM ONE DARK
1~.---~::':":;;':"":=::':':"'---"'-__-r-..,....J
~I
.~ ,~.~
•~~ON~'E~DA~R~K~r_:::_~~
::
GOOD PICK
IL.______~~
READY____~
TO
PICK LOGIC
TO COLUMN COurnEr,
DATA CONTROL & SYNC
LOGIC,AND PICK LOGIC
______-+~4-________~
paR ____~
- TO
..
POR
POWER ON
RESET &
3 SEC DELAY
FRQr1 ERROR LOGIC .
----'H;;;.;EC;...K--,l.
.
---
GPR
FROf1 OSCILLATOR {:..
I:lC
SYNC
& FOUR PHASE
...~---,I:l::..:D~-t'l.rC:::O:N~TR:O:L..J
GENERATOR
_
PCR
t~
FROf1 PICK LOGIC
-~-"';"":''-'-----'
•
f
-
-~
..
fACTIVATE
r-__~I[DE~L_AY~
p __
POR
+
RESET
GATE
_._--
-
POR + RESET_
'!'"
PICK LOGIC &
COLUMN COUNTER
TO ERROR LOGIC
~
rtA~AL
BLOWER
CONTROL
S1
... BLOWER
RELAY I--l-~--"'::"::'::":':"::::":'-':":':'~:'::""--I~
DRIVER
~
0-0 AUTO o--i~-"'ir---.J
FROf1 PICK LOGIC .
_ .~..!P~C1LiK---1"'~--'---"_ _ _ _--+~~
FROM COLUMN COUNTER __ 84CR +CR
.....
RESET
CONTROL
FROf1 RESET SlnTCH .
_ ._,;.;;RE:,;;S;,;E..;..T_..."
... _ _ _ _
______ ____•
~~
RESET
J-----....---:.;.;;.;;.;;.;......:.;.;;.;.:.:..:...:....--...
Vee a
I
~_ _~~lr---------~sirs---~5irs----~~-----------~
POWER ~_
.
TURN ON
I
POR ,..,_ _ _,,.<;"r-r---- 3 SEC
I
cyr--.:...----,.....;
----;--0',..5
-----!'S-S- - - - !
~~S----~i~------~
,I
READY ,.S____---'_____________---..;.1--!5}----S>.--J
L-_ _-!
I
SWITCH DEPRESS_........r-H....,~ S,JlTCH RELEASE
RESET,.5------~--------------~I-_)~
~>--,
POR + RESET rS_____---'______________.....Jj
LI---------~'.~I----------~----~5
I
~>-I
~~I- - ' - - . . . ! . . . - - - - . . ;
ONE DARK rS--------------------~'~rS---~
CPR
jr------------------~s>---?,..~---~-----~§!5~------~--~s
ANY CHECK
CONDITION jr----------------~j~5rS---------~~~~-----~
OR STOP
Figure 4-5 - Block and Timing Diagram, Control Logic
4-6
operation. POR is also used to initialize the Pick Logic and Column
Counter.
OR'ed with RESET to form POR + RESET resets the
Error Logic. The reader is now brought to the ready state by the operator depressing and releasing the RESET switch. Note that while the
RESET Switch is depressed, RESET is routed to initialize the Pick Logic
and Column Counter and RESET activates the POR + RESET signal to the
Error Logic. The Reset Control is designed to ignore all RESET swit~
signals while a read cycle is in progress. Signals PCLK and 84CR or CR
identify the beginning and end of a read cycle.
ron
Reader READY is signalled to the controlling device by the Ready/Stop
Logic when the RESET Switch is released provided HOPPER CHECK is
not being presented by the Error Logic. (All other Error Logic Check
signals will be reset by POR or RESET.) Reader READY is indicated
to the operator by the RESET Switch lighting green. The controlling
device can now begin a read cycle by transmitting a PICK COMMAND to
the reader. READY will be reset upon receipt of any CHECK signal from
the Error Logic or if the STOP Switch is depressed by the operator and
RESET INHIDIT is not present. The Ready/Stop Logic gates the STOP
signal with RESET INHIBIT, preventing READY from being reset due to
STOP during a card readcy~!~. RESET INHIBIT, generated by the
Reset Control, is set by PCLK and reset by 84CR or CR. The Stop Condition
is indicated by the STOP switch lighting red.
The Good Pick Sync Control is initialized by Pick Command Reset (PCR).
During a card read cycle, the Good Pick Sync Control detects a ONE
DARK and processes this Signal with clock phase (tSc and (tSD to produce
Good Pick Reset (GPR). GPR is used to:
a. Initialize the Column Counter.
b. Begin the data synchronization process by the Data Control and Sync
Logic.
c. Verify to the Pick Logic that a Pick Command has been successful.
The Blower Control provides signa.ls to control A C power to the reader
blower motor and drive motor. These motors automatically shut down
when a HECK (Hopper Empty Check) condition exists and switch 81
is in the A UTO position. After the HECK condition is corrected by
reloading the input hopper, depressing of the RESET switch will cause
the Blower Control Logic to activate the 3-second (nominal) PORe
When the SHUTDOWN switch is in the MAN position, all motors remain
on as long as reader power is applied.
4. 3. 10 3
Pick Logic
Once the reader is brought to ready condition, a PICK CMD from the
4-7
controlling device can be accepted by the Pick Control.
see diagram and timing. )
The
1.
2.
3.
4.
5.
6.
(Figure 4-6,
Pick Logic will then:
Generate PCLK
Initiate a PICK pulse that drives the picker solenoid.
Control the PICK pulse length.
Wait out the interval while the card leading edge is accelerated to
the read station (14 to 27 ms).
If the leading edge has not arrived in 50 ms, generate another pick
pulse.
Repeat the pick attempt six times and if the leading edge has not
appeared, generate a pick fail alarm (PSET).
The Pick Control generates PCLK (Figure 4-6 timing) until a GPR is
received or READY goes false due to the pick fail signal (PSET). PCLK
gated from Pick Control is divided by two decade MSI counters to a frequency of 1. 2 KHz. The 1. 2 KHz is then counted by the Pick Control
LOCAL
?cIT
..
TO CONTROL
LOGIC
BSY (BUSY)
-
TO CONTROLLI NG
DEVICE
51
~
0
REMOTE
FROM CONTROLLING
DEVICE
PICK CMD
FROM {
CONTROL
LOGIC
FROM COLUMN
COUNTER
FROM 4.8MHZ OSC {
AND FOUR PHASE
GENERATOR
GPR
:
:
:
-.r"1+
~
POR
RESET
84CR +CR
..-
~
f
Ci
Tg
I
liD
I
RESET
POR
GPR
READY
PICK CHD
PICK
CONTROL
COUNTER
10 1.,. 10
...
IIC
READY
FROM CONTROL
LOGIC
__~
KHZ)
PCLK _i_l~O
PICK
CONTROL
--.
--.
1
~
t;:::-
-
PCR
'"III
TO CONTROL
LOGIC
!
PICK
DRIVER
PICK
FF
SOLENOID
~ TO
DRIVER
...
]
:I
...
~
OR
~ill
--1t--1 US MIN.
PICK
ATTEIIPT
COUNTER
~. TO ERROR
LOGIC
...
',I
I
I
I
~rli+:--------',\---iWM=W~~'"·
=~~=~.~
'"wA""""'"'
I
PCLK
---"h.
,
I r l - - -....~~b- - - . . . . : . . . - - - - - \
Cl
li--------~~~z------.:ml
1 1
I
1
PCR---"~~\L--i-I--....,,~---....!....-----\
,
1
I
1
"
r-
GPR---....r',)'r~~1:-;-::-::-:---:-::-:::-:-7I--~\I--.L1
---..Ij"r---~---"'"
1 1--7.5 or 4.2 MS--i
"
I 1
DEPENDING UPON
I
BSy------lI.I'r~-:1_1_MO_DE_L...;.S...;.PE...;.ED_ _I_ _.......$)$)_--!
I
84CR - -....I~~-::~--------~~--r:------~~~---~----4
1-1..
PICK INTERVAL----.....
I.>- CARD IN READ STATIOIl---i
0 - -_ _
1
Figure 4-6
I
·1
Block and Timing Diagram, Pick Logic
4-8
Counter. At the count of one the Pick Control Counter sets the Pick FlipFlop (FF). This begins the PICK pulse interval. The Pick Control Counter continues to count the 1. 2 KHz until count 10 (for M200, 300 and 600)
or 6 (for M1000, M1200) is decoded generating a reset to the Pick F.F
ending the PICK pulse. PCR, generated by the Pick FF, is used by the
Control Logic to initialize the Good Pick Sync Control. The Pick Control
Counter continues to count the 1. 2 KHz while awaiting a GPR. If no GPR
is received by the count of 63, the Pick Control Counter resets to all
zeros and begins its count cycle again generating another PICK and PCR
pulse. PICK and PCR pulses will continue to be generated until a GPR
is received or the PICK Attempt Counter counts six PCRs and the Pick
Control Counter reaches Count 56. When six PCRs have been counted
and count 56 is reached PSET is generated. PSET will cause READY to
go false terminating PCLK.
Upon receipt of a GPR, the Pick Control signals Busy (BSY) to the controlling device to indicate a card has entered the read station. BSY
remains true until 84CR \indicating the card has left the read station
and another PICK CMD can be accepted.
The position of Switch Sl determines the source of the PICK CMD. In
LOCAL, the PICK CMD signal is held true so that whenever the reader
is READY, PICK CMDs are generated internally each time 84CR
is reached. When in REMOTE, only a PICK CMD from the controlling
device can initiate a read cycle.
4. 3. 1. 4
Column Counter
The Column Counter (Figure 4-7) provides a record keeping control
function by counting and decoding columns as the card passes through
the Read Station. Following GPR, a STQC followed by a STf{>D (Refer
to timing diagram of Figure 4-7) will be generated for each column by
the Data Control and Sync Logic. STf{>C is used to drive the Column
Counter and STf{>D to sample the Count Gating. The Column Counter
generates OCR (0 column reset), 1CR, 81CR, 84CR. These Signals
are used by the Control LogiC, Data Control and Sync Logic, Pick Logic
and Error Logic as follows:
COUNT
USED BY
OCR
1.
Error Logic for a Dark Check and set Stack FF.
1CR
1.
Data Control and Sync Logic to set the Index
Mark Control Flip Flop (IMFF).
4-9
FROM DATA {
CONTROL &
SYNC LOGIC
FROM {
CONTROL
LOGIC
-----
ST0C
COLUMN
COUNTER &
COUNT GATING
ST0D
4~
RESET
paR
GPR
...
OR
cc::
cc::
cc::
u
u
u
0
.....
..... co
cc::
DCKS ..
OR
..
u
oq-
co
~... ~
...
.......
COLUMNS
ST0C )
a
1
C9 I
TO ERROR LOGIC
2
80
81
82
I 55 I I
83
TO DATA CONTROL &
SYNC LOGIC, PICK LOGIC,
ERROR LOGIC, AND
CONTROL LOGIC
84
I Is
\
CD\~
ST0D S
I
OCR
s
\
------'----""--~s~~s---.:.----_:_..l.Il
S-S
1
CR~S------~~-~sl~s--~-----_:_~s
81
CRS~---------------~S'S~--~--------~S
84
CR~S------------------~~~S------------~~S
Figure 4-7 - Block and Timing Diagram, Column Counter
COUNT
BICR
USED BY
1.
2.
3.
Data Control and Sync Logic to Reset the IMFF.
Error Logic for a Dark Check.
Error Logic for a Stadt Check.
4-10
Control Logic to reset the RESET INIDBIT Flip
Flop.
Pick 'Logic to enable the Pick Control for the next
PICK CMD and reset BUSY.
Error Logic for a Light Check.
Data Control and Sync Logic to reset the Sync
Control Logic.
1.
84CR
2.
3.
4.
FROM ONE DARK
FROM COLUMN
COUNTER
•
ONE DARK
84 CR
Vee
ERROR
UGHTCHECI<
DARK CHECK
--PICK CHECK
STACK CHECK
HOPPER CHECK
ONE L!GHT
DCKS (O+81CR)
FROM ONE L!GHT
FROM COLUMN
COUNTER
TO CONTROLLING
DEVICE
}TO CONTROL
LOGIC
PSET
FROM PICK LOGIC
MOCK
FROM STACK
PHOTOTRANSISTOR
FROM COLUMN {
COUNTER
FROM HOPPER
STACKER
FULL SWITCH
FRm~
STACK
CHECK
Vee
STACK CHECK
INDICATOR
HECK
81 CR
HOPPER EMPTY
EMPTY SWITCN {
FROM CONTROL
LOGIC
STACK
OCR
TO CONTROLL! NG
DEVICE
TO CONTROL
LOGIC
HOPPER CHECK INDICATOR
Vee
HCK
TO CONTROLL! NG
DEVICE
paR + RESET
RESET I NH IB IT
STACKER FULL
PICKRECEIVED
C~ND -------~----~llrS------------------------------------------~~
RESET INHIBIT
~---(H~--------------------------------~--II
I
I
I
I
OCR, 81 CR, --------~--~S~rS------~I__------------------------~I~I-------~~
& S4tlf
IOCR
81 CR
84 CR
I
II
Wff_
I
I
I
1"-= 300 ms-1
I
CHECK CONDITIONS
I
I
I
COL COL
I
18 22
I I
s
HT.~'
DARK CHECK HOPPER EMPTY
DARK CHECK,
LIGHT CHECK,
PICK CHECK
SW CLOSURE
STACK CHECK
Figure 4- 8. Block and Timing Diagram, Error Logic
4-11
STACKER FULL
The Column Counter counts until 84CR is generated. The Column
Counter is reset to zero by each GPR and RESET or POR.
4.3.1. 5
Error Logic
The Error Logic of Figure 4-8 contains the error/alarm detection circuits.
Once a PICK CMD is accepted by the reader, the Error Logic is sampled
at intervals of card processing for error and reader conditions. These
error/reader conditions are referred to as CHECK CONDITIONS and
shown in the timing diagram of Figure 4-7. Should a CHECK CONDITION
occur the reader READY will be reset. The first test is Pick Check. If
a PSET is signalled to Pick Check, a Motion Check (MOCK) will be sent
to the controlling device. PSET will occur approximately 300 ms after
PICK CMD was received and reader READY will be reset. Pick Check
will be signalled to the operator by the PICK CHECK control panel indicator. If PICK CHECK does not occur, a read cycle will be in process
and OCR will sample the Dark Check circuits. Should ONE LIGHT be
present during the check, indicating a failed LED, phototransistor, or
a torn card leading edge, an ERROR signal will be sent to the controlling device and READY dropped. The reader control panel will indicate
READ CHECK.
The Hopper Empty circuit senses closure of the Hopper Empty microswitch. This switch is located under the riffle cap and senses when the
last card has left the Hopper. As shown in the timing for CHECK CONDITIoNs the hopper empty switch will close between columns 18 and 22
of the last card. Hopper Empty is signaled to the controlling device and
READY is reset. Hopper Empty is signalled to the operator by the
HOPPER CHECK indicator.
OCR will be followed by 81 CR which samples the Stack Check circuits
and again samples the Dark Check circuits. The stack check sensor is
located at the exit of the card track and detects that the tail of a card is
clear of the card track (fully seated in the output stacker). The Stack
Check logic is designed to test the stack sensor light-to-dark transition
(i. e. , track clear) between the time an OCR Signal occurs (card entering
the read station) and the 81CR signal occurs. Should this transition not
have taken place, a STACK CHECK alarm is generated. This signal
generates a MOTION CHECK to the controlling device, resets the READY
line and lights the STACK CHECK indicator on the control panel.
84CR occurs next in the read cycle and samples the Light Check circuitry.
A ONE DARK present at 84CR indicates a failed LED phototransistor or
4-12
excessive card slip in the read track. This error is signalled to the controlling device as an ERROR and the READY line is reset. The reader
control panel will indicate READ CHECK•.
Since 84CR is also used to reset RESET ImnBIT, the Stacker Full circuit
will be checked for a closure of the Stacker Full Switch. If the switch is
closed. the Stacker Full circuitry will send STACKER FULL to the controlling device, Reset READY, and light the HOPPER/STACKER Indicator.
All error conditions are cleared by the Reset Switch.
4.3.2
DATA DETECTION
The following is a detailed description of each block shown under Data Detection
in Figure 4- 2 Block Diagram, M Series Card Reader.
4.3.2.1
Data Amplifiers and Inverters
The Light Station contains one infrared Light Emitting Diode (LED) and
the Read Station one Phototransistor for each of the 12 punched card rows.
Light emitted by the LEDs is allowed to pass to the Phototransistors by
the presence of punched holes in the tab card. Figure 4-9 presents a
block diagram and typical waveform for the Data Amplifiers and Inverters.
Light reaching the Phototransistor (PT) is amplified by the PT and cmverted into an electrical signal at its' emitter. A typical PT's emitter
waveform is ROW 12 (A). As the leading edge of the card passes over
the PT lens, the received light is reduced causing a reduction in the PT's
output voltage. The emitter of the PT is coupled to pull down resistor R
and the input of a high impedance TTL inverter. When the PT's emitter
voltage drops through the switching threshold of the inverter (nominally)
1. 4 volts) the inverter changes states. The High Impedance Inverters
output is amplified by the Inverter and then used to drive the One Light
and One Dark Logic. As can be seen from the waveforms each time the
High Impedance Inverters threshold is crossed the device switches states
driving the inverter to produce waveform ROW 12(B).
4.3.2. 2
One Dark and One Light
In order to provide the Dark Check at OCR and 81CR and the Light Check
at 84CR, the outputs of the Data Amplifiers and Inverters are OR'ed in a
One Light nor gate and inverted and OR'ed in a One Dark nor gate. These
nor .gates consist of 12 each open collector, TTL inverters in a wired OR
configuration. Figure 4-10 is a block and timing diagram for the One
Dark and One Light logic.
4-13
,..------DATA AMPLIFIERS-----.....,
ROW 12 AMPLIFIER
LIGHT
EMITTING
DIODE
ROW 12@
z
·1
--z
·1
ROW 11
AMP
1
ROW 0
AMP
1
i
ROW 11
•
ROW 0
•
TO ONE DARK
& ONE LIGHT
LOGIC
I
I
I
I
I
ROW 1 THRU 8 AMPLIFIERS
I
I
I
I
I
I
z
·1
ROW 9
ROW 9
AMP
CARD LEADING EDGE
ROW 120
TYPICAL
CARD TRAILING EDGE
v~
-7;' ---------,,
I
,
IC THRESHOLD
ROW 12@
•
~
I
I
I
I
I
I
55
$
I
ss
I
Figure 4-9. Block and Timing Diagram, Data Amplifiers and Inverters
4-14 .
The timing of Figure 4-10 shows the normal waveforms for ONE DARK
and ONE liGHT. When OCR occurs, ONE liGHT should be low indicating all PTs are dark. The same is true for 81CR. At 84CR, ONE DARK
should be low indicating light is being received by all PTs. If the foregoing conditions are not met, a READ CHECK will result and the reader
READY will be reset.
4.3.3
DA T A STORAGE
The following describes the blocks shown under Data Storage in Figure 4-2 Block
Diagram, M Series Card Reader.
4.3.3.1
Data Control and Sync Logic
The Data Control and Sync Logic provides the synchronization and control
necessary for data storage. Figure 4-11 is the block diagram, timing
and illustration that should be referenced to fully understand the following
description.
Following a GPR, the Data Control and Sync Logic must measure by
means of logic counters two distances to determine where the Column
Storage Data Strobe should begin. As shown on the card illustration,
---+
ONE DARK
(NOR GATE)
OI~E
DARK
-
TO ERROR LOGIC &
CONTROL LOGIC
, "12
FROM DATA
AMPLIFIERS
-
DATA
12
: INVERTERS :
ONE L1GI ~T
(NOR GATE)
,
12"
I
ONE LIGHT
r-------CARO DATA
GPR
ONE
\
DARK ~
....
-
TO DATA REGISTER
TO ERROR LOGIC
I
FIELD~
I
:~~
A
IOCR
BlCR I
K
I~·~:
r..:;~==~il
I
I
I
~~~""';~i'm;:o)~_
ONE LIGHT ,
:
~~~--~~~~li~~~~~~I~~
LEADING EDGE
CORNER NOTCH
Figure 4-10. Block and Timing Diagram, One Dark
and One Light
4-15
1'\ '
I
I
I
B4CR
the first measurement is the PRESET DISTANCE. PRESET is the distance from the card's leading edge (GPR) to the point in column 0 1 where
the Column Storage Data Strobe (CSDS) should begin. This distance is
equal to .063 inch. The PRESET DISTANCE is predetermined and a
PRESET count calculated by knowing the PRESET distance, card velocity
and the Preset Counter's input clock rate. The sole purpose of the
PRESET DISTANCE is to establish an end point for measuring OFFSET.
As the PRESET DISTANCE is being counted, the OFFSET DISTANCE is
measured. The OFFSET is the distance from the trailing edge of the
last Timing Disc tooth to pass the magnetic pickup to where the CSDS
should begin. Since there are precisely two timing disc teeth for each
Column on the card, the reader logic can now count the next two teeth's
trailing edges, add the Offset Count and again be positioned to provide
CSDS.
Because the Timing Disc's teeth rotate past the magnetic pickup asynchronously with respect to the arrival of the card's leading edge in the
Read Station, the OFFSET DISTANCE is a variable and subsequently
measured and stored for each card read.
The Synchronirzation process is initialized when a GPR is received by the
Sync Control Logic and Preset Counter. GPR presets the predetermined
count in the Preset Counter and causes the Sync Control Logic to generate
PRCLK (see timing of Figure 4-11). A zero crossing amplifier (AMP)
converts the sine wave produced by the Magnetic Pickup to a TTL compatible squarewave TSTl. Following GPR, the first negative transition
of TST1 (corresponds to tooth trailing edge) generates TST2 that causes
the Sync Control Logic to generate OSCLK (Offset Clock). OSCLK at
120 KHz drives the eight stage Offset Storage Counter, counting it upwards, while and until the Preset Counter reaches all ones. ZERO is
--:--now generated by the Preset Counter terminating both PRCLK and OSCLK.
The OFFSET has now been measured electronically and stored in the
Offset Storage Counter.
The Sync Control counts two negative transitions of TST1 and generates
Offset Up- Clock (OSUCLK). OSUCLK is used to count the Offset Counter
up until the Comparator detects an equal value between the Offset Storage
Counter and Offset Counter. CSDS for Column 0 is now generated by the
Strobe Logic. The Strobe Logic's ST0B resets the Sync Control Logic,
ST0C resets the Data Register and ST0C and ST£)D a,re used to drive the
Column Counter. The Sync Control Logic repeats this cycle for every
other TSTl causing the Strobe Logic to generate CSDS, ST£)B, ST£)C
and ST£)D each time.
4-16
FROM {
COLUMN
COUNTER
FROM 4. 8MHZ {
OSCILLATOR AND
FOUR PHASE GEN.
MAGNETIC
PICK UP
----
ICR
BICR
B4CR
'-.---
5T08
OFFSfT
CLOCK _
OSCLKC"P
CI
"C
C
,
~
AMP
-~
TIMING
STRDSE
GEN.
+
OFFSET
STORAGE
COUNTER
~
.,.
/
,
SYNC
CONTROL
LOGIC
TSTR
COMPARATOR
OSR
r---+
I
PRCLK
FROM {
CONTROL
LOGIC
--
.
GPR
-
-ZERO
PRESET
COUNTER
RESET
,-
•
I
OSUCLK ...
.,.
GPR
~
I
I
__~I______~/______~____~IL-____~____~__~
:
I
,
,
1
I
:
!
I
I
I
ZERO
~
PRESET:
I
r-- COUNT I
_"\\\\\1I - - OFFSET:I
---t
!
!
COUNT I
LI_ _ _ _
I
I
.223"
PRESET
DISTANCE
I
I
I
I
OSUCLK j
_lIfIIlOI
rJI/oWI/OlIIII1
ST"SI j
I
l
ST"C
I
~ ..........
CSDS j~_______________I~-+I________~r--l~
~1 ~
COL 01
COL 0
COL 1
.....
IMS ____________________________________________
j~
COUNTER & DATA
REGISTER
~I----~----------~--~
I
r-,
-
1
.1\'u\\\\\\.I~
OSCLK S ~
REGISTER
TO COLUMN
--. TOCOUNTER
COLUMN
.250"
S~--~----------------------------------------~
~t~~~
-. TO DATA
5T0C
o
01
-
CSDS
ST0D
OFFSET
COUNTER
GPR
CARD COLUMNS
/
/' 7
TO ERROR
LOGIC
1M (INDEX
MARKS) _ TO CONTROLLlrlG
DEV ICE
STROBE
LOGIC
4
--
-IMFF
,~I
/ 7
I
I I
l
I
________
I
I
I
I
I
I
Ci?r-:
*~-L~~
1 CR ~-----------------------------------------L----~l
I
r---OFFSET DISTANCE
!
!
!!
II
GPR
DC
Figure 4-11. Block and Timing Diagram, Data Control and Sync Logic Drivers
,,/1
"J CARD MOTION
I
FROM ONE DARK &
ONE LIGHT LOGIC
------------
-----
ROW
ROW
ROW
ROW
ROW
ROW
ROW
ROW
ROW
ROW
ROW
ROI,
12
11
0
1
2
3
4
5
6
7
8
9
..
....
·.•
....
....
...
·..
..
...
....
..
DATA
REGISTER
(12 BIT
STORAGE)
--...
-.....
...
.....
......
....
...
......
...
...
•
.,.
CSDS
_(DATA ENABLE)
FRor4 DATA
ST0C (DATA RESET)
CONTROL ~
.,.
---
----
o 12
o 11
oa
~
DATA
DRIVERS
D1
o2
D3
D4
D5
D6
o7
o8
D9
----..
-
-----
-------
TO CONTROLLING
DEVICE
-.
-.
-.
[I
ST0C
~S--.:...--~-+---------L.---4S
CSDS
§-S----~
5
.......
RmJ N
DN
......
5
~S---...I
I
t-j- - - - -....
I
I
----1
I
Figure 4-12. Block and Timing Diagram, Data Register and Data Drivers
4-18
lCR from the Column Counter sets the Index Mark Control Flip Flop (IMFF)
in the Strobe Logic. The Strobe Logic generates 6fJ. s Index Marks (IM) for
each Column. The IM indicates to the controlling device the beginning of the
guaranteed data period. When the 81CR is received by the Strobe Logic, the
IMFF resets preventing any further IM's from being sent to the Controlling
Device. The Data Control and Sync Logic will continue to generate CSDS
signals until 84CR resets the Sync Control Logic.
4. 3. 3. 2
Data Registers
Data detected by the Data Amplifiers and Inverters is routed through the
One Dark and One Light circuitry to the Data Register for transfer to
the Controlling Device. Figure 4-12, Data Registers and Data Drivers
diagram and timing details this sequence.
The 12 bit Data Register is reset each time ST(jC is generated by the
Data Control and Sync Logic. The 1 us STOC is followed in approximately
4 us by the Column Storage Data Strobe, CSDS. CSDS is synchronized
with the card movement by the Data Control and Sync Logic so that they
occur in the center of the card's data columns. Any ROW's input to ~e
Data Register that is low during CSDS will cause a "1" to be stored for
the row. When CSDS goes low, a period of guaranteed data occurs. This
period lasts until CSDS again goes true.
The data drivers provide the necessary buffering between the Data Register and the Controlling Device.
4-19
SECTION 5
INTERFACE
5.1 GENERAL
Thi s suction covers the interface between the M Series punched card readers and the equipment into which it transfers data.
5.2 TIMING
In interfacing the M Series card readers to an external system or card reader controller,
three separate categories of interface signals must be considered. The fir::;t are the
signals which control and report the status of card processing, the second are the data
signals themselves with their associated index marks, and the third are the various
alarm signals provided. In the description following, refer to the timing diagram shown
in figure 5-1.
5.2.1
PICK CONTROL
The PICK COMMAND initiates the card read cycle, and depending upon its duration,
the card reader will either continuous run or operate in a card-at-a-time mode.
This signal can be presented to the reader at any time, but the reader will only
accept it when the READY line is TRUE. The READY signal indicates that the
card reader is cleared of errors and is ready to receive a PICK COMMAND from
the external program control. A visual indication of the READY line is the green
RESET indicator on the front control panel.
The conditions which must be present for the READY line to be TRUE are:
1.
2.
:j.
4.
Power applied and the 3-second run-up completed.
The input hopper has been loaded.
REMOTE is selected on the LOCAL/REMOTE MODE switch.
Depress and release of the RESET pushbutton.
Should all of the above conditions be satisfied, the presence of a PICK COMMAND
signal will generate the PICK pulse to the picker solenoid. The first card is introduced into the card track, and after a delay (see A, figure 5-1), the leading edge
will arrive at the read station. The BUSY signal will go TRUE as soon as the leading edge of the card enters the read station.
To initiate the card pick cycle, the PICK COMMAND must be present for at least
1 microsecond (us) concurrently with the READY signal. Once the pick cycle is
initiated, the PICK COMMAND line is ignored until the BUSY signal goes FALSE,
indicating the end of the card read cycle. In card-at-a-time operation, it is suggested that the PICK COMMAND be retained TRUE until receipt of the column 1
index mark. In the continuous run mode, the PICK COMMAND may be left in the
TRUE condition and a new PICK signal will be automatically generated within 1 us
of the BUSY signal going FALSE.
5-1
READY
I--- TIME
VARIABLE
PICK COMMANO
_ _-l---ln
A
PICK (SOLENOIDI
BUSY
r"-"rn
I
n'--__
~~:----------r!--~~IL~-,-~-SE-C----------~
i
!"-r-"=l
----+--'1I i :
.I
u
Lt-J
OATA LINES
IIIIt=
INDEl( MARKS
80 EA
::Ill
IIII
BUSY
DATA COLUMN I
DATA LINES
I
1--.
BEGIN CARD
READ CYCLE
INDEX MARKS
GUARANTEED
C--1
SHADED AREA NOT GUARANTEED
2fLSEC
__________~n~·__--------------~n~---------
---j!--
PICK
(SDLENOIDI
COLUMN 2
GUARANTEED
6 ,u. SEC
0
-----l.1
----------i----t~ '_'"
tI
BUSY
DATA LINES
INDEX MARKS
I
J
DATA COLUMN 80
GUARANTEED
I
~I·=~~~-E-----·~I----END CARD READ CYCLE
MODEL
..!!!!.!..!..
WAVEFORMS NOT
SHOWN TO SCALE.
A
(MINI
B
c
o
E
CARD PICK
CYCLE
M200
24
6250
1314
2014
8050
200
M300
24
2600
435
870
102,660
200
M600
24
2600
435
870
3480
100
MIOOO
15
1860
240
478
1910
60
111200
14
MSEC
1120
240
4011
11129
110
W SEC
fL SEC
fL SEC
po SEC
M SEC
Figure 5-1. Interface Timing Diagram
5-2
Should the picker fail to engage the card, the Pick Control logic will wait 50 milliseconds (ms) and automatically try again. It will continue to generate a PICK
pulse every 50 ms 1.Ultil 6 attempts have been made. Mter6 attempts have been
1.Ulsuccessful (300 ms), a PICK CHECK alarm will be generated, disabling the
READY line.
5.2.2
DATA READOUT
The card read cycle starts with the recognition that the card leading edge has entered
the read station. At this time the BUSY line goes TRUE. Eighty equally spaced
Index Marks of 6 us duration are generated while the BUSY signal is present. The
time spacing of the Index Marks and the BUSY signai are shown by intervals, B, D,
and E on figure 5-1.
It can be seen from the timing diagram that data signals may appear on the data
output lines before the occurrence of the associated Index Mark. Since torn webs
are sometimes enco1.Ultered which could partially obscure the hole, all Documation
card readers feature a wide data acceptance interval to provide greater tolerance
to this damage. During this interval, any signal from the read station sensors
indicates a hole; and therefore is recognized as a valid data bit and is stored into
the Character Buffer. Since the contents of the Character Buffer are subject to
change throughout this interval, the data is not guaranteed 1.Ultil the end of the
acceptance interval. This period is terminated 2 us prior to the Index Mark.
By the time the Index Mark is generated, the data will have been read, stored, a.nd
the data lines settled. Data levels are guaranteed to remain on the output lines
available for transfer to the external equipment for interval C.
5.2.3
ALARMS
A descripticn of the standard alarm signals provided in the M Series reader follows:
5.2.3.1
Hopper Check
The HOPPER CHECK signal remains FALSE during normal card reader
operation, but goes TRUE if either the input hopper is empty or the output stacker is full. If the input· hopper is empty and the SHUTDOWN
switch is in AUTO position, the motors are also automatically switched
off; when the input is reloaded and RESET depressed, the motors will
automatically turn on.
5-3
When the last card leaves the input hopper, the switch which senses the
empty condition immediately signals a HOPPER CHECK and disables the
READY signal. This occurs at the Slst data column. The reader continu
the read cycle; however, when the BUSY line next goes FALSE the reader
is stopped. In the case of a full output stacker, the HOPPER CHECK
signal only appears at the end of the read cycle during which it occurred.
5.2.3.2
Error
The ERROR signal is produced by failure of the LIGHT or DARK check.
This usually indicates that a card has a tear at the leading or trailing
edge (DARK CHECK). If the read statim should experience an emitter/
sensor failure while reading a card, the LIGHT CHECK will pick it up.
Either type of failure will be Signalled by the ERROR line going TRUE
and a READ CHECK indication on the front panel.
5.2.3.3
Motion Check
The MOTION CHECK signal is a composite of the PICK CHECK and
STACK CHECK alarm. Both alarms are conditions requiring operator
intervention and are furnished to the interface as a single alarm line.
The condition is displayed on the front panel indicator lights as either a
PICK CHECK or a STACK CHECK. The MOTION CHECK signal will
occur within 300 ms of the initiation of an unsuccessful pick attempt or
in time to inhibit the picking of the second card after the stacker sensor
detects that a card is not completely clear of the card track.
5.3 CONNECTORS
The 38-pin output connector provides access for all control, data a.nd alarm lines. The
output connector is Elco part no. 00-8016-038-000-707 and the mating connector is Elco
part no. 00-8016-038-217-704 with solder-type pins (#60-8017-0513). This mating connector assembly is available from Documa.tion and is shipped unassembled as a kit
(P/N 10139401).
The power connector is Hubbell part no. 7486. The mating connector is Hubbell part no.
7484. The mating AC power connector is supplied on the.standard accessory power cord;
however, it is identified if it is desired to fabricate a special power interface.
5-4
The standard M Series pin assignment configuration is listed as follows:
J2 I/O SIGNAL CONNECTOR PIN LIST
PIN
A
B
C
D
E
F
H
J
K
L
M
N
P
R
S
T
U
V
W
SIGNAL
DESCRIPTION
PIN
SIGNAL
D12
Dll
DO
D1
D12 (RET)
D11 (RET)
DO (RET)
D1 (RET)
D2
D3
D4
D5
D2 (RET)
D3 (RET)
D4 (RET)
D5 (RET)
D6
D7
D6 (RET)
Row 12 Data
Row 11 Data
Row o Data
Row 1 Data
X
Row
Row
Row
Row
FF
D7 (RET)
D8
D9
1M
RDY
D8 (RET)
D9 (RET)
1M (RET)/GRD
RDY (RET)
ERROR
HCK
MOCK
PC
BSY
Error (RET)
HCK (RET)
MOCK (RET)
PC (RET)
BSY (RET)
2
3
4
5
Data
Data
Data
Data
Row 6 Data
Row 7 Data
Y
z.
AA
BB
CC
DD
EE
HH
JJ
KK
LL
MM
NN
PP
RR
SS
TT
POWER CONNECTOR PIN LIST
PIN
W
X
Y
SIGNAL
Safety Ground
Neutral
115 Volts
5-5
(green)
(white)
(black)
DESCRIPTION
Row 8 Data
Row 9 Data
Index Mark
Ready
Signal Ground
Error
Hopper Check
Motion Check
Pick Command
Busy
5.4 SIGNAL CHARACTERISTICS
The standard interface is supplied as the output d. TTL type 7404. Signal sense is specified as a Logical TRUE and is a positive level; logical FALSE is a ground level. Circuit
characteristics are shown in figure 5-2. Other output drive configurations are available.
5.5 GROUNDING
·Grounding within the M Series card readers maintains AC power and signal ground separate.
Signal ground is the logic power return (Vcc return) and is transformer isolated from the
AC power distribution system. The chassis is protected by connection to the safety wire
(green) in the AC power cord.
It is recommended that twisted pair cable be used to connect the M Series card re aders to
external equipment. The signal returns should be terminated as close as possible to the
signal receivers. It should be noted that pin EE (Index Mark return) is designated as
SIGNAL GROUND on the pin assignment chart. If twisted pair interconnection is not used,
it is recommended that pin EE be connected to the external equipment signal return.
Vcc
Output Drive
TTL type 7416
Logical TRUE
I load "" -400 ua @ 2.4V min (with R=5. 6K)
Logical FALSE
I sink = 16 rna @ 0.4V
max
Vce
330 ohms
Input Impedance
(PICK COMMAND)
1 DTL
Load
.01 ufd
Figure 5-2. Circuit Characteristics
5-6
SECTION 6
ADJUSTMENT PROCEDURES
6.1 GENERAL
The adjustment procedures necessary for proper reader operation are listed
separately in this section for ease in reference. These adjustments should be chec~
ed when minor malfunctions occur and before major repair is attempted. They will
also be used after major repair and replacement.
To perform any of the adjustment procedures in this section, it is necessary to
remove the top cover and/or the rear panel as follows:
CD ' figure 6-1, which
a.
Using a 5/64 Allen wrench, remove five screws
hold the top cover.
b.
Lift cover sufficiently to disconnect the control panel connector, figure
6- 3, and remove cover.
c.
Using a 5/64 Allen wrench, remove six screws
hold the rear panel.
d.
Move panel out slightly, disconnect fan connector and remove panel.
e.
After adjustments have been completed, replace top cover and/or rear
panel removed.
® ' figure 6-2, which
6.2 TENSION ON THE MAIN DRIVE MOTOR BELT
a.
Using a Phillips screwdriver, LOOSEN three motor mounting screws
figure 6-3.
CD '
CAUTION
THE DRIVE MOTOR BELT TENSION IS CRITICAL. TOO
MUCH TENSION CAN CAUSE EXCESSIVE WEAR OF DRIVE
ROLLER BEARING. IT MAY ALSO CAUSE DEFLECTION
OF DRIVE ROLLER BEARING SHAFT RESULTING IN READ
CHECKS. TOO LITTLE TENSION MAY CAUSE BELT TO
JUMP A COG OR CREATE A NON-CONSTANT TRACK
SPEED RESULTING IN LOSS OF TIMING, INCORRECT DATA,
OR READ CHECKS.
b.
Move motor back and forth to be sure it slides freely. Attach spring
scale to motor stand off so that pulling on spring scale from front of
card reader and in line with motor mounting slots will apply tension to
main drive motor belt. Pull on spring scale until it reads 24 ounces.
Hold tension at that level and tighten three motor mounting screws.
6-1
Figure 6-1.
Figure 6-2.
Top Cover Removal
Rear Panel Removal
6-2
CONTROL PANEL
CONNECTOR
~:---~~~=-l HOPPER
EMPTY
SWITCH LEADS
Figure 6-3. Drive Motor Belt Tension Adjustment
6.3 MAGNETIC PICKUP ADJUSTMENT
The magnetic pickup is adjusted to ensure that timing pulses are developed
correctly. There are two adjustments: horizontal alignment and air gap. Refer
to figure 6-4.
a.
Using a 5/64 Allen wrench. LOOSEN set screw that is holding timing
disc on drive roller shaft and position timing disc on drive roller shaft
so that it is in a horizontal plane with center of magnetic pickup tip.
CAUTION
IF THE TIMING DISC MUST BE REMOVED.
EXERCISE EXTREME CAUTION. DAMAGE
TO DISC WILL RESULT IN ERRONEOUS
MACHINE OPERATION.
I~
~ I'~
TIMING
DISK
SET SCREW
AIR GAP - .007 ± .001
Figure 6-4. Magnetic Pickup Adjustment
6-3
b.
Align disc in correct position and tighten set screw, making sure that
set screw is tightened on flat side of shaft.
c.
To adjust air gap between magnetic pickup and timing disc, LOOSEN set
screw holding magnetic pickup in its mounting block and reposition
pickup. The air gap should be set to . 007" ~ .001". (One punch card
may be used as gauge.)
d.
Rotate timing disc and check two other positions to make sure that air
gap is maintained.
6.4 ADJUSTMENT OF STACK PHOTOCELL
The stack photocell is adjusted to ensure that it correctly monitors stacking of cards
and so that it is not in the way of cards entering output stacker.
a.
Using a 1/16 Allen screwdriver, LOOSEN the set screw in the stacker
casting which retains the stack photocell l1 Wrench (short arm)
1/16" Allen Wrench (short arm)
AMP Extraction Tool
"AMP Leaf Contact" Extraction Tool
"AMP Modified Fork" Contact Extraction Tool
"AMP Mod IV" Cootact Extraction Tool
Deutsch Insertion/Extraction Tool(on base plate
IC Removal Tool
Elco Extraction Tool
Elco Insertion Tool
Feeler Gauge Set 0.0015" thru 0.025"
Long Nose Pliers
Ie Test Clip
Medium Flat Blade Screwdriver 3" long
Medium Flat Blade Screwdriver 6" long
6" Metal Scale, decimal/fraction per inch
1/4" - Open End or Socket Wrench
1/2" - Open End Wrench
11/32" - Open End or Socket Wrench
7/16" - Open End or Socket Wrench
#1 Phillips Screwdriver 6" long
#2 Phillips Screwdriver 6" long
Printed Circuit Card Extender
#2 Retaining Ring Remover
Side Cutter
Solder Removal Tool
60-Watt Soldering Iroo
32-oz. Spring Scale
9-4
AMP 91022-1
AMP 465195-2 or 465275-1
AMP 91037-2
AMP 91029-1A
M15570-16
AMP 91049-1
Elco 061877-04
Elco 061742-04
AP Inc. 923700
Documation PiN 103099501
FAN MOTOR
CONNECTOR
REAR
CONNECTOR
PANEL
BOTTOM PLATE
Figure 9-3.
Figure 9-4.
Rear View, Cover Removed
Front View, Main Mounting Plate Removal
9-5
9.3 MAIN DRIVE MOTOR BELT
a.
Remove top cover, rear panel, rear connector panel, and main mounting
plate per paragraph 9.1, steps a. through q.
b.
Using a Phillips screwdriver, remove three main drive motor mounting
screws CD , figure 9-5, and remove belt from motor pulley. Set motor
aside.
c.
Using a 5/64 Allen wrench.
LOOSEN set screw in timing disc, figure 9-6.
CAUTION
REMOVE TIMING DISC USING EXTREME
CARE NOT TO DAMAGE TEETH ON DISC.
WRAP DISC IN SOFT TISSUE WHILE NOT
IN READER.
d.
Remove main drive motor belt.
e.
Replace belt over timing disc pulley and roller pulley.
f.
Reposition motor to replace belt over motor pulley, and replace motor
mounting screws but do not tighten.
g.
Adjust tension on the main drive motor belt per paragraph 6.2.
h.
Replace timing disc on shaft, align with tip on magnetic pickup, figure 6-4,
and tighten set screw. Check for. 007 ~ .001 inch clearance between magnetic pickup tip and timing disc. Adjust if necessary per paragraph 6.3,
steps c. and d.
i.
Replace main mounting plate, rear connector panel, rear panel, and top
cover in reverse order of paragraph 9.1 (steps q. through a.).
9.4 · MAGNETIC PICKUP
a.
Remove top cover and rear panel per paragraph 9.1, steps a. through d.
b.
Using a 1/16 Allen wrench, LOOSEN set screw in magnetic pickup mounting
block, figure 9-6.
c.
Disconnect read head connector from card cage, figure 9-7.
d.
Free magnetic pickup cable from read head connector cable and unsolder
wires (note colors) from pins J, K, and L on read head connector,
figure 10-3.
9-6
~:-----~~~~-LHOPPEREMPTY
SWITCH LEADS
Figure 9-5.
Partial Front View, Cover Removed
MAGNETIC PICKUP
MOUNTING BLOCK
MAGNETIC PICKUP
MOUNTING BLOCK SET SCREW
MAGNETIC
PICKUP
MAGNETIC
PICKUP TIP
TIMING DISK
SET SCREW
TIMING DISK
MAIN DRIVE
MOTOR BELT
MAIN DRIVE
MOTOR
Figure 9-6.
Bottom View, Main Mounting Plate
9-7
e.
Solder wires of new magnetic pickup to read head connector pins J, K, and
L. Ensure wires replaced as noted in step c.
f.
Rewrap magnetic pickup cable and read head connector cable and insert new
pickup unit into mounting block.
g.
Adjust spacing between timing disc teeth and tip of magnetic pickup for
• 007 ~ .001 inch, figure 6-4. Tighten set screw.
h.
Replace rear panel and top cover in reverse order of paragraph 9.1 (steps d.
through a. ).
9.5 SOLENOID
a.
Remove top cover, rear panel, rear connector panel, and main mounting
plate per paragraph 9.1, steps a. through q.
b.
To adjust solenoid, perform steps I. through n. only. To replace solenoid
perform steps c. through n. Refer to figure 9-8.
c.
Remove solenoid spring from spring post and arm stud.
d.
Using a 1/16 Allen wrench, LOOSEN two set screws in top solenoid coupling.
e.
Using a 9/64 Allen wrench, remove two screws
plate. Remove solenoid.
f.
Using a 11/32 wrench, remove two mounting nuts
from mounting plate.
g.
Using a 1/16 Allen wrench, LOOSEN two set screws holding coupling on
solenoid shaft. Remove coupling.
CD holding solenoid mounting
® to remove solenoid
NOTE
Remove the set screws from the coupling.
Apply LOCTITE GRADE C to the screws and
replace. LOCTITE GRADE C should be ,
applied to all operational and mounting type
hardware, with the exception of panel screws.
h.
Place coupling on new solenoid shaft locating bottom coupling set screws on
two flat sides of shaft.
i.
Tighten bottom coupling set screws and replace solenoid on mounting plate
making sure holes are in proper position, with wires extending from left side,
as viewed from bottom of main mounting plate •.
9-8
j.
Replace solenoid on mounting posts, sliding top coupling onto picker shaft.
k.
Replace solenoid return spring between spring post and arm stud.
1.
With two screws in top solenoid coupling LOOSE, depress top of solenoid
sufficiently to result in .010 to .015 inch clearance between the wafers of the
coupling. Check by using feeler gauge.
m. Maintain proper pressure on coupling and tighten two set screws, ensuring
set screws are on two flat sides of shaft.
NOTE
When this adjustment is made properly,
the picker sector will have sufficient
driving force to reliably pick cards and
be capable of fully returning to rest
position. If picker sector does not return
to rest position, coupling has been compressed too far.
n.
Replace main mounting plate, rear connector panel, rear panel, and top
cover in reverse order of paragraph 9.1 (steps q. through a.).
READ HEAD CONNECTOR
REMOVED FROM CARD CAGE
Figure 9-7. Partial Top Left View, Cover Removed
9-9
SPRING
POST
SOLENOID
RETURN
ARM
~1_;:-W/h-Wh-Whr-lSrT_UD--...,..,.-,..,..-------~~~--~DOWNWARD
__~~~~-L~
SET SCREWS
IN TOP
COUPLING
SET SCREWS
IN BOTTOM
COUPLING
PRESSURE
.010 TO .015
SOLENOID LEADS
~~~~----,I
,.ll-1JL.=t:==::;::==::;:::=~---1LU, __ MOUNTING PLATE
FORWARD MOST SOLENOID
MOUNTING HOLE
Figure 9-8. Solenoid Replacement and Adjustment
9-10
9.6 STACKER CASTING
The stacker casting must be removed to replace any of the following assemblies
and installed after the replacement of the assembly. These assemblies are:
Roller Bearings, Read Head, or Light Station.
a.
To remove stacker casting, proceed as follows:
1.
Remove top cover, rear panel, rear connector panel, and main mounting
plate per paragraph 9.1, steps a. through q.
2.
Using a flat blade knife, remove stack guide plate, figure 9-7.
NOTE
The stack guide plate is fastened on
with Pliobond cement. The old cement
must be cleaned off and new cement
applied when replacing stack guide plate.
3.
Using a Phillips screwdriver, remove two screws 1 holding side support
plate, figure 9-9.
4.
Remove two screws i
5.
Using a 5/64 Allen wrench, LOOSEN set screw in timing disc. Remove
timing disc, figure 9-6.
from input hopper wall, figure 6-9.
CAUTION
REMOVE TIMING DISC USING EXTREME
CARE NOT TO DAMAGE TEETH ON DISC.
WRAP DISC IN SOFT TISSUE WHILE NOT
IN READER.
i
6.
LOOSEN three screws
7.
Remove main drive motor belt.
8.
Using a 3/32 Allen wrench, LOOSEN set screws in two stacker pulleys,
figure 9-9. Remove pulleys.
9.
Remove tie-wrap on solenoid mounting plate holding light station cable.
10.
holding main drive motor, figure 9-5.
Using a 9/64 Allen wrench, remove three screws holding stacker
casting. Set stacker casting to one side.
9-11
ECOND STACKER
_-::;~::;:::;::~";1 ROLLER PULLEY
-SE:CO'ND STACKER
ROLLER PULLEY
SET SCREW
Figure 9-9. Side View, Main Mounting Plat e
LIGH T STATION
CONNECTOR
STACKER SHAFT
STACKER SHAFT
COLLAR SET SCREW
~;:::""'_I STACKER SHAFT
....
SUPPORT
BEARINGS
Figure 9-10. Re ar Vi ew, Cover and Rear Conne ctor Panel Removed
9-12
b.
To replace stacker casting proceed as follows:
1.
Reposition stacker casting and insert three mounting screws but do not
fully tighten.
2.
Make a gauge using eight new unpunched cards cut to 2 x 5 inches.
3.
Insert gauge between picker casting and stacker casting but avoid covering read station window. Apply even pressure to stacker casting toward
picker casting and tighten stacker casting mounting screws. Remove
gauge. Observe that steel rollers cause a slight depression on rubber
rollers.
4.
Position main mounting plate on reader in order to test read head output
voltage.
5.
Connect read head connector to card cage, figure 9-7.
6.
Connect light station connector, figure 9-10.
7.
Using extender board on control card and, with power applied, connect
voltmeter between R17 and card ground. Verify voltage is
2.3 vdc and
<4.3 vdc. (Nominal 3 to 4 vdc)
8.
Repeat step 7. at R18 through R28.
9.
If any reading is outside limits, LOOSEN stacker casting mounting
screws and reposition for optimum value.. Tighten screws and re-check
per steps 7. and 8.
10.
Remove extender board and replace control card in card file.
11.
Remove main mounting plate from reader.
12.
Replace cable wrap holding light station cable.
13.
Replace two stacker pulleys.
CAUTION
USE MODERATE TORQUE TO TIGHTEN
PULLEY SET SCREW. DO NOT OVERTORQUE OR DAMAGE WILL RESULT TO
PULLEY.
14.
Replace timing disc and adjust per paragraph 6.3.
15.
Complete stacker casting replacement in reverse order of paragraph 9.6,
a (steps 4. through 1. ).
9-13
9.7 STACKER ROLLER BEARING ASSEMBLIES
a.
Remove stacker casting per paragraph 9.6, a.
b.
Using a 1/16 Allen wrench, LOOSEN set screw in bottom roller of assembly
to be removed. Remove roller and spacer washer, figure 9-11.
c.
Lift shaft straight up out of casting. Observe spacer washer between top
roller and bearing seat.
d.
To remove top bearing, use L-shaped tool to lift bearing from assembly.
e.
To remove bottom bearing, use a straight tool to tap edge of bearing from
inside of shaft hole to drop bearing from casting.
f.
Install new bearings. Place spacer washer on top bearing and replace shaft
in shaft hole.
g.
Replace bottom roller with spacer washer between roller and bearing seat.
h.
Apply firm finger pressure between top and bottom rollers and tighten set
screw in bottom roller.
i.
Check for vertical play in stacker shaft. If there is vertical play, repeat
step h.
j.
Replace stacker casting per paragraph 9. 6, b.
9.8 READ HEAD ASSEMBLY
a.
Remove stacker casting per paragraph 9.6, a.
b.
Using a Phillips screwdriver, remove two screws CD ' figure 9-11, to remove read head, and disconnect read head connector. Unwrap read head
cable.
c.
Using a 1/16 Allen wrench, LOOSEN set screw in magnetic pickup mounting
block and remove magnetic pickup, figure 9-6.
d.
Using a 1/16 Allen wrench, LOOSEN set screw in stacker casting holding
stacker photocell and remove photocell, figure 9-9. Read head assembly is
now free.
e.
Replace read head assembly, insert two mounting screws and tighten.
f.
Insert magnetic pickup in mounting block and adjust per paragraph 6.3, c.
9-14
SECOND STACKER
ROLLER ASSEMBLY
FIRST STACKER
ROLLER ASSEMBLY
SECOND PICKER
ROLLER ASSEMBLY
FIRST PICKER
ROLLER ASSEMBLY
LIGHT STATION
l ----:==:!- SOLENOI D
RETURN SPRING
ROLLER
1~~~==~~~~=WASHER
BEARING
r
.t.---SET SCREW
L.,,.........,,....l--- SET
SCREW
MAINFRAME
Figure 9-11. Stacker Casting Removal and Bearing Replacement
9-15
g.
Replace photocell in stacker casting, align flush with stacker casting faceplate, and tighten photocell set screw.
CAUTION
MAKE SURE PHOTOCELL DOES NOT EXTEND BEYOND SURFACE OF CASTING OR
DAMAGE MAY RESULT TO PHOTOCELL
OR CARDS.
NOTE
If light station is to be replaced at this time,
see paragraph 9.9, step b. through d.
h.
Replace stacker casting per paragraph 9.6, b.
9.9 LIGHT STATION ASSEMBLY
a.
Remove stacker casting per paragraph 9.6, a.
b.
Using a Phillips screwdriver, remove four screws
remove light station assembly.
c.
Remove cable wrap and disconnect light station connector, figure 9-10.
Light station assembly is now free.
d.
Replace light station assembly and tighten four mounting screws. Replace
cable wrap and connect light station connector.
® , figure 9-11, to
NOTE
If read head is to be replaced at this time,
see paragraph 9.8, steps b. through g.
e.
Replace stacker casting per paragraph 9.6, b.
9.10 STACKER SHAFT SUPPORT BEARINGS
a.
Remove top cover, rear panel, and rear connector panel per paragraph 9.1,
steps a. through e.
b.
Using a 5/16 Allen wrench, LOOSEN stacker shaft collar set screw.
9-16
CD
c.
Using a Phillips screwdriver, remove two screws
from underneath mainframe holding stacker shaft support casting, figure 9-10.
d.
Move stacker shaft support casting to rear and slide off shaft to left.
e.
Using an arbor press, remove and replace two bearings in stacker shaft
support casting.
f.
Reassemble in reverse order of disassembly.
g.
Replace rear connector panel, rear panel, and top cover in reverse order
of paragraph 9.1 (steps e. through a. ).
9.11 VACUUM PUMP MOTOR ASSEMBLY BELT
a.
Remove top cover, rear panel, rear connector panel, and main mounting
plate per paragraph 9.1, steps a. through q.
b.
Remove screw holding ground strap to subframe.
CAUTION
USE A 1/2 INCH OPEN-END WRENCH TO
HOLD MOUNTING POST TO A VOID TWISTING
OFF THE PUMP PLATE RUBBER SHOCK
MOUNTS.
c.
Remove four Phillips head mounting screws]) holding vacuum pump motor
assembly, figure 9-10.
d.
The vacuum pump assembly may now be removed from card reader.
e.
LOOSEN three hex vacuum pump mounting bolts
f.
Replace vacuum pump belt.
g.
Using a spring scale, adjust vacuum pump for a belt tension of 4-6 ounces.
This is about 3/64" belt deflection.
h.
With appropriate belt tension a.pplied, tighten three hex vacuum pump mounting bolts.
i.
Check pulleys to make sure they are in the same plane. Also check each
pulley set screw to make sure it is secure.
j.
Replace vacuum pump motor assembly in reverse order of disassembly.
k.
Replace main mounting plate, rear connector panel, rear panel, and top
cover in reverse order of paragraph 9.1 (steps q. through a.).
9-17
J) , figure 9-13.
RED 6 BLUE
CAPACITOR
LEADS
VJ.\~,UUIVI
MOTOR AC
CONNECTOR
RELAY CONNECTOR
YELLOW LEAD
Figure 9-12. Front View, Main Wiring Connections
SPRING SCALE
Figure 9-13. Vacuum Pump Belt Adjustment
9-18
HOSE
Figure 9-14.
Stacker Panel Removal
1.12 STACKER FULL SWITCH
a.
Remove top cover per paragraph 9.1, steps a. and b.
b.
Using a Phillips screwdriver, remove two screws
frame holding stacker front panel, figure 9-14.
c.
Remove two leads from stacker full switch, figure 9- 15.
d.
Using a Phillips screwdriver, remove two screws holding switch.
e.
Replace switch, connect leads, and adjust per paragraph 6.7.
f.
Replace top cover in reverse order of paragraph 9. 1 (steps b. and a.).
9-19
CD from underside of main-
STACK ER FULL SW ITCH
Figur e 9-15. Stacke r Full Switch Replacement
9.13 HOPPER EMPTY SWITCH
a.
Remove top cover per paragraph 9.1, steps a. and b.
b.
Using a 3/32 Allen wrench, remove two screws holding riffle cap, figure 9-5.
c.
Remove two leads from hopper empty switch.
d.
Using a 1/16 Allen wrench, remove two screws holding switch.
e.
Replace switch, connect leads, and adjust so that switch is activated with
card in hopper and disengaged with hopper empty. See paragraph 6.6 for
adjustment.
f.
Replace top cover in reverse order of paragraph 9.1 (steps b. and a.).
9-20
9.14 PICKER
a.
Remove top cover, rear panel, rear connector panel, and main mounting
plate per paragraph 9.1, steps a. through q.
b.
Remove solenoid per paragraph 9.5, steps c. through e.
c.
Using a #2 retaining ring remover tool, remove retaining ring from top of
picker shaft, figure 9-16.
d.
Remove spacers from picker shaft.
CAUTION
ALL SPACERS MUST BE REPLACED
IN REASSEMBLY.
e.
Using a 5/64 Allen wrench, LOOSEN two set screws holding picker sector,
figure 9-5.
f.
Remove picker shaft from underside of main mounting plate.
g.
Using a Phillips screwdriver, remove throat block, figure 6-9.
h.
Remove picker sector from rear side of picker casting.
i.
Replace picker sector, shaft, all spacers and retaining ring.
j.
Rotate shaft to place flat side of shaft under picker sector set screws.
k.
Adjust per paragraph 6.8, steps a. through k.
1.
Replace solenoid per paragraph 9.5, steps j. through m.
m. Replace throat block, insert screw, but do not fully tighten.
n.
Using a feeler gauge, adjust pick throat for a clearance of .008 between
throat block and picker sector. Tighten throat block.
o.
Replace main mounting plate, rear connector panel, rear panel, and top
cover in reverse order of paragraph 9.1 (steps q. through a.).
9-21
RETAINING RING
SPACERS UNDER
RETAINING RING
Figure 9-16.
Top View Casting Assembly
1.15 INDICATOR LAMPS
a.
Remove top cover per paragraph 9.1, steps a. and b.
b.
To replace any indicator lamp, push center terminal, at base of lamp socket,
to one side.
c.
Remove old lamp, replace with new lamp, and push center terminal back to
center of lamp socket.
d.
Replace top cover in reverse order of paragraph 9. 1 (steps b. and a.).
9-22
IJI PICKER ROLLER BEARINGS
a.
Remove picker casting as follows:
1.
Remove top cover, rear panel, rear connector panel, and main mounting
plate per paragraph 9.1, steps a. through q.
2.
Using a flat blade knife, remove stacker guide plate figure 9-7.
NOTE
The stack guide plate is fastened on
with Pliobond cement. The old cement
must be cleaned off and new cement
applied when replacing stack guide
plate.
b.
3.
Using a Phillips screwdriver, remove two screws (1) holding side support plate, figure 9-9.
4.
Using a Phillips screwdriver, remove three main drive motor mounting
screws
figure 9-5, and remove belt from motor pulley. Set motor
aside.
5.
Remove solenoid spring from spring post and arm stud, figure 9-8.
6.
Using a 1/16 Allen wrench, LOOSEN two set screws in top solenoid
coupling.
7.
USing a 9/64 Allen wrench, remove two screws holding solenoid mounting
plate. Move solenoid down and set aside.
8.
Using a Phillips screwdriver, remove screw holding throat block to
stacker casting and remove throat block, figure 6-9.
9.
Using a 9/64 Allen wrench, remove six screws holding picker casting to
main mounting plate and remove picker casting.
aj ,
Replace first picker roller bearings per paragraph 9.7, steps b. through i.
9-23
c.
Replace second picker roller bearings as follows:
NOTE
The second picker rollers are each
mounted on its own shaft.
d.
1.
Using a 1/16 Allen wrench, LOOSEN set screw in roller and remove
roller and washer.
2.
Remove shaft from center of casting.
3.
USing a straight tool, tap edge of bearing from inside shaft hold to drop
bearing from casting.
4.
Install new bearing. Place shaft into shaft hole from center of casting.
5.
Replace washer and roller on shaft. Apply firm finger pressure between
roller and shaft end and tighten set screw in roller.
6.
Check for vertical play in shaft. If there is vertical play, repeat step 5.
To replace picker casting proceed as follows:
1.
Reposition picker casting and insert six mounting screws but do not fully
tighten.
2.. Make a gauge using eight new unpunched cards cut to 2 x 5 inches.
3.
Insert gauge between picker casting and stacker casting but avoid covering read station window. Apply even pressure to picker casting toward
stacker casting and tighten picker casting mounting screws. Remove
gauge. Observe that steel rollers cause a slight depression on rubber
rollers.
4.
Position main mounting plate on reader in order to test' read head output
voltage.
5.
Connect read head connector to card cage, figure 9-7.
6.
Connect light station connector, figure 9-10.
7.
Using extender board on control card and, with power applied, connect
voltmeter between R17 and card ground. Verify voltage is
2.3 vdc and
4.3 vdc. (Nominal 3 to 4 vdc. )
>
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8.
Repeat step 7. at R18 through R28.
9-24
9.
If any reading is outside limits, LOOSEN picker casting mounting screws
and reposition for optimum value. Tighten screws and re-check per
steps 7. and 8.
10.
Remove extender board and replace control card in card file.
11.
Remove main mounting plate from reader.
12.
Replace solenoid on mounting posts, sliding top coupling onto picker
shaft. Tighten screws holding solenoid.
13.
Replace solenoid return spring between spring post and arm stud.
14.
With two screws in top solenoid coupling LOOSE, depress top of solenoid
sufficiently between the wafers of coupling. Check by using feeler gauge.
15.
Maintain proper pressure on coupling and tighten two set screws,
ensuring set screws are on two flat sides of shaft.
NOTE
When this adjustment is made properly,
the picker sector will have sufficient
driving force to reliably pick cards and
be capable of fully returning to rest
position. If picker sector does not return
to rest position, coupling has been compressed too far.
16.
Replace throat block, insert mounting screw, but do not tighten. Adjust
gap between throat block and picker sector to • 008 inch.
17.
Complete picker casting replacement in reverse order of paragraph
9.16, a (steps 3. through 1.).
9-25
SECTION 10
DRAWINGS
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8zeorxo
IZ
I
DO\,IT
S
12
[7'
1><
1-"'"&-2
8
Y'" '(
I
B
~
/VIe.; 1
~~
~'"
eJ AO&2.eo~2. 12
I
0"7
fL
\0
~
e
De
~rll>
8~~
"
i-
"
2I
Is
4
~
W
PICK A,'TTE't"'\PT CO,JN"'e.~
A€:-l
1
r
177
I"
v«
L~
o Q~
p
ceo
L-....;c
\-OZ-I2.
¢D
~
~
..
r
L~ls
c9
"'e
;;;'"
~
~o
.0
~
..
q~
~
D " \. ..
.
~~
~,Q
.,1
c.",~&
-..n
M8-11
,2
c""
lie.
;;;~
~'"
0>
RJI2 1'1300 JUMPEii? A-F
M ZtJO/t.otYI()(}qIf2ao
JUMPE2A-B
3>
F02M3{)() JLJMPEilH-J
,..., 2OO/~/IOOOJI200
JLJ~P£E!J.l-l.
~\C'l<
Figure 10-16. Schematic Diagram, Sync Card, (Sh. 2 of 3)
CONTR;OI..
B1 JUMPER WIRING (pRESET COUNTER)
B1-1
M8-15
M8-H
~
GP~
Ii!-A£-12.
I-C!-I
M6·<. D-
2-"'5-/0
_SET
:
D:2
4
~
~~~~~Q~~~~voc
"
Figure 10-17. Schematic Diagram, Sync Card, (Sh. 3 of 3)
TO
Bl-16
-2
-3
-4
-9
-5
-10
-11
-12
-14
-13
-'1
-6
-16
-15
(Vee)
(OND)
(OND)
(OND)
(vee)
(vee)
(Vee)
(Vee)
TO
PRESET COUNTER
----"
32
8
16
64
4
~
~
(
2
1
gl
110
0
g2
69
~
~4
~
00
;g
\
128
PRESET TIMING REQUIREMENTS
6g
Model
1
M
M
M
M
Bl
UIl~J ~6
200
300/600
1000
1200
Count
176
75
44
39
Time In [J:sec
1466.0
625.0
366.5
325.0
Vee
lK
TO CSDS
DURA TION COUNTER
(:Q
~
""
....
:@
[~-----------~-----------~\
1
2
4
8
16
32
CSDS TIMING REQUIREMENTS
64 Not Used
6 go g2 k g ~ g g
11
D6
Model
M
M
M
M
200
300/600
1000
1200
Count
Time In {-Lsec
72
599.7
324.9
91. 6
75.0
39
11
9
lK
To program the counters, so that they are loaded with the complement of the
required count, proceed as follows:
"I", and strap pins 5, 6, 7 and/or 8 to create
8.
Let ground represent logic
the required count.
b.
Strap all other pins to Vee, at pins 13, 14, 15 and/or 16.
Figure 10-17A.
Preset and CSDS Counter Strapping
10-17A
1-1
o
I
1-1
00
IS
o
Cll-IO SGt.1
L - -_ _ _~..._--------.J
~~~~t&'=f::M ~4.
~FL.aG6D~
~~.!'Y~~
Figure 10-18. Assembly Diagram, Control Card
(Dwg. No. 1040619)
APPI
I
I
•
I
""r~ASS
f
Jro-Fk
Jr-p::..
,"
-
•
OV.cC
1-
8(/$Y
1m""
IIcc
.,..".
"'"
AV4
r
~"'"
~c_a~.~._.~C~~
__________
""
~~~
\
i
dl
~-E p-~S~~~~----------4------------------4--+-------+-~
"
/I
8
PCZ;<
yee
-
LIt.T~C"""""'T
I..A$T
Ma-/~
M6-C
___________/~/~CI'~'~O~________________________________________________________________----~~
c-~C-~'
P-------------~.~D3
~~D
"
4
Figure 10-19. Schematic Diagram, Control Card (Sh. 1 of 2)
-'NI-L
~
o
I
I:\:)
o
Figure 10-20. Schematic Diagram, Control Card (Sh. 2 of 2)
SECTION 11
SIGNAL MNEMONICS AND ABBREVIATIONS
MNEMONIC
DESCRIPTION
LOCATION
Vcc
+5 volts
MB-l
RTN
+5 volts return
MB-A
TST
TST RTN
SHIELD
TSTI
6A
Cl
6B
6c
6D
ONE DARK
POR
PCR
ZERO
RESET
ST6B
GPR
TST2
TSTR + POR
PRCLK
OSCLK
OSR
OSUCLK
ST 6 C
ST6D
IMST
1M
1M RTN
SHIELD
CR
OCR
DCKS
81CR
84CR
PICK COMMAND
PICK COMMA ND RTN
STOP
READY
Timing Strobe
Timing Strobe Return
Shield for Timing Strobe
Timing Strobe One
Clock Phase A
Basic Clock
Clock Phase B
Clock Phas e C
Clock Phase D
Read Station Any Dark
Power On Reset
Pick Control Reset
Preset Decode
Gated Reset Switch
Column Strobe Phase B
Good Pick Reset
Timing Strobe Two
Timing Strobe Reset
Preset Clock
Offset Clock
Offset Reset
Offset Up-Clock
Column Strobe Phase C
Column Strobe Phase D
Index Mark Strobes
Index Marks
Return for Index Marks
Shield for Index Marks
Column Reset
Zero Column Reset
Dark Check Strobes
81st Column Reset
84th Column Reset
Pick Command Input
Pick Command Input Return
Stop
Ready
J3-T
J3-S
J3-R
D9-9
MB-S
MB-14
MB-F
MB-K
MB-9
MB-6
MB-ll
MB-C
MB-N
MB-2
MB-4
MB-H
C8-9
MB-M
MB-15
MB-P
MB-J
MB-R
MB-V
MB-7
MB-T
J3-A
J3-B
J3-C
MB-B
MB-5
MB-8
MB-13
MB-D
J8-2
J8-3
MB-E
MB-16
11-1
SOURCE
5 volt power supply
(Mother Board)
5 volt power supply
(Mother Board)
Reluctance Pickup
Reluctance Pickup
Reluctance Pickup
Clock Card
Clock Card
Clock Card
Clock Card
Clock Card
Clock Card
Control Card
Error Card
Sync Card
Sync Card
Sync Card
Sync Card
Clock Card
Clock Card
Clock Card
Clock Card
Clock Card
Clock Card
Clock Card
Sync Card
Sync Card
Sync Card
Clock Card
Clock Card
Clock Card
Clock Card
Clock Card
Clock Card
Clock Card
Clock Card
Control Card
Control Card
Error Card
Error Card
LOCATION
MNEMONIC
DESCRIPTION
BUSY
PCLK
Vcc
Row 12
Row 11
Row 0
Row 1
Row 2
Row 3
Row 4
Row 5
Row 6
Row 7
Row 8
Row 9
ONE LIGHT
D12
D11
DO
D1
D2
D3
D4
D5
RTN
D6
D7
D8
D9
CSDS
STACKER FULL
STACKER FULL RTN
HOPPER EMPTY RTN
HOPPER EMPTY
STACK
STACK Vcc
RESET SW
RESET SW
PSET
LIGHT CHECK
DARK CHECK
HECK
PCK
STACK CHECK
J8..,1
Busy Output
MB-L
Pick Clock
J8-12
+5V to Read Sensor Array
J8-13
Read Sensor Input Row 12
J8-14
Read Sensor Input Row 11
J8-15
Read Sensor Input Row 0
J8-16
Read Sensor Input Row 1
J8-17
Read Sensor Input Row 2
J8-18
Read Sensor Input Row 3
J8-P
Read Sensor Input Row 4
J8-R
Read Sensor Input Row 5
J8-S
Read Sensor Input Row 6
J8-T
Read Sensor Input Row 7
J8-U
Read Sensor Input Row 8
J8-V
Read Sensor Input Row 9
MB-3
Read Station Any Light
J8-L
Data Row 12 Output
J8-M
Data Row 11 Output
J8-K
Data Row 0 Output
Data Row 1 Output
J8-H
J8-J
Data Row 2 Output
Data Row 3 Output
J8-N
Data Row 4 Output
J8-F
J8-E
Rata Row 5 Output
Data Drivers Return
J8-5
. J8-B
Data Row 6 Output
Data Row 7 Output
J8-D
Data Row 8 Output
J8-A
Data Row 9 Output
J8-C
Column Storage Data Strobe
MB-18
Stacker Full Switch
J4-1
Stacker Full Switch Return
J4-A
Hopper Empty Switch Return
J4-6
Hopper Empty Switch
J4-5
Stack Sensor Input
J4-C
Stack Sensor +5 volts
J4-2
Reset Switch Normally Open
J4-9
Reset Switch Normally Closed J4-7
Pick Check Set
MB-17
Light Check
C2-9
Dark Check
B2-9
Hopper Empty Check
B4-8
Pick Check
B2-5
Output Stacker Check
B5-8
11-2
SOURCE
Control Card
Control Card
Control Card
Control Card
Control Card
Control Card
Control Card
Control Card
Control Card
Control Card
Control Card
Control Card
Control Card
Control Card
Control Card
Control Card
Control Card
Control Card
Control Card
Control Card
Control Card
Control Card
Control Card
Control Card
Control Card
Control Card
Control Card
Control Card
Control Card
Sync Card
Error Card
Error Card
Error Card
Error Card
Error Card
Error Card
Error Card
Error Card
Sync Card
Error Card
Error Card
Error Card
Error Card
Error Card
MNEMONIC
DESCRIPTION
LOCATION
PCKI
HCK
SHUTDOWN STATUS
PORTR
STOP SW
RCKDR
PCKDR
SCKDR
HCKDR
HCK
HCK RTN
ERROR
ERROR RTN
MOCK
MOCK RTN
READY
READY RTN
RDYDR
STOP DR
PICK
PICK RTN
SHIELD
BUSY
Pick Check Indicator
Input or Output Hopper Check
Mode Switch Input
Power on Reset Trigger
Stop Switch Input
Read Check Lamp Driver
Pick Check Lamp Driver
Stack Check La.mp Driver
Hopper Check Lamp Driver
Hopper Check Output
Hopper Check Output Return
Error Output
Error Output Return
Motion Check Output
Motion Check Output Return
Ready Output
Ready output Return
Ready Lamp Driver
Stop Lamp Driver
Pick Driver Output
Pick Driver OUtput Return
Shield for PICK
Busy Signal
B2-2
C4-9
Sl-C
A5-12
J4-B
J4-P
J4-J
J4-N
J4-K
J4-H
J4-10
J4-E
J4-M
J4-F
J4-11
J4-D
J4-L
J4-R
J4-S
J5-A
J5-B
J5-C
MB-U
11-3
SOURCE
Error Card
Error Card
Error Card
Error Card
Error Card
Error Card
Error Ca.rd
Error Card
Error Card
Error Card
Error Card
Error Card
Error Card
Error Card
Error Card
Error Card
Error Card
Error Card
Error Card
Sync Card
Sync Card
Sync Card
Control Card
SECTION 12
ILLUSTRA TED PARTS BREAKDOWN
12-1
INTRODU CTION
This section contains, in breakdown order, the complete card reader's
assemblies, subassemblies, sub-subassemblies, detail parts of each, and
as sociated attaching parts.
The unit is divided into ten significant assemblies (refer to figure 12-2), each
illustrated, and provided with a parts listing keyed to the illustratIons. The
assembly parts breakdown illustrations and associated parts lists identify and
describe all parts of the 115 VAC 60 Hz and the 230 VAC 50 Hz models of the
Card Reader. Most parts are common to both models, when a part is common
only to the 50 Hz models, it is listed immediately after the equivalent part for
the 60 Hz model. In the MAIN FRAME assembly breakdown, for example,
(Figure 12-4), under index #16, two circuit breakers are listed for the same
index number.
16
00000188 •
00000185 •
CIRCUIT BREAKER, 8 amp (115 VAC, 60 Hz models)
CIRCUIT BREAKER, 6 amp (230 VAC, 50 Hz models)
Table 12-1 list the major assemblies and subassemblies and associated components of the card reader with the figure number in which they are listed and
illustrated. In the parts list, Documation parts or assemblies are identified by
an eight-digit number. Parts or assemblies that Documation purchases from
suppliers and used "as is" are identified by manufacturer part number. The
manufacturers' are identified by manufacturers codes in the description column
of the parts list. Table 12-2 list the names and addresses of all manufacturers'
codes used in the parts list.
12-2
HOW TO USE THE ILLUSTRA TED PARTS BREAKDOWN
a.
When the Part Number is not known (Figure 12-1):
1)
Refer to Figure 12-2 and locate the index number of the major
assembly from which the part was removed.
2)
In the major assembly listing of Figure 12-2 use the index
number to locate the figure number of the parts breakdown illustration
for that assembly.
3)
In the major assembly parts breakdown illustration, locate the
index number of the part.
12-1
4)
In the illustration part listing, use the index number to find the
part number, description and quantity per unit.
b.
When the assembly and/or the major component of which an item is part
of is known, refer to Table 12-1 to locate the figure number which illustrates and list the individual components or parts.
c.
To simplify the updating of Section 12 of this manual, only.QQQ.. numbered
pages are used.
12-1a
FIGURE 12-2 M-200 CARD READER
t
10
INDEX
NO.
t
NO.
Trim Group Assembl7
1W
2
Main Frame Assemb17
12-4
3
Control Panel Aeeembl7
12-6
•
Pick Support Assembl7
12-6
5
Drive Roller Support Aseembl7 '12-'
•
tr
10
CD
®
FIG.
ASSEMBLY
Drive Motor A•• emb17
Main Plate Aaaemb17
12-9
Vacuum Pump Assemb17
12-10
Power SuPP17 Aesemb17
12-11
Card File Aaeemb17
FIGURE 12-8 DRIVE MOTOR ASSEMBLY
12-8
12-12
In Figure 12-2, locate index number of major assembly from which part was removed.
DESCRIPTION
1234567
20092903
10092'904
UNITS
PER
VENDOR
ASSV PART NO.
DRI\'E MOTOR ASS£:o.rBLY - 115 VAC. &0 nertl
DRNE MOTOR A5::iULBLY ... 2'30 V.-\C. $0 Herb
-1
00000&82
11OTOn
-a
20127001
'0127002
..J
10121001
9GOl
PL"LLEY - 115 VAC, 60 H~rts
peLLEY - 2lIJ \' AC, 50 Hertz
(Attaching P:art" •
• SCREW, Set
(1~070)
RUOJl...
STASDOF
In Figure 12-2, use index number of maJor assembly to find figure number of major
assembly parts breakdown illustration.
In major assembly parts breakdown
illustratio~,
locate index number of part.
In the illustration parts list, use index number of part to find part number, description
and quantity per unit.
FIGURE 12-1 HOW TO USE ILLUSTRATED PARTS BREAKDOWN WHEN PART NUMBER IS NOT KNOWN
TABLE 12-1 QUICK REFERENCE LIST
Assembly
Figure
Page
12-3
TRIM GROUP ASSEMBLY
Fan
Capacitor
12-11a
12-11b
12-11b
12-4
MAIN FRAME ASSEMBLY
Switeh, Hopper Full
Circuit Breaker
Transformer, 12 Volt
Transformer, 24 Volt
Power Supply Assembly
Solenoid Driver Assembly
Vacuum Pump Assembly
Relay
Filter Assembly
Connector Panel Assembly
Rectifier, Diode Bridge
Capacitor, 17. 5 /-Lf
Capacitor, 10/-Lf
Capacitor, 4600 /-Lf
Spring
Fuse
Solenoid Driver Assembly
12-13c
12-13c
12-13c
12-13c
12-13c
12-13d
12-13e
12-13e
12-13e
12-13e
12-13e
12-13e
12-13f
12-13f
12-13f
12-13f
12-13f
12-13f
12-5
CONTROL PANEL ASSEMBLY
Lamp
12-15a
12-15a
12-6
PICK SUPPORT ASSEMBLY
Switch Assembly, Hopper Empty
Sector Assembly
Drive Roller, 2nd Pick Drive Assembly
Stack Drive, 1st Pick Drive Assembly
12-17a
12-17a
12-17a
12-17a
12-17b
12-7
DRIVE ROLLER SUPPORT ASSEMBLY
First Stack Drive Assembly
Second Stack Drive Assembly
12-19a
12-19a
12-19a
12-8
DRIVE MOTOR ASSEMBLY
Motor
Pulley
12-21a
12-21a
12-21a
'12-5
TABLE 12-1 QUICK REFERENCE LIST (CONT'D)
Figure
Assembly
Page
12-9
MAIN PLATE ASSEMBLY
Drive Motor Assembly
Solenoid Assembly
Pick-up
Timing Disc Assembly
Pulley
Belt
Capacitor, 2 p.f
Capacitor, 3 p.f
Read/Light Station Assembly
12-23b
12-23b
12-23c
12-23c
12-23c
12-23c
12-23c
12-23c
12-23c
12-23d
12-10
VACUUM PUMP ASSEMBLY
Motor
Blower
Belt
Pulley
12-25a
12-25a
12-25a
12-25a
12-25a
12-11
POWER SUPPLY ASSEMBLY
P. C. Board Assembly
12-27a
12-27a
12-12
CARD FILE ASSEMBLY
Connector, Single Row
Connector, Tab
12-29a
12-29a
12-29a
12-13
P. C.ASSEl\IillLY - Control Card
12-31a
12-14
P. C. ASSEMBLY - Sync Card
12-33a
12-15
P. C. ASSEMBLY - Clock Card
12-35a
12-16
P. C. ASSEMBLY - Error Card
12-37a
12-5a
TABLE 12-2 LIST OF MANUFACTURERS
CODE
MANUFACTURER
CODE
MANUFACTURER
00779
Amp, Incorporated
P. O. Box 3608
Harrisburg, Pennsylvania
05063
Hamilton - Avnet Electronics
70 State Street
Westbury, N.Y. 11590
17105
01121
Allen Bradley Company
1201 2nd Street
Milwaukee, Wisconsin 53212
05245
Components Corporation
2857 N. Halsted Street
Chicago, Illinois 60657
01295
Texas Instruments, Incorporated
Semi-Conductor Components Division
13500 North Central E",-pressway
Dallas, Texas 75231
05411
DuPage Manufacturing Company
2250 Curtiss Avenue
Downers Grove, nUnois 60515
05972
01634
Aluminum Co. of America
1501 Alcoa Building
Pittsburg, Pennsylvania 15219
Loctite Corporation
705 N. Mountain Road
Newington, Connecticut
01963
Cherry Electrical Products Corp.
3600 Sunset Avenue
Wa.ukegan, illinois 60085
02697
Parker Seal Company
2360 Palumbo Drive
Lexington, Kentucky 40509
02735
RCA Corporation
Solid State Division
Route 202
Somerville, N.J. 08876
03597
General Electric Company
Turbine Division of Apparatus Group
Schenectady, N. Y.
03786
Industrial Enterprises, Incorporated
5900 N. Telegraph Road
Dearbon, Michigan 48127
06229
Electrovert, Incorporated
86 Hartford Avenue
Mt. Vernon, N. Y. 10553
06383
Panduit Corporation
17301 Ridgeland
Tinley Park, minois
Amaton Electronic Hardware
Division of Mite Corporation
446 Blake Street
New Haven, Connecticut
07108
R. & J. Dick Co., Inc.
912 E. 5th Street
Muscatine, Iowa 52763
07137
Tee, Incorporated
6700 Washington A venue
South Eden Prairie, Minn.
55343
Fairchild Semi-Conductor
464 Ellis Street
Mountain View, California
94040
Minnesota Mining and Mfg. Company
Center Street
St. Paul, Minnesota 55101
04713
Motorola
Semi-Conductor products, Inc.
5005 East McDowell Road
Phoenix, Arixona 85008
04866
Nylok - Detroit
1893 Barrett Road
Troy, Michigan 48084
12-7
60477
06540
07263
04963
06111
07355
AirPax Electronic, Inc.
Central Engineering Division
6601 N. W. 19th Street
Ft. Lauderdale, Florida 33310
07446
Engler Instrument Company
250 Culver Avenue
Jersey City. N.J. 07305
TABLE 12-2 LIST OF MANUFACTURERS (CONT'D)
CODE
MANUFACTURER
CODE
MANUFACTURER
07679
Hardware Specialty Co., Inc.
48 - 75 36th Street
Long Island City, N. Y. 11101
12505
Air Product/Chemical Incorporated
P. O. Box 1231 R
Hanover A venue
Morristown, N. J. 07960
07707
USM
"Pop" Rivet Division
510 River Road
Shelton, Connecticut 06484
12617
Hamlin, Incorporated
Grove and Lake Streets
Lake Mills, Wisconsin 53551
13103
Thermalloy Company
8717 Diplomacy Row
Dallas, Texas 75247
14519
Designatronics, Incorporated
Stock Drive Products
55 South Denton Avenue
New Hyde Park, N. Y. 11040
14563
Neuman & Company
8136 N. Lawndale
Skokie, minois 60076
14927
Kubar, Incorporated
21 Erie
Cambridge, Massachusetts
07886
National Radio Co., Incorporated
Commercial Products Dhision
78 Stone Place
Melrose, Massachusetts 02176
08524
Deutsch Fastener Corporation
70001 West Inperial Highway
Los Angeles, California 90045
08806
General Electric. Company
Miniature L:Jmp Department
Nela Park
Cleveland, Ohio 44112
09021
Speer Carbon Company
Speer Resistor Division
A Division of Air Reduction Co., Inc.
Foster Brook Road
Bradford, Pennsylvania 16701
09023
09353
09922
10108
11214
11253
Cornell - Dubilier
Division of Fed. Pac. Electric Co.
2526 Dalrymple
Sanford, North Carolina 27330
C. & K. Components, Incorporated
103 ~1orse Street
Watertown, Massachusetts i)2172
Burndy Corporation
Richards A venue
Norwalk, Connecticut
14936
General Instrument Corporation
P:O. Box 600
600 W. John Street
Hicksville, New York 11802
16059
Devcon Corporation
59 Endicott Street
Danvers, Massachusetts
18324
Hardigg Industries, Incorporated
N. Main Street
South Deerfield, Mass. 01373
Signetics Corporation
811 E. Arques
Sunnyvale, CalifOrnia
01923
94086
18583
Curtis Instruments, Incorporated
200 Kisco Avenue
Mount Kisco, N. Y. 10549
18655
Computer Products
1400 N. W. 70th Street
Ft. Lauderdale, 1- lorida
06852
Hurst Manufacturing Corporation
64 East Princeton Road
Princeton, India'::- 47570
02139
18677
Elrad Manufactuling Company
4300 N. California Avenue
Chicago, Illinois 60618
12-7a
33307
Scanbe Manufacturing Corporation
3445 Fletcher Avenue
EI Monte, California 91731
TABLE 12-2 LIST OF MANUFACTURERS (CONTID)
CODE
MANUFACTURER
CODE
MANUFACTURER
18714
RCA Corporation
SoUd State Division
Fostoria Road
Findley, Ohio 45840
27264
Molex Products Company
5224 Katrine A venue
Downers Grove, nIinois 60515
28523
18788
General nIumination, Incorported
2233 University Avenue
St. Paul, Minnesota 55114
Gulf Electronics Corporation
1740 N. W. 69th Avenue
Miami, Florida 33148
28818
19070
Eastern Air Devices, Incorporated
385 Central Avenue
Dover, New Hampshire 03820
Soundcoat Co., Incorporated
515 Madison Avenue
New York, N. Y. 10010
29227
19401
Gladwin Industries, Incorporated
Gladwin Educational Division
P. O. Box 80545/1940 Will Ross Ct.
Chamblee, Georgia 30341
Herco
Hecht Rubber Corporation
482 - 484 Riverside A venue
Jacksonville, Florida 32202
29440
19701
Electra/Midland Corporation
P.O. Box 760
Mineral Wells, Texas 76067
Winfred - Berg
499 Ocean Avenue
East Rockaway, L. I., N.Y.
33062
20772
Spectronics, Incorporated
24 Kinkle Street
Westbury, N.Y. 11590
Fairport, New York
Electro - Space Fabricators, Inc.
101 - 125 Centre Avenue
Topton, Pennsylvania 19562
34936
23880
23936
24161
Ferronics, Incorporated
66 N. Main Street
33498
22589
11518
Stanford Applied Engineering
340 Martin Avenue
Santa Clara, California 95050
14450
Automation Components
One Short Avenue
Peckville, Pannsylvania
18452
Nashua Corporation
44 Franklin Street
Naushua. New Hampshire
03060
46384
William J. Purdy Company
Pamotor Division
770 Airport Boulevard
Burlingame, California 94010
Penn Eng. and Mfg. Corporation
Old Easton Highway
Doylestown, Pennsylvania 18901
50521
Gates Rubber Company
999 South Broadway
Denver, Colorado 80217
HEI, Incorporated
Johnathan Industrial Center
Chaska, Minnesota 55318
50522
Monsanto
Electronic Special products
10131 Bubb Road
Cupertino, California 95014
55719
Snap - On Tools Corporation
8026 28th A venue
Kenosha, Wisconsin 53140
24211
Grisby - Barton, Incorporated
3800 Industrial Drive
Rolling Meadows, D1inois 60008
27014
National Semi-Conductor Corporation
2950 San Ysidro Way
Santa Clara, California 95051
12-7b
TABLE 12-2 LIST OF MANUFACTURERS (CONT'D)
CODE
MANUFACTURING
56289
Sprague Electric Company
North Adams, Massachusetts
60361
64475
65083
70276
70854
70903
71034
71279
71590
71744
71785
CODE
MANUFACTURING
71838
Toro Manufacturing Company
8111 Lyndale Avenue South
Minneapolis, Minnesota 55420
Standard Pressed Steel Company
Industrial Fastener Division
4444 Lee Road
Cleveland, Ohio 44128
71984
Welch Allyn, Incorporated
Jordan Road
Skaneateles Falls, New York
Dow Corning Corporation
South Saginaw Road
Midland, Michigan 48641
72136
Elmenco
South Park and John Streets
Willimantic, Connecticut 06226
72619
Dialight Corporation
60 Stewart Avenue
Brooklyn, New York
01247
13153
Westinghouse Electric Corporation
Lamp Division
MacArthur A venue
Bloomfield, New Jersey 07003
11237
Allen Manufacturing Company
P.O. Box 570
Hartford, Connecticut 06101
72653
G. C. Electronics Company
400 S. Wyman Street
Rockford, illinois 61101
Barden/NMB
200 Park A venue
Danbury, Connecticut
73138
Belden Corporation
415 S. Kilpatrick Avenue
Chicago, lllinois
Beckman Instrument, Incorporated
Heliport Division
2500 Harbor Boulevard
Fullerton, California 92634
74364
Bliley Electric Company
2545 W. Grandview Blvd.
Erie, Pennsylvania 16512
Eastman Chemical Product, Inc.
Eastman Road
Kingsport, Tennessee 37662
74545
Hubbell Har:vey, Incorporated
State Street and Bostwick Avenue
Bridgeport, Connecticut 06602
75511
Centralab Electric
5757 N. Greenbay Avenue
Milwaukee, Wisconsin 53201
Lamb Electric/Ametek
627 Lake Street
Kent, Ohio 44240
75915
Chicago Miniature Lamp Works
4433 Ravenswood A venue
Chicago, Illinois 60640
Littlefuse, Incorporated
800 E. Northwest Highway
Des Plaines, illinois 60016
76005
Cinch Manufacturing Company
Division of T. R. W., Inc.
Elk Grove Village, illinois
Lord Manufacturing Company
1635 West 12th Street
Erie, Pennsylvania 16512
76599
The Murray Corporation
Industrial Park
CockeYSville, Maryland 21030
06810
Cambion
445 Concord Avenue
Cambridge, Massachusetts
02138
12-7c
TABLE 12-2 LIST OF MANUFACTURERS (CONT'D)
CODE
MANUFACTURER
CODE
MANUFACTURER
79023
United Elastic Company
Division of Stevens, J. P. &: Co., Inc.
P. O. Box 391 50 Payson Avenue
East Hampton, Massachusetts 01027
81840
Ledex, Incorporation
Ledex Division
123 Webster Street
Dayton, Ohio 45402
79136
Waldes Kohinoor, Inc.
47 - 16 Austel Place
Long Island, N. Y. 11101
83014
The Hartwell Corporation
9035 Venice Blvd.
Los Angeles, California 90034
79405
Wood Electric Corporation
Danvers Industrial Park
Danvers, Massachusetts 01923
83259
Parker Seal Company
10567 Jefferson BIYd.
Culver City, California
80089
Essex International
Controls Division
131 Godfrey Street
Logansport, Indiana
83330
H. H. Smith, Incorporated
812 Snedicker Avenue
Brooklyn, New York 11207
83584
80103
Lambda Electronics Corporation
515 Broad Hollow Road
Huntington, New York 11749
Drive-Lok, Incorporated
1140 Park Avenue
Sycamore, Dlinois 60178
84830
80183
Sprague Products Company
Beaver Street
North Adams, I\'[assachusetts
Lee Spring Company
30 Main Street
Brooklyn, New York 11201
85446
80223
T. R. W. Electronic Components
United Transformer Division
150 Varick Street
New York, N. Y. 10013
Bokers, Incorporated
3104 Snelling Ayenue
Minneapolis. Minnesota
86577
Bournes, Incorporated
1200 Columbia Avenue
RiverSide, California 92507
Precision Metal Prod. of l\Ialden, Inc
41 Elm Street
stoneham, Massachusetts 02180
87034
Air Reduction Co. t Incorporated
150 E. 42nd 9i:reet
New York, N. Y. 10017
Marco - Oak Industries, Incorporated
P.O. Box 4011 207 S. Helena
Anaheim, California 92803
87730
Ametek Hunter Spring
1 Spring Avenue
Hatfield, Pennsylvania 19440
United Mineral and Chemical Corp.
129 Hudson Street
New York, N. Y.10013
88132
Winchester Electronics
Main Street and Hillside Avenue
Oakville, Connccticut 06779
Goodyear Rubber Company
25 Hamlin
Middletown, Co~ecticut 06457
91506
Augat, J ~:lrporated
33 Perry Avenue
Attleboro, Massachusetts
80294
80382
80545
81312
81541
Airpax Electronics, Incorporation
Woods Road
Cambridge, Maryland 21613
91637
12-7d
90231
55406
02703
Da.le Electronics, Incorporated
P.O. Box 609
Columbus, Nebraska 68601
TABLE 12-2 LIST OF MANUFACTURERS (CONTI D)
CODE
MANUFACTURER
CODE
MANUFACTURER
91662
Elco Corporation
Maryland Road and Computer Avenue
Willow Grove, Pennsylvania 19090
Dearborn Wire and Cable Company
9299 Evenhouse
Rosemont, nlinois
92194
Alpha Wire
711 Lidgerwood Avenue
Elizabeth, New Jersey
Extron Corporation
P.O. Box 10725
Knoksville. Tennessee
Raytheon Company
Components Division
Industrial Components Operation
465 Centre Street
Quincy, Ma.ssachusetts 02169
Merit Fastners
127 Atlantic Boulevard
Maitland. Florida 32951
94144
94222
Southco, Incorporated
Lester, Pennsylvania 19113
94452
Berkley and Company
Highway 9 and 71
Spirit Lake, Iowa 51360
95275
Vitramon, Incorporated
P.O. Box 544
Bridgeport, Connecticut
37919
Millitary Packing Company
P.O. Box 460
Orlando, Florida 32802
Motronics Corporation
Riverside Industrial Park
Little Falls, N. Y. 13365
National Gard. Product, Incorporated
P. O. Box 7353
Memphis, Tennessee 38107
06601
Pipeline Service Company
Weckesser Co., Incorporated
4444 West Irving Park Road
Chicago, IllinoiS 60641
3240 N. Manheim Road
Master Specialties Company
1640 Monrovia
Costa Mesa, California 92627
1200 E. Broadway
96881
Thomson Industries, Incorporated
1029 Plandome Road
Manhasset, New York 11030
2920 Eunice Avenue
Orlando, Florida 32802
99743
IMC Magnetics Corporation
6058 Walker Avenue
Maywood, California 90270
95987
Franklin Park,1l11nois
60131
Potter - Brumfield
96182
Princeton,. Indiana
47470
Reynolds Aluminum Supply Company
Sunset Wire and Cable, Incorporated
P.O. Box 224
Cape Canaveral, FlOrida 32930
The Torrington Company
Clinton Bearing Plant
Clinton, South Carolina
Active and Passive Components
121 - 18 Du Pont Street
Plainview, N. Y. 11803
Thorgren Tool and Moulding Company
110 Evans A, ',lue
Valparaiso, indiana 46383
Consolidated Wire and Cable
1637 South Clinton
Chicago, Illinois 60616
Tri - Power, Incorporated
Akron, Ohio
12-7e
TABLE 12-2 LIST OF MANUFACTURERS (CONT'D)
CODE
MANUFACTURER
CODE
Voyce - Legier
523 N. W. 28th Street·
Miami, Florida 33127
12-7f
MANUFACTURER
7
2
10
9
INDEX
ASSEMBLY
FIG.
NO.
1
Trim Group Assembly
12-3
2
Main Frame Assembly
12-4
3
Control Panel Assembly
12-5
"
Pick Support Assembly
12-6
5
Drive Roller Support Assembly
12-7
8
Drive Motor Assembly
12-8
7
Main Plate Assembly
12-9
8
Vacuum Pump Assembly
12-10
9
Power Supply Assembly
12-11
Card File Assembly
12-12
NO.
8
10
M2
FIGURE 12-2 M-200 CARD READER
12-9
--o
M2
FIGURE 12-3 TRIM GROUP ASSEMBLY
12-11
FIGURE 12-3 TRIM GROUP ASSEMBLY
FIG.
INDEX PART
NO.
NUMBER
DESCRIPTION
1234567
20059001
20059002
TRIM GROUP ASSEMBLY - 115 VAC, 60 Hertz
TRIM GROUP ASSEMBLY - 230 VAC, 50 Hertz
-1
40076801
•
-2
-3
40053503
40052501
-4
-5
00000114
20043801
-6
-7
00000382
00000413
-8
-9
-10
-11
-12
00000296
20028004
00000558
REF
20062301
-13
-14
-15
00000096
00000062
20102301
-16
-17
00000114
00000301
MAIN FRAME ASSEMBLY
1
COVER ASSEMBLY
• COVER
(Attaching Parts)
SCREW, Button Head BLK 6 - 32 x 1/4
BAR, Tamp
(Attaching Parts)
SCREW, Machine, Pan Head 8 - 32 x 3/8
CONTROL PANEL ASSEMBLY (Fig. D-5)
(Attaching Parts)
SCREW, Button Head BLK #6 - 32 x 3/8
TAG, Series
FOAM DAMPING, 1/4" x 4" x 10" Voyce-Legier
RUBBER 1//6 x 1" x 7 1/2"
GUIDE, Stacker
(Attaching Parts)
SCREW, Button Head, #4 - 40 x 1/4
NUT, Hex #4 - 40
CARD DEFLECTOR
(Attaching Parts)
•
SCREW, Machine, Button Head #6 - 32 x 1/4
• NUT, Hex #6 - 32
1
-18
-19
-20
-21
Not
Not
Not
Not
-22
Not Used
-23
-24
-25
20061601
20042701
20042801
-26
40055701
40082801
-27
40050101
40082901
-28
00000114
•
•
STACK BUMPER PLATE ASSEMBLY
• PLA TE, Stack Bumper
RUBBER BUMPER
•
1
4
1
2
1
PANEL, Rear - 115 VAC, 60 Hertz
PANEL, Rear - 230 VAC, 50 Hertz
(Attaching Parts)
SCREW, Button Head BLK ~6 - 32 x 1/4
12-11a
DPA-7164B
2
1
1
1
1
2
2
1
2
Used
Used
Used
Used
REAR :?ANEL ASSEMBLY - 115 VAC, 60 Hertz
REAR PANEL ASSEMBLY - 230 VAC, 50 Hertz
•
UNITS
PER
VENDOR
ASSY PART NO.
1
.1
1
1
1
1
1
6
GP-2
FIGURE 12-3 TRIM GROUP ASSEMBLY (CONT'D)
FIG.
INDEX PART
NO.
NUMBER
-29
DESCRIPTION
1 2 3 4 5 6 7
·
00000325
00000035
00000499
00000127
00000164
00000059
00000058
00000326
00000035
00000449
00000087
00000530
00000452
00000156
00000059
00000058
-30
-31
00000323
00000473
-32
-33
-34
-35
00000302
00000295
00000301
00000324
-36
-37
-38
00000356
00000301
00000842
-39
-40
-41
00000343
00000301
00000558
-42
20028104
20028102
-43
00000488
-44
20014801
20087902
FAN - 115 VAC, 60 Hertz (23936)
W/INTEGRAL COMPONENTS
CONTACT, Pin (00779)
HOUSING, Pin (00779)
TUBING, Heatshrink 1/8 Dia. x 1/2" (92194)
WIRE, Elec. AWG 20 T\VPR BLK-WHT 3" (92194)
MOUNT, Cable Tie (06383)
TIE, Cable (06383)
FAN - 230 VAC, 50 Herts (23936)
W/INTEGRAL COMPONENTS
CONTACT, Pin (00779)
HOUSING, Pin (00779)
TUBING, Heatshrink 3/32 Dia. x 1" (92194)
RECEPTACLE, Faston (.250) (00779)
HOUSING, Receptacle (00779)
WIRE, Elec. A WG 18 TWPR BLK 6 1/2-WHT 7"
(92194)
MOUNT, Cable Tie (06383)
TIE, Cable (06383)
4600
2
1
2
1
1
1
1
60618-1
1-408319-0
FIT-105
1854/19
TA158
SSTIM
2050
2
1
1
3
3
60618-1
1-408319-0
FIT-105
61370-1
480416-0
1
1
1
1854/19
TA158
SSTIM
1
1
5503
65-175
4
4
4
1
5501
1
1
1
GP-2
4
MS-21318-9
CORD, Power, 115 VAC, 60 Hertz
CORD, Power, 230 VAC, 50 Hertz
1
1
· ·
·
1
SCREEN, Fan (23936)
GUARD, Finger, Metal Fan (IMC)
(Attaching Parts)
SCREW, Pan Head #6 - 32 x 1/2
WASHER, Flat #6
NUT, Hex#6 - 32
BRACKETS, Mtg (Pair) (23936)
(Attaching Parts)
SCREW, Machine, Flat Head #6 - 32 x 1/4
NUT, Hex #6 - 32
CAPACITOR, 2.0 Jlf 370 VAC and Clamp
(230 VAC, 50 Hertz Model only) (56289)
(Attaching Parts)
SCREW, Button Head BLK 6 - 32 x 3/8
NUT, Hex #6 - 32
FOAM, Damping 7 3/8 x 3 3/8 (115 VAC, 60 Hertz only)
Joyce Legier
TAG, Model Information - 115 VAC, 60 Hertz
TAG, Model Information - 230 VAC, 50 Hertz
(Attaching Parts)
PIN, Drive
· ·
· · .
·
·
UNITS
VENDOR
PER
ASSY PART NO.
·.
·
·
· ·
~
0
(7)
IJ':>
0
N
.-t
.-t
...:l
.......
~
12-11b
4
4
1
200P1901TP
2
2
FIGURE 12-3 TRIM GROUP ASSEMBLY. (CONTID)
FIG.
INDEX PART
NO.
NUMBER
-45
-46
-47
30158601
30158401
30158301
-48
";49
-50
-51
-52
00000346
10011901
20158501
00000518
00000431
-53
-54
00000065
00000272
DESCRIPTION
1 2 3 4 5 6 7
·
FOLLOWER ASSEMBLY
PLATE, Card Follower
SUPPORT, Follower
(Attaching Parts)
SCREW, Flat Head, Phillips, #4-40 x 1/4
SHAFT, Roller - Card Follower
ROLLER, Card Follower
COMPOUND, "0" Ring C-557-7, 1/2I.D. (83259)
SPACER, Shaft. 004 (29440)
(Attaching Parts)
WASHER, Flat #4
SCREW, Pan Head, Phillips, #4-40 x 5/8
·.
··
·
.
.
i
-
12-11c
UNITS
VENDOR
PER
ASSY PART NO.
1
1
1
2
4
4
4
4
4
4
5-230
852-27
34
........
I
45 (FIG. 12-11)
39,40
55 (FIG 12-4,SHT 2)
5,6,7,8,9
63,64
,
I
27
:.~
•
'@@
~~60,61,62
~
,
23, 24,25,26
'"-,",,,'?'"-<1
1"",
71i--:--+~-:;~of!J::::2:::::"---__ 90 (FIG.12 -9), 91,91A
I
37;38
I
lr
59
!-77
85,86,87,88,89
84
78
75
76
M2
FIGURE 12-4 MAIN FRAME ASSEMBLY (Sheet 1 of 3)
12-13
58
(FIG.12-IO)
97
9'~
I
III
M2
FIGURE 12-4 MAIN FRAME ASSEMBLY (Sheet 2 of 3)
12-13a
--,.---~-
!
~
('oj
\\
I
('oj
~
I&.
\
\
\
\
\
\
II)
10
~-E
......
o
0".>
<0
tO
.."
.-<
......
is'
;n-
.,.
.,.iii
(11
O
C\I
lQ
t-
O
.."
.,.,..
.-<
......
M2
FIGURE 12-4 MAIN FRAME ASSEMBLY (Sheet 3 of 3)
12-13b
FIGURE 12-4 MAIN FRAME ASSEMBLY
FIG.
INDEX PART
NO.
NUMBER
DESCRIPTION
1 2 3 456 7
UNITS
PER
VENDOR
ASSY PART NO.
40075205
40076901
MAIN FRAME ASSEMBLY, 115 VAC, 60 Hertz
MAIN FRAME ASSEMBLY, 230 VAC, 50 Hertz
-1
40076801
· BASE PLATE
1
-2
20043001
·
1
-3
-4
00000345
00000062
·· ·
·
2
2
-5
-6
20042901
00000313
·
1
1
-7
-8
-9
00000296
00000272
00000062
·
PLA TE, Spring
(Attaching Pa.rts)
SCREW, Machine Flat Head, #4 - 40 x 1/2
NUT, Hex #4 - 40
BRACKET, Switch Mounting
SWITCH, Hopper Full (01963)
(Atta.ching Parts)
SCREW, Pan Head, #6 - 32 x 3/8
SCREW, Machine, Pan Head #4 - 40 x 5/8
NUT, Hex #4 - 40
··
·
-10
Not Used
-11
-12
Not Used
Not US.ed
-13
-14
400553D
30052001
··
-15
00000382
··
-16
00000188
00000185
·
·
2
2
2
CARD FILE ASSEMBLY (Figure 12-12)
BAR SPACER
(Attaching Parts)
SCREW, Pan Head #8 -32 x 3/8
1
1
CIRCUIT BREAKER, 8 amp - 115
CIRCUIT BREAKER, 6 amp - 230
(Attaching Parts)
SCREW, Machine Flat Head #6
SCREW, Button Head #6 - 32 x
VAC, 60 Hertz (07355)
VAC, 50 Hertz (07355)
1
1
- 32 x 1/4
1/4
1
1
2
00000356
00000114
··
··
20015602
20073902
·
·
-20
-21
-22
00000299
00000294
00000382
··
··
··
'2
2
2
-23
20015502
20074002
·
1
1
-17
-18
-19
-24
M2
00000299
TRANSFORMER, 12 Volt - 115 VAC, 60 Hertz
TRANSFORMER, 12 Volt - 230VAC, 50 Hertz
. (Attaching Pa,rts)
NUT, Hex #8 - 32
WASHER, Flat #8
SCREW, Machine, Pan Head #8 - 32 x 3/8
TRANSFORMER, 24 Volt - 115 VAC, 60 Hertz
TRANSFORMER, 24 Volt - 230 VAC, 50 Hertz
(Attaching Parts)
NUT, Hex #8 - 32
·
··
12-130
E21-85HX
1
.
2
UPGI-I-6-2-802
UPGI-I-6-2-602
FIGURE 12-4 MAIN FRAME ASSEMBLY (CONT'D)
FIG.
INDEX PART
NO.
NUMBER
DESCRIPTION
1 2 3 4 5 6 7
UNITS
PER
VENDOR
ASSV PART NO.
-25
-26
00000294
00000382
··
-27
20042201
·
PLATE, Trim
1
-28
20041701
1
-29
-30
-31
00000294
00000299
30041603
·
··
-32
00000379
BRA CKET, Stack Spring
(Attaching Parts)
WASHER, Flat #8
NUT, Hex #8 - 32
SUPPORT ASSEMBLY, Stacker Bearing
(Attaching Parts)
SCREW, Machine Pan Head #8-- 32 X 1/2
-33
20053801
-34
00000297
-35
20039801
-36
00000382
-37
20039301
-38
00000498
-39
30046401
-40
00000382
-41
30054001
·
-42
30040201
-43
-44
00000345
00000062
Y, Stacker
· TRA
(Attaching Parts)
Machine, Flat Head #4 - 40 x 1/2
· · SCREW,
NUT, Hex #4 - 40
··
-45
30029505
·
-46
-47
-48
-49
00000296
00000567
00000295
00000301
·
··
· ·
·
·
·
WASHER, Flat #8
SCREW, Machine, Pan Head #8 - 32 x 3/8
2
2
1
1
1
·
2
BUSHING, Retaining
(Attaching Parts)
SCREW, Set #8 - 32 x 3/16
1
·
1
PLA TE, Support
(Attaching Parts)
SCREW, Machine Pan Head #8 - 32 x 3/8
1
FASTENER, Bracket
(Attaching Parts)
RIVET, Pop
1
·
2
COVER, Rear, Stacker
(Attaching Parts)
SCREW, Machine Pan Head, #8 - 32 x 3/8
1
·
2
ROD, Stack Follower
1
POWER SUPPLY ASSEMBLY (Figure 12-11)
(Attaching Parts)
SCREW, Machine Pan Head #8-32 x 1/2
WASHER, Nylon (95987)
WASHER, #6
NUT #6 - 32
1.42
12-13d
1
SD44BS
1
3
3
1
4
8
4
4
SW-6-NA
FIGURE 12-4 MAIN FRAME ASSEMBLY (CONT'D)
FIG.
INDEX PART
NO.
NUMBER
20040701
·
-51
00000379
··
-52
-53
00000487
00000132
-54
00000498
-55
-56
30045801
00000479
-57
00000498
-58
40033302
40033306
-59
00000379
·
-60
00000109
00000112
·
-61
-62
00000303
00000294
-63
20072001
-64
00000498
-65
30058201
30082001
40057601
40082701
'"
-66
-67
00000296
00000476
20114401
wer
ohm.:: 10% 1/4W
· RESISTOR, 10K_+10% 1/2W
· TRANSISTOR, Power NPN (10295)
(01295)
· DIODE
HEATSINK (13103)
· (Attaching Parts)
SCREW, Machine Pan Head, #4-40 x 3/8
· WASHER,
Torque (supplied with item 103)
NUT, Plain Hex #4-40
.
· . COMPOUND, Heatsink (13103)
· CAPACITOR, 6200 p.f, 75VDC (03597)
· WIRE,
Electrical AWG 18 BRN 13" (92194)
·· WIRE, Electrical
AWG 18 TP ORN-BRN 14" (92194)
WIRE, Electrical AWG 18 TP WHT-WHT 16" (92194)
·
7" (92194)
·· CABLE,
RECEPTACLE, Faston (.250) (00779)
TERMINAL, Ring Tongue (00779)
· CONTACT,
(00779)
· HOUSING, PinPin (00779)
· CONTACT, Connector, Ampleaf (00779)
·
·
·
·
·
··
·
·
··
·
··
··
·
··
·
·
··
·
·
·
·
·
CONTA CT, Connector, Ampleaf (00779)
TUBING, Heat Shrink 3/16 x 1/2 (92194)
TUBING, Heat Shrink 3/32 x 1/2 (92194)
HOUSING, Receptable (00779)
CABLE ASSEMBLY, Fan
CABLE ASSEl\ffiLY, Drive Motor
CABLE ASSEMBLY, Bridge to Cap
CABLE ASSEMBLY, Vacuum Pump Relay
CABLE ASSEMBLY, Vacuum Pump Cap.
CABLE ASSEMBLY, Relay
CABLE ASSEMBLY, Hopper Full
CABLE ASSEMBLY, Hopper Empty
CABLE ASSEMBLY, Fuse
WIRING DIAGRAM - 115 VAC, 60 Hertz
WIRING DIAGRAM - 230 VAC, 50 Hertz
ADHESIVE, Pliobond (88132)
COMPOUND, Heatsink (13103)
LOCTITE, Grade C
TIE, Cable (06383)
MOUNT, Cable (06383)
SCREW, Cap Socket Head, #4-40 x 5/8
WASHER, Flat #4
NUT, Hex #4-40
BRACKET, Cover Support
NUT, Hex #8
BRACKET, Support
BRACE, Support
WASHER, Flat #8
·
·
··
·
·
·.
··
·
··
M2
12-13g
UNITS
PER
VENDOR
ASSY PART NO.
1
1
1
1
1
1
1
7717-145
2N2102
RC07GF271K
RC20GF103K
TP41C
1N4003
6107A-14
1
1
1
AIR
1
1
1
1
1
2
1
2
2
2
1
2
1
2
86F177M
1857/19-7
1858/A
1857/19-1
3221-1-2
61370-1
32949
60818-1
1-480319-0
42839-4
42840-3
FIT-105
FIT-105
480416-0
1
1
1
1
1
1
1
1
1
AIR
A/R
A/R
16
8
4
4
4
1
1
1
1
4
SSTIM
TA1S8
FIGURE 12-4 MAIN FRAME ASSEMBLY (CONTID)
FIG.
INDEX PART
NO.
NUMBER
-148
-149
00000299
00000296
DESCRIPTION
1 2 3 4 5 6 7
..
.
.
NUT, Hex #8-32
SCREW, Machine Pan Head, #8-32 x 3/8
M2
12-13h
UNITS
VENDOR
PER
ASSY PART NO.
4
2
I
I
I
I
2
~
M2
FIGURE 12-5 CONTROL PANEL ASSEMBLY
12-15
FIGURE 12-5 CONTROL PANEL ASSEMBLY
FIG.
INDEX PART
NO.
NUMBER
00000413
-1
-2
00000318
DESCRIPTION
1234567
CONTROL PANEL ASSEMBLY (07137)
CONTROL PANEL (07137)
LAMP, Incandescent, 6V @ .2A T-l 3/4 Mid FIg. Base
(18788)
.
.
"'2
12-153.
UNITS
VENDOR
PER
ASSY PART NO.
DPA 7164B
1
7
381
13
~/
31
30,,®
32
1
"®
I
I
I
""
" ">
/
/
/
/
/
5
/'
/'
~3
M2
FIGURE 12-6 PICK SUPPORT ASSEMBLY
12-17
FIGURE 12-6 PICK SUPPORT ASSEMBLY
FIG.
INDEX PART
NO.
NUMBER
UNITS
PER
VENDOR
ASSY PART NO.
DESCRIPTION
1 2 3 4 5 6 7
40047102
PICK SUPPORT ASSEMBLY
-1
40070902
·
SUPPORT, Pick
1
-2
20027701
00000096
10023501
20023401
-6
-7
-8
00000272
00000066
00000062
SWITCH ASSEMBLY, Hopper E'mpty
(Attaching Parts)
SCREW, Machine Pan Head 4 - 40 x 1/4
SWITCH, Hopper Empty
BRACKET, Switch
(Attaching Parts)
SCREW, Machine Binder 4 - 40 x 5/8
WASHER, Lock Int. tooth #4
NUT, Plain Hex #4 - 40
1
-3
-4
-5
·
·
·
··
·
· .
2
2
2
-9
30003701
1
-10
-12
-13
20101401
00000429
00000467
00000297
·
·
-14
10004101
-15
-16
00000398
00000295
-17
10004701
-18
-19
00000293
00000294
-20
30023303
·
-21
00000391
··
-22
20005901
-23
-24
00000292
00000432
-11
·
2
1
1
SECTOR ASSEMBLY
(Attaching Parts)
SHAFT, Pick Assembly
BEARING, (14927)
RING, Snap (79136)
SCREW, Set, Cup PT 8 - 32 x 3/16
1
2
2
2
STOP, Pick
(Attaching Parts)
SCREW, Cap, Socket Head 6 - 32 x 5/8
WASHER, Flat #6
1
BUMPER, Pick
(Attaching Parts)
SCREW, Cap, Socket Head 8 - 32 x 1/2
WASHER, Flat #8
1
2
2
· ·
·
·
2
2
CAP ASSEMBLY, Riffle Air
(Attaching Parts)
SCREW, Cap, Socket Head, 4 - 40 x 3/4
1
DRIVE ROLLER, 2nd Pick Drive Assembly
CAPSTAN
(Attaching Parts)
SCREW, Set Knurled Cup, 6 - 32 x 3/16
SPACER, Bearing (29440)
·
·
·
M2
12-17a
SFR188TT (3)
5100-25
2
I
2
2
2
88-2-27, 28 or 30
FIGURE 12-6 PICK SUPPORT ASSEMBLY
(CONT'D)
FIG.
INDEX PART
NO.
NUMBER
-25
-26
-27
10002201
00000429
00000467
-28
20005901
-29
-31
-32
00000391
00000432
10003003
00000429
-33
20004801
-34
00000564
-35
DESCRIPTION
1 2 3 4 5 6 7
·
·
·
UNITS
PER
VENDOR
ASSY PART NO.
2
4
2
SHAFT, Drive Roller
BEARING (14927)
RING, Snap (79136)
STACK DRIVE, 1st Pick Drive Assembly
CAPSTAN
(Attaching Parts)
SCREW, Set, Knurled Cup, 3 - 32 x 3/16
SPACER, Bearing (29440)
SHAFT, Stack Drive
BEARING (14927)
·
2
· ·
··
2
2
1
2
Pick Vacuum
· TUBE,
(Attaching Parts)
· · SCREW, Set, 4 - 40 x 3/32
1
20008101
·
1
-36
00000346
··
2
-37
20072801
2
-38
00000565
Pick Support
· INSERT,
(Attaching Parts)
· · SCREW, Machine, Undercut, Phillips HD 2 - 56 x 3/16
-30
·
GUIDE, Card
Attaching Parts)
SCREW, Machine, Flat Head #4 - 40 x 1/4
M2
12-17b
1
2
SFR188TT (3)
5100-25
SS-2-27, 28 or 30
SFR188TT (3)
7
8
.9
I
.-..
I
B
16~
M2
FIGURE 12-7 DRIVE ROLLER SUPPORT ASSEMBLY
12-19
FIGURE 12-7 DRIVE ROLLER SUPPORT ASSEMBLY
FIG.
INDEX PART
NO.
NUMBER
-1
-2
-3
30051202
30050801
DESCRIPTION
1 2 3 4 5 6 7
DRIVE ROLLER SUPPORT ASSEMBLY
SUPPORT, Drive Roller
·
FIRST STACK DRIVE ASSEMBLY
SHAFT, Stack Drive
SPACER, Bearing (29440)
SPACER, Bearing (29440)
SPACER, Bearing (29440)
BEARING (14927)
ROLLER, Drive
(Attaching Parts)
SCREW, Set, Knurled Cup PT 6 - 32 x 3/16
-4
-5
10003001
00000431
00000432
00000433
ODOO0429
20002101
-6
00000292
-7
-8
-9
-10
10003002
00000431
00000432
00000433
00000429
20002101
-11
00000292
-12
10075801
-13
00000305
·
-14
20176501
·
-15
00000382
-16
00000492
·.
SECOND STACK DRIVE ASSEMBLY
SHAFT, Stack Dri"e
SPACER, Bearing (29440)
SPACER, Bearing (29440)
SPACER, Bearing (29440)
BEARING, (14927)
ROLLER, Drive
(Attaching Parts)
SCREW, Set, Knurled Cup PT 6 - 32 x 3/16
·
·
UNITS
VENDOR
PER
ASSY PART NO.
1
1
AIR
AIR
AIR
2
2
2
1
AIR
AIR
AIR
2
2
2
THROAT, Pick
(Attaching Parts)
SCREW, Machine, Pan Head #4 - 40 x 1/4
1
GUIDE, Throat
(Attaching Parts)
SCREW, Phillips Head #8 - 32 x 3/8
1
· .
2
·
PIN, Dowel. 250 Dia. x 1/2 Hard Steel (70276)
1
g
C
CO)
.....
.....
.,;t
........
~
M2
12-19a
SS-27
SS-28
SS-30
SFR188TT (3)
1
S8-27
SS-28
SS-30
SFR188TT (3)
M2
FIGURE 12-8 DRIVE MOTOR ASSEMBLY
12-21
FIGURE 12-8 DRIVE MOTOR ASSEMBLY
UNITS
PER
VENDOR
ASSV PART NO.
FIG.
INDEX PART
NO.
NUMBER
-1
-2
-3
-4
-5
-6
-7
20092903
20092904
00000682
20127001
20127002
20127001
20049601
00000434
00000295
00000610
DESCRIPTION
1 2 3 4 5 6 7
DRIVE MOTOR ASSEMBLY - 115 VAC, 60 Hertz
DRIVE MOTOR ASSEMBLY - 230 VAC, 50 Hertz
MOTOR (19070)
PULLEY - 115 VAC, 60 Hertz
PULLEY - 230 VAC, 50 Hertz
(Attaching Parts)
SCREW, Set 6 - 32 (Supplied with item 2)
STANDOFF
STUD, Threaded 10 - 32 x 3/4
CONTACT, Connector Socket (00779)
HOUSING, Connector, 6 Pos. SKT (00779)
1
1
1
.
2
3
3
6
1
.
i
M2
12-21a
H34CBR-5
60617-1
1-480270-0
2 (F"IG.12-7l,3,4
8,9
c:?
. ....
.....
"-
"-
I
I
I
I
I
I
I
I
I
I
21
I
5(F"IG. 12-6 l, 6,7
I
I
I
I
)
1
"
./
./
....
)
,., ./
./
II
M2
FIGURE 12-9 MAIN PLATE ASSEMBLY (Sheet 1 of 2)
12-23
"- ....
IO~
19
~30'3I42
,Y
I
,
I
,
41
P
, r'
I
,
,
.
43,44
45,46
38,39
23
I F'1G.12-8)
26
M2
FIGURE 12-9 MAIN PLATE ASSEMBLY (Sheet 2 of 2)
12-2330
FIGURE 12-9 MAIN PLATE ASSEMBLY
FIG.
INDEX PART
NUMBER
NO.
-1
-2
40051611
40051608
40040402
30051202
-3
-4
00000396
00000294
-5
40047102
-6
-7
00000396
00000294
-8
30051101
-9
-10
00000063
00000379
-11
20043201
-12
-13
00000396
00000294
-14
20043102
-15
-16
00000392
00000295
-17
-18
~19
00000438
00000285
30039501
-20
00000358
-21
20040301
-22
00000382
-23
20092903
20092904
-24
-25
00000561
00000442
DESCRIPTION
1 2 3 4 5 6 7
MAIN PLATE ASSEMBLY - 115 VAC, 60 Hertz
MAIN PLATE ASSEMBLY - 230 VAC, 50 Hertz
• PLA TE, Picker Mounting
• DRIVE ROLLER SUPPORT ASSEMBLY
(Figure 12-7)
(Attaching Parts)
SCREW, Cap Socket Head, 8 - 32 x 5/8
WASHER, Flat #8
•
1
3
3
1
WALL, Input Hopper
(Attaching Parts)
SCREW, Machine Pan Head, 4 - 40 x 1/2
SCREW, Machine Pan Head, 8 - 32 x 1/2
1
RAIL, Guide
(Attaching Parts)
SCREW, Cap Socket Head, 8 - 32 x 5/8
WASHER, Flat #8
PIN, Spring (83584)
SPRING, Solenoid (84830)
SUPPORT, Side Plate
(Attaching Parts)
SCREW, Machine Flat Head, 8 - 32 x 3/8
•
1
1
1
PICK SUPPORT ASSEMBLY (Figure 12-6)
(Attaching Parts)
SCREW, Cap Socket Head, 8 - 32 x 5/8
WASHER, Fla.t #8
BLOCK, Guide
(Attaching Parts)
SCREW, Cap, Socket Head, 6 - 32 x 1/2
WASHER, Flat #6
•
UNITS
PER
VENDOR
ASSY PART NO.
6
6
1
2
1
2
2
1
2
2
1
1
1
2
BRACKET, Side Plate Mtg.
(Attaching Parts)
SCREW, Machine Flat Head, 8 - 32 x 3/8
2
DRIVE MOTOR ASSEMBLY - 115 VAC, 60 Hz (Fig. 12-8)
DRIVE MOTOR ASSEMBLY - 230 VAC, 50 Hz (Fig. 12-8)
(A ttaching Parts)
SCREW, Cap, Socket Head, 10 - 32 x 1/2
WASHER, Flat #10
3
3
12-23b
1
G33-16 x 1-2
LE-026-C2MW
FIGURE 12-9 MAIN PLA TE ASSEMBLY (CONT'D)
FIG.
INDEX PART
NO.
NUMBER
DESCRIPTION
1234567
SOLENOID ASSEMBLY
• STANDOFF (Solenoid)
(Attaching Parts)
SCREW, Cap Socket Head, 8 - 32 x 5/8
WASHER, Flat #8
SCREW, Machine, Flat Head, 8 - 32 x 3/8
SCREW, Machine, Flat Head, 8 - 32 x 1/2
PLA TE, Solenoid Mounting
SOLENOID, Pick
(Attaching Parts)
WASHER, Flat #8
NUT, Hex 8 - 32
• COUPLING, Solenoid
(Attaching Parts)
SCREW, Set Knurled Cup PT 6 - 32 x 3/16
CONTACT, Socket (00779)
HOUSING, Socket (00779)
• MOUNT, Cable Tie (06383)
UNITS
PER
VENDOR
ASSY PART NO.
1
-26
-27
20049801
10022002
-28
-29
-30
-31
-32
-33
00000396
00000294
00000358
00000298
20049701
20010601
-34
-35
-36
00000294
00000299
10010501
-37
-38
-39
-40
00000292
00000526
00000448
00000059
-41
20031901
-42
00000358
-43
20010401
-44
-45
00000304
00000447
-46
00000867
-47
-48
20125801
00000292
GEAR, Timing
• SCREW, Set Knurled Cup PT, 6 - 32 x 3/10
1
1
-49
-50
-51
-52
20101801
20127005
00000282
00000504
•
•
1
•
•
FITTING AIR OUTLET
(Attaching Parts)
SCREW, Machine, Flat Head, 8 - 32 x 3/8
•
•
•
MAGNETIC PICKUP HOLDER
(Attaching Parts)
• SCREW, Machine, Flat Head, 6 - 32 x 1/2
PICK-UP, Magnetic (07355)
(Attaching Parts)
• SCREW, Set, 6 - 32 x 1/8 Flat
PLATE, Stack Guide
PULLEY
BELT (07108)
JUNCTION, Terminal (08524)
2
2
2
1
1
1
1
3
3
1
4
2
1
1
60617-1
1-480318-0
TA158-C
1
2
1
2
1
1-0194/086-2110019
1
2
1
1
130 XL025
TJ1IA-05-02
----------------------------------------53
-54
00000511
00000205
00000289
•
•
1
1
•
CAPACITOR, 21-1f, 270 VAC (115 VAC, 60 Hz) (03597)
CAPACITOR, 31-1f, 370 VAC (230 VAC, 50 Hz) (03597)
CLAMP, Capacitor (03597)
(Attaching Parts)
• SCREW, Machine, Pan Head 8 - 32 x 3/8
-55
00000382
-56
20042601
•
PLATE, Stack Guide
1
12-230
1
2
45F270
45F271
K9827065P21
FIGURE 12-9 MAIN PLA TE ASSEMBLY (CONTID)
FIG.
INDEX PART
NO.
NUMBER
-57*
10158904
30014401
-58
-59*
00000344
30057201
-60
00000353
-61
-62
-63
-64
-65
-66
00000058
00000059
00000498
20027505
20027607
20139101
20139102
20139101
20139102
00000555
-67
-68
DESCRIPTION
1 2 3 4 5 6 7
READ/LIGHT STATION ASSY (Matched)
LIGHT STATION ASSEMBLY
(Attaching Parts)
SCREW, Machine, Flat Head 2 - 56 x 1/4
READ STATION ASSEMBLY
(Attaching Parts)
SCREW, Machine, Flat Head, 4 - 40 x 1/4
.
.
.
TIE, Cable (06383)
MOUNT, Cable Tie (06383)
RIVET, Pop
CABLE ASSEMBLY, One Wire
CABLE ASSEMBLY, Two Wire
CABLE ASSEMBLY, 115 VAC, 50
CABLE ASSEMBLY, 230 VAC, 60
CABLE ASSEMBLY, Drive Motor
CABLE ASSEMBLY, Drive Motor
COMPOUND ADHESIVE, Pliobond
Hertz
Hertz
(115 VAC, 60 Hz)
(230 VAC, 50 Hz)
(88132)
* Light Station and Read Station Assy must be ordered as a
matched set... #10158904
12-23d
UNITS
PER
VENDOR
ASSY PART NO.
1
1
4
1
2
5
3
1
1
1
1
1
A/R
SSTIM
TA158-C
SD44BS
1040333 (c)
00
3
III
14
17, 16,19,20
21
211
22
IO~
FIGURE 12-10 VACUUM PUMP ASSEMBLY
FIGURE 12-10 VACUUM PUMP ASSEMBLY
FIG.
INDEX PART
NO.
NUMBER
123 456 7
-2
00000379
VACUUM PUMP ASSEMBLY, 115 VAC, 60 Hertz
VACUUM PUMP ASSEMBLY, 230 VAC, 50 Hertz
• MOTOR, 60 Hz, 3350 rpm, ll5 VAC, 60 Hertz (03597)
• MOTOR, 50 Hz, 230 VAC, (03597)
(Attaching Parts)
SCREW, Machine, Pan Head, 8 - 32 x 1/2
-3
30055902
00000541
•
•
-1
40033319
40033306
00000539
00000540
DESCRIPTION
-4
-5
00000441
00000855
-6
30076701
-7
-8
-9
00000381
00000294
00000505
00000291
10002004
00000926
-10
-11
-12
-13
-14
-15
00000519
00000520
20076101
20076102
•
•
00000591
20023901
20058602
•
,..16
00000407
•
-17
20037901
•
-18
-19
-20
00000296
00000445
00000301
•
•
•
-21
10002005
•
-22
-23
00000293
00000294
•
•
BLOWER, 230 VAC, 50 Hertz
BLOWER, 115 VAC, 60 Hertz (75511)
(A ttaching Parts)
WASHER, Flat #1/4
SCREW, Cap, Hex Head, 1/4 - 20 x 5/8
PLATE, Blower
(Attaching Parts)
SCREW, Machine, Pan Head, 8 - 32 x 3/4
WASHER, Flat, No. 8-7/80D (76005)
• MOUNT. Rubber (76005)
MOUNT, Rubber (76005)
STANDOFF
• RIVET, Pop 1/8 x 1/2 (Merit)
BELT, ll5 VAC, 60 Hertz (24161)
BELT, 230 VAC, 50 Hertz (24161)
PULLEY, 115 VAC, 60 Hertz
PULLEY, 230 VAC, 50 Hertz
(Attaching Parts)
• SCREW, Set, Nyloc Cup Point STLN BLK,
1/4 - 20 x 3/8 (83014)
ADAPTER ASSEMBLY, Vacuum, 115 VAC, 60 Hertz
ADAPTER ASSEMBLY, Vacuum, 230 VAC, 50 Hertz
(Attaching Parts)
• CLAMP (76599)
GROUND STRAP ASSEMBLY
(Attachi!'g Parts)
• SCREV.', Pan Head, 6 - 32 x 3/8
• WASHER, Lock, Int. Tooth, #6
• NUT, Hex, 6 - 32 '
STANDOFF
(Attaching Parts)
• SCREW, Cap, Socket Head, 8 - 32 x 1/2
• WASHER, Flat #8
12-25a
UNITS
PER
VENDOR
ASSY PART NO.
1
1
1
1
4
1
1
KCPMPG-190A
5KCP19PG222
60-115626
3
3
1
4
8
2
2
4
8
1
1
1
1
J2049-1
100PD2
100PD4
AD46ABS
5 M 545
5 M 580
1
1
1
1
1
1
1
2
2
2
H-24
FIGURE 12-10 VACPUM PUMP ASSEMBLY (CONT'D)
FIG.
INDEX PART
NO.
NUMBER
-24
-25
-26
-27
-28
-29
20160701
00000058
00000059
00000525
00000531
00000555
DESCRIPTION
1 2 3 4 5 6 7
·
·
·
STRIP, Grommet
TIE, Cable (06383)
CABLE TIE, Mount (06383)
RECEPTACLE, Faston (.250) (00779)
LOCTITE, Grade C
ADHESIVE, Pliobond
12-25b
UNITS
VENDOR
PER
ASSY PART NO.
1
2
1
3
AIR
AIR
SSTI:M
TA1S8
60414-1
21'f
.
20~~22
28"f
e
.
30~
I
n~
I
I
I
I
I
I
1.---
_-1
I
I
_J
4
17
I
10,11
16
7
~22
~25'"
M2
FIGURE 12-11 POWER SUPPLY ASSEMBLY
12-27
FIGURE 12-11 POWER SUPPLY ASSEMBLY
FIG.
INDEX PART
NO.
NUMBER
-1
-2
-3
-4
-5
-6
-7
-8
-9
-10
DESCRIPTION
123 456 7
30029505
POWER SUPPLY ASSEMBLY
20032803
30032703
00000844
ASSEMBLY
· PCPCBOARD
BOARD
· · CAPACITOR, 10.0 UF, 12 VDC ± ~O% (80183)
·· ·· CAPACITOR, .1 UF, 100 VDC:!: 10% (80183)
~0000190
·
·
·
·
·
·
·
·
··
-12
-13
-14
-15
-16
-17
-18
-19
-20
00000195
00000209
00000069
00000207
00000070
00000140
00000107
00000570
00000460
00000570
00000232
00000238
00000671
00000463
20029101
00000137
-21
00000568
-22
-23
-24
-25
-26
00000445
00000502
00000491
00000569
00000567
-27
00000115
··
-28
00000568
-29
-30
-31
00000569
00000445
00000491
··
··
·· ·
·
-11
-32
00000108
··
·· ··
··· ··
·· ···
CAPACITOR, .001 UF, 200 VDC (80183)
RESISTOR, Prec., -6.81K::!: 1% 1W
RESISTOR, 100 ohm ::!: 10% 1/4W
RESISTOR, .10 ohm ;:1% 3W
RESISTOR, 1K ohm::!: 10% 1/4W
TRANSISTOR, NPN (04713)
PAD, Transistor mount (red) (13103)
RESISTOR, (SAT):!: 10% 1/4W range 33 to 100 ohm
SOCKET. Miniature Spring (00779)
RESISTOR, (SAT)::!: 10% 1/4W range 82 to 120 ohm
RESISTOR, Variable,.10K-::!: 10% 1W
RESISTOR,. 7. 5K, ::!: 5% 1/2WCONTACT, Electrical (.025 sq. MODU) (00779)
TERMINAL, Ring Tongue (00779)
HEAT SINK
TRANSISTOR, NPN, Power (04713)
(Attaching Parts)
SCREW, Machine, Phillips Head 6 - 32 x 5/8
Nickel Brass Plate
WASHER, Lock internal tooth #6
WASHER, Shoulder, nylon (95987)
WASHER, Nylon (95987)
NUT, Plain, Hex 6 - 32, Nickel Brass Plate
WASHER, Insulating (13103)
··
··
··
···
···
···
···
···
···
·
INTEGRA TED CIRCUIT, Regulator
(Attaching Parts)
SCREW, Machine, Phillips Head, 6 - 32 x 5/8
Nickel Brass Plate
NUT, Plain, Hex 6 - 32, Nickel Brass Plate
WASHER, Lock internal tooth #6
WASHER, Nylon (95987)
·
·
·
·
UNITS
VENDOR
PER
ASSY PART NO.
1
1
1
2
1
1
1
1
1
1
1
4
10
1
1
1
7
2
1
~
2N3771
2
3
2
1
2
1
SW-6-NA
NW-6-312NA
1
MC 1469R
2
2
4
2
NW-6-3124NA
-
COMPOUND, Heats1nk (13103)
M2
12-27a
TE 1128
TG-P10
5HK-D10
RN60D6911F
RC07GFl01K
RW79UR100F
RC07GF102K
2N706
7717-148
RC07GF
3-331677-6
RC07GF
3009P-1-103
RC2OGF752J
86094-2
32939
A/N
43-03-04
6,7,8
jO
--~
..
18
FIGURE 12-12
CARD FILE ASSEM
--------ELY
FIGURE 12-12 CARD FILE ASSEMBLY
FIG.
INDEX PART
NO.
NUMBER
-1
-2
400553XX
300294XX
40061901
40061905
40061907
40061910
40061902
UNITS
VENDOR
PER
ASSY PART NO.
DESCRIPTION
1234567
CARD FILE ASSEMBLY
CARD CAGE W/GUIDES
P.C. CARD ASSEMBLY,
P. C. CARD ASSEMBLY,
P. C. CARD ASSEMBLY,
P.C. CARD ASSEMBLY,
P. C. CARD ASSEMBLY,
··
·
·
·
·
Control
Control
Control
Control
Control
1
1
1
1
1
1
(PT)
(PTRP)
(GTRP)
(PTOC)
(GTOC)
-3
40035303
·
P. C. CARD ASSEMBLY, Sync (SINGLE)
1
-4
40076501
40076505
40076503
40066611
40076502
·
··
··
P. C.
P.C.
P. C.
P. C.
P.C.
CARD ASSEMBLY,
CARD ASSEMBLY,
CARD ASSEMBLY,
CARD ASSEMBLY,
CARD ASSEMBLY,
Clock
Clock
Clock
Clock
Clock
(PT)
(PTRP)
(GTRP)
(PTOC)
(GTOC)
1
1
1
1
1
-5
40061001
40061003
40061007
40061011
40061002
·
·
·
·
P.C.
-P. C.
P. C.
P. C.
P. C.
CARD
CARD
CARD
CARD
CARD
Error
Error
Error
Error
Error
(PT)
(PTRP)
(GTRP)
(PTOC)
(GTOC)
1
1
1
1
1
-6
-7
-8
00000029
00000030
00000061
-9
-10
-11
00000064
00000066
00000062
-12
-13
-14
00000032
00000702
20036201
-15
-16
-17
00000064
00000066
00000062
-18
-19
00000032
40032401
-20
00000063
00000066
00000062
-21
-22
·
ASSEMBLY,
ASSEMBLY,
ASSEMBLY,
ASSEMBLY,
ASSEMBLY,
HOUSING, Crimp, Snap-in (00779)
· CONN
PLUG, Keying (00779)
..· SPRING, Retaining (00779)
(A ttacliing Parts)
Machine, Pan Head, SSL 4 - 40
· · SCREW,
WASHER, Lock, Internal Tooth #4
4
16
20
3/8
8
8
8
Singe Row (00779)
· CONNECTOR,
CONTA CT, Connector (00779)
·
BAR, Connector
· BUS
(A ttaching Parts)
Machine, Pan Head, SSL 4 - 40x 3/8
· · SCREW,
WASHER, Lock Internal Tooth #4
· · }TUT, Plain, Hex, 4 - 40
1
1
1
·
· ··
11;
NUT, Plain, Hex 4 - 40
··
·
1-582191-5
582501-5
42973-2
583302-1
583259-2
2
2
2
I
CONNECTOR, Tab, Solder Loaded (00779)
P. C. CARD, Mother Board
(Attaching Parts)
SCREW, Machine, Pan Head, SSL 4 :- 40 x 1/2
WASHER, Lock, Internal Tooth #4
NUT, Plain, Hex 4 - 40
·
··
··
··
M2
12-29a.
4
1
8
8
8
58334-1
2
-1
ill
9
f-@}-
5 4 6
FIGURE 12-13 P. C. ASSEMBLY - Control Card
FIGURE 12-13 P. C. ASSEMBLY - Control Card
FIG.
PART
INDEX
NUMBER
NO.
UNITS/ASSY
DESCRIPTION
1 2 3 4 5 6 7
a..
l-
a..
P. C. ASSEMBLY, Control Card
PRINTED CIRCUIT BOARD
HANDLE, Extractor with roll pin (18617)
BUS BAR, 4 Pin
BUS BAR, 6 Pin
BUS BAR, 3 Pin
BUS BAR, 5 Pin
BEAD, Ferrite (33062)
DIODE, Zener 6.8V (04713)
CAPACITOR, Elec., 20/lf, 6V (03597)
CAPACITOR, Mylar, O. l/lf, lOOV (03597)
CAPACITOR, 0.01 /If, 100V (80813)
RESISTOR, 300 ohm, :t: 10%, 1/4W
RESISTOR, 1K ohm, :!: 10%, 1/4W
RESISTOR, 470 ohm, :!: 10%, 1/4W
RESISTOR, 100 ohm, :!: 10%, 1/4W
RESISTOR, 560 ohm, :t: 5%, 1!4W
RESISTOR, 5.6K, ± 10%, 1!4W
INTEGRATED CIRCUIT, Hex Inverter (18324)
INTEGRA TED CIRCUIT, Quad 2 input DTL gate
(07236)
INTEGRATED CIRCUIT, 2 input (18324)
INTEGRATED CIRCUIT, Dual D Flip-Flop
(18324)
INTEGRATED CIRCUIT, 4Bit Counter (18324)
INTEGRATED CIRCUIT, Low Pwr. Hex Inv.
(Fairchild)
INTEGRATED CIRCUIT, Hex Inverter (18324)
SWITCH,SPDT PC Mount (09353)
WIRE, Bus 18 AWG 11/16"
JUMPER, 0 ohm Resistor (Speer)
INTEGRATED CIRCUIT, Hex Buffer Non !nv.
(18324)
INTEGRA TED CIRCUIT, Hex Inverter (18324)
SCHEMATIC
l-
C!)
a..
II:
II:
I-
l-
a..
C!)
u
u
I-
I-
0
a..
0
VENDOR
PART NO.
C!)
-1
-2
-3
-4
-5
-6
-7
-8
-9
-10
-11
-12
-13
-14
-15
-16
-17
-18
-19
REF
40064901
00000060
20031104
20031106
20031103
20031105
00000088
00000039
00000025
00000024
00000023
00000075
00000070
00000076
00000069
00000258
00000080
00000049
00000043
-20
-21
00000046
00000044
·
2
3
2 2 2 2
3 3 3 :f
N7400A
N7474A
-22
-23
00000054
00000057
·
3
2
3 3 3 3
2 2 2 2
N8281ADC
U6AL0459X
-24
-25
-26
-27
-28
00000050
00000083
00000020
00000198
00000124
12
1
1
1
9
1
1
1
N7404A
nOlA
-29
-30
00000123
40065001
·
·
·
1
2
10
1
1
7
1
1
3
1
34
1
16
2
1
12
2
6
4
1
2
10
1
1
7
1
1
3
1
1
2
10
1
1
7
1
1
3
1
34
1
16
2
1
12
12-31a
1
34
34
1
.1
16
16
2
2
1
1
12
12
15 15 2
6 6 6
4 4 4
1
S-203
1
10
1
1
7
21-030-F
1
IN5235
1
76F02CC200
3
1
BAI2AI04B
34 T6-S10
1
RC07GF331K
16 RC07GFI02K
2
RC07GF471K
RC07GFI0lK
1
12 RC07GF561J
RC07GF562K
2
6
N7405A
4
U6A994659X
8 9 8
1 1 1
1 1 1
1 1 1
4
4
-
-
-
3
3
1 1 1 1
1
-
-
,
M2 M3 MIs,MIO,MI2
1
2
10
1
1
7
1
1
3
-
Res. Jumper 0"
N7417A
N7416A
0 hm
3:
N
3:
'"iii:
2
'"
-3:
_0
iii:
N
G
o
~
G
6
G
oD
~
G
SO$
[J
666
00
0
m
~
OOOBO D D D []
CD
CD
a~~ n ~ ~ 0s0 D a
ru
~
~
~
~
,
'
~
"[]
B
[J
w
8S
CD
CD·[I]
I
FIGURE 12-14 P.
[I]
1
5
c.
m
[I]
~
10
3
ASSEMBLY - Sync Card
IT]
4
FIGURE 12-14 P. C. ASSEMBLY - Sync Card
FIG.
INDEX PART
NO.
-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
NUMBER
40035303
40060001
00000060
20031104
20031105
20031107
00000088
00000039
00000025
00000023
00000024
00000070
00000076
00000072
00000042
00000054
00000055
00000047
00000044
00000045
00000046
()0000050
00000053
00000020
40094301
10167801
DESCRIPTION
1 2 3 4 5 6 7
P. C. ASSEMBLY - Sync Card
• PRINTED CIRCUIT BOARD
HANDLE, Extractor with Roll Pin (18617)
• BUS BAR, 4 Pin
• BUS BAR, 5 Pin
• BUS BAR, 7 Pin
• BEAD, Ferrite (33062)
• DIODE, Zener 6.8V (04713)
• CAPACITOR, Electrolytic, 20 !-If, 6V (03597)
• CAPACITOR,. 01 !-If, 50V (56289)
CAPACITOR, Mylar, .I!-1f (03597)
RESISTOR, lK ohm, :t 10% 1/4W
• RESISTOR, 470 ohm, :!: 10%, 1/4W
• RESISTOR, 220 ohm, ± 10%, 1/4W
• INTEGRA TED CIRCUIT, Hybrid Driver (07886)
• INTEGRATED CIRCUIT, Counter Register (18324)
• INTEGRA TEE CIRCUIT, 4 Bit Comparator O. C. (18324)
• INTEGRA TED CIRCUIT, Single 8 Input Gate (18324)
INTEGRATED CIRCUIT, Dual D Flip-Flop (18324)
• INTEGRA TED CIRCUIT, Dual 4 Input Buff (18324)
• INTEGRA TED CIRCUIT, Quad 2 Input Gate (18324)
• INTEGRA TED CIRCUIT, Hex Inverter (18324)
INTEGRA TED CIRCUIT, Counter Register (18324)
• WIRE, Bus #AWG 18, 11/16
• SCHEMATIC
• WIRE LIST
M2,M3,M ,M 10, MI2
12-33a
UNITS
VENDOR
PER
ASSV PART NO.
1
2
9
8
1
S-203
1
1
1
21-030-F
IN5235
76F02CC200
TG-SIO
BAI2AI04B
RC07GFI02K
RC07GF471K
RC07GF221K
H6F22009XX
N8281ADC
N8242A
N7430A
N7474A
N7440A
N7400A
N7404A
N8280ADC
25
2
6
3
1
1
8
2
4
6
3
2
3
2
1
5
3
4
FIGURE 12-15 P. C. ASSEMBLY - Clock Card
FIGURE 12-15 P. C. ASSEMBLY - Clock Card
FIG.
PART
INDEX
NUMBER
NO.
-1
-2
-3
-4
-5
-6
-7
-8
-9
-10
REF
40079901
40032201
40062601
00000060
20031104
~0031l05
-12
-13
-14
-15
-16
-17
-18
-19
-20
20031107
00000088
00000039
00000025
00000024
00000022
00000023
00000077
00000070
00000073
00000080
00000225
00000056
00000053
00000046
00000048
-21
00000047
-22
-23
-24
00000045
00000044
00000123
-25
-26
-27
-28
-29
-30
00000050
00000124
00000067
00000198
00000020
40080001
40030801
40062701
-11
UN ITS/ASS V
DESCRIPTION
1 2 3 456 7
P. C. ASSEMBLY, Clock Card
PRINTED CIRCUIT BOARD
PRINTED CIRCUIT BOARD
PRINTED CIRCUIT BOARD
HANDLE, Extractor with Roll Pins (18617)
BUS BAR, 4 Pin
BUS BAR, 5 Pin
BUS BAR, 7 Pin
BEAD, Ferritte
DIODE, Zener 6.8V (04713)
CAPACITOR, Electrolytic, 20/-lf, 6V (03597)
CAPACITOR, Mylar, .1/-1f, 100V (03597)
CAPACITOR, .02 /-If, 100V (56289)
CAPACITOR, .0I/-1f, 100V (56289)
RESISTOR, 4.7K ± 10%, 1/4W
RESISTOR, 1K ± 10%, 1/4W
RESISTOR, 2.2K :!: 10%, 1/4W
RESISTOR, 5.6K :!: 10%, 1/4W
RESISTOR, lOOK:!: 10%, 1/4W
INT.E;GRA TED CIRCUIT, Comparator (07886)
INTEGRA TED CIRCUIT, Counter Register· (18324)
INTEGRA TED CIRCUIT, Quad 2 input gate (18324)
INTEGRA TED CIRCUIT, Single 3 input gate
(18324)
INTEGRATED CIRCUIT, Single 8 input gate
(18324)
INTEGRA TED CIRCUIT, Dual 4 input gate (18324)
INTEGRATED CIRCUIT, Dual D Flip Flop (18324)
INTEGRATED CIRCUIT, Hex Buff, Inv. O. C •.
.(18324)
INTEGRA TED CIRCUIT, Hex Inverter (18324)
INTEGRATED CIRCUIT, Hex :Suff, Non Inv. O. C.
OSCILLATOR, Crystal 4.8 MHz (04713)
RESISTOR, 0 ohm Jumper (Speer)
WIRE, Bus AWG #18 1l/16
SCHEMATIC
SCHEMATIC
SCHEMATIC
·
·
·
··
·
·
·
··
·
·
·
··
·
··
·
·
·
·
·
·
·
··
·
·
·
·
·
·
M2 M3 M .MIO.MI2
12-35a
IL
Q.
U
u
....IL ....c:t ....a:IL ....a:c:t 12 ....0
IL c:t
1
-
2
8
5
1
1
1
1
1
1
16
1
1
1
-
1
1
4
2
1 1
- - -
2
8
5
1
1
1
3
1
1
16
1
7
1
1
1
1
1
4
2
2
8
5
1
1
1
3
1
1
16
1
7
1
1
1
1
1
4
2
-
1
-- -
2
8
5
1
1
1
-1
1
16
1
6
1
VENDOR
PART NO.
1
2
8
5
1
1
1
3
1
1
16
1
7
1
--
-1
1
1
1 1
4 4
2 2
S-203
21-030-F
IN5235
76F02CC200
BA12AI04B
TG-820
TG-SI0
RC07GF472K
RC07GFI02K
RC07GF222K
RC07GF562K
RC07GFI04K
LM31lD
N8280ADC
N7400A
N7410A
5
5 5 5 5
N7430A
1
12
1 1 1 1
12 12 12 12
1
N7440A
N7474A
N7416A
5
1
1
1
-
5 5
1
1 1
1 1
1 1
1 1
-
-5 5
1 1
1 1
1
1 1
1
-
-
- - -1 -- -
N7404A
N7417A
KI035AOO710
2
FIGURE 12-16 P. C. ASSEMBLY - Error Card
FIGURE 12-16 P. C. ASSEMBLY - Error Card
FIG.
PART
INDEX
NUMBER
NO.
-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
REF
40081001
00000060
20031105
20031104
20031107
00000088
00000039
00000041
00000040
00000025
00000024
00000026
00000027
00000021
00000023
00000081
00000071
00000068
00000076
00000078
00000070
00000074
00000080
20031103
00000051
00000044
00000046
00000047
-29
-30
00000050
00000043
-31
-32
00000052
0000042
-33
00000123
-34
00000124
-35
-36
-37
-38
-39
00000083
00000082
00000198
00000020
40081401
UNITS/ASSY
DESCRIPTION
I-
1 2 3 4 5 6 7
II.
P. C. ASSEMBLY - Error Card
PRINTED CIRCUIT BOARD
HANDLE, Extractor with Roll Pin (18617)
BUS BAR, 5 Pin
BUS BAR, 4 Pin
BUS BAR, 7 Pin
BEAD, Ferrite (33062)
DIODE, Zener 6.8V (04713)
DIODE, Signal
DIODE
CAPACITOR, Electrolytic, 20 J.l.f, 6V (03597)
CAPACITOR, 0.1 J.l.f, 100V (03597)
CAPACITOR, 400 J.l.f, 6V (03597)
CAPACITOR, 30 J.l.f, 12V (03597)
Cj\PACITOR, .22 J.l.f, 25V (56289)
CAPACITOR, .01 J.l.f, 100V (56289)
RESISTOR, 68 ohm, ± 10%,1/2W
RESISTOR, 10K ohm, :!: 10%, 1!4W
RESISTOR, 10 ohm, : 10%, 1/4W
RESISTOR, 470 ohm, ± 10%, 1/4W
RESISTOR, 1K ohm, :!: 5%, 1/4W
RESISTOR, lK ohm, ± 10%, 1/4W
RESISTOR, 27K ohm,: 10%, 1/4W
RESISTOR, 5.6K ohm, :!: 10%, 1/4W
BUS BAR, 3 Pin
INTEGRA TED CIRCUIT, Dual Driver (01295)
INTEGRA TED CIRCUIT, Dual D Flip Flop (18324)
INTEGRA TED CIRCUIT, Quad 2 input gate (18324)
INTEGRA TED CIRCUIT, Single 8 input gate
(18324)
INTEGRATED CIRCUIT, Hex Inverter (18324)
INTEGRA TED CIRCUIT, Triple 3 input gate
(18324)
INTEGRA TED CIRCUIT, Delay Element (07263)
INTEGRA TED CIRCUIT, Quad 2 input DTL gate
(07263)
INTEGRATED CIRCUIT, Hex Buff Inv. O. C.
(18324)
INTEGRA TED CIRCUIT, Hex Buff, Non. Inv. O. C
(18324)
SWITCH, SPDT, P. C. Mount (09353)
SWITCH, SPDT, Push, P. C. Mount (09353)
JUMPER, 0 ohm, Resistor (Speer)
WIRE, Bus #A WG 1B, 11/16
SCHEMATIC
·
·
CI
II.
0:
II.
lCI
0
u
III.
lCI
0
0
VENDOR
PART NO.
2
4
5
5
1
1 1 1
1
S-203
2
2 2 2
6
6 6 6
8
8 8 8
1
1 1 1
21-030-F
1
1 1 1
IN5235
1
1 1 1
2
2 2 2
IN914
IN4003
1
1 1 1
76F02CC200
1 1 1
1
BA12AI04B
1
1 1 1
76F02Cl\I401
1
1 1 1
76F02ED300
1 1 1
1
4
4 4 4 2C023224X0250A3
19 19 19 19 TG-S10
6
RC20GF680K
6 6 6
RC07GFI03K
1
1 1 1
RC07GF100K
1
1 1 1
RC07GF471K
1
1 1 1
RC07GF561J
1
1 1 1
8
8 8 8
RC07GFI02K
RC07GF273K
1
1 1 1
4
4 RC07GF562K
2 2 2
2
4
4 4 4
SN75450N
5 5 5 5 N7474A
5
5 5 5
N7400A
N7430A
1
1 1 1
·
6
1
5
1
5 5 5
1 1 1
N7404A
N7410A
·
·
·
·
·
1
1
1
1
1 1 1
1 1 1
U6A960159X
U6A994659X
-
1
-
-
N7416A
-
-
1 1 1
N7417A
1
1
1
1
1
1
1
1
1
1
1
1
·
·
·
·
·
·
·
·
·
·
·
··
M2 M3 M & MIO MI2
12-37a '
1
2
6
8
1
1
1
2
1
1
1
1
1
4
19
6
1
1
1
1
8
1
l-
II.
0:
I-
-
-
1
1
1
1
1
nOlA
1
1
P8121R
1 Res-Jumper 0 0 hm
1
Source Exif Data:
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