Documation_M 400L_Card_Reader_Technical_Manual_Feb1973 Documation M 400L Card Reader Technical Manual Feb1973
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TECHNICAL MANUAL
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FEBRUARY 1973
1
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DOCUMATION. INCORPORATED. 1971
Conten.. or this manual may not be reproduced in whole or in part without written
permi.. ion or Documation. Incorporated.
II
I 1
CCCUMATICN
I.
INCORPORATED
POST OFFICE BOX 1240
MELBOURNE. FLORIOA 32901
IMPORTANT NOTICE
THIS TECHNICAL MANUAL IS SUPPLIED'"
WITH DO CUMATI ON CARD READER SERIAL
NUMBER
'THIS MANUAL' SHOULD REMAIN WITH 'THAT
,
~CARD
READER."
,
'
'
.
Technical Manual Change Record
This Technical Manual has been updated to reflect Customer Specifications. Minor changes
to text or schematics are marked on the pages affected. Major changes to text or schematics
are corrected by direct replacement of pages a.ffected, or a.re contained in an Addendum.
Customer:
GENERAL AUTOMATION
Model:
M4.00L
Volta.ge
115 Fr~quency
60
Options: 01,02,03,09,23 CS No.:
171
Addendums:
_____________________________________________________
~n~-~a~
Text Changes: 1-1, 4-10. 4-11',.:j.~4:::-1=-3J.l'L.:;41::::-;.:;.1J..5_ _ _ _ _ _ _ _ _ _ _ _ _ _ _~_ _
Schematic Changes:
.
Drawing No. or
Modifi en ti on
Title
-
Wiring Diagram, AC Power Distribution, 115 VAC, 60 Hz •••••••.
Wiring Diagram, AC Power Distribution, 230 VAC, 50 Hz ••••••••
Card Cage, P. C. Card Location ••
1241999
Wiring Diagram, Card Cage •••••
.g:.
Wiring Diagram, Control Panel •.••••...••
~ f;>
5V Power Supply, 115 VAC, 60 Hz •••• ~ ••••••••••. #i}'~ ~
5V Power Supply, 230 VAC, 50 Hz •••••••
,§ ~ ~ ...
Solenoid Driver, 115 VAC, 60 Hz •••
~~ 4.,0 vO
Solenoid Driver, 230 VAC, 50 Hz ••••••••••••• ~ 4?;:;~ .....
Clock Card Assembly. • • • • • • • • • • . • • . • • •. 4.,0 ~at:<, •••••••
Schematic, (sheet 1 of 3) •••
~~~
Schematic, (sheet 2 of 3) • • • • • • • • • • •• §~. ~ ........
MODIFIED PER OPT. 02
Schematic, (sheet 3 of 3). • • • • • • •• •• .{>\.>~$
Error .card Assembly
tJ>~ .••••
Schematic, (sheet 1 of 2) •• ~
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OPT
01
12'·'716
Schem a.t IC,
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••••••.•••••••
Sync Card Assembly ~
o. ~ ~ J.y • • • • • • • • • • • • • • •
. Schemat~c, (sheet 1 of 3). o. ~~§ o.
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Schematic, (sheet 2 of 3) o . ~ •.,-::. r..
••••••••
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Schematic, (sheet 3 of 3) •• tj!S' ,,-0$ ..••
Control Card Assembly
o • • • s:; t>.~Ay
. Schematic, (sheet 1 of 2) ••• ~ &4f4? .•.•
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1241715
Schematic, (sheet 2 of 2) • • • •• .•
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••••
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Doc. No. __________________
__
M3001 JJ
Verified
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.
.
.
.
.
3- 1
3- 1
3- 1
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
•
4- 1
4- 2
3- 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. Registers. . . . . . • • . . • . . • • . • • •
i
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
Paragraph
Page
5.1
5.2
5- 1
5.3
5.4
5.5
General
Timing
5.2.1
Pick Control . . . . . . . . . . . . . . . . . . . . . . . .
5.2.2
Data Readout. . . . . . . . . . . . . . . . . . . . . . . .
5.2.3
Alarms
5.2.3.1 Hopper Check . . . . . . . . . . . . . . . . . . . . . . • . . .
5.2.3.2 E r r o r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.3.3 Motion Check .. . . . .. . . . . . . . . . . . . . . . . . ..
Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Signal Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5- 1
5555555-
1
3
3
3
4
4
4
5- 6
5- 6
SECTION 6
ADJUSTMENT PROCEDURES
6.1
6.2
6.3
6.4
6. 5
6.6
6.7
6. 8
6.9
6.10
General
Tension on the Main Drive Motor Belt . . . . . . . . . . . . . . . . . . . . . .
Magnetic Pickup Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustment of Stack Photocell . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stacker Roller Shaft Bearing Preload . . . . . . . . . . . . . . . . . . . . . .
Hopper Empty Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . .
Stacker Full Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . .
Picker Sector Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vacuum Pump Belt Tension Adjustment . . . . . . . . . . . . . . . . . . . . .
Picker Casting Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.
.
.
.
.
.
.
.
.
6- 1
6- 2
6- 3
6- 5
6- 6
6- 7
6- 8
6- 9
6-13
6-17
SECTION 7
PREVENTIVE MAINTENANCE·
7.1
7.2
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2.1
Picker Sector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2.2
Casting Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2.3
Cooling Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . .
7.2.4
Exterior Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0
7.3
7777-
1
1
1
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
Paragraph
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
9.17
9.18
9.19
9.20
9.21
9.22
9.23
Page
Genera,l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Required Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Drive Motor Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Third Stacker Roller Drive Belt • . • • • • • . . • . . • • . . • . . . . • . .
First Stacker Roller Drive Belt . • . • . • • . • . . . . • . . • . • . . • • .
Second Stacker Roller Drive Belt • . • • • • • • • . • . . . . • . . . . . . .
First, Second and Third Stacker Roller Bearing Assemblies ...••
Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vacuum Pump Motor Assembly Belt .••••.••.••.•.••.•.••
Ma.gnetic Pickup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Picker Support Ass embly •....•.•••••••••••••••••••••
Rea,d Hea,d
9-1
9-1
9-3
9-5
9-7
9-8
9-9
9~15
9-17
9-21
9-24
9-27
9-28
9-28
9-32
9-33
9-35
9-36
9'-36
9-38
9-39
9-39
9-39
••.•••.••....••••.•••••••.•..•.••.•..•
Light Sta.tion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fourth an4 Fifth Stacker Roller Bearing Assemblies ••.•••.•..
First and Second Picker Roller Bearings •••••.•••••.••.••.
Picker Sector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stacker Photocell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .
Hopper Negator Spring ••.•.•••••.•.•..•.••••••••••••
Lower Stacker Negator Spring. • • . • • • • . • • . • • • • • • • • • • • • • •
Upper Stacker Negator Spring •••.••••••••••••••.••••••
Hopper Empty Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sta.cker Full Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Indicator Lamps
SECTION 10
DRAWINGS
SECTION 11
SIGNAL MNEMONICS AND ABBREVIATIONS
SECTION 12
ILLUSTRATED PARTS BREAKDOWN
LIST
OF
ILLUSTRATIONS
Page
Figure
1-1
1-2
2-1
3-1
Card Reader, Three-Quarter Front View (Typical) . . . ' . . . . . . . .
Card Reader, Three-Quarter Rear View (Typical)'. . . . . . . . . . . .
Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Switch and Indicator Location . . . . . . . . . . . . . . . . . . . . . . . . . .
iii
.
.
.
.
1123-
0
0
2
2
Page
Figure
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
6-13
6-14
6-15
6-16
6-17
6-18
7- 1
9- 1
9- 2
9;.. 3
9999-
4
5
6
7
9- 8
9- 9
Operational Flow ChEJ,rt ..•.••.•••.•..•..•....•..•.•.•.
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front :panel and Top Cover Removal . . . . . . . . . . . . . . . . . . . . . . .
Rear Panel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Motor Belt Tension Adjustment . . . . . . . . . . . . . . . . . . . . . .
Magnetic Pickup Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Card Cage Repositioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Location of Photocell Set Screw . . . . . . . . . . . . . . . . . . . . . . . . . .
Stacker Photocell. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Roller Shaft Bearing Preload Adjustment . . . . . . . . . . . . . . . . . . . .
Hopper Empty Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . .
Stacker Full Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . .
Picker Sector Adjustment, Rear View . . . . . . . . . . . . . . . . . . . . . .
Picker Sector Adjustment, Front View . . . . . . . . . . . . . . . . ' . . . . .
Removal of Vacuum Tube Adapter . . . . . . . . . . . . . . . . . . . . . . . . .
Solenoid Preload Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal of Rear Subframe Panel . . . . . . . . . . . . . . . . . . . . . . . . .
Disconnecting Vacuum Blower Motor Assembly . . . . . . . . . . . . . . .
Removal of Vacuum Blower Motor Assembly . . . . . . . . . . . . . . . . .
Adjustment of Vacuum Blower Motor Belt Tension . . . . . . . . . . . . . .
Solenoid Lubrication . . . . . . . . '. . . . . . . . . . . . . . . . . . . . . . . . . .
Front Panel and Top Cover Removal . . . . . . . . . . . . . . . . . . . . . . .
Rear Panel Removal. . . . . . . . . . . . . . . . . . . . . '.' . . . . . . . . . . .
Main Drive Motor Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stacker Drive Train Belt Arrangement ; . . . . . . . . . . . . . . . . . . . .
Stacker Drive Train Pulley Arrangement . . . . . . . . . . . . . . . . . . . .
Pulley and Belt Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pictorial, Stacker Roller Bearing Assembly . . . . . . . . . . . • . . . . . .
Pictorial, Solenoid Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal of Rear Subframe Panel, Main Card Cage Cover and Panel ..
iv
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- 1
6- 2
6- , 3
6-4
6- 4
6- 5
6- 6
6- 7
6- 8
6~ 8
6- 9
6-10
6-10
6-12
6-13
6-14
6-15
6-16
7- 2
9- 2
9- 2
9- 4
9- 4
9- 6
9- 6
9-11
9-16
9-18
Page
Figure
9-10
9-11
9-12
9-13
9-14
9-15
9-16
9-17
9-18
9-19
9-20
9-21
9-22
9-23
10-1
10-lA
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
10-17A
10-18
10-19
10-20
Vacuum Pump Assembly Connections •••••.••.••..••..•.••
Removal of Vacuum Pump Motor Assembly .••••••.•••.•.••
Vacuum Pump Belt Replacement ••.•••••••••••••••••••••
Magnetic Pickup Replacement. • • • • • • • • • • • • • • • • • • • • • • . ••
Ca,rd Cage Repositioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Card Cage in Extended Position ••••••.•••••••.••••• ••••
Picker Ca,sting Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hopper Follower Assembly Removal ••••••••••.••••••••••
Picker Casting Removed from Reader • • . • • • • • • • • • • • • • • • ••
Replacement of Picker Casting and Picker Sector, Front View. • • •
Picker Sector, Rear View . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Location of Stacker Photocell .•.•••••••.••••••.••••••••
Sta.cker Negator Spring Replacement •••••••••••••••••••••
Stacker Full Switch Replacement. • • • • • • • . • . • • • ••••••••••
Wiring Diagram, AC Power Distribution, 115V, 60/50 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) •••••..••••••.••
Preset and CSDS Counter Strapping . . . . . . . . . . . . . • . . . • . . . .
Assembly Diagram, Control Card . . . . . . . . . . . . . . . . . . . . . . .
Schematic Diagram, Control Card (sheet 1 of 2) . • . . . . . . . . . . .
Schematic Diagram, Control Card (sheet 2 of 2) . . . . . . . • . . . . .
v
9-18
9-20
9-20
9-22
9-22
9-23
9:-23
9-25
9-26
9-26
9-34
9-36
9-37
9-38
10-1
10-lA
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
10-17A
10-18
10-19
10-20
Figure
12-1
12-2
12-3
12-4
12-5
12-6
12-7
12-8
12-9
12-10
12-11
12-12
12-13
12-14
12-15
12-16
Page
How To Use Illustrated Parts Brea.kdown When Part Number is Not .
Known . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M-Series Ca rd Reader . . . . . . . . . . . . , . . . . . . . . . . . . . . . . . . .
Trim Group Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Frame Assembly (sheet 1 of 3) •.•••••••••..•.•.•.••.
Main Frame Assembly (sheet 2 of 3) ..•••...•.•••••••••••.
Main Frame Assembly (sheet 3 of 3) .•.•••••••••.••.••••••
Control Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pick Support Assembly (sheet 1 of 2) •.••••.•.•••.•••.•.•.•
Pick Support Assembly (sheet 2 of 2) ..•••••••••..••.••••••
Stack Support Assembly (sheet 1 of 2) •••••.•••••••••••••••
Stack Support Assembly (sheet 2 of 2) ..••••••••••..•••....
Drive Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ba.se Plate Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vacuum Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Supply Assembly •••.•••••••••••••••••••.•.•••••
Ca,rd 'File Assembly . . . .
P. C. Assembly - Control Ca.rd •••.•.••••••••••••••.•.•••
p.e. Assembly - Sync Card . . . . . . . . . . . . . . . . . . . . . . . . . . .
P.C. Assembly - Clock Card... •••• .•• • •••••.• ••• •••••.
P. C. Assembly - Error Card •.•••••.•••••••.••••••••••
41
••••••••••••••••••••••••••••
vi
12-3
12-9
12-11
12-13
12-13
12-13
12-15
12-17
12-17
12-19
12-19
12-21
12-23
12-25
12-27
12-29
12-31
12-33
12-35
12-37
a
b
a
a
CONTROL AND
INDICATOR PANEL
INPUT
HOPPER
CARD
----TRACK
OUTPUT
STACKER-----,~
"'--MAINFRAME
BASEPLATE
Figure 1-1.
Card Reader, Three-Quarter Front View (Typical)
REAR
CONTROLS
COOLING
FAN
I/O CONNECTOR
Figure 1-2.
POWER INPUT
Card Reader, Three-Quarter Rear View (Typical)
1-0
SECTION 1
INTRODUCTION
1.1 GENERAL
This tccmical manual contains operation, maintenance, interface, and repair information
to properly set up, operate, and maintain the Documation Model M400L Card Reader. An
Illustrated Parts Breakdown is included In Section 12 to aid in locating and identifying
parts if replacement becomes necessary.
The M400L Card Reader shown infigures 1-1 and 1-2 is designed to read standard 12-row,
80 column. punched cards. The hopper capacity is adequate to hold approximately 1000
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 are 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
singJ.e card selection or cmtinuous run. In the continuous mode, the reader will read
400 cards per minute.
1.2 DESCRIPTION
The entire reader is constructed around a mainframe, figure 1-1. Mounted on top of the
. mainframe are the input hopper and output stacker, card track mechanism and control ruld
indicator panel and printed circuit card cage. All logic circuitry is contained on printed
circuit boards within the card cage. Located on the underside of the mainframe are the
drive motor, drive train, and a portion of the card pick mechanism. The bottom of the
mainframec'ontains a baseplate which mounts the vacuum pump motor assembly ruld the
remainder of the electronics.
Located m the rear of the reader, figure 1-2, are three controls, "a circuit breaker, the
power input, the I/O, connector, pnd a cooling fan.
1.3 SPECIFICATIONS
READING SPEE.D:
400 cards per minute maximum in continuous run.
Single Card Cycle: 167 millisecmds.
CARD TYPE:
Standard 80 column cards.
CONTROL:
Demand fee~ me card-at-a-time 1.I1der external
program control. Reader will cmtinuous run as
long as the Pick Cpmmand remains TRUE.
HOPPER SIZE:
7.25 mcbes (apprOXimately 1000 cards of 7 mil
thickness).
STACKER SIZE:
7. 25 inche~ (apprOXimately 1000 cards of 7 mil
thickne.s).
1-1
}lOWE R REQUIREl\'1ENTS:
Voltage:
115 VAC ± 10%, single pha.se, 60 Hz (sta.nda.rd model).
230 VAC ± 10%, single pha.se, 50 Hz (export model).
Power:
1650 VA (MAX) sta.rting load for 3 sec
600 VA (MAX) running load
Height:
16-1/4 inches
41. 2 cm
Width:
23-1/16 inches
58.6 cm
Depth:
18 inches
45.,7 cm
77 pounds
34.4 Kg
SIZE:
WEIGHT:
OPERATING ENVIRONMENT:
Dry Bulb Temperature
Relative Humidity
Wet Bulb Temperature
Thermal Shock
Altitude' .
50 to 100 o F.
30 to 90% non-condensing
80 o 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
f
"
•
'CARD STOCK
The card must meet American National Standard's specification ANSI X3.1l-1969,
Specification for General Purpose Paper Cards for Information Processing.
PUNCH DATA
Punch data must ,rneetAmerican 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 ina 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 Incorpora.ted.
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 isolEltors 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.
Place the CIRCUIT BREAKER (rear connector panel) to ON.
c.
Set the MODE switch (rear panel) to LOCAL.
d.
Set the SHUTDOWN switch (rear panel) to A UTa.
e.
Depress the POWER switch to energize the reader. The POWER indicator
illuminates and, after approximately a 3-second delay, the STOP and
HOPPER CHECK indicator illuminates.
f.
Depress and hold momentarily the LAMP TEST switch (rear panel) and
observe that all front panel indicators illuminate. Release switch.
g.
Pull the hopper follower back with one hand and load approximately 3 inches
of unpunched cards into the hopper area.
h.
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 indica.tors illumina.te.
i.
Depress the POWER switch to turn off the reader. All indicators are
extinguished.
2-1
j.
Pull the stacker plate toward the front of the reader with one hand and
remove the cards.
k.
This completes the initial off-line test.
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.
Pull the hopper follower back with one hand 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 1000 cards).
CAUTION
00 NOT PACK THE INPUT HOPPER
SO FULL THAT THE RIFFLE ACTION
AT THE AIR RIFFLE CAP IS INHmITED
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, pull the follower back 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 back with one hand 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 back 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
BB
FRONT CONTROL PANEL
0
LAMP TEST
l©)
c=J
c=J
0
SHUTDOWN
.-(~~ro
c=J
c:=)
MODE
c=J
c:=)
0
(~
REMOTE
~
LOCAL
\~
0
1'-"-1.
iii
REAR PANEL
~.-- .. - - - - - ' ..
1_..
Figure 3-1. Switch and Indicator Location
3.3.1
FRONT PANEL CONTROLS AND INDICATORS
Located on the front panel are three pushbutton type switches.
POWER
STOP
RESET
3-2
,-, -- .. ~
.. _ _ .. _ _.~.,J----.i
Located within these switches are lighted indicators showing reader status; they
are POWER ON (white), RESET (green), and STOP (red).
Four other "error" indicators are located on the front panel.
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/A UTO
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.
Place the AC power circuit breaker in the ON position to allow power ON/
OFF control from the front panel.
b.
Select the mode of operation, MANUAL or AUTO. When the MANUAL mode
is selected, the drive motor and vacuum/blower will run continuously when
A C power is applied. When the AUTO mode of operation is selected, all
motors will turn off after the last card is read.
c.
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.
d.
With the LOCAL mode of opera.tion established, depress the POWER switch
on the front panel to apply primary power to the reader. The drive motor
and vacuum/blower will not come on at this time due to the input hopper
being empty and AUTO shutdown selection.
e.
Depress the LAMP TEST switch and check that all front panel indicators are
lighted.
3-3
f.
Load the input hopper and depress the RESET switch. The RESET switch is
, a momentary action pushbutton indicator 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.
g.
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.
h.·
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.
i.
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.
j.
The HOPPER CHECK indicator will light when the input hopper is empty
or when the output stacker is full. l'his is normal operation.
k.
The STOP switch is a momentary action pushbutton switch indicator 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
!!2!!..!
POWER CORD CONNECTED TO PROPER
VOLTAGE a FREQUENCY AVAILABLE
BEFORE POWER SWITCH IS DEPRESSED
NO
CHECK THAT
CIRCUIT BREAKER IS ON
SET SWITCHES TO
DESIRED MODE
DEPRESS LAMP TEST
SWITCH TO.ASSURE PROPER
OPERATION ON INDICATORS
HOPPER CHECK ALARM
REMAINS 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 CARO
FOR SEVERE DAMAGE
OR STACKER BLOCKAGE
HOPPER IS EMPTY
OR STACKER IS FULL
UN LOAD STACKE R
RELOAD HOPPER
DEPRESS RESET SWITCH
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 VACUUM IN PICKER
SECTOR HOLES PULLS CARDS
IN AGAINST SECTOR AND
CARD MOVES TOWARD PINCH
WHEN SECTOR TURNS
MOTOR
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 stacking. 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 CHE 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 at the Phototransistor's
4-2
READER FUNCTIONAL AREAS
DATA DETECTION
DATA STORAGE
r-----------'r------
I
I
I
I
I
I
r+I
-
-
20
0
I-
::;J'"
- ' I-
:c
~
t
~
-
-'
I
,
Vl~
201-
;z.
~~
b
Vl
I-e
~;5
f-+
DATA
AMPLIFIERS
AND
INVERTERS
~rlINVERTER
I
ONE DARK
I
ONE LIGHT
I
112/.
I"
L.fONE LlGHT}--
I
Vl
DATA
REGISTER
ex
~
i
i
DATA
\
"
"-'>:c
~
z:
II~
CSDS
I
ERROR INDICATORS
We
I
"---
I
TIMING
STROBE
LOGIC
r~
I
cx
ST0C
TST!
~~
I
I
I
r--
!:::.cx
-
1
HOPPER EMPTY
/STACKER FULL
STACK
STATION
.
I
I
I
12"
CONTROL
SWITCHES
I
I
I
-:-~
;::
1
1.1
----I$
S
I
0C~s------~rl~------------~~
0DS~--------~rl~--------~$
ff 5S-------,
j
Figure 4-4 - Block and Timing Diagram, 4. 8 MHz Oscillator
and Four-Phase Generator
4-5
FROM STOP
SWITCH
...~_ _ _ _.....:::..ST:..::O~P_ _ _ _ _ _- ,
~
f :..·-----=P~IC:.:;K--=C:.:;HE:.:C:;.:K'-----l-~
:~
LIGHT CHECK
DARK CHECK
~
FROM
ERROR LOG IC
FROM ONE DARK
STOP
READY
•
READY / STOP
HOPPER CHECK
1----.:.::::.::::..:----._ TO CONTROLLING
..:.P.:::;CR~_ _..Jt
MA~AL
Sl
FRO~l
....,
"
DEVICE
0 + 5VDC
- - TO PICK LOGIC
GPR
- : TO COLUMN COUNTER,
DATA CONTROL & SYNC
LOGIC, AND PICK LOGIC
=-
----+--+-+------:..:PO;:.:;R:.---.... TO PICK LOGIC &
COLUMN COUNTER
POR
POR
+
POR + RESE~ TO ERROR LOGIC
RESET
GATE
+ACTIVATE
Ir-__~I[D~E~LA~Y~ r----~
4
BLOWER
RELAY
DRIVER
BLOWER
CONTROL
0-0
AUTO
"
(0\
\..J
!.-__
POWER ON
RESET &
3 SEC DELAY
FROM ERROR LOGIC.
_~H;:.:EC:;.:K--.
2./
-
'_
1)C
~
GOOD PICK
FROM OSCILLATOR
_
-..
SYNC
{
& FOUR PHASE
__--"1)-=-D-~~W
CONTROL
GENERATOR
-.. L...,............- - - '
FROM PICK LOGIC.
__
READY/STOP INDICATORS
IL-___~R~EA~D~Y_ _~-.
~A~
•
=-.JO~NIEJD~A!iR~K..I~=::_::=~
ERROR LOGIC
.,r
1~_a~---.:.:S::.:T.:.AC.:;:K:;.,C..:::H;.:;E::;;CK~--_l~__:r...,LO~G""lIcr-or-..J
~I
•• TO
Ir-----......;;;.:~.:.---_I
---
BLOWER CONTROL
i
TO BLOWER MOTOR SOLID
STATE RELAY
---
RESET
PICK LOG IC -. .._..!P~CIL~K_I~--L--1-----_+__t-----~.::.:..---_l.
TO PICK LOGIC
::84CR +CR -..
RESET
RESET
& COLUMN COUNTER
FROM COLUMN COUNTER -"'--'---I-..~
CONTROL
INHIBIT
RESET
FRO~l RESET SWITCH ~.-~RE:.:S:.::E:.:.T_1L1__ _ _ _j--------4I~--..::.::.::.::..:~.::.:;.:::.:.;---I. TO ERROR LOGIC
.~
.,
I
55
S
Vee a ' ___~).'lr---------------~5~5-----~~----~~--------~
POWER 5TURN ON
POR 5
,
I
I
,~r---S-E-C-=----=L--:l l - - - - . . . ,,5
,j
S
I
~Sl----~£ll-------~
:
READY l-5-----'----------....:.1-55~s.-J
'----...,
SWITCH DEPRETS---....r~ SWITCH RELEASE
-.w
RESET ..
5 -----'--------------:.-,
-PO-R-+-R-E-SE-T l-5____-'-_ _ _ _ _ _ _ _ _ _
-
£\1------'-----05
~~~,..J~-----~5\l--------~---O
I
.-------,Js,l_------'---....
ONE DARK 5-5- - - - - - - - - - - - - - - . . . . , > ' 5 - - - 5 l - 5- - - '
GPR
ANY CHECK
CONDITION
OR STOP
r----------------~·~5r_--~--~S~5S-----~--~
5r_-------------~.S--5Sr_------~j.s-------'
Figure 4-5 - Block and Timing Diagram, Control Logic
4-6
operation. POR is also used to initialize the Pick Logic and Column
Counter. 'P01t' 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 switch
signals while a read cycle is in progress. Signals PCLK and 84CR or CR
identify the beginning and end of a read cycle.
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 INHIBIT is not present. The Ready/Stop Logic gates the STOP
signal with RESET INIITBIT, preventing READY from being reset due to
STOP during a card read cycle. 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 (peR).
During a card read cycle, the Good Pick Sync Control detects a ONE
DARK and processes this signal with clock phase (lic and (liD 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 success~l.
The Blower Control provides signals 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 AUTO 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. 1. 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.
(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).
5.
6.
The Pick Control generates PCLK (Figure 4-6 timing) until a GPR ~
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
SI
FROM CONTROLLING
DEVICE
~
FROM {
CONTROL
LOGIC
FROM COLUMN
COUNTER
FROM 4. 8MHZ OSC {
AND FOUR PHASE
GENERATOR
REMOTE
-
::
:
PICK CMD
POR
PCLK
.;._1~0__ KHZ)
-,J
-I.;. 10 1.;. 10~Fl.
PICK
CONTROL
RESET
PICK
CONTROL
COUNTER
84CR +CR
,.~
J
Ci.
IE, ~
I
I
0C
POR
GPR
r-\I
--I
E
PIC: :::
PCLK
_
1J
]
;::VI
'"
PICK
DRIVER
,.
4
PICK
ATTalPT
,.
COUNTER
')\
II
PCR
TO CONTROLLING
DEVICE
TO CONTROL
LOGIC
e.
~
OR
TO CONTROL
LOGIC
-
PICK
FF
READY
RESET
-
BSY (BUSY)
GPR
00
FROM CONTROL
LOGIC
-
PcLK
0
I
',I
I '
~ DRIVER
TO SOLENOID
TO ERROR
~ LOGIC
1
1
Ji+i--l-US-M-I-N·-----..,~>j--~~====:>;>;~~ii~§{;@}~~~~:'7:"I1
1
----'l'~n
Ir---___',I)~~....._-----''----___',
CI
, nlli--------...!~~Z------.:.ml
I I
I
I
PCR--~'~
,
----'~~)_b_---;.I_ _ _--',!>'>-)')_ _ _......:-_ _---'I
!-ol
1
I
i
GPR----~~~I~----~I--~~--~I------'~~~------~----~
1 1--7.5 or 4.2 MS--1
1 I
I I
DEPENDING UPON
MODEL SPEED
I
1
i
.
r-I----\'I>~---_i
I
~~I
~
MCRORCR----~I~b-Ir----------------~~----~I---_\~~:------L---_\
BSY
1
I'
I
I
PICK INTERVAL
• I'
I
CARD IN READ STATlON--i
1
Figure 4-6 - 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. 2KHz until count 10 (for M200, 300 and 600)
or 6 (forM1000, M1200) is decoded generating a reset to the PickFF
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 arid begins its coimt cycle again generating another PICK and PCR
pulse. PICK and PCR pulses will continue to be generated until a GPR
is received o>r the PICK Attempt Counter counts six PCRs and the Pick
Control COlmter reaches Count 56. When six PCRs have been counted
and count 56 is reached PSET is generated. PSET will cause READY to
go false terminatlngPCLK.
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 lDltil 84CR or CR indicating the card has left the read station.
and another PICK CMD can be accepted.
The position of Switch S1 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 or CR
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 ST¢)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 STt>D to sample the Count Gating. 'The Column Counter
generates OCR (0 column reset). lCR, 8lCR, 84CR and CR. These signals
are used by the Control LogiC. Data Control and Sync Logic, Pick Logic
and Error Logic. as follows:
USED, BY
COUNT
OCR
lCR
'. 1.
Error Loglc for a Dark Check
1. 'Data Control and Sync Logic to set the Index
Mark Control Flip Flop (IMFF).
4-9
FROM DATA {
CONTROL &
SYNC LOGIC _
----
ST~C
COLUMN
COUNTER &
COUNT GATING
ST0D
RESET
FROM { - . POR
CONTROL···
LOGIC
GPR
---
.~
........
.
OR
OR
-y
ex:
ex:
0
......
u
u
cx:
cx:
u
u
.....
'<:t
co
cx:
u
co
.
COLUMNS
ST0C
~
0
1
Q;) I
2
80
81
82
83
.
....
DCKS ..
..
....
...
....
TO ERROR LOGIC
)
TO DATA CONTROL &
SYNC LOGIC. PICK LOGIC •
ERROR LOGIC. AND
CONTROL LOGIC
84 203 204 205 206 207
I 55 I I
I I ,5 I
I
I ss I
I
I
I
s
I
s
\
ST0DS
CD\~
I
\
I
I
I
I
I
I
I
I
I
I
I
I
I.
I
I
I
I
I
I
I
I
I
s
OCR 5
SS
1 CR S
SS
S~
i
81 CR S
SS
S5
§
84 CR S
~S
S5
S
CR S
~S
SS
5
'j~
Figure 4-7 - Block and Timing Diagram, Colu:rnn Counter
USED BY
COUNT
81CR
1.
2.
3.
Data Control and Sync Logic to Reset the IMFF.
Verify punch in IBM 129 Series keypunched cards.
Error Logic for a Stack Check.
84CR
1.
Control Logic to reset the RESET INlflBIT Flip
Flop.
4-10
Opt. 02
2. Pick 'Logic to enable the Pick Control for the next
PICK CMD and reset BUSY.
3. Error Logic for a Light Check.
4. Data Control and Sync Logic to reset the Sync
Control Logic.
CR (M300 Only)
ONI'. DARK
FROM ONE DARK
84 CR
FROM COLUMN
COUNTER
FROM ONE LIGHT
FROM COLUMN
COUNTER
1. Control Logic to reset the RESET INHIBIT Flip Flop.
2. Pick Logic to enable the Pick Control for the next
PICK CMD and reset BUSY.
3. Data Control and Sync Logic to reset the Sync Control
Logic.
ERROR
ONE LIGHT
•
DCKS (0-1
,
TO CONTROLLING
DEVICE
DARK CHECK
}
r ____..:.P..:.:Ic:::.:;K~C:;:H;:;E;;:CK::;;;;;:...
'/
IOOG~~NTROL
STACK CHECK
HOPPER CHECK
FROM PICK LOGIC
MOCK
FROM STACK
PHOTOTRANSISTOR
FROM COLUMN {
COUNTER
STACK
OCR
TO CONTROLLING
DEVICE
I..w-__--'~-~-------+£+--~Vcc
..._-:.;81:....;;.;CR.:...---II--~
STACK CHECK
INDICATOR
HECK
FROM HOPPI'.R
EMPTY SWITCH {
FROM CONTROL
. LOGIC
FROM STACKER
FULL SWITCH
PICK COMMAND
RECElVED
RESET INHIBIT
HOPPER EMPTY
HOPPER CHECK INDICATOR
Vee
. .-!..::PO::!R...:+...:R~E~SE:.:.T~___--I
...
TO CONTROL
LOGIC
L~:!!J-
RESET INHIBIT
__.;.;HC~K.:...-.
~~~~~~~
TO CONTROLLING
DEVICE
STACKER FULL
I
I
ss
------1
~s~-----------------------------~~
I
I
I
I
I
CHECK CONDITIONS
tS
is
I
I
81 CR
IOCR
I
I
t--"'"300'u S-I
I
I
51
~
84 CR
COL COL
18 22
/rl~'
I
I
I I
""
PICK CHECK
DARK CHECK
HOPPER EMPTY ;VERIFY PUNCH
IWrl'CH CLOSURE STACK CHECK
Figure 4-8. Block and Timing Diagram, Error Logic
4-11
s
LIGHT CHECK.
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 4-8. 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 controllillg 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 theST ACK 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 or CR is also used to reset RESET INHIBIT, 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 HOPPER CHECK to
the controlling device, Reset READY, and light the HOPPER CHECK 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 wavefonn for the Data Amplifiers and Inverters.
Light reaching the Phototransistor(PT) is amplified by the PT and Catverted into an electrical signal at its' emitter. A typical PT's emitter
waveform is ROW 12 (A). As the leadi·ng 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 tnverteJ". 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 Inve rter 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 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 collectpr, 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
. Opt., 02
~-----DATA
AMPLIFIERS------...,
ROW 12 AMPLIFIER
ROW 12@
ROW 11
AMP
ROW 11
ROW 0
AMP
ROW
•
a
TO ONE DARK
& ONE LIGHT
LOGIC
I
ROW 1 THRU 8 AMPLIFIERS
I
·1
1
I
I
1
ROW 9
ROW 9
AMP
_*___;_ _ :
CARD LEADING EDGE
ROW 12@
TYPICAL
VI
ROW 12@
CARD TRAILING EDGE
IC THRESHOLD
I
'~S--~I
~I__~
I
II
•
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. At 84CR, ONE DARK should be low indicating light
is being receiv~d by all PTs. If the foregoing conditions are not met,
a READ CHECK wiU result and the reader READY will be reset.
4.3.3
DATA 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 synchronbation 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,
~
FROM DATA
~PLIFIERS
-
ONE DARK
(NOR GATE) .
ONE DARK
1"12
t INVERTERSJ
12L .
,
...
__---;I~m
1\IOCR
GPR
\
~
,
ONE L.IGHT
ONE L1G1:T
(NOR GATE)
,,-
ONE DARK
DATA
IV
,
--
--
TO ERROR LOGIC &
CONTROL LOGIC
TO DATA REGISTER
TO· ERROR LOGIC
,
CARD DATA FIELO-----4
¥il
.
ONE LIGHT~
I~I\11-.- LEADING EOGE
.CORNER NOTCH
.
Figure 4-10~ Block and Timing Diagram, . One Dark
4-15
.Opt. 02
I
J__......1 ~ s
._~H))J
and One Light
•
I \84CR
.:
'-+-!-~
,
the first measurement is the PRESET DISTANCE. PRESET is the distance from the card's leading edge (GPR) to the point in column 01 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
Golumn 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 Synchronization 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)
C;onverts the sine wave produced by the Magnetic Pickup to a TTL compatible squarewave TST!. 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, counUng 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 are used to drive the
Column Counter. The Sync Control Logic repeats this cycle for every
other TST1 causing the Strobe Logic to generate CSDS, STfDB, STfDC
andST¢)D each time.
4-16
---
lCR
81CR
84CR
"-.
FROM {
COLUMN
COUNTER
--
"--
ST0B
OFFSET
CLOCK
OSCLK
C1
FROM 4.8MHZ {
OSCILLATOR AND - .
FOUR PHASE GEN.
l ,-~
MAGNETIC
PICK UP
0C
1
, "
TIMtNG
STROBE
GEN.
AMP
+
~
SYNC
CONTROL
LOGIC
TST2
r--.
OFFSET
STORAGE
COUNTER
i
TSTH
COMPARATOR
--
GPR
-
•
,
-ZERO
PRESET
COUNTER
RESET
,-
r----.
OSUCLK ..
•
.250"
o
01
CARD COLUMNS
ST0C
+
GPR
rt~~I----~----~:'------~,----~:------L-----~---4
PRCLK s
--
OSCLK I
ZERO
I
I
I
I
~
I
.--COUNT I
OFFSET I
r-I
I
COUNT I
~
---i
I
PRESET
DISTANCE
I~----~I----~----------~--~
,
,
I
I
I
Ss----------limnUIllIm!1I11111111W/mIlmlIHIlmi-1U--"IIIITVYlllllllllllmmIIII1"""UllUml-M-----i
I
I I
SS----------------------------i-l------------+'~/
----~l
ST0Bf
ST0C
r-,
CSDS .sS-______________..I..I__-!I_______
COL 01
....JnL---___.....J1
I
COL 0
\.Y-t
COL @~
I
I
I
..
S-S----~-------------~I--~
I
r---OFFSET DISTANCE
I
I
I
I
IMS 5S-----------------------------------------~~-L~t
1 CR
TO COLUMN
COUNTER
TO COLUMN
COUNTER & DATA
REGISTER
!U\ll\\\\\\mUuunt
I
OSUCLK
TO DATA
REGISTER·
I
»I\\\\\\m~Um\\\\\\\\\m~· PRESET:
I
I
I
----
.223"
GPR ~f--~----------------------------------------~
TIIT2
CSDS
5T0D
OFFSET
COUNTER
TO ERROR
LOGIC
-
I
//7
--
1M (INDEX
MARKS) _ TO CONTROLL! rlG
DEVICE
STROBE
LOGIC
~
I
-IMFF
, I
~
OSR
PRCLK
FROM {
CONTR.OL
LOGIC
V
/ 7
I
I
I
GPR
I
I
I
DC
Figure 4-11. Block and Timing Diagram, Data Control and Sync Logic Drivers
<:
CARD MOTI ON
--------..
ROW 12
ROW 11 •
ROW 0
ROW 1
ROW 2
ROW 3
ROW 4
ROW 5 ...
- . ROW 6 ...
ROW 7
ROW
8"
-.
ROW·9
~
~
FROM ONE DARK &
ONE LIGHT LOGIC
-----
.
D 12
D 11
D0
....
D1
D2
•
....
11'"
...
.
~
~
~
....
DATA
REGISTER
(12 BIT
STORAGE)
~
.
~
~
~
....
~
....
....
~
~
•
...
....
..
~
-
~
..
~
~
~
~
~
..
CSDS
~(DATA ENABLE)
ST0C (DATA RESET)
--
~Il
DATA
DRIVERS
D3
D4
D5
D6
D7
D8
D9
------
---------
TO CONTROLLING
DEVICE
----
-----
[I
FROM DATA
CONTROL ~
ST0C
rs--------~~~I~,----~~----------L---~5
"
CSDS
)-S- - - - - - I
......
s
ROW N ~5------,
DN j r - - - - -.....
......
I
I
I
-----!
I
Figure 4-12.
Block and Timing Diagram, Data Register and Data Drivers
4-18
ICR from the Column Counter sets the Index Mark Control Flip Flop (IMFF)
in the Strobe Logic. The Strobe Logic generates 6M s Index Marks (1M) for
each Column. The 1M indicates to the controlling device the beginning of the
guaranteed data period. When the 8ICR is received by the Strobe Logic, the
IMFF resets preventing any further 1M's from being sent to the Controlling
Device. The Da.ta Control and Sync Logic will continue to generate CSDS
signals until 84CR (or CR) 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 STQ$C 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 the
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
This section covers the interface between the M Series punched card readers and the
equipment into which it transfers data.
5.2 TIMING
In interfa cing the M Series ca rd readers to an externa I system or card reader controller,
three separate categories of interface signals must be considered. The first 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 continuously run or operate in a card-at-atime 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.
3.
Power applied and the 3-second run-up completed.
The input hopper has been loaded.
Depress and release of the RESET pushbutton.
Should all of the above conditions be satisfied, and the unit is in the remote mode
of operation 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 atleast
1 microsecond (jJ.s) 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 fJ.s
of the BUSY signal going FALSE.
5-1
READY
I--- TillE
VARIABLE
PICK COMMAND
PICK I SOLENOIDl
BUSY
__---Irf I
nL.-.__
rq-qTh
L-~:----------~I--~~11L--I-~-sE-c----------~
r'r-q=l
.I
i
u
Lt-J
-----+--'1I i :
DATA LINES
lit::
INDEW IIARKS
80 EA
=Ill
II
BUSY
COLUMN I
DATA LINES
..I..
GUARANTEED
IlA TA PERIOD
----r---.C
••
---~
SHADED AREA
I
~~2~SEC
BEGIN CARD
READ CYCLE
INDEX MARKS
COLUMN 2
GUARANTEED
NOT GUARANTEED
__________~n~·________________~n~_________
---jr
~I
6 ,u. SEC
0 _ _ _ ..
PICK
I SOLENOIDl
--11-------------------------------~I_.______
I JJ. SEC
BUSY
DATA LINES
INDEX MARKS
DATA
I
COLUMN
t
I
80
GUARANTEED
-.ll
I
==--=---=--E--......;....-.
.
t----I~..
1
- -
END CARD READ CYCLE
MODEL
NOTE'
WAVEFORMS NOT
SHOWN TO SCALE.
A
CMINl
B
C
0
E
CARD PICK
CYCLE
M200
24
6142
1421
2020
.7384
211
M300
24
2626
·606
864
100.780
1116
M600
24
2626
606
864
,3168
MIOOO
15
1608
346
496
1813
MI200
14
1232
280
408
1480
50
p.·SEC
p.SEC
P. SEC
M SEC
MSEC
P.
SEC
Figure 5-1. Interface Timing Diagram
5-2
100
60
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 until 6 attempts have been made. Mter 6 attempts have been
unsuccessful (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 signal 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 encountered 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 until 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, and
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 description 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 continues
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 staticn 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 interlace 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 lIDsuccessful 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. and 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 Documation and is shipped unassembled as a kit
(P IN 10139401).
The power ccnnector 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
D12
DII
DO
D1
D12 (RET)
Dll'(RET)
DO (RET)
Dl (RET)
D2
D3
D4
05
02 (RET)
03 (RET)
D4 (RET)
D5 (RET)
Row
Row
Row
Row
D6
07
D6 (RET)
12
11
0
1
Data
Data
Data
Data
PIN
SIGNAL
X
Y
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)
Z
AA
BB
CC
DD
EE
Row
Row
Row
Row
2
3
4
5
Data
Data
Data
Data
FF
HH
JJ
KK
LL
MM
NN
. Row 6 Data
Row 7 Data
PP
RR
SS
TT
DESCRIPTION
Row 8 Data
Row 9 Data
Index Mark
Ready
Signal Ground
Error
Hopper Check
Motion Check
Pick Command
Busy
POWER CONNECTOR PIN LIST
PIN
W
X
Y
SIGNAL
Safety GrOlmd
Neutral
115 Volts
* For Non-Standard Units,
(green)
(white)
(black)
see Wiring Diagram, figure 10-3.
5-5
5.4 SIGNAL CHARACTERISTICS'
The standard interface is supplied as the output of TTL type 7404. Signal sense is specified as a Logical TRUE and is a positive level; logical FALSE is a grOlmd 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 recomIIlended that pin EE be connected to the external equipment signal return.
Vcc
Output Drive
TTL type 7404 (or equivalent)
(~oad
Logical TRUE
I load = -400 ua @ 2.4V min
(I
Logical FALSE
I s~n
. k = 16 ma'@ 0.4V max
~ink
Vcc
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 checked 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 adjustments in this section, it will be necessary to remove the
front, top and rear panels. Remove all three panels using a 5/64 Allen wrench.
CD
a.
Remove six screws
figure 6-1.
b.
Remove four screws
c.
Remove six screws
d.
Move rear panel out slightly and disconnect fan, then remove panel.
CD
®
which hold front panel and remove panel,
which hold top cover and remove cover
which hold rear panel , figure 6-2.
RIFFLE
CAP
Figure 6-1, Front Panel and Top Cover Removal
6-1
Figure 6-2 . .Rear Panel Removal
6.2 TENSION ON THE MAIN DRIVE MOTOR BELT
The drive motor belt tension is adjusted to ensure constant card speed and timing.
a.
Using a 9/64 Allen wrench, LOOSEN four motor mounting plate screws,
figure 6-3.
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.
6-2
b.
Move motor mounting plate back and forth to be sure it slides freely.
Attach spring scale to motor so that pulling on spring scale from rear
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 four motor mounting plate screws.
DEFLECT BELT
MOTOR MOUNTING SCREWS
DRIVE ROLLER
SHAFT PULLEY
TIMING DISC
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 1/16 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.
6-3
21
TIMING
DISK
SET SCREW
AIR GAP - .007 ± .001
Figure 6-4. Magnetic Pickup Adjustment
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".
d.
Rotate timing disc and check two other positions to make sure that air gap
is maintained.
If either of these two adjustments of the magnetic pickup are not correct, card synchro-
nization may be erratic resulting in read checks or incorrect data being read.
REAR CARD CAGE COVER
Figure 6-5. Card Cage Repositioning
6.4 ADJUSTMENT OF STACK PHOTOCELL
The stack photocell is adjusted to ensure that it correctly monitors the stacking of cards
and so that it is not in the way of the cards entering the output stacker.
The card cage must be repositioned in this adjustment to allow easy access to the rear of
the stacker photocell.
a.
Using a 5/64 Allen screwdriver, remove the 4 button head screws retaining the
rear card cage cover, figure 6-5.
b.
Using the same tool, remove the 4 screws retaining the main card cage cover.
c.
Use a 9/ 64 Allen screwdriver to remove the 3 socket head screws from the
underside of the mainframe which is holding the card cage in place, figure 6-5.
d.
M~ve
e.
To gain access to the stack photocell set screw, the drive roller must be removed. Using a 1/16 Allen screwdriver loosen the set screw in the drive roller
and remove the roller, figure 6-6.
f.
USing the same tool, loosen the set screw in the stacker casting which retains
the s tack photocell, figure 6- 6.
the card cage to the rear of the reader, approximately 3 inches and replace
one of the two rear mounting screws.
PHOTO CELL SET SCREW
DRIVE
ROLLER
SET SCREW
Figure 6- 6.
Location of Photo Cell Set Screw
6-5
STACKER PHOTO CELL
Figure 6-7. Stacker Photo Cell
g.
Remove photocell from rear of stacker casting and inspect photocell lens
for any damage , figure 6-7.
h.
Replace stack photocell and align photocell lens flush with surface of
stacker casting.
i.
Tighten photocell set screw . .
j.
Replace drive roller and adjust for proper preload per paragraph 6-5.
k.
Reinstall card cage in its normal mounting position.
6.5 STACKER ROLLER SHAFT BEARING PRELOAD
The preload of bearings on drive and stacker roller shafts is very important. This
ensures that there is not detectable end play in shafts. If there is any detectable end
play, excessive wear of the support bearings will result .
a.
Preloading bearings can be accomplished by rotating roller of shaft to be
adjusted to conveniently expose the set screw. Using a 1/16" Allen screwdrive , LOOSEN set screw in top roller, figure 6-8.
b.
From bottom side of mainframe push shaft upwards as far as possible.
6- 6
1!~~;;:Br~ROLLER
BEARING
}/
h~~~L'S'ACER WASHER
BEARING
BEARING
~~~~~~SPACER
WASHER
SET SCREW
ISS
SET SCREW
MAINFRAME
Figure 6-8. Roller Shaft Bearing Preload Adjustment
c.
Using a fee~er gauge set, select gauge that will shim shaft in this position.
Place selected gauge between bottom roller and main' frame .•
NOTE'
The size of the gauge required may be
different for each shaft (5 to 25 mils).
d. Ensure that set screw is on flat side of shaft.
e.
With feeler gauge in place, exert downward pressure on top roller and
tighten set screw.
If the end play is excessive. a chattering
nois~
will be detected when drive motor '
is on.
6.6 HOPPER EMPTY SWITCH ADJUSTMENT
The adjustment of hopper empty switch, located under riffle air cap. ensures that
input hopper empty condition is detected.
a.
Using a 3/32 Allen wrench, remove two screws holding riffle air cap,
figure 6-1.
b.
Check that operating arm of switch is parallel to top of picker casting,
and that arm is not bent.
6-7
ACTUATOR
SWITCH ACTUATOR
CENTERED IN NOTCH
BLACK WIRE
MOUNTING PLATE SCREWS
Figure 6-9. Hopper Empty Switch Adjustment
c.
Using a 1/16 Allen screwdriver, LOOSEN two screws holding switch
mounting plate, figure 6-9.
d.
Center switch arm in picker casting counter bore. Exert slight pressure
on switch arm, pressing arm into casting. Tighten switch mounting plate
set screws.
e.
Replace riffle air cap.
If hopper empty switch is faulty or misadjusted, an eroneous status condition will be
developed. Refer to paragraph 9.21, Hopper Empty Switch.
6.7 STACKER FULL SWITCH ADJUSTMENT
The stacker full switch is adjusted to ensure that output stacker full condition is
detected.
a.
Place approximately one inch of cards in hopper. Depress POWER switch
placing the machine in operation.
SET SCREW
UPPER
NEGATOR
SPRING
UPPER NEGATOR
SPRING SCREW
STACKER FULL
SWITCH SCREWS
STACK SHAFT
SUPPORT
Figure 6-10. Stacker Full Switch Adjustment
6-8
b.
After a few moments , the STOP indicator should illuminate. Pull stacker
follower toward front of reader. Approximately 1/8" before end of travel,
HOPPER CHECK light should illuminate. If this condition is not met, stacker
full switch must be repositioned.
c.
Using a small Phillips screwdr.iver, LOOSEN two screws retaining stacker
full switch bracket, figure 6-10.
d.
Adjust switch bracket horizontally until HOPPER CHECK indicator illuminates
when stacker follow is approximately 1/8" before end of travel. Secure
bracket mounting screws.
6.8 PICKER SECTOR ADJUSTMENT
The picker sector is adjusted to ensure that cards are picked properly. There are six
adjustments to picker sector assembly; height, vacuum adapter air gap, rest stop,
throat block, solenoid coupling, and forward bumper stop.
CAUTION
IT IS VERY IMPORTANT THAT THE
ADJUSTMENTS BE FOLLOWED IN THE
SEQUENCE STATED.
a.
Check picker sector height adjustment. Using a 6" steel rule, measure
distance from top of mainframe to center of middle row of holes in picker
sector. This should be exactly 1-5/8" , figure 6-11.
1. 625" FROM MAINFRAME UP
TO MIDDLE ROW OF HOLES
IN VERTICAL LINE
.007 to .008
I
I
THROAT
BLOCK
VACUUM ADAPTER
PLATE SET SCREW
Figure 6-11. Picker Sector Adjustment, Rear. View
6-9
PICKER SECTOR
SET SCREWS
PICKER
BUMPER
SCREWS
RETAINING RING HOP PER EMPTY
AND SPACERS
SWITCH
PICKER
SECTOR
PICKER STOP
SCREWS
SWITCH
SCREWS
HOPPER EMPTY
SWITCH TIE-,DOWN
Figure 6-12. Picker Sector Adjustment, Front View
VACU:J M
~U6t EL~OW
Figure 6-13. Removal of Vacuum Tube Adapter
b.
If height of picker sector requires adjustment, use a 5/64 Allen wrench and
LOOSEN set screws in back of picker sector, figure 6-12.
c.
Adjust picker sector until there is exactly 1-5/8" between mainframe and
center of middle rows of holes on picker sector.
d.
The second adjustment is air gap between picker sector and vacuum adapter
plate. The tolerance between sector and plate is . 002"to allow for maximum
vacuum with free sector travel.
e.
Using a .050 Allen wrench, LOOSEN set screw in vacuum tube adapter elbow
located on underside of mainframe, figure 6-13. Remove elbow from sleeve.
Prop open hopper using about one inch of cards inserted at a right angle.
6-10
f.
Using a .050 Allen wrench. LOOSEN vacuum adapter plate set screw.
figure 6-11.
g.
Insert a .002 feeler gauge between picker sector and vacuum adapter plate..
From bottom side of mainframe push vacuum adapter plate upward. Exert
upward pressure and tighten vacuum adapter plate set screw.
h.
Replace vacuum tube adapter elbow.
i.
Check picker sector rest position. The back edge of last row of holes on the
picker sector should line up with middle of vacuum adapter plate set screw
hole. The position is established by placement of the rest stop.
j.
Using a 5/64 Allen wrench. LOOSEN two picker stop screws, figure 6-12.
k.
Using a 6" steel rule to gauge picker sector rest position. and while holding picker sector firmly in alignment push rest stop against picker sector
and tighten the screws.
1.
Check gap between throat block and picker sector. The gap should be .008
inches to ensure that only one card is picked at a time.
m. Using a small Phillips screwdriver LOOSEN screw holding throat block,
figure 6-11.
n.
Place an .008 feeler gauge between throat block and picker sector face.
o.
Exert slight pressure on rear of throat block and tighten the mounting screw.
p.
Check solenoid coupling adjustment. The solenoid coupling is used to transfer rotational solenoid motion to picker sector.
q.
Using a 1/16 Allen screwdriver. LOOSEN two set screws in the top of the
solenoid coupling. figure 6-14.
r.
Depress coupling slightly with fingers and while maintaining pressure, tighten
two coupling set screws, ensuring one set screw is on flat portion of shaft.
Remove return spring on load shaft and check that solenoid return tension is
just sufficient to return load on its stop position. Too much tension could
cause solenoid to not provide enough drive action to load shaft.
s.
Replace return spring and check solenoid action, by operating picker sector
manually while power is applied, vacuum is applied, and cards are in the
input hopper.
6-11
t.
Check adjustment of picker sector bumper. This bumper is used to limit
picker sector over-travel to . 020 inche~ beyond point where card is
delivered to pinch rollers.
u.
Place about 2" of cards in the input hopper. Depress POWER switch. With
reader in LOCAL, depress RESET switch and run a few cards into stacker.
Depress STOP switch.
v.
Manually operate picker sector. Note point at which card reaches pinch
rollers. After card is picked, there should be approximately .020" of overtravel of sector before it reaches bumper.
w. Using a 9/64 Allen wrench, LOOSEN two picker bumper socket head screws,
figure 6-12.
x.
Adjust picker bumper to proper position and tighten screws.
SPRING
POST
---~--!o+--r- DOWNWARD PRESSURE
SET SCREWS
IN TOP
COUPLING
SET SCREWS
IN BOTTOM
COUPLING
r!!::I~~===~~~~~_MOUNTING PLATE
\
FORWARD MOST SOLENOID
MOUNTING HOLE
Figure 6-14. Solenoid Preload Adjustment
6-12
6.9 VACUUM PUMP BELT TENSION ADJUSTMENT
The vacuum/blower motor belt tension is a critical adjustment. A reduction in amount
of vacuum or riffle air can cause erratic picking. The vacuum/blow er assembly must
be removed from base plate to accomplish adjustment procedure.
a.
Using a Phillips screwdriver , remove four screws from rear subframe
panel,
,figure 6-15.
b.
Remove five screws
panel.
c.
Cut the cable tie holding main connector cable to baseplate. Move subframe
pe.~1el backward and bend outward.
CD
CD
from bottom of baseplate retaining rear subframe
CARD CAGE COVER
REAR PANEL
~
Figure 6-15. Removal of Rear Subframe Panel
6-13
NOTE
Be sure to tag the wires to be
removed in the following step
to ensure they are replaced on
the proper terminals.
d.
Remove rubber hood from motor run capacitor and disconnect red
and blue clip leads, figure 6-16.
e.
Remove yellow clip lead from solid state relay .
f.
LOOSEN blower hose clamp on side of pump and remove hose from pump.
VACUUM
HOSE
VACUUM PUMP
HOSE CLAMP
VACUUM
PUMP HOSE
CLAMP
YELLOW RELAY
LEAD
Figure 6-16.
BLUE
CAPACITOR
LEAD
RED
CAPACITOR
LEAD
Disconnecting Vacuum Blower Motor Assembly
6-14
g.
LOOSEN vacuum adapter clamp on top of pump and remove from pump,
figure 6-17 .
h.
Using a Phillips screwdriver, remove ground strap from pump mounting
plate.
CAUTION
USE A t INCH OPEN -END WRENCH
TO HOLD MOUNTING POSTS TO
AVOID TWISTING OFF THE PUMP
PLATE RUBBER SHOCK MOUNT S .
CD holding the vacuum pump
i.
Remove four Phillips head mounting screws
motor assembly.
j.
The pump assembly can now be removed from reader and belt tension
adjusted.
CLAMP
SCREW
VACUUM TUBE
ELBOW SET SCREW
VACUUM
ADAPTER
GROUND
STRAP
SCREW
Figure 6-17. Removal of Vacuum Blower Motor Assembly
6-15
k.
Using a 7/ 16 open-end wrench, LOOSEN three hex bolts G)holding pump
assembly in place, figure 6-1 8.
1.
Using a spring scale, adjust for approximately 4 to 6 ounces of belt
tension. This should cause belt to deflect 3/ 64 inch when properly
adjusted.
m.
Check pulleys to make sure they are in the same plane. Also check
motor pulley set screw to make sure it is secure.
n.
Install pump in reverse order of disassembly and check reader for
proper operation.
o.
Refasten main connector cable to baseplate and replace rear subframe
panel.
SPRING SCALE
MOTOR PULLEY
SET SCREW
Figure 6-18. Adjustment of Vacuum Blower Motor Belt Tension
6-16
6.10 PICKER CASTING ADJUSTMENT
a.
Position picker casting in place, insert mounting screws but do not fully
tighten.
b.
Make a gauge using 8 new unpunched cards cut to 2 x 5 inches and staple
together.
c.
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.
I
d.
Using extender board on control card,connect voltmeter between R17 and
card ground. Verify voltage is :....- 2.3 vdc and ..:: 4.3 vdc. (Nominal
3 to 4 vdc)
e.
Repeat step d. at R18 through R28 .
f.
If any reading is outside limits, LOOSEN picker casting mounting screws and
reposition for optimum reading. Tighten screws and re-check per p&ragraph d. and e.
g.
If a dial caliper is available, measure distance from outside face of stacker
casting to outside face of picker casting. This measurement should be
2.98 inches + 1 mil.
6-17
SECtiON 7
PREVENTIVE MAINTENANCE
7.1 GENERAL
The following paragraphs provide information for preventive maintenance and genera! care
of the M-Series card readers. The card readers are of rugged construction and are
designed to provide many hours of failsafe, reliable operation; as such, preventive maintenance consists primarily of routine cleaning.
7.2 CLEANING
Keeping the card reader clean is very important and can prevent problems which appear
to be major malfunctions.
7.2.1
PICKER SECTOR
The picker sector is the heart of the card reader; it is the mechanism that must
operate properly to remain on-line. .
After each 40 hours of operation, the neoprene surface of the picker sector
should be wiped with a cloth or paper wiper saturated with a solvent such as
Freon TF. This will remove the glaze buildup from the ink which rubs off
of the cards. This is especially prevalent where new cards are used exclusively. If this glaze is allowed to remain, it reduces the coefficient of friction
of the picker sector to the point that erratic pick operation may result.
After each 160 hours of operation, the picker sector should be examined to see if
any of the vacuum holes have become plugged with lint, trash, or card meal which
the solvent scrub has failed to dislodge. If so, gently push this debris through the
holes with a paper clip while the reader is on. The vacuum system will remove
the debris.
7.2.2
CASTING ASSEMBLIES
After each 160 hours of operation, the card track should be cleaned. Using a
5/64 Allen wrench, remove four button head screws
Figure 9-1, holding
top panel cover. RBll ove this cover and use a vacuum cleaner to remove any
card debris buildup around the picker and stacker castings. Use a small brush
to clean around the picker and stacker rollers and picker sector.
®,
7-1
7.2.3
CoollNG FAN
The cooling fan air-intake screen performs the function of preventing dirt and dust
from entering the card reader interior. Depending upon the operational atmosphere,
the screen should be cleaned as necessary. Use a flat-blade screwdriver and remove the screen, then clean in a solvent or use a vacuum cleaner as necessary.
7.2.4
EXTERIOR CLEANING
The exterior should be cleaned as often as practical. Wipe the exterior with a
clean, lint-free cloth saturated wi th a mild solvent such as denatured alcohol or
household ammonia after each 40-hour operational period. If persistent dirt
buildup is present, the exterior should be rubbed down with a heavier solvent.
Attention to this routine will keep the anodized finish of the reader with a like-new
appearance indefinitely.
7.3 LUBRICATION
The rollers of the rotary solenoid should be checked and one drop of lubricant applied to
each roller every four months of operation. The amount of lubricant required will be
determined by the humidity, use, and speed of the machine, but the four month application
will maintain a safe level. Sparingly appl y light lubricant, (Part No. 124048-001), to each
of the three roller grease points (Figure 7 -1). This is available from Documation or
Ledex, Inc., Dayton, Ohio.
RETURN SPRING
COUPLING
GREASE POINT (3)
SOLENOID
Figure 7-1.
Solenoid Lubrication
7-2
SECTION 8
TROUBLESHOOTING
. J
'.1 GENERAL '
If trouble persists after checking the adjustme'nt procedures in Section 6, use the following
fault isolation chart to analyze the problem. If it is determined that a part is defective and
needs replacement, use the repair and replacement procedure in Section 9, and the illustrated parts breakdown.
FAULT ISOLATION CHART
SYMPTOM
PROBABLE CAUSE
POWER indicator falls to '
light.
A given lamp faUs to light
when lamp test switch is
activated (POWER indicator
excluded).
REMEDY
1. Power cord is not con·nected to reader or power
source.
1. Connect power cord to
reader and power source.
2. Circuit breaker CB1 is
not on
3. Fuse Fl is defective.
2. Place circuit breaker CBl
to ON position.
3. Replace Fl.
4. Lamp is burned out.
4. Replace lamp.
5. +5 volt power regulator
defective.
5. Replace +5 volt power
regulator.
1. Lamp is burned out.
2. Defective Error Card.
1. Replace defective lamp.
2. Replace Error Card.
When LAMP TEST switch is 1. Defective lamp test
activated, none ci the lamps
switch.
( I l the control panel willligbt. 2. Defective Error Card
(POWER indicator excluded).
1. Replace lamp test switch.
HOPPER CHECK indicator
does not light when hopper
goes empty or stacker goes
full. No other error indicatims.
1. Lamp is' burned out.
1. Replace lamp.
2. Defective Error Card.
2. Replace Error Card.
.
HOPPER CHECK indicator
1. Hopper emptY switch not
does not light when hopper
adjusted properly.
JOes empty and PICK CHECK 2. Defective hopper empty
indicator is lit.
switch.
8-1
2. Replace Error Card.
1. Adjust hopper empty
switch per paragraph 6. 6.
2. Replace hopper empty
switch.
SYMPTOM
REMEDY
PROBABLE CAUSE
1. Adjust stacker full switch
HOPPER CHECK indicator
doe s not light when stacker
goes full.
1. Stacker full switch is not
2. Defective stacker full
switch.
2. Replace stacker full
switch.
PICK CHECK indicator fails
to light when reader makes
six attempts and fails to
pick a card.
1. Lamp is burned out.
1. Replace lamp.
2. Defective Error Card.
2. Replace Error Card.
ST ACK CHECK indicator
fail s to light when there is
a stack check condition.
1. Lamp is burned out.
1. Replace lamp.
2. Defective Error Card.
2. Replace Error Card.
PICK CHECK indicator
lights regularly after making six pick attempts.
1. Dirty picker sector.
1. Clean picker sector with
2. Maladjustment of picker
stops, vacuum plate,
throat clearance, or
solenoid coupling.
0.
" Defective Sync Card.
4. Defective Error Card.
READ CHECK indicator
fails to light when a dark
check or light check condition occurs.
Reader picks three cards,
and then stops with a PICK
CHECK.
per paragraph 6. 7.
adjusted properly.
denatured alcohol.
2. Readjust picker sector
per paragraph 6.8.
j~
d.
Replace Sync Card.
5. Defective Clock Card.
4. Replace Error Card.
5. Replace Clock Card.
1. Lamp is burned out.
2. Column "0" output or
1. Replace lamp.
2. Replace Clock Card.
Column "81" output is
missing from the Clock
Card.
3. One light or one dark
output missing from the
Control Card.
3. Replace Control Card.
4. Defective Error Card.
4. Replace Error Card.
1. Good pick reset output
is missing from the Clock
Card.
1. Replace Clock Card.
2. Clear pick control is miss- 2. Replace Sync Card.
ing on the Sync Card.
3. Pick attempt counter is
not being cleared out
properly.
8-2
3. Replace Sync Card.
SYMPTOM
REMEDY
PROBABLE CAUSE
Reader picks two to six cards Pick attempt counter is not
and then stops with a PICK
being reset at good pick reCHECK.
set time. Defective Sync
Card.
Reader picks one card but
the reader will not pick
additional cards. Unable
to stop the reader by pressing the STOP switch.
Reader reads erroneous
data.
Sharp, metallic noise from
picker sector while reading
cards.
1. Column "84CR or CR"
Replace Sync Card
1. Replace Clock Card
output is missing from
the Clock Card.
2. Column strobe phase "B"
or phase "D" is missing
from Sync Card.
2. Replace Sync Card.
3. Clock phase "C" or
phase "D" is missing
from Clock Card.
3. Replace Clock Card.
4. Clock phase "B" is
missing from Clock
I
Card.
4. Replace Clock Card.
1. Defective Clock Card.
2. Defective Sync Card.
3. Defective Control Card.
1. Replace Clock Card.
1. Picker sector maladjusted.
2. Rubber roller worn.
3. Bearing bad.
4. Belt too tight.
2. Replace Sync Card.
3. Replace Control Card.
1. Adjust picker sector per
procedure in paragraph
6.8.
2. Replace roller.
3. Replace bearing.
4. Readjust belt.
NOTE
When using test equipment for troubleshooting, connect test equipment ground
to card logic ground to obtain accurate
values.
8-3
SECTION 9
REPAIR PROCEDURES
9.1 GENERAL
The following repair procedures detail step by step methods for those parts for which
replacement may be required during the Ufe of the reader. It is recommended that these
procedures are followed closely and performed by a technician familiar with tools, their
use and disassembly/assembly techniques.
'
9.2 REQUIRED TOOLS
The following tools are required to perform removal and replacement procedures in this
section and adjustment procedures in Section 6.
Manufacturer and Part
Description
Number of Special Tools
1/16" Allen Screwdriver
3/32" Allen Wrench (long arm)
5/64" Allen Wrench (long arm)
7/64" Allen Wrench (long arm)
1/8" Allen Wrench (long arm)
9/64" Allen Wrench (long arm)
. 050" Allen Wrench (short arm)
1/16" Allen Wrench (short arm)
AMP Extraction Tool
AMP 91022-1
"AMP Leaf Contact" Extraction Tool
AMP 465195-2 or 465275-1
"AMP Modified Fork" Contact Extraction Tool
AMP 91037-2
"AMP Mod IV" Contact Extraction Tool
AMP 91029-1A
Deutsch Insertion/Extraction Tool(on base plate) M15570-16
IC Removal Tool
AMP 91049-1
Elco Extraction Tool
Elco 061877-04
Elco Insertion Tool
Elco 061742-04
Feeler Gauge Set 0.0015" thru 0.025"
Long Nose Pliers
AP Inc. 923700
IC 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/Hi" - Open End or Socket Wrench
#1 Phillips Screwdriver 6" long
#2 Phillips Screwdriver 6" long
Printed Circuit Card Extender
Documation PiN 103099501
#2 Retaining Ring Remover
Side Cutter
Solder Removal Tool
60-Watt Soldering Iron
32-oz. Spring Scale
9-1
RIFFLE
CAP
Figure 9-1.
Front Panel and Top Cover Removal
Figure 9-2. Rear Panel Removal
9-2
9.3 MAIN DRIVE MOTOR BELT
CD
a.
Using a 5/64 Allen wrench, remove six 6 x 32 button head screws
holding front panel and remove front panel, figure 9-1.
b.
Using a 5/64 Allen wrench, remove six 6 x 32 button head screw s ®
holding rear panel, move rear panel out slightly, disconnect fan motor connector, and remove rear panel, figures 9-2 and 9-14.
c.
Using a 9/64 Allen wrench, LOOSEN three 8 x 32 socket head motor mounting plate screws (bottom of mainframe). Remove fourth motor mounting
plate screw, figure 9-3.
d.
Using a 1/16 Allen wrench, LOOSEN 8 x 32 set screw in timing disc, figure
9-4.
CAUTION
REMOVE TIMING DISC USING EXTREME
CARE NOT TO DAMAGE TEETH ON DISC.
WRAP DISC IN SOFT TISSUE WHILE NOT
IN READER.
e.
Using a 1/16 Allen wrench, LOOSEN set screw in fifth stacker roller
pulley, figure 9-5.
f.
Remove fifth stacker roller pulley from stacker-roller shaft.
g.
Using a. 3/32 Allen wrench, LOOSEN set screw in bottom fourth sta.cker
roller pulley.
h.
Remove bottom fourth stacker roller pulley.
i.
Remove main drive motor belt, figure 9-4.
j.
To replace main drive motor belt:
CAUTION
PULLEY CONFIGURATION MUST BE MAINTAINED.
ALWAYS REPLACE PROPER PULLEY IN ITS
CORRECT POSITION (UPPER OR LOWER) ON ITS
RESPECTIVE SHA FT. FIGURE 9-6 SHOWS THE
CORRECT CONFIGURATION.
9-3
MOTOR MOUNTING SCREWS
REMOVE THIS SCREW
Figure 9-3.
FIRST STACKER
DRIVE BELT
Main Drive Motor Mounting
SECOND STACKER
DRIVE BELT
MAIN DRIVE
MOTOR BELT
TIMING DISC
TIMING DISC
SET SCREW
MAIN DRIVE
MOTOR PULLEY
THIRD STACKER
DRIVE BELT
Figure 9-4.
MAGNETIC PICKUP
MOUNTING BLOCK
Stacker Drive Train Belt Arrangement
9-4
1.
Place belt over main drive motor pulley.
2.
Slip belt over upper fourth stacker roller pulley, figure 9-5.
3.
Place belt over fifth stacker roller pulley and replace this pulley on
fifth stacker roller shaft.
4.
Replace bottom fourth stacker roller pulley
5.
Locate fourth stacker roller pulley so that set screw is on flat side
of shaft and carefully tighten set screw.
CAUTION'
USE MODERATE TORQUE TO TIGHTEN'
PULLEY SET SCREW. DO NOT OVERTORQUE OR DAMAGE WILL RESULT TO
PULLEY.
6.
Push fifth stacker roller pulley up against mainframe, then pull
VERY SLIGHTLY downward making sure pulley is free from mainframe.
7.
Locate fifth stacker roller pulley so that set screw is on flat side of
shaft and carefully tighten set screw.
k.
Replace timing disc on fifth stacker roller shaft and tighten set screw
lightly.
1.
The main drive motor belt tension must be adjusted first. Refer to paragraph 6.2.
m. Second, the magnetic pickup and timing disc must be adjusted. Refer to
paragraph 6.3.
9.4 THIRD STACKER ROLLER DRIVE BELT
a.
Using steps a. and b. of paragraph 9.3, remove front and rear panels,
figures 9-1 and 9-2.
.
b.
Using a 3/32 Allen wrench, LOOSEN set screw in bottom fourth stacker
roller pulley, figure 9-5 .
c.
Pull bottom pulley down to disengage third stacker drive belt. Remove
pulley and belt.
9-5
FOURTH STACKER
ROLLER PULLEYS
THIRD STACKER
ROLLER PULLEYS
•
FIFTH STACKER
ROLLER PULLEY
SECOND STACKER
ROLLER PULLEYS
SET SCREW
SET SCREWS
SET SCREWS
SET SCREWS
Figure 9-5. Stacker Drive Train Pulley Arrangement
/---.--------
M 300-M 600
.....
~
"
20127008
IS-Tooth (60 Hz)
20127006
18-Tooth (SO Hz)
lSXL037
80XL02S
20080404
IS-Tooth
80XL02S
lSXL037
D
20080401
14-Tooth
D
20080401
14-Tooth
Figure 9- 6.
....
\.
~
14XL037
D
D
lSXL037
20127004
(60 Hz)
20127003
(50 Hz)
0
0
20127003
Pulley and Bel t Configuration
9- 6
'''~
20127003
70XL02S
20127007
14-Tooth (60 Hz)
20127009
16-Tooth (50 Hz)
16XL037
16XL037
--------
lSXL037
20080404
IS-TOOTH
M 1000
D
..........
20127004
(60 Hz)
20127003
(50 Hz)
D
d.
Replace third stacker drive belt on bottom third stacker roller pulley and
around fourth stacker roller shaft.
e.
Replace bottom pulley of fourth stacker roller on shaft and push up until it
engages with belt and is against top pulley.
f.
Position fourth stacker roller pulley so that set screw is on flat side of
shaft and belt is parallel to other drive belts. Carefully tighten set screw.
g.
Replace front and rear panels .
• .5 F.IT ITACKElIIOLLER DRIYEBELT
CAUTION
USE MODERATE TORQUE TO TIGHTEN
PULLEY SET SCREW. DO NOT OVERTORQUE OR DAMAGE WILL RESULT TO
PULL£Y.
a.
Using steps a. and b. of paragraph 9. 3, remove front and rear panels,
figures 9-1 and 9-2.
b.
Using a 3/32 Allen wrench, LOOSEN set screw in bottom second stacker
roller pulley, figure 9-5.
c.
Pull bottom pulley down to disengage first stacker drive belt. Remove
pulley and belt.
d.
Replace first stacker drive belt on bottom first stacker roller pulley and
around second stacker roller shaft.
e.
Replace bottom pulley of second stacker roller on shaft and push up until
it engages with" belt and is against top pulley.
f.
Position second stacker roller )pulley so that set screw is on flat side of
shaft and belt is parallel to other drive belts. Carefully tighten set
screw.
g. . Replace front and rear panels.
9-7
9.6 SECOND STACKER ROLLER DRIVE BELT
CAUTION
USE MODERATE TORQUE TO TIGHTEN
PULLEY SET SCREW. DO NOT OVERTORQUE OR DAMAGE WILL RESULT TO
PULLEY.
a.
Using steps !i. and b. of
figures 9-1 and 9-2.
b.
Using a 3/32 Allen wrench, LOOSEN set screw in bottom second stacker
roller pulley.
c.
Pull bottom pulley down to disengage first stacker drive belt. Remove
pulley and belt.
d.
Using a 3/32 Allen wrench ,LoOSEN set screw in bottom fourth stacker
roller pulley.
e.
Pull bottom pulley down to disengage third stacker drive belt. Remove
pulley and belt.
f.
Using a 3/32 Allen wrench,IDOSEN set screw in top second stacker roller
pulley.
g.
Pull top pulley down to disengage second stacker drive belt. Remove
pulley and belt.
h.
Replace second stacker drive belt on top third stacker roller pulley and
around second stacker roller shaft.
i.
Replace top pulley' of second stacker roller on shaft and push up until it
engages with belt.
par~graph
9.3, remove front and rear panels,
NOTE
Observe position of upper pulleys with
respect to mainframe, figure 9-5. Note
that pulleys three, four and five are
installed close to mainframe with a slight
clearance. Pulley number two should
be lowered sufficiently to allow belt to
line up with pulley number three.
9-8
j.
Position top second stacker roller pulley so that set screw is on flat side of
shaft and belt lines up with top pulley of third stacker roller. Carefully
tighten set screw.
k.
Replace first stacker drive belt on bottom first stacker roller pulley and
around second stacker roller shaft.
1.
Replace bottom pulley of second stacker roller on shaft and push up until
it engages with belt and is against top pulley.
m. Position second stacker roller on shaft so that set screw is on flat side of
shaft and belt is parallel to other drive belts. Carefully tighten set screw.
n.
Replace third stacker drive belt on bottom third stacker roller pulley and
around fourth stackp.J' roller shaft.
o.
Replace bottom pulley of fourth stacker roller on shaft -and push up until it
engages with belt flnd is against top pulley.
p.
Position fourth stacker roller pulley so that set screw is on flat side of
shaft and belt is parallel to ether drive belts. Carefully tighten set screw.
q.
Replace front and rear panels.
9.7 FIRST, SECOND, AND THIRD STACKER ROLLER BEARING ASSEMBLIES
NOTE
Replace both bearings and shaft
with new matched assembly to
assure proper operation.
a.
Using steps a. and b. of paragraph 9.3, remove front and rear panels,
figures 9-1 and 9-2. Also remove four screws ® ,figure 9-1, holding
top panel cover.
b.
Use a 1/2 inch thick group of cards to prop stacker follower in extended
position.
c.
To replace first stacker roller bearings, perform step d; to replace second
stacker roller bearings, perform step e; to replace third stacker roller
bearings perform step f.
d.
To replace first stacker roller bearing assembly perform the following
substeps.
9-9
CAUTION
USE MODERATE TORQUE TO TIGHTEN
PULLEY SET SCREW. DO NOT OVERTORQUE OR DAMAGE WILL RESULT TO
PULLEY.
1.
Using a 3/32 Allen wrench, LOOSEN set screw in bottom second
s·tacker roller pulley, figure 9-5.
2.
Pull bottom pulley down to disengage first stacker drive belt. Remove
pulley and ,belt .
3.
Using a 3/32 Allen wrench, LOOSEN set screw in first stacker roller
pulley. Remove pulley.
4.
Perform the following substeps to replace bearing assembly.
a.
Using a 1/16 Allen wrench, LOOSEN set screw in bottom roller
of stacker roller assembly.
b.
Lift stacker shaft straight up and out of stacker casting. Observe
that there is a spacer washer between the top roller .and the bearing seat, figure 9-7. Remove top roller from shaft.
c.
To remove top bearing, use L-shaped tool to lift bearing from
assembly.
d.
To remove bottom bearing, slide out bottom roller and spacer
washer. Use a straight tool to tap edge of bearing from inside of
shaft hole to drop bearing from casting.
e.
Install new bearings. Place spacer washer on top bearing. Slide
bottom roller and spacer washer under shaft hole.
f.
Replace top roller on new shaft, flush with (or slightly below)
shaft end. Replace shaft in shaft hole. Select feeler gauge
(5 to 25 mils) to force roller against bearing.
g.
Insert feeler gauge between main frame and bottom roller.
Apply firm finger pressure on top roller and tighten set screw in
bottom roller.
h.
Check for vertical play in stacker shaft. If there is vertical play,
LOOSEN set screw in bottom roller and repeat step g.
9-10
PHOTO CELL SET SCREW
DRIVE
ROLLER
SET SCREW
ROLLER
SET SCREW
SPACER WASHER
J.7E;::;=S~t;J~ BEARING
BEARING
'"'-:~~~~==SPACER WASHER
SET SCREW
ROLLER
PULLEY
L..,~...r---SET SCREW
MAINFRAME
Figure 9-7.
Pictorial, Stacker Roller Bearing Assembly
9-11
•
e.
5.
Replace first stacker roller pulley on first stacker roller shaft in position shown in figure 9-5.
6.
Position first stacker roller pulley so that set screw is on flat side of
shaft. Carefully tighten set screw.
7.
Replace first stacker drive belt on first stacker roller pulley and
around second stacker roller shaft.
8.
Replace bottom pulley of second stacker roller on shaft and push up
until it engages with belt and is against top pulley.
9.
Position second stacker roller pulley so· that set screw is on flat side of
shaft and belt is parallel to other drive belts. Carefully tighten set
screw.
To replace second stacker roller bearing assembly perform the following
substeps.
CAUTION
USE MODERATE TORQUE TO TIGHTEN
PULLEY SET SCREW. DO NOT OVERTORQUE OR DAMAGE WILL RESULT TO
PULLEY.
1.
Using a 3/32 Allen wrench, LOOSEN set screw in bottom second stacker
roller pulley.
2.
Pull bottom pulley down to disengage first stacker drive belt. Remove
pulley and belt.
3.
Using a 3/32 Allen wrench, LOOSEN set screw in top second stacker
roller pulley.
4.
Pull top pulley down to disengage second stacker drive belt. Remove
pulley.
9-12
f.
5.
Perform step d. 4. to replace bearing assembly.
6.
Place second stacker drive belt on third stacker roller pulley and
around second stacker roller shaft.
7.
Replace top pulley of second stacker roller on shaft and push up until
it engages with belt.
8.
Position second stacker roller pulley so that set screw is on flat side
of shaft and belt is parallel to other drive belts. Carefully tighten
set screw.
9.
Place first stacker drive belt on first stacker roller pulley and around
second stacker roller shaft.
10.
Replace bottom pulley of second stacker roller on shaft and push up
until it engages with belt.
11 .
Position second stacker roller pulley so that set screw is on flat side
of shaft and belt is parallel to other drive belts. Carefully tighten
set screw.
To replace third stacker roller bearing assembly perform the following
substeps.
CAUTION
USE MODERATE TORQUE TO TIGHTEN
PULLEY SET SCREW. DO NOT OVERTORQUE OR DAMAGE WILL RESULT TO
PULLEY.
1." Using a 3/32 Allen wrench, LOOSEN set screw in bottom second stacker
roller pulley.
2.
Pull bottom pulley down to disengage first stacker drive belt. Remove
pulley and belt.
3.
Using a 3/32 Allen wrench, LOOSEN set screw in bottom fourth stacker
roller pulley.
4.
Pull bottom pulley down to disengage third stacker drive belt. Remove
pulley and belt.
5.
Using a 3/32 Allen wrench, LOOSEN set screw in bottom third stacker
roller pulley. Remove pulley.
9-13
6.
Using a 3/32 Allenwrench,LOOSEN set screwin top second stacker
roller pulley.
7.
Pull top pulley down to disengage second stacker d'rive belt. Remove
pulley and belt.
8.
Using a 3/32 Allen wrench, LOOSEN set screw in top third stacker
roller pulley. Remove pulley.
9.
Perform step d. 4 to replace bearing assembly.
10.
Replace top third stacker roller pulley on third stacker roller shaft
in position shown in figure 9.5.
11.
Position third stacker roller pulley so that set screw is on flat side
of shaft. Carefully tighten set screw.
12.
Place second stacker drive belt on third stacker roller pulley and
around second stacker shaft.
13.
Replace top pulley of second stacker roller on shaft and push up until
it engages with belt.
14.
Position second stacker roller pulley so that set screw is on flat side
of shaft and belt is parallel to other drive belts. Carefully tighten
set screw.
15.
Replace bottom pulley on third stacker roller shaft.
16.
Position third stacker roller pulley so that set screw is on flat side of
shaft. Carefully tighten set screw.
17 ~
Place third stacker drive belt on third stacker roller pulley and around
fourth stacker roller shaft.
.
18.
Replace bottom pulley of fourth stacker roller on shaft and push up
until it engages with belt.
19. , Position fourth stacker roller pulley so that set screw is on flat side
I
of shaft and belt is parallel to other drive belts. Carefully tighten
set screw.
20.
Place first stacker drive belt on first stacker roller pulley and around
second stacker shaft.
9-14
21 .
Replace bottom pulley of second stacker roller on shaft and push up
until it engages with belt.
22.
Position second stacker roller pulley so that set screw is on flat side
of shaft and belt is parallel to other drive belts. Carefully tighten
set screw.
g.
Remove cards used to prop stacker in extended position.
h.
Replace front and rear panels and top panel cover.
9.8 SOLENOID
a.
Using steps a. and b. of paragraph 9.3, remove front and rear panels,
figures 9-1, and 9-2.
NOTE
Hold lugs on board with long nose
pliers while unsoldering or soldering leads in the following procedure.
This will prevent the lugs from
being disconnected from the land on
the bottom side of the board.
b.
Unsolder two white leads from solenoid drive circuit board.
c.
Remove solenoid return spring from spring post and arm stud, figure 9-8.
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
mounting plate. Remove solenoid downward.
CD
holding solenoid
NOTE
Viewing the bottom of the solenoid plate.
note that the solenoid mounting holes are
not in line with the mounting plate holes.
To ensure that the solenoid is reinstalled
correctly, make sure the wires are extending from the right side (viewed from the
front of the reader) and that the forwardmost solenoid mounting hole is on the right
side.
9-15
SOLENOID
ASSEMBLY
SPRING
POST
SOLENOID
RETURN
SPRING
SOLENOID
LEADS
ARM
STUD
\fdAWffkffffffffffffffl!
------1.-'--~---r--
DOW NWAR D PRESSU R E
SET SCREWS
IN TOP
COUPLING
SET SCREWS
IN BOTTOM
COUPLING
,.ll---1JL.;:::c======:=::t:;"'-..l.l.---Ll,~_ MOU NT I NG PLAT E
FORWARD MOST SOLENOID
MOUNTING HOLE
Figure 9-8.
Pictorial, Solenoid Assembly
9-16
®
f.
Using an 11/32 wrench, remove two mounting nuts
g.
Using a 1/16 Allen wrench, LOOSEN two set screws retaining coupling
on solenoid shaft. Remove coupling.
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 the shaft.
i.
Tighten bottom coupling set screws and replace solenoid on mounting plate
making sure holes are in proper position, with wires extending from right
side.
j.
Replace solenoid on mounting post, sliding top coupling onto picker shaft.
k.
Replace solenoid return spring between spring post and arm stud.
1.
Solder two white leads to solenoid drive circuit board, terminals 3 and 4.
m. Preload solenoid coupling per paragraph 6.8, steps q. , r. , and s.
NOTE
If proper pick action does not result after
preloading the solenoid, perform the
Picker Sector Adjustment, paragraph 6.8.
n.
Replace front and rear panels.
9.9 VACUUM PUMP MOTOR ASSEMBLY BELT
a.
Remove front and rear panels. Refer to steps a. and b. of paragraph 9.3 ,
figures 9-1 and 9-2.
b.
Remove four Phillips head screws
9-9.
9-17
CD
at rear of subframe panel, figure
CARD CAGE COVER
Figure 9-9.
REAR PANEL
Removal of Rear Subframe Panel,
Main Card Cage Cover and Panel
VACUUM
HOSE
VACUUM PUMP
HOSE CLAMP
VACUUM
PUMP HOSE
CLAMP
YELLOW RELAY
LEAD
Figure 9-10.
BLUE
CAPACITOR
LEAD
RED
CAPACITOR
LEAD
Vacuum Pump Motor Assembly Connections
9-18
c.
Remove five Phillips head screws
holding subframe panel.
®
on bottom, rear edge of card reader,
NOTE
Tag the wires to be removed in the
following step. They must be replaced on the proper terminals.
d.
Remove two connectors from capacitor and one connector from relay to
disconnect vacuum pump motor, figure 9-10.
e.
Loosen vacuum hose clamp on vacuum pump and remove hose from pump.
f.
Using a j 050 Allen wrench, LOOSEN set screw in vacuum tube elbow and
pull elbow downward, figure 9-11.
g.
LOOSEN vacuum adapter clamp screw at top of vacuum pump assembly
and remove adapter from card reader with a slight upward pressure.
h.
Remove screw holding ground strap to submme.
CAUTION
USE A t INCH OPEN-END WRENCH TO
HOLD MOUNTING POSTS TO AVOID
TWISTING OFF THE PUMP PLATE RUBBER SHOCK MOUNTS.
i.
Remove four Phillips head mounting screws holding vacuum pump motor
assembly, figure 9-11.
j.
The vacuum pump assembly may now be removed from card reader.
k.
LOOSEN three hex ,'acuum pump mounting bolts (j)figure 9-12.
1.
Replace vacuum pump belt.
m. Using a spring scale, adjust vacuum pump for a belt tension of 4-6 ounces.
This is about 3/64" belt deflection.
n.
With appropriate belt tengion applied, tighten three hex vacuum pump
mounting bolts.
o.
Check pulleys to make sure they are in the same plane. Also check each
pulley set screw to make sure it is secure.
9-19
CLAMP
SCREW
VACUUM
ADAPTER
VACUUM TUBE
ELBOW SET SCREW
GROU ND
STRAP
SCREW
Figure 9-11.
Removal of Vacuum Pump Motor Assembly
SPRING SCALE
MOTOR PULLEY
SET SCREW
Figure 9-12.
Vacuum Pump Belt Replacement
9-20
p.
Reinstall vacuum pump assembly into card reader in reverse order of
disassembly.
q.
Replace panels removed.
9.10 MAGNETIC PICKUP
a.
Using step b. of paragraph 9.3, remove rear panel, figures 9-2 and 9-14.
b.
Using a 1/16 Allen wrench, LOOSEN set screw in magnetic pickup mounting
block, figure 9-13.
c.
Remove magnetic pickup from mounting block.
d.
Remove two button head screws on each side of card cage cover. slide
backward. and lift off, figure 9-9.
e.
Remove four button head screws holding rear panel of card cage and remove rear panel.
f.
Using a 9/64 Allen wrench, remove three socket head screws CD holdjng
card cage in place. Move card cage to rear and remount using two rear
screws. figures 9-14 and 9-15.
g.
Remove all cards from card cage using card extractor levers. figures 9-15.
NOTE
Tag magnetic pickup wires so that they
can be identified with their proper position in the card cage connector. figure
9-15.
h.
Using AMP tool 465195-2, remove two magnetic pickup wires and shield
from card cage connectors.
i.
Replace wires from new magnetic pickup unit into their proper positions
in card cage connector. figure 10-3.
j.
Insert the pickup unit into mounting block, figure 9-13.
k.
Refer to paragraph 6.3 for adjustment of magnetic pickup.
I.
Reassemble reader in reverse order of disassembly.
9-21
TIMING
DISK
MAINFRAME
MAGNETIC
PICKUP TIP
SET SCREW
Figure 9-13.
SUPPORT
FOLLOWER
CASTING
FOLLOWER
SHAFT
MAGNETIC
PICKUP
MAGNETIC PICKUP
MOUNTING BLOCK
Magnetic Pickup Replacement
HOPPER
FOLLOWER
\
FAN MOTOR
CONNECTOR
Figure 9-14.
Card Cage Repositioning
9-22
REMOVE CARDS
MAGNETIC PICKUP
WIRES
Figure 9-1 5.
CARD CAGE MOUNTED
IN EXTENDED POSITION
Ca r d Cage in E x tended Position
Figure 9-1 6.
Picker Cas ting R em oval
9-23
9.11 PICKER SUPPORT ASSEMBLY
The Picker Support Assembly must be removed to replace any of the following assemblies and installed after the replacement of the assembly. These assemblies are:
Read Array
Light Station
a.
Fourth and Fifth Stacker Roller Bearing Assemblies
First and Second Picker Roller Bearing Assemblies
To remove the Picker Support Assembly proceed as follows:
1.
Using steps a. and b. of paragraph 9.3, remove front and rear panels,
figures 9-1 and 9-2.
2.
Using a 5/64 Allen wrench, remove four' bu tton head screw s
holding top panel cover, figure 9-1.
3.
Using a 9/64 Allen wrench, remove two socket head screws
stacker follower casting, figure 9-16, front of reader.
4.
Using a 9/64 Allen wrench, remove two socket head screw s holding
hopper support follower casting, figure 9-17.
5.
Remove hopper follower shaft.
6.
Pull hopper support follower beyond rear of mainframe sufficiently to
expose negator spring screw.
7.
Using a Phillips screwdriver, remove negator spring screw and allow
spring to slowly return to its roller. Remove hopper follower.
® ,
CD
holding
I
8.
Using a .050 Allen wrench, LOOSEN vacuum tube elbow set screw.
figure 9-11. Slide elbow off vacuum tube and move to left.
9.
LOOSEN adapter clamp screw at top of vacuum pump assembly and
with a slight upward pressure remove this adapter from card reader.
10.
LOOSEN screw on two large hose clamps; remove blower hose, figure
9~10.
11.
Remove solenoid return spring, figure 9-8.
12.
Using a 1/16 Allen wrench, LOOSEN two top solenoid coupling set
screws.
13.
Using a 9/64 Allen wrench, remove two socket head screws CD
holding solenoid assembly. Lay solenoid assembly on baseplate.
9~24
HOPPER FOLLOWER
SHAFT
HOPPER
FOLLOWER
REAR OF
READER
HOPPER SUPPORT
FOLLOWER SCREWS
Figure 9-17. Hopper Follower As sembly Removal
b.
®
14.
Using a 9/64 Allen wrench, remove six socket head screws
picker casting.
holding
15.
Remove plastic tie-down holding light station cable on solenoid mounting post.
16.
Remove plastic tie-down holding hopper empty switch cable. figure
9-19.
17.
Lift picker casting straight up and lay on chassis, figure 9-18.
To replace the Picker Support Assembly proceed as follows:
1.
Set picker casting in place, figure 9-19.
2.
Using LOCTITE GRADE C, set all six socket head screws
9-16, BUT DO NOT TIGHTEN.
3.
Adjust position of picker casting per paragraph 6.10.
4.
The remainder of the reader may now be assembled in reverse order
of disassembly.
5.
Readjust the picker sector per paragra.ph 6.8.
9-25
®
,figure
FOURTH STACKER
ROLLER BEARINGS
Figure 9-18.
Picker Casting Removed From Reader
PICKER SECTOR
SET SCREWS
PICKER
BUMPER
SCREWS
Figure 9-19.
RETAINING RING HOPPER EMPTY SWITCH
AND SPACERS
SWITCH
. SCREWS
PICKER
SECTOR
PICKER STOP
SCREWS
HOPPER EMPTY
SWITCH TIE-DOWN
Replacement of Picker Casting And
Picker Sector, Front View
9-26
9.12 READ HEAD
a.
Remove. picker support assembly per paragraph 9.11 a.
b.
Remove two button head screws each side of card cage cover and remove
main card cage cover sliding back slightly and lifting upward, figure 9-9.
c.
Remove four button head screws and remove rear card cage panel.
d.
Using a 9/64 Allen wrench, remove three socket head screws CD holding
card cage in place. Move card cage to rear and remount using two rear
screws. figures 9-14 and 9-15.
.
e.
Remove all cards from card cage using extractor levers, figure 9-15.
f.
Using AMP tool 465195-2, remove read head wires from connector per the
following diagram.
_~~~~~~"'-!
®
VIEWED FROM
FRONT OF
READER
L - !lREEN/W
L!§//!ji~L
BLUE/W
YELLOW/W
ORANGE/W
RED/W
BROWN/W
CD
g.
Remove two flat head Phillips screws
9-18.
h.
Replace read head and connectors in card cage making sure wires are
installed in proper color coded positions.
i.
Replace picker support assembly per paragraph 9.11 b.
9-27
to remove read head, figure
9.13 LIGHT STATION
a.
Remove picker support assembly per paragraph 9.11. a.
b.
Remove four flat head Phillips screws
figure 9- IS.
c.
Slide off plastic tie-down holding light station cable connector on power
supply.
d.
Remove light station connector from power supply.
e.
Replace light station, plug connector into power supply, and replace
tie down.
f.
Replace picker support assembly per paragraph 9.11. b.
®
to remove light station,
9.14 FOURTH AND FIFTH STACKER ROLLER BEARING ASSEMBLIES
NOTE
Replace both bearings and shaft
with new matched assembly to
assure proper operation.
a.
Remove picker support assembly per paragraph 9.11. a.
b.
To replace fourth stacker roller bearings, perform step c. To replace
fifth stacker roller bearings, perform step d.
c.
To replace fourth stacker roller bearing assembly, figure 9-14, perforrn
the following substeps.
1.
Using a 3/32 Allen wrench, LOOSEN set screw in bottom pulley of
fourth stacker roller, figures 9-5 and 9-6.
2.
Pull bottom pulley down to disengage third stacker drive belt. Remove
belt and pulley.
3.
Using a 1/16 Allen wrench, LOOSEN set screw in top pulley of fourth
stacker roller.
4.
Pull pulley downward to disengage it from main drive motor belt.
Remove pulley.
9-28
5.
Using a 1/16 Allen wrench to LOOSEN set screw in bottom roller of
fourth stacker roller assembly, figure 9-7.
6.
Lift fourth stacker shaft from stacker casting. Observe that there is
a spacer washer between the top roller and the bearing seat. Remove
top roller from shaft.
7.
To remove top bearing, use L-shaped tool to lift bearing from casting.
8.
To remove bottom bearing, slide out bottom roller and spacer. Use
a straight tool to tap edge of bearing from inside shaft hole to drop
bearing from casting.
9.
Replace bearing, place spacer washer on top bearing and slide bottom
spacer and roller under shaft hole.
10.
Replace top roller on new shaft, flush with (or SLIGHTLY below)
shaft end.
11.
Place main drive motor belt around hole for fourth stacker roller shaft.
Replace roller shaft in hole. Select feeler gauge (5 to 25 mils) to force
roller against bearing.
12.
Insert feeler gauge between top plate and bottom roller. Apply firm
finger pressure on top roller and tighten set screw in bottom roller.
13.
Check for vertical play in fourth stacker shaft. If there is vertical
play, LOOSEN set screw in bottom roller and repeat sub step 12 to
eliminate play.
14.
Place main drive motor belt on motor pulley, on fifth stacker roller
pulley, and around fourth stacker roller shaft. Hold drive belt in
this position.
15.
Replace top pulley of fourth stacker roller on shaft and push pulley
upward until it is engages with main drive motor belt, figures 9-5
and 9-6.
16.
Adjust drive motor belt and top pulley, if necessary, so that drive
belt is completely engaged with motor pulley, and .fourth and fifth
stacker roller pulleys.
9-29
CAUTION
USE MODERATE TORQUE TO TIGHTEN
PULLEY SET SCREW. OVERTORQUE
WILL DAMAGE PULLEY.
d.
17 .
Position top pulley so that set screw is on flat side of shaft. Make
sure pulley· is slightly away from top plate and tighten set screw.
18.
Replace third stacker drive belt on third stacker roller and around
fourth stacker shaft. Hold drive belt in this position.
19.
Replace bottom pulley of fourth stacker roller on shaft and push pulley
upward until it is engaged with drive belt and is against top pulley.
20.
Adjust third stacker drive belt and bottom pulley, if necessary, so
that drive belt is completely engaged with pulleys and is parallel to
other belts.
21.
Rotate bottom pulley so that set screw is on flat side of shaft.
Tighten set screw.
22.
Replace picker support assembly per paragraph 9.16.
To replace fifth stacker roller bearings, figure 9-14, perform the following
substeps.
CAUTION
USE EXTREME CARE NOT TO DAMAGE
TIMING DISC. KEEP DISC IN SOFT
TISSUE WHEN NOT IN CARD READER.
1.
Using a 1/16 Allen wrench, LOOSEN set screw in timing disc,
figure 9-4. Carefully remove disc and wrap it in soft tissue.
2.
Use a 1/16Allen wrench to LOOSEN set screw in fifth stacker roller
pulley.
9-30
b~lt.
3.
Pull pulley downward to disengage it from main drive motor
Remove pulley.
4.
Use a 1/16 Allen wrench to LOOSEN set screw in bottom roller of fifth
stacker roller assembly, figure 9-7.
5.
Lift fifth stacker shaft from stacker casting. Observe that there is a
spacer washer between top ;roller and bearing seat. Remove top
roller from shaft.
6.
To remove top bearing, use L-shaped tool to lift bearing from casting.
7.
To remove bottom bearing, slide out bottom roller and spacer. U5e
a straight tool to tap edge of bearing from inside shaft hole to drop
bearing from casting.
8.
Replace bearings. Place spacer washer on top bearing and slide
bottom spacer and roller under shaft hole.
9.
Replace top roller on new shaft, flush with (or SLIGHTLY below)
shaft end.
10.
Place main drive motor belt around hole for fifth stacker roller shaft.
Replace roller shaft in hole. Select feeler gauge (5 to 25 mils) to
force roller against bearing.
11.
Insert feeler gauge between top plate ·and bottom roller. Apply firm
finger pressure on top roller and tighten set screw in bottom roller.
12.
Check for vertical play in first stacker shaft. If there is vertical play.
LOOSEN set screw in bottom roller and repeat sub step 11 to eliminate
play.
13.
Place main drive motor belt on motor pulley, on fourth stacker roller
pulley, and around fifth stacker roller shaft. Hold drive belt in
this position.
14.
Replace fifth stacker roller pulley on shaft and push pulley upward
until it is engaged with main drive motor belt, figures 9-5 and 9-6.
15.
Adjust drive motor belt and pulley, if necessary, so that drive belt
is completely engaged with motor pulley, and fourth and fifth stacker
roller pulley s .
9-31
CAUTION
USE MODERATE TORQUE TO TIGHTEN
PULLEY SET SCREW. OVERTORQUE
WILL DAMAGE PULLEY.
16.
Position pulley so that set screw is on flat side of shaft. Make sure
pulley is slightly away from top plate and tighten set screw.
17.
Replace timing disc on fifth stacker roller shaft. figure 9- 4. Rotate
timing disc so that set screw is on flat side of shaft and line up timing
disc teeth with magnetic pickup tip. Tighten timing disc set screw.
18.
The main drive motor belt tension must be adjusted first. Refer to
paragraph 6.2.
19.
Second, the magnetic pickup and timing disc must be adjusted:
to parag-raph 6.3.
20.
Replace picker support assembly per paragraph 9.11. b.
Refer
9.15 FIRST AND SECOND PICKER ROLLER BEARINGS
a.
Remove picker support assembly per paragraph 9.11. a.
b.
To replace first picker roller bearings, perform step c. To replace second
picker roller bearings, perform step d.
c.
To replace first picker roller bearings, perform the following substeps .
1.
Using a 1/16 Allen wrench, LOOSEN set screw in bottom roller of first
picker roller, figure 9-14.
2.
Pull first picker roller shaft from picker assembly. Remove bottom
roller and spacer, and top spacer.
3.
To remove top or bottom bearing, use L-shaped tool to pull bearing
from casting.
4.
Replace bearing, place spacer on top bearing, and replace roller
shaft in shaft hole.
5.
Replace bottom spacer and roller on shaft.
9-32
d.
e.
6.
Apply firm finger pressure on top and bottom rollers and tighten set
screw in bottom roller.
7.
Check for vertical play in first picker shaft. If there is play, LOOSEN
set screw in bottom roller and repeat sub step 6 to eliminate play.
To replace either of the second picker roller bearings, perform the following substeps.
1.
Using a 1/16 Allen wrench, LOOSEN set screw in roller. Remove shaft
and retaining ring, roller, and spacer.
2.
To remove· bearing use a slender straight or L-shaped tool to either
push or pull bearing from picker assembly.
3.
Replace bearing, shaft and retaining ring, spacer, and roller.
4.
Apply firm finger pressure to retained ring and roller, and tighten
set screw in roller.
Install picker support assembly per paragraph 9.11. b .
9.16 PICKER SECTOR
®
a.
Using a 5/64 Allen wrench, remove four button head screws
top panel cover, figure 9-1.
holding
b.
Perform steps a. and c. through f. of paragraph 9.8. Prop open input
hopper follower by taping together 3/4 inch of cards and placing in hopper
at right angles.
c.
Using a #2 retaining ring remover tool. remove the retaining ring from
the top of the picker shaft, figure 9-19.
d.
Remove spacers located under the retaining ring, figure 9-19.
CAUTION
ALL OF THE SPACERS MUST BE
REPLACED IN REASSEMBLY.
e.
Using a 5/64 Allen wrench. LOOSEN two set screws holding picker sector.
f.
Remove picker shaft from bottom of chassis.
9-33
g.
Using a Phillips screwdriver, remove throat block, figure 9-20.
h.
Remove picker sector from rear side of picker casting.
i.
Replace picker sector, shaft, all spacers, and retaining ring.
j.
Adjust shaft to place sector set screws on flat side of shaft .
k.
Using a 6" metal ruler, measure 1.625" from the mainframe up to the center
of the row of holes on the picker sector.
1.
Retaining this measurement, tighten two picker sector, set screws, figure
9-19.
m. Reassemble reader in reverse order of disassembly.
n.
Refer to paragraph 6.8 for adjustment of picker sector.
1. 625" FROM MAINFRAME UP
TOMIODLE ROW OF HOLES
IN VERTICAL LINE
I
I
THROAT
BLOCK
FEELER
GAUGE
Figure 9-20.
VACUUM ADAPTER
PLATE SET SCREW
PICKER
SECTOR
THROAT BLOCK
SCREW
Picker Sector, Rear View
9-34
9.17 STACKER PHOTOCELL
®
a.
Using a 5/64 Allen wrench, remove four button head screws
top panel cover, figure 9-1.
holding
b.
Remove two button head screws each side of card cage cover, slide backward
about 2" and lift off, figure 9-9.
c.
Remove four button head screw s from rear card cage panel and remove
panel.
d.
Using a 5/64 Allen wrench, remove six 6 x 32 button head screws holding
rear panel, move rear panel out slightly, disconnect fan motor connector,
and remove rear panel, figures 9-2 and 9-14.
e.
Using a 9/64 Allen wrench, remove three socket head screws 8 holding
card cage in place. Move card cage to rear and remount using two rear
screws, figures 9-14 and 9-15.
f.
Remove all cards from card cage using extractor levers, figure 9-15.
g.
Using a 1/16 Allen wrench. LOOSEN set screw in top fourth stacker roller
figure 9-7. Remove stacker roller and preload washer.
h.
Using a 1/16 Allen screwdriver, LOOSEN set screw in stacker casting
holding stacker photocell.
i.
Tag black and white wires from photocell. Using AMP tool 465195-2,
remove connectors from card cage.
j.
Remove photocell from rear of stacker casting, figure 9-21.
k.
Replace photocell, 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.
1.
Replace connectors in card cage.
m . Replace stacker roller making sure there is no vertical play in stacker
roller shaft. Refer to paragraph 6. 5 for preloading bearings.
n.
Reassemble i!l reverse order of disassembly.
9-35
STACKER PHOTO CELL
Figure 9-21.
Location of Stacker Photocell
9.18 HOPPER NEGATOR SPRING
a.
Use steps b. , c. , and e. , of paragraph 9.17 to gain access to negator
spring retaining screw.
b.
Hold spring and remove spring screw.
c.
Pull spring from roller and roll new spring onto roller.
d.
Replace spring screw and reassemble input hopper follower assembly,
figure 9-17 .
9.19 LOWER STACKER NEGATOR SPRING
a.
Using a 5/64 Allen wrench, remove six button head screws retaining front
panel and remove front panel, figure 9-1.
b.
Remove two button head screws each side of card cage cover, slide cover
back slightly and lift off, figure 9-9.
9-36
CD holding front
c.
Using a 9/64 Allen wrench , remove two socket head scr ews
stacker shaft support, figure 9- 22.
d.
LOOSEN set screw in rear stacker shaft support , figur e 9-23.
e.
Remove stacker shaft, figure 9-22.
f.
Move stacker follower sufficiently beyond front edge of chassis to reveal
negator spring screw.
g.
Hold spring, remove screw , and pull spring from roller.
h.
Reroll new spring onto roller and replace spring screw.
i.
Reassemble in reverse order of disassembly.
SCREW HOLDING SPRING
STACKER SHAFT UNDER STACKER SHAFT SLIDE
STACKER
FOLLOWER
FRONT STACK
SHAFT SUPPORT ________
MOVE BEYOND FRONT EDGE OF
CHASSIS TO REMOVE SCREW
Figure 9-22.
Stacker Negator Spring Repla cem ent
9-37
SET SCREW
UPPER
NEGATOR
SPRING
UPPER NEGATOR
SPRING SCREW
STACKER FULL
SWITCH SCREWS
STACKER FULL
SWITCH
LOWER
NEGATOR
SPRING
DRUM SHAFT
SET SCREW
STACK SHAFT
SUPPORT
Figure 9-23. Stacker Full Switch Replacement
9.20 UPPER STACKER NEGATOR SPRING
a.
Remove two button head screws each side of card cage cover, slide cover
back slightly and lift off.
b.
Remove upper stacker negator spring screw, figure 9-23.
c.
Pull spring from roller and roll new spring onto roller.
d.
Replace spring screw.
e.
Replace card cage cover.
9-38
9.21 HOPPER EMPTY SWITCH
®
a.
Using a 5/64 Allen wrench. remove four button head screws
9-1, holding top panel cover.
,figure
b.
Using a 3/32 Allen wrench, remove two socket head screws holding
riffle cap.
c.
Remove two connectors from hopper empty switch, figure 9-19.
d.
Using a 1/16 Allen wrench, remove two button head screws holding switch.
e.
Replace switch and adjust per paragraph 6.6.
f.
Reassemble in reverse order of disassembly.
9.22 STACKER FULL SWITCH
a.
Remove two button head screws on each side of card cage cover, slide
cover back slightly and lift off.
b.
Remove two Phillips head screws holding stacker full switch, figure 9-23.
c.
Unsolder leads from switch, and solder to new switch.
d.
Mount switch and adjust per paragraph 6.7.
e.
Replace card cage cover.
9.23 INDICATOR LAMPS
a.
Grasp indicator lens with thumb .and forefinger and pull upward with a
rocking motion to remove lens.
b.
Pull lamp from lens.
c.
Insert new lamp into lens.
d.
Press lens firmly into switch.
9-39
SECTION 10
DRAWINGS
TO
POWER SWITC/-f
CABLE AStly
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102027521
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BREAKER
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CABLE ASS
7
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4
~t>4
1~r......---II+--------I-~---+I---1
1- ..5-.3
po
~
STOP
"Ia-E..
~~rt;___-~_'0_.._)'c------"I __
.QlUF
z-B'7-S
I'\S-I..\
'::!5.,:
~
F
'It.DY°C.
-t>
e.
o"K
D'I1l'T1>J
_____--'' ' '__
~
Bu'!.¥'
CZ-'4 <>------i
c: t- '4 0-------1
.~-14 o-,--.----t'
C:;,f2.
"
Figure 10-13. Schematic Diagram, Error Card (Sh. 2 of 2)
:I II
I
j
'li2
<.MO-"
3
2Pt.ACE'5
....
o
....I
;!::.
18~---'
I.,------J
NOTES;
Q>.
29
COMPONENT.5 F£AGGCD AU
~~?oi.°g;[fN RJRP05D
20
9P1..4C~5
Figure 10-14.
Assembly Diagram, Sync Card
(Dwg. No. 1040353)
•
I1B-9
.
13~12
00
_9~8_____ ~r~IlL--.
~~---
7'10"l
___________---'a~
2-90-2
___________"-s-.,,"C--i....
118-7
_______________-"'PU"'LL'-"-tI~ 2-68-'\
TSTR
MB-M
"
vee
l-IC!10"'.
1/4W
OSCU<
MB-P
WIOESTROBE
CONTROLFF
80 3 F3 11
5 Bl
_ _ _ _ __""-I2 .83 ~
~
13
~--------'-'-I8 :: ~ Fl
,
i
Bl
"-------"'182 "" F2 10
L.----_"-I'S2 "" F2 10
L
"--_______ ,'-'-j2 83
~
~-------','-'-I,
~
~-----'.'1: ~
,
AI
1 AO
I
FO 3
'I
C5DS
DURATION
COUNTER
_,
AD
82'12
Fl
AI
Fa
~____c""s'!Oos,__ 1'18-18
82-<12
....
o
"
....enI
2:5~~1~
1>-'",,''--------------___+-----------'
HB-J ••--'O"SR"-_ _ _ _-"-U~"'lO'------+_----
~'1
_______________ ll~lO----------------------+-----------_r-------------------------------------
~
MQ-14
..
Ci
__ OS
MO-'
1~~,--------
_________________________+_~
~.,
1~2
I
---------------------------------------~
______________________________________________-'swTOO
"'--_._
.
118-4
DB
7'10<1
HB-K
..
DC
_______________________~3~~,'-_______
1~2
74~"
~a4
LAST NO.
RIO
UNUSEDNUMBERS
US~~ED
THIS
SHEEr---1
~~s~~;~~~17,C18.C21__c23
--1
Figure 10-15. Schematic Dia.gram, Sync Card (Sh. 1 of 3)
(Dwg. No. 1640943)
_____________________S"-'T~OC'__tl
. . . MB-V
PIel< ::'ONTROl
1-38-13
eO!~NTER
PULL-UP (R8)
-,
~
VCC~-.---J
lK
MB-l
..
PClK
r=~g=~ c>-,G~PR~_ _ _ _ _--,~
3-20-1
1'18-11
vee
C>~R='="~T-------'Sl
POR
13
o>-----~
b-'!-_ _ _ _ _ _ _ _ _'-P"'''"T_~
MB-12
...--'-P",CK'--_ _ _ __
R.
~------"N>~_o
MB-17
vee
560
~MB-C
R5
CR2
47
IN'I003
PICK
R6
IK
PICK ATTEMPT COUNTER
vee
r=P--i 1
li'l'r
<>-~I III
lK
I
I
4
,
NOTES:
FOR M300/600 JUMPER A-B.
FOR M200/1000/12GO JUMPER A-F.
C
LAST NO.
RIO
CR2
IClOCATION
NUMBERS USED
USED THIS SHEET
Rl.R'l-R8
CR2
I
~
3A.5A-8A.6B9B.bC.8C.9C.7D-9~
FOR H200/300/600 JUMPER J-H.
FOR 1000/1200 JUMPER l-H.
f3---...
~
1-20-12 [:::-----"00'-_ _ __
Figure 10-16. Schematic Diagra.m, Sync Ca.rd (Sh. 2 of 3)
FOR M200 CUT LAND C TO D.
JUMPER C TO E.
r-----~--~-----------
==--====--~====~~:=r~-"------
--
--------~--- -------~_=____,
HB-N
743'::·
- - 0:.3t:T
.
•
_.
__ ._-- -
-------";
23
PRCLK
MB-1S . _ _ _ _ - - - - ~.----,-.----,----------,------
4
MB-(,
~
J
_.
3
._----.;;
~~PK
- -.-~-=---->
---------~
------ - ---
RF.SE:
~-~~~-
--+--
RJ
~ ---*--------------'\- --0 VCC
it--
17~1
18~
I
MB"-l
~---.Yi.~-j~J- ---*
.------0
• 22ljH
+ I C1 g
::;;oV
.)';'
[ 2CCF
RTN
MB-A
,
:~r~-~·---·~----··-
T
I
I
__ --J
.-L
Figure 10-17. Schematic Diagram, Sync Card (Sh. 3 of 3)
--~~--:> 2-:;~-'
TO
PRESET COUNTER
Itl
~
r
Itl
fI)
~
/'..
2
1
4
8
16
32
64
128
M-SERIES
,
PRESET TIMING REQUIREMENTS
gl ~lO g2 g k 6 6 g
4
1
Model
M
M
M
M
M
Bl
Count
-
200
200 (310 CPM)
300/600
1000
1200
176
164
75
43
35
Time in gsec
1466.0
1366.6
625.0
358.3
291. 7
lK
TO CSDS
Itl
DURA TION COUNTER
,.,.
~
r~-----------~---------~,
1
2
4
8
16
32
64 Not Used
~
..,;t
b go g2 k g J; g 8
ll
D6
CSDS TIMING REQUIREMENTS
Model
M
M
M
M
M
200
200 (310 CPM)
300/600
1000
1200
Count
72
72
31
18
15
Time in gsec
600.0
600.0
258.3
150.0
125.0
lK
To program the counters, so that they are loaded with the complement of the
required count, proceed as follows:
a.
Let ground represent logic "1", and strap pins 5, 6, 7 and/or 8 to create
the required count.
b.
Strap all other pins to Vcc, at pins 13, 14, 15 and/or 16.
Figure 10-17A.
Preset a.nd CSDS Counter Strapping
10-17A
--l
C I.
~
'A
---@)-GL.----':-='-A
@D
,e
L--f---f--+-------+----+--.J.
~~
~~
,
j
~~~AV~~~ fl:M ~4
CQM~l:; F;."'~DAI1C
!
7~a-
Figure 10-lS.
Assembly Diagram, Control Card
(Dwg. No. 1040619)
=~~1~-:r~~
NOTES .-
[I::>
+l20u~
J?--"
.o/UF
----.1
.-----H(CII
-""B-II I>--,PQ=:!;R>--+---,~.
_-H
-0
I
CO
ID
~-z
12 £ ) p Q
~SEr
~
B4i>c)1!!.+------8U.~::!:s:Ly-_i> M8-V
BUSY
8
81
PCI
FF
Vce
>---------....~
R"4
"'Ck
2
~D
10
"Ie'"
Co"""",",ND
.3 D
"'7W
It!
IT
MB-E
.3
P Q
~
BZ
BI
STOP
a
Q~6__~______~II~
c
CL
vec
MS-/6
M8-1'"
M8-C
_AIOY
e,
/I
CI
3 D3
10
4
Figure 10-19.
Schematic Diagram, Control Card (Sh. 1 of 2)
(Dwg. No. 1241715)
I> 6
10
"
'2
"'"S
Vee
,II'"
470J1.
-
vt'c
Vee
Vee
13~
1/1
0
I
I.
"~
IS
~ C7 6
,~
I
cr
2
17
3
C7
".
M
5
C7
.
-
,.,
DZ
J
as
t'¢
0
P
13 A7 12
At
II
A7
10
:;,
AT
B
I
1/7
Z
3
A7
4
.
5
T
u
V
I
-=-L _
INTC.q,:;tOCE
Vee
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 volt return
MB-A
OA
OB
OC
Clock Phase A
Clock Phase B
Clock Phase C
Clock Phase D
81st Column Reset
84th Column Reset
Busy Output
Busy Signal
Basic Clock
Column Reset
Column Storage Data Strobe
Data Row 0 Output
Data Row 1 Output
Data Row 2 Output
Data Row 3 Output
Data Row 4 Output
Data Row 5 Output
Data Row 6 Output
Data Row 7 Output
Data Row 8 Output
Data Row 9 Output
Data Row 11 Output
Data Row 12 Output
Dark Check Strobes
Dark Check
Error Output
Error Output Return
Good Pick Reset
Hopper Check Output
Input or Output Hopper Check
Hopper Check Lamp Driver
Hopper Check Output Return
Hopper Empty Check
MB-S
MB-F
MB-K
MB-9
MB-13
MB-D
J8-1
MB-U
MB-14
MB-B
MB-18
J8-K
J8-H
J8-J
J8-N
J8-F
J8-E
J8-B
J8-D
J8-A
J8-C
J8-M
J8-L
MB-8
B2-9
J4-E
J4-M
MB-H
J4-H
C4-9
J4-K
J4-10
B4-8
~D
81CR
84CR
BUSY
BUSY
Cl
CR
CSDS
DO
Dl
D2
D3
D4
D5
D6
D7
D8
D9
DIl
D12
DCKS
DARK CHECK
ERROR
ERROR RTN
GPR
HCK
HCK
HCKDR
HCK RTN
HECK
11-1
ORIGINATING
SOURCE
5 volt power supply
(Mother Board)
5 volt power supply
(~other Board)
"
I
Clock Card
Clock Card
Clock Card
Clock Card
Clock Card
Clock Card
Control Card
Control Card
Clock Card
Clock Card
Sync 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
Clock Card
Error Card
Error Card
Error Card
Clock Card
Error Card
Error Card
Error Card
Error Card
Error Card
MNEMONIC
LOCATION
DESCRIPTION
HOPPER EMPTY
Hopper Empty Switch
HOPPER EMPTY RTN Hopper Empty Switch Return
Stacker Full Switch
STACKER FULL
STACKER FULL RTN
Stacker Full Switch Return
T1\1
Index Marks
IM RTN
Return for Index Marks
IMST
Index Mark Strobes
LIGHT CHECK
Light Check
'
MOCK
Motion Check Output
I\TOCK RTN
Motion Che'ck Output Return
()CR
Zero Column Reset
ONE DARK
Read Station Any Dark
ONE LIGHT
Read Station Any Light
OSCLK
Offset Clock
OSR
Offset Reset
OSUCLK
Offset Up-Clock
PCK
Pick Check
PCK DR
Pick Check Lamp Driver
peKI
Pick Check Indicator
PCLK
Pick Clock
peR
Pick Control Reset
PICK
Pick Driver Output
PICK RTN
Pick Driver Output Return
PICK COMMAND
Pick Command Input
PICK COMMAND RTN
Pi ck Command Input Return
POR
Power On Reset
PORTR
Power On Reset Trigger
rncLK
Prf'set Clock
PSET
Pick Check Set
n(;K DR
Read Check Lamp Driver
RDY DR
Ready Lamp Driver
READY
Roady
READY
Ready Output
READY RTN
Ready Output Return
RESET
Gated Reset Switch
RESET SW
Reset Switch Normally Open
RESET SW
Reset Switch Normally Closed
Row 0
Read Sensor Input Row 0
Row 1
Read Sensor Input Row 1
Row 2
Read Sensor Input Row 2
Row 3
Read Sensor Input Row 3
Row 4
Read Sensor Input Row 4
Row 5
Read Sensor Input Row 5
11-2
J4-5
J4-6
J4-1
J4-A
J3-A
J3-B
MB-T
C2-9
J4-F
J4-11
MB-5
MB-6
MB-3
MB-P
MB-J
MB-R
B2-5
J4-.T
B2-2
MB-L
MB-C
J5-A
J5-B
J8-2
J8-3
MB-ll
A5-12
MB-15
MB-17
J4-P
J4-R
MB-16
J4-D
J4-L
MB-2
J4-9
J4-7
J8-15
J8-16
J8-17
J8-18
J8-P
J8-R
ORIGINATING
SOURCE
Error Card
Error Card
Error Card
Error Card
Clock Card
Clock Card
Sync Card
Error Card
Error Card
Error Card
Clock Card
Control Card
Control Card
Clock Card
Clock Card
Clock Card
Error Card
Error Card
Error Card
Control Card
Sync Card
Sync Card
Sync'Card
Control Card
Control Card
Error Card
Error Card
Clock Card
Sync Card
Error Card
Error Card
Error Card
Error Card
Error Card
Sync Card
Error Card
Error Card
Control Card
Control Card
Control Card
Control Card
Control Card
Control Card
'.-
'.
(
MNEMONIC
DESCRIPTION
LOCATION
ORIGINATING
SOURCE
Row 6
Row 7
Row 8
Row 9
Row 11
Row 12
RTN
SCK DR
SHIELD
SHIELD
SHIELD
SHUTDOWN STATUS
STACK
STACK CHECK
STACK Vcc
Read Sensor Input Row 6
Read Sensor Input Row 7
Read Sensor Input Row 8
Read Sensor Input Row 9
Read Sensor Input Row 11
Read Sensor Input Row 12
Data Drivers Return
Stack Check Lamp Driver
Shield for Index Marks
Shield for PICK
Shield for Timing Strobe
Mode Switch Input
Stack Sensor Input
Output Stacker Check
Stack Sensor +5 volts
Column Strobe Phase B
Column Strobe Phase C
Column Strobe Phase D
Stop
Stop Lamp Driver
Stop Switch Input
Timing Strobe
Timing Strobe Return
Timing Strobe One
Timing Strobe Two
Timing Strobe Reset
+5V to Read S'ensor Array
Preset Decode
J8-S
J8-T
J8-U
J8-V
J8-14
J8-13
J8-5
J4-N
J3-C
J5-C
J3-R
SI-C
J4-C
B5-8
J4-2
MB-4
MB-V
MB-7
MB-E
J4-S
J4-B
J3-T
J3-S
D9-9
C8-9
MB-M
J8-12
MB-N
Control Card
Control Card
Control Card
Control Card
Control Card
Control Card
Control Card
Error Card
Clock Card
Sync Card
Reluctance Pickup
Error Card
Error Card
Error Card
Error Card
Sync Card
Sync Card
Sync Card
Error Card
Error Card
Error Card
Reluctance Pickup
Reluctance Pickup
Clock Card
Clock Card
Clock Card
Control Card
Sync Card
ST~B
ST~C
ST~D
STOP
STOP DR
STOP SW
TST
TST RTN
TSTI
TST2
TSTR + POR
Vcc
ZERO
11-3
I
SECTION 12
ILLUSTRATED PARTS BREAKDOWN
12.1
INTRODUCTION
This section contains, in breakdown order, the complete carrl reader's
assemblies, subassemblies, sub-subassemblies, detail parts of each, and
associated 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 rrnrl
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 if: common
only 'to the 50 Hz models, it is listed immediately after the equivalent prrrt for
the 60 Hz model. In the BASE PLATE ASSEMBLY breakdown, for example,
(Figure 12-9), under index #19, two capacitors are listed for the same index
number.
19
00000202 . . CAPACITOR 17/-tf, 370 VAC (60 Hz Models)
00000206 •• CAPACITOR 10 /-tf, :165 VAC (50 Hz Models)
The Quick Reference List (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' rrre identified by manufacturereR
codes in the description column of the parts list. Table 12-2 list the names and
address of all manufacturers' codes used in the parts list.
12.2
HOW TO USE THE ILLUSTRATED 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 lists the individual components or parts.
c.
To simplify the updating of Section 12 of this manual, only ODD numbered
pages are used.
M6 ,M3,M 10
12-1 a
-.
~tiriJ/ p ~: ___ :--.-..-.-~.
~
!
·
·
: .- _________
~
fir!
l
mURE 12-7 STACK SUPPORT ASSEMBLY
FIG.
IICO£X 'ART
110.
NUMBER
_..
.. _so
"'1105
-I
DESCRIPTION
1 2 3 4 5 6 7
STACK SUPPORT AISDIIILI'
SUPPORT. Stack
_UOI
.Utl ARRAY ASSEMBLY
(Altaebla. Pamt
SCREW. Flat Hnd 4 ...... all'
FUtST STACIC DRIVE ASS!:DLT
I
•
-C
,,
I
1_",
SHA FT. Staet Drive
:.. ______ ,
.
l . . ________ .. ______ .. '
o
··
o
~
INDEX
NO.
1
•
~ •
fI"-.:
,•
-
I,
•
10
ASSEIOILY
TRIM GROUP ASSEMBLY
KAlil FaA.,E ASSE&IBLY
CONTROL PANEL ASSEMBLY
PICK SUPPORT ASSEMBLY
STACK SUPPORT ASSEMBLY
DRIVE MOTOR ASSEMBLY
BASI PLATE ASSEMBLY
VACWM PUMP ASSEMBLY
POWER SUPPLY ASSEMBLY
CARD FILE ASsEMBLY
nGUU
NO.
12-3
12-4
12-5
12-6
12-1
,l!r-SI.J'
12-8
12-'
12-10
12-11
12-12
FIGURE 12-2 M 600 L CARD READER
In figure 12-2, locate index number of major assembly from which part
was removed.
In fipre 12-2, use index number of major assembly to find figure number
of major assembly parts breakdown Ulustratton.
In major asBembly part, breakd01m Ulustratton, locate index number of
part.
In accompanying parts Ust, use index number of part to find part number,
deacriptlon, and quantity per unit.
mURE 12-7 STACK SUPPORT ASSDmLY
FIGURE 12-1 HOW TO USE PARTS BREAKDOWN WHEN PART NUMBER IS NOT KNOWN
UNITS
PER
YENDOII
ASSY PART NO.
TABLE 12-1 QUICK REFERENCE LIST
ASSEMBLY
FIGURE
PAGE _
12-3
TRIM GROUP ASSEMBLY
Fan
Capacitor
Cord, Power
12-11
12-11 a
12-11 b
12-11 b
12-4
MAIN FRAME ASSEMBLY
Yoke, Stack Shaft
Spring, Negator
Drum, Spring
Shaft, Spring Drum
Shaft, Pick Follower
Solenoid Assembly
Timing Disc Assembly
Pulleys, Stack Drive Assemblies
Belts, Stack Drive Assemblies
Magnetic Pickup Assembly
Pick Follower Assembly
Stack Bumper Plate Assembly
Circuit Breakers
Filter
Light Station Assembly
Read Array Assembly
12-13
12-13 d
12-13 d
12-13 d
12-13 d
12-13 d
12-13 d
12-13 d
12-13 e
12-13 e
12-13 e
12-13 e
12-13 f
12-13 f
12-13 g
12-13 g
12-13 g
12-5
CONTROL PANEL ASSEMBLY
Bulbs
12-15 a
12-15 a
12-6
PICK SUPPORT ASSEMBLY
SWitch Assembly, Hopper Empty
Sector Assembly
Cap, Riffle Air
Drive Roller, 2nd Pick Drive.Assembly
Stack Drive, 1st Pick Drive Assembly
Drum, Spring
Spring, Negator
Shaft, Spring Drum
Tube, Pick Vacuum
12-17 b
12-17 b
12-17 b
12-17 b
12-17 b
12-17 c
12-17 c
12-17 c
12-17 c
12-17 c
M6,M3,MIO
12-5
QUICK REFERENCE LIST (CONT'D)
FIGURE
12-7
PAGE
ASSEMBLY
STACK SUPPORT ASSEMBLY
1st, 2nd, 3ro, Stack Drive Assemblies
4th Stack Drive Assembly
5th Stack Drive Assembly
Stack Photocell Assembly
Drum, Spring
Spring, Negator
Shaft, Spring Drum
Throat, Pick
Switch Assembly, Stacker Full
,
12-19
12-19
12-19
12-19
12-19
12-19
12-19
12-19
12-19
12-19
b
b
b
c
c
c
c
c
c
c
a
a
a
a
12-8
DRIVE MOTOR ASSEMBLY
Motor
Sprocket, Timing Belt
Connector
12-21
12-21
12-21
12-21
12-9
BASE PLATE ASSEMBLY
Driver Assembly, Solenoid
Capacitor, Vacuum Pump Motor Run
Relay, Vacuum Pump and Drive Motor
Capacitor, Logic Power Supply
Transformer Assembly, Solenoid Driver
Transformer Assembly, Logic Power Supply
Rectifier, Diode Bridge
Capacitor, Driver Motor Run
Fuse, 1 amp Slo-Blo
Junc~on, Terminal
12-23 a
12-23 a
12-23 a
12-23 a
12-23 b
12-23 b
12-23 b
12-23 b
12-23 c
12-23 c
12-23 c
12-10
VACUUM PUMP ASSEMBLY
Motor (50 and 60 Hz)
Blower
Belt
Pulley
Adapter Assembly
12-25
12-25
12-25
12-25
12-25
12-25
"I,"3,MI0
12-5 a
a
a
a
a
a
a
QUICK REFERENCE LIST (CONT'D)
FIGURE
ASSEMBLY
PAGE
12-11
POWER SUPPLY ASSEMBLY
PC Board Assembly
12-27 a
12-27 a
12-12
CARD FILE ASSEMBLY
Connectors
PC Card (Mother Board)
12-29 a
12-29 a
12-29 a
12-13
PC ASSEMBLY - CONTROL CARD
12-31 a
12-14
PC ASSEMBI,Y - SYNC CARD
12-33 a
12-15
PC ASSEMBLY - CLOCK CARD
12-35 a
12-16
PC ASSEMBLY..., ERROR CARD
12-37 a
N6,M3,MIO
12-5 b
TABLE 12-2 LIST OF MANUFA CTURERS
CODE
MANUFACTURER
CODE
MANUFACTURER
00779
Amp, Incorporated
P.O. Box 3608
Barn.burg. Pennsylvania
05063
Hamilton - Awet Electro.n1c.
70 State Street
Westbury, N. Y. 11590
1'7105
01121
Allen Bradley Comp:my
1201 2nd Street
Milwaukee. Wisconsin 53212
052'5
Components Corporation
2857 N. Halsted Street
Chicago. Illinois 60657
01295
Texas Instrumenta, Incorporated
Semi-Conductor Components Division
13500 NorthCentral Expressway
Dallas. Texas 75231
05411
DuPage Ma.nufa.cturing Company
2250 Curtiss Avenue
Downers Grove. nIlnois 60515
05172
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
Waukegan. nlinois 60085
02697
Parker Seal Compa.ny
2360 Palumbo Dnve
Lexington, Kentucky 40509
02785
06229
Electrovert. Incorporated
86 Hartford Avenue
Mt. Vemoll, N. Y. 10553
06383
Panduit Corporation
17301 Ridgeland
TiDley Park, nUnois
Amaton Electronic Hardware
Division of Mite Corporation
446 Blake Street
New Haven. CODnecticut
07108
R. at J. Dick Co •• Inc.
912 E. 5th Street
IIDecatble, Iowa 52763
07137
Tee. Incorporated
8700 W...blngtonAvenue
South Eden Prairie. Minn.
55343
Fairchild Semi-Conductor
464 Ellis Street
Mountain View. California
94040
SoUd State Divi.lon .
Route 202
Somerville. N. J. 08876
General ElectriC Company
TarbiIle Division of Apparatus Group
Schenectady, N. Y.
03786
IDdptrtal E1Jierprhle8. IllCIOrporated
5900 N. Telegraph Road
DearboD. Michigaa 48127
07263
. 04963
04713
04886
Minnesota MinJn, and Mfg. Company
Ceater Street
St. Paul, Minneeota 551()1
07355
AlrPax Electronic, Inc.
.Central EngIneering Division
1601 N. W. 19th Street
ft. Lauderdale, Florida 33310
0'1446
Engler Instrument Company
250 Culver Avenue
Jersey City, N.J. 01305
- Motorola
8emi-conductorProduct•• IDo.
5005 Eut AlcDowell Road
Phoenix, A riXOD& 85008
Nylok - Detroit
1893 Barrett Road
Tzoy. Mloblpa' 48084
60477
06540
RCA Corporation
03587
06111
TABLE 12-2 LIST OF MANUFACTURERS (CONTID)
CODE
MANUFACTURER
CODE
MANUFACTURER
07679
Hardware Specialty Co., Inc.
48 - 75 36th Street
Lolli uland City, N. Y. ll101
12505
Air Prodyct/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
Hamlln,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 Division
78 Stone Place
Melrose, Massachusetts 02176
08524
Deutsch Fastener Corporation
70001 West Inperial Highway
Los Angeles, California 90045
08806
General Electric. Company
Miniature Lamp Department
Nela Park
Cleveland, Ohio 44112
09021
Speer Carbon Company
Speer Resistor Dhision
A Division of Air Reduction Co., Inc.
Foster Brook Road
Bradford, Pennsylvania 16701
09023
09353
09922
10108
11214
11253
'Cornell - Dubiller
Division of Fed. Pac. Electric Co.
2526 Dalrymple
Sanford,North Carolina 27330
C. If K. Components, Incorporated
103 Morse Street'
'Watertown, Massachusetts 02172
Burndy Corporation
Richards Avenue
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, Florida
06852
Hurst Manufacturing Corporation
64 East Princeton Road
Princeton, Indiana 47570
02139
18677
Elrad Manufacturing Company
4300 N. CaUfornia 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
Solid State Division
Fostoria Road
Findley, Ohio 45840
27264
Molex Products Company
5224 Katrine A venue
Downers Grove, nIinois 60515
28523
18788
General nlumination, Incorported
2233 University A venue
St. Paul, Minnesota 55114
Gulf Electronics Corporation
1740 N. W. 69th Avenue
Mlami, Florida 33148
28818
19070
Eastern Air Devices, Incorporated
385 Central Avenue
Dover, New Hampshire 03820
Sound coat Co., Incorporated
515 Madison A venue
New York, N. Y. 10010
29227
19401
Gladwin Industries, Incorporated
Gladwin Educational Division
P. O. Box 80545/1!HO Will Ross Ct.
Chamblee, Georgia 30341
Herco
Hecht Rubber Corporation
482 - 484 Riverside Avenue
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.
20772
Spectronics, Incorporated
24 Kinkle Street
Westbury, N. Y. 11590
22589
Electro - Space Fabricators, Inc.
101 - 125 Centre A venue
Topton, Pennsylvania 19562
33062
Ferronics, Incorporated
66 N: Main Street
Fairport, New York 14450
33498
Automation Components
One Short A venue
Peckville, Pannsylvania
34936
23880
23936
24161
11518
Stanford Applied Engineering
340 Martin Avenue
Santa Clara, California 95050
18452
Nashua Corporation
44 Franklin Street
Naushua, New Hampshire
03060
46384
William J. I>urdy 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 Avenue
Kenosha. Wisconsin 53140
24211
Grisby - Barton, Incorporated
3800 Industrial Drive
ROlling Meadows, minois 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
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
Diali~ht
CODE
MANUFACTURING
56289
Sprague Electric Company
North Ada.ms, Massachusetts
60361
64475
65083
70276
70854
70903
71034
71279
71590
71744
71785
01247
13153
Westinghouse Electric Corporation
Lamp Division
MacArthur Avenue
Bloomfield, New Jersey 07003
Corporation
60 Stewart Avenue
Brooklyn, New York
11237
Allen Manufacturing Company
P. O. Box 570
Hartford, Connecticut 06101
72653
G. C. Electronics Company
400 S. Wyman Street
Rockford, OIinois 61101
Barden/NI\!B
200 Park A venue
Danbury, Connecticut
73138
Belden Corporation
415 S. Kilpatrick Avenue
Chicago, minois
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 Harvey, 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 Avenue
Chicago, Illinois 60640
Littlefuse, Incorporated
800 E. Northwest Highway
Des Plaines, minois 60016
76005
Cinch Manufacturing Company
Division of T. R. W., Inc.
Elk Grove Village, minois
Lord Manufacturing Company
1635 West 12th Street
Erie, Pennsylvania 16512
76599
The Murray Corporation
Industrial Park
Cockeysville, Maryland 21030
06810
Cambion
445 Concord A venue
Cambridge, Massachusetts
02138
12-7c
TABLE 12-2 LIST OF MANUFACTURERS (CONT'D)
CODE
MANUFACTURER
CODE
MAl'roFACTURER
'19023
Valled El:lstlc Company
DiY.lslOll of Stevens, J. P. "Co., Inc.
P.O. Box 391 50 Payson Avenue
East Hampton, Massachusetts 01027
81840
Ledex. IneorporatiDG
Ledcx DiVision
123 Webster Street
Davton, Ohio 45402
79136
Waldes Kohinoor, Inc.
47 - 16 Austel Plac~
Long Island, N. Y. 11101
83014
Wood Electric Corporation
Danvers Industrial Pa.rk
Danvers, l\lassachul'letts 01923
83259
80089
Essex Internlltibnal
Controls Division
131 Godfrey 5tr('')t
Logansport, Indiana
83330
H. H. Smith, Incorporated
812 Snedicker Avenue
Brooklyn, New York 11207
83584
80103
Lambda Electronics Corporation
515 Br,oad Hollow Rond
Huntington, New York 11749
Drive-Lok, Incorporated
1140 Park Avenue
Sycamore, nlinois 60178
84830
80183
Sprague Products Company
Beaver Street
North Adams, Massachusetts
L"e Spring Company
30 .!\.lain Street
Brooklyn. New York
79405
85446
80223
80294
80382
80545
81312
The Hartwell Corporation
9035 Venice Blvd.
Los Angeles. California
90034
Parker Seal Company
10567 Jefferson nh·d.
Culver City, California
90231
11201
Bokc'!:'s, Incorporated
3104 Snelling Ayenue
Minneapolis, Minnesota
T.R. W. Electronic Components
United Tr:l.Dsfonner Dinsion
150 Varick Street
New York, N. Y. 10013
86577
Bournes, Incorporated
1200 Columbia Avenue
Riverside, California 92507
Precision Metal Prod. of l\lalden, Inc
41 Elm Street
Stoneham. 1I1assachusetts 02:; E()
87034
Air, Reductiop Co., Incorporated
150 E. 42nd &trect
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 Hurlson Street
New York. N.Y. 10013
88132
Winchester Electronics
Main Street and HillSide Avenue
Oakville. Connecticut 06779
Goodyear Rubber Company
25 Hamlin
Middletown, Cognecticut 06457
91506
55406
Augat, Incorporated
33 Perry A venue
81541
Airpax ElectrOnics, Incorporation
Woods Road
Cambridge. Maryland 21613
Attleboro. Massachusetts
91637
12-7d
02703
Dale ElectrOnics, Incorporated
P.O. Box 609
Columbus, Nebraska 68601
TABLE 12-2 LIST OF MANUFACTURERS (CONT'D)
CODE
M\NUFACTURER
i1662
Elco Corporation
Maryland Road 3.Ild Computer Avenue
Willow Grove, Pennsylvania 19090
Dearborn Wire und Cable Company
9299 Evenhouse
Rosf''''n:mt, nUnoi.
92194
Alpha Wire
711 Lidgerwood Avenue
Elizabeth, New Jersey
Extr:m Corporation
P.O. Box 10725
Knoksville, Tennessee
Raytheon Company
Components Division
Industrial Components Operation
465 Centre Street
Quincy. Massachusetts 02169
Merit Fa stners
127 Atlantic Boulevard
Maitland, Floripa 32951
94144
94222
Southco, Incorporllted
Lester, Pennsylvania
95275
37919
Mlllitary Packing Company
I). O. Box 460
Orlando. Florida 32802
D1l3
Motronlcs Corporation
Riverside Industrial Park
Little Falls, N. Y. 13365
Berkley and Company
Highway 9 and 71
Spirit Lake, Iowa 51360
.
MANUFACTURER
CODE
Vitramon, Incorporated
P. O. Box 544
Bridgeport, Connecticut
National Gard. Product, Incorporated
P. O. Box 7353
Memphis, Tennessee 3RI07
06601
95987
WeCkC'lRCr Co .• Incorporated
4444 W(,!lt [y-,rin~ Park Road
Chicago, Illinois 60641
96182
Master Specialties Company
1640 Monrovia
Costa Mesa, California 92627
96881
Thomson Industries, Incorporated
1029 Plandome Road
ManhaR'lft. New'York 11030
99743
IMC rt:1~etics Corporation
6058 Walker Avenue
Maywood, Calif.oI'rJa 90270
Pipeline Service Company
3240 N. l\Ianheim Road
Franklin Park, illinois 60131
Potter - Brumfield
1200 E. Broadway
Princeton, Indiana 47470
Reynolds Aluminum Supply Company
2920 Eunice A venue
Orlando, Florida 32802
Sunset Wire and Cable, Incorporated
P.O. Box 224
Cape Canaveral, Florida 32930
Thp Torrington Company
Clinton Bearing Plant
CHnton, South Carolina
- Active and Passive Components
121 - 18 Du Pont Street
Plainview, N.Y. 11803
Thorgren Tool and Moulding Company
110 Evans Avrnue
Valparaiso, Indiana 46383
Consolidated Wire and Cable
1637 South Clinton
Chicago, minois 60616
Tri - Power, Incorporated
Akron, Ohio
12-7e
TABLE 12-2 LIST OF MANUFACTURERS (CONT'D)
CODE
CODE
l\otANUFACTURER
MANUFACTURER
Voyce .. Legler
523 N. W. 28th Street
Miami. I'lorida 33127
!
,
-
12-7f
,
I
o
~
•
[,oa]
~'
I
•I
r------.J
I
I
r----------..1
,
:
,
I
I
I
I'- ______ ,
I
I
/'
I
,
I
L ________________ ..,
.
I
I
~.
INDEX
NO.
1
2
3
4
5
6
7
8
9
10
ASSEMBLY
TRIM GROUP ASSEMBLY
MAIN FRAME ASSEMBLY
CONTROL PANEL ASSEMBLY
PICK SUPPORT ASSEMBLY
STACK SUPPORT ASSEMBLY
DRIVE MOTOR ASSEMBLY
BASE PLATE ASSEMBLY
VACUUM PUMP ASSEMBLY
POWER SUPPLY ASSEMBLY
CARD FILE ASSEMBLY
M6
FIGURE 12-2 M-SERIES (SLOPE) CARD READERS
12-9
FIGURE
NO.
12-3
12-4
l2-5
12-6
12-7
l2-8
12-9
12-10
12-11
12-12
II
.... 113... 10
FIGURE 12-3 TRIM GROUP ASSEMBLY
12-11
FIGURE 12-3 TRIM' GROUP ASSEMBLY
FIG.
INDEX PART
NO.
NUMBER
UNITS
DESCRIPTION
123 456 7
PER
ASSY
TRIM GROUP ASSEMBLY - 115 VAC, 60 Hertz Model
TRIM GROUP ASSEMBLY - 230 VAC, 50 Hertz Model
HOOD, Control Panel
(Attaching Parts)
SCREW, Machine, Button Head 6 - 32 x 3/8
-1
40049401
40049404
30031602
-2
00000343
-3
-4
40045501
40045591
-5
00000343
-6
40031501
·
-7
00000343
··
"
-8
30005801
·
PLATE, Cover, Top
1
-9
40048601
40048602
·
COVER ASSEMBLY, Rear - 115 VAC, 60 Hertz Model
COVER ASSEMBLY, Rear - 230 VAC, 50 Hertz Model
(Attaching Parts)
SCREW, Machine, Button Head 6 - 32 x 3/8
PANEL,Rear - US VAC,50-/60Hertz
PANEL, Rear - 230 VAC,60 Hertz
SCREEN, Fan (23936)
MOUNTING BRACKETS, Fan (Pair) (23936)
(Attaching Parts)
SCREW. Pan Head 6 - 32 x 1/4
• NUT, Hex 6 - 32
TAG, Series (Specify Model)
1
·
1
··
"
ASSEMBLY, Front (Modified)
·· ·COVER
COVER, Front
(.Attaching Parts)
· · · SCREW, Machine, Button Head 6 - 32 x 3/8
1
1
COVER, Track
(Attaching Parts)
SCREW, Machine, Button Head 6 - 32 x 3/8
·
··
· ·
VENDOR
PART NO.
6
1
-12
-13
00000343
40045'701
40045702
00000323
00000324
-14
-15
-16
00000375
00000301
200280XX
· ·· ·
·
·
4
4
1
-1'7
00000325
- 115 VAC, 50/60 Hertz (23936)
· · .FAN
W/INTEGRAL COMPONENTS
1
4600
2
1
2
1
1
1
1
60618-1
1-480319-0
FIT-105
1854/19
TAIB8
2
1
1
3
3
6
8
60618-1
1-480319-0
FIT-lOS
613'70-1
480416-0
-10
-11
00000035
00000449
00000127
00000164
00000059
00000058
20098301
00000035
00000449
00000087
00000530
00000452
00000114
00000301
00000302
··
··
··
··
CONTACT. Pin (00779)
HOUSING. Pin (00779)
TUBING. Heatshrtnk 1/8 DIA. x 1/2 (92194)
WIRE. Elec. AWG 20 TWPR BLK-WHT 3"
MOUNT. Cable Tie (06383)
TIE. Cable (06383)
FAN ASSEMBLY - 230 VAC, 50 Hertz
W/INTEGRAL COMPONENTS
CONTACT. Pin (00779)
HOUSING, Pin (00779)
TUBING, Heatshrink 3/32 x 1" (92194)
RECEPTACLE, Faston (250) (00779)
HOUSING. Receptacle (00779)
SCREW. Button Head 6 - 32 x 1/4
NUT. Hex 6 - 32
SCREW, Pan Head 6 - 32 x 1/2
12-11 a
6
1
1
1
1
4
5503
5501
SSTIM
FIGURE 12-3 TRIM GROUP ASSEMBLY (CONT'D)
FIG.
INDEX PART
NO.
NUMBER
-18
-19
00000295
00000059
00000058
00000156
00000155
00000302
00000301
-20
00000511
-21
00000289
-22
-23
00000375
00000301
-24
20028101
20028102
-25
00000488
-26
-2'1
20014801
00000456
00000555
DESCRIPTION
123 4 5 6 7
···
···
WASHER. Flat 16
MOUNT. Cable TIe (06383)
TIE, Cable (06383)
WIRE, Elec. - AWG 16 WHT '1" - BLK 6 1/2
(Attach1hg Parts)
SCREW, Pan Head 6 - 32 x 1/2
NUT, Hex 6 - 32
2.0 I-'f 2'10 VAC Nom.. (230 VAC, 50 Hz)
· · CAPACITOR,
(03597)
Cap. Mtg. (0359'1)
· · BRACKET.
(Attaching Parts)
Pan Head 6 - 32 x 1/4
· · · SCREW,
NUT, Hex 6 - 32
···
Information - 115 VAC, 60 Hertz
· TAG,
TAG, Information - 230 VAC, 50 Hertz
· (Attaching Parts)
· · PIN, Drive
··
·
CORD, Power (115 VAC, 60 Hertz)
CORD, Power (230 VAC, 50 Hertz)
ADHESIVE, PUobond
(
M3,MS.aj 10
12-11 b
UNITS
PER
VENDOR
ASSY PART NO.
4
1
1
1
TAIB8
SSTIM
1858/19
4
4
1
1
4SF270
K9827065P21
2
2
1
1
"
1
1
A/R
MS-21318-9
.
1'1250
e
i~
i
.
~~
iJ
13 (fiG. 12-5)
10, II, 12
12-12)
122
119, 120
I
~
121
3
MI, M6.MIO
FIGURE 12-4 MAIN FRAME ASSEMBLY (Sht. 1 of 3)
12-13
32
... ...
...
... ...
'
.
.
i
;-""""'40
"-39
FIGURE 12-4 MAIN FRAME ASSEMBLY (sheet 2 of 3)
12-13 a
~. .
,
,
i
.-~
:
12~
.
,
-- .... - ...........
66
(FIG: 12-81
12
,,
----------~F~I[(GHURE
12--1: 1\.
---------IAIN
FIL\~IE
.
ASSEMBLY (sheet 3 of
~3)
.
,,
..
,
,,
,-,,'
,,
,
FIGURE 12-4 MAIN FRAME ASSEMBLY
UNITS
PER VENDOR
ASSY PART NO.
FIG.
INDEX PART
NO.
NUMBER
-1
-2
40048903
40048905
40045001
40075101
40075113
40075103
1 2 3 4 5 6 7
DESCRIPTION
MAIN FRAME ASSEMBLY - 60 Hertz Models, 115 VAC
MAIN FRAME ASSEMBLY - SO Hertz Models, 230 VAC
MAIN FRAME
BASE PLATE ASSEMBLY - 60 Hertz Models (Fig. 12-9)
BASE PLATE ASSEMBLY - 50 Hertz Models, 11S VAC
(Figure 12-9)
BASE PLATE ASSEMBLY - SO Hertz Models, 230 VAC
(Figure .12-9)
·
··
1
1
1
·
(Attaching Parts)
SCREW, Machine, Pan Head a - 32 x 3/8
-3
000003a2
··
-4
4004a201
·
-5
-6
00000396
00000294
· ··
·
6
-7
40021205
·
1
-8
-9
00000396
00000294
··
-10
40061216
-11
-12
00000396
00000294
-13
3003a301
-14
-15
00000396
00000294
-16
-17
18
PICK SUPPORT ASSEMBLY (Fig. 12-6)
(Attaching Parts)
SCREW, Machine, Socket Head 8 - 32 x 5/a
WASHER, Flat No. 8
1
6
STACK SUPPORT ASSEMBLY (Fig. 12-7)
(Attaching Parts)
SCREW, Machine, Socket Head a - 32 x s/a
WASHER, Flat No. a
a
8
··
FILE ASSEMBLY (Fig. 12-12)
· CARD
(Attaching Parts)
Machine, Socket Head 8 - 32 x 3/a
· · SCREW,
WASHER, Flat No. 8
··
..
1
3
3
CONTROL PANEL ASSEMB'LY (Fig. 12-5)
· (Attaching
Parts)
SCREW; Machine, Socket Head a - 32 x 3/a
··
· · WASHER, Flat No. a
3
20000101
·
1
-18
-19
00000396
00000294
20000102
··
··
-20
-21
-22
00000396
00000294
.30046502
-23
-24
00000395
00000294
··
··
2
2
-25
30049201
·
1
-26
00000396
··
"'6 M3
GUIDE, Card Edge, Stack
(A ttaching Parts)
SCREW, Machine, Socket Head a - 32 x 5/a
WASHER, Flat No. 8
GUIDE, Card Edge, Pick
(Attaching Parts)
SCREW, Machine, Socket Head a - 32 x 5/a
WASHER, Flat No. 8
COVER, Pick Slide
(Attaching Parts)
SCREW, Machine, Socket Head 8 - 32 x 3/a
WASHER, Flat No. a
·
··
·· ·
COVER, Stack Slide
(Attaching Parts)
SCREW; Machine, Socket Head a - 32 x 5/S
12-13 c
1
3
2
2
1
2
2
1
2
MAIN FRAME ASSEMBLY (CONT'D)
FIG. &
INDEX PART
NO.
NUMBER
UNITS
DESCRIPTION
PER
ASSY
1 2 3 4 56' 7
-27
00000294
··
-28
20122801
-29
-30
00000396
00000294
Stack Shaft
· YOKE,
(Attaching Parts)
Machine, Socket Head 8 - 32 x 5/8
· · SCREW,
WASHER, Flat No. 8
··
-31
-32
00000306
00000297
-33
-34
-35
WASHER, Flat No. 8
2
1
2
2
·
SPRING, Negator (80545)
SETSCREW, 8 - 32 x 3/16
1
1
20012703
20047601
20000503
··
DRUM, Spring
SHAFT, Spring Drum
SHAFT, Pick Follower
1
1
1
-36
20000502
-37
0000029'1
-38
20000201
-39
-40
.00000396
00000294
·
··
·
·· ··
-41
20022501
-42
10002002
10002003
00000439
00000285
-a
-44
-45
··
·
·
SHAFT, Stack Follower
(Attaching Parts)
SETSCREW, 8 - 32 x 3/16
1
SUPPORT, Follower Shaft
(Attaching Parts)
SCREW, Machine. Socket Head 8 - 32 x 5/8
WASHER, Flat No. 8
2
SOLENOID ASSEMBLY
(Atfl.ch1ng Parts)
STANDOFF, Plain
STANDOF~. With Arm Stud Hole
PIN GROOVED TYPE
SPRING, Solenoid (84830)
..· ··
·· ··
·· ·· ··
·· ·· ·
··
·· ·· ·
··
··. ·· ·
..
VENDOR
PART NO.
SL6F24
1
2
2
1
J,
1
1
1
LE026C2MW
(AttachJng Parts)
-48
-47
-48
-49
-50
00000358
00000396
00000294
20010601
20001201
SCREW, Machine, Flat Head.8 - 32 x 3/8
SCREW, Machine, Flat Head 8 - 32 x 5/8
WASHER, Flat No. 8
SOLENOID
MOUNTING PLATE
2
2
2
1
1
(AttacbfDg Parts)
-51
-52
-18
-54
-55
00000299
00000269
10010501
-158
00000566
000002'10
20022301
-15'1
0000029'1
• .NUT , Plain, Hex 8 - 32
WASHER, Lock, Int.tooth No.8
COUPLING
(Attacblng Parts)
SETSCREw, Knurled CUp Point" - 40 x 3/11
CONNECTOR, PIn (00779).
TIMING DISC ASSEMBLY
2
2
1
4
2
1
(Attac!dng Parts)
SETSCREW, 8/32 x
3/1e
MI MS,IIOO
. 12-13 d
1
10598-5
MAIN FRAME ASSEMBLY (CONTID)
FIG.
INDEX PART
NO.
NUMBER
-58
00000274
-59
20080404
-60
-61
00000273
20127003
DESCRIPTION
1 2 3 4 5 6 7
·
·
·
·
PULLEY, First, Second (Top), and Third (Bottom)
Stack Drive Assemblies (07108)
PULLEY, Second (Bottom), and Third (Top)
Stack Drive Assemblies (07108)
PULLEY, Fourth (Bottom) Stack Drive Assemblies (07108)
PULLEY, Timing (Fourth (Top) and Fifth
Stack Drive Assemblies (07108)
(Attaching Parts)
SETSCREW, 10 - 24 X 1/4
UNITS
PER
VENDOR
ASSY PART NO.
3
15XL037
2
1
14XL037
2
··
8
00000281
00000280
00000283
·
·
·
2
1
1
-66
30016201
30016203
30016204
-67
-68
-69
-70
-71
1000200i
00000293
00000294
00000298
00000379
MOTOR ASSEMBLY - 60 Hertz Models - 115 VAC
· DRIVE
DRIVE MOTOR ASSEMBLY - 50 Hertz Models - 230 VAC
· DRIVE MOTOR ASSEMBLY - 50 Hertz Models - 115 VAC
· (Attaching Parts)
· · STANDOFF
Machine, Socket Head 8 - 32 x 1/2
·· · SCREW,
WASHER, Flat No. 8
·
· · SCREW, Machine, Flat Head 8 - 32 x 1/2
-72
20016101
-73
-74
00000447
20010401
-75
-76
00000292
00000304
-77
20031901
-78
00000358
-79
-80
-62
-63
-64
-65
BELT, First and Second Stack Drive (07108)
BELT, Third Stack Drive (07108)
BELT, Fourth Stack Drive (07108)
··
SCREW, Machine, Pan Head 8 - 32 x 1/2
1
1
1
4
4
4
2
2
· MAGNETIC PICKUP ASSEMBLY
PICKUP, Magnetic (07355)
·· ·· HOLDER,
Pickup
(Attaching Parts)
Flat 6 - 32 x 3/16
· · .. SETSCREW,
SCREW, Machine, Flat Head 6 - 32 x 1/2
··
1
Air Outlet
· FITTING,
(Attaching Parts)
· . SCREW, Machine, Flat Head 8 - 32 x 3/8
1
00000407
20059901
·
·
1
1
-81
-82
00000293
00000294
·.
-83
-84
-85
30104401
30101002
30047701
·
·
-86
00000271
CLAMP, Hose (76599)
BRACKET, Vacuum Pump Hose Support
(Attaching Parts)
SCREW, Machine, Socket Head 8 - 32 x 1/2
WASHER, Flat No. 8
PICK FOLLOWER ASSEMBLY
FOLLOWER, Card
BRACKET, Card Follower
(Attaching Parts)
SCREW, Machine, Button Head, 4 - 40 x 3/16
.
M6 M3
12-13 e
80XL025
70XL025
160XL025
1
1
-0194/086-211001~
1
2
2
1
1
1
1
5
H - 24
-'"
--'-~,--
-'
-..-
---~
MAIN FRAME-ASSEMBLY (CONT'D)
FIG.
INDEX PART
NO.
NUMBER
-87
20000301
-88
-89
-90
-91
00000096
10011801
10011901
00000518
-92
00000272
00000065
-93
REF' 20000301
DESCRIPTION
1 2 3 456 7
·
·
·
··
·
·
·
·
·
·
·
·
1
1
2
2
A/R
A/R
40104301
20012501
30012401
-101
-102
00000346
30078801
-103
-104
-105
-106
00000271
10011801
10011901
00000518
-107
-108
00000272
00000065
REF
40104301
-109
-110
REF
REF
REF
00000397
00000065
00000409
00000495
00000495
··
··
·
-111
30023702
30076301
·
·
-112
00000382
SOfDl801
30018101
00000188
00000186
··
-115
00000375
·
·
·· ··
BUMPER PLATE ASSEMBLY
· STACK
CARRIER, Card Follower
· · BUMPER, Card
· · (Attaching Parts)
SCREW, Machine, Flat Head 4 - 40 x 1/4
· · ·FOLLOWER,
Card
· · (Attaching Parts)
SCREW, Ma,chine, Button Head 4 - 40 x 3/16
· · ·ROLLER
·· · SHAFT CARD FOLLOWER
RING (83259)
· · "0"
(Attachlng Parts)
.. · • . SCREW, Cap, Socket Head 4 - 40 x 5/8
·· ·
WASHER, Flat No. 4
STACK BUMPER PLATE
(Attaching Parts)
SCREW, Cap, Socket Head 4 - 40 x 1/4
WASHER, Flat #4
BUSHING, Ball
SPONGE, Neoprene Closed Cell
RUBBER, Neoprene
3
1
3
1
1
1
5 - 23D
1
1
2
2
11
1
PANEL ASSEMBLY, Subframe - 115 VAC, 60 Hertz
PANEL ASSEMBLY, Subframe - 230 VAC, 50 Hertz
(Attaching Parts)
SCREW, Pan Head, 8 - 32 x 3/8
PANEL, Subframe - 115 VAC, 60 Hertz
PANEL, Subframe - 230 VAC, 50 Hertz
CIRCUIT BREAKER, 8A - 115 VAC, 60 Hertz
CmCUIT BREAKER, 5A - 230 VAC, 50 Hertz
(Attaching Parts)
SCREW, Machine, Pan Head, 6 - 32 x 1/4
1
1
12-13f
A61014
1
1
·
··
·
·
··
··
·· ··
···
5 - 23D
1
· ··
-98
-99
-100
Ma,MS, MIO
4
1
1
1
1
1
00000397
00000065
00000409
00000495
00000573
00000557
-114
1
··
-94
-95
-96
-97
-113
BEARING, Follower Support
(Attaching Parts)
SCREW, Machine, Button Head, 4 - 40 x 1/4
ROLLER, Card Follower
SHAFT
.
"0" RING
(Attaching Parts)
SCREW, Cap, Socket Head, 4 :- 40 x 5/8
WASHER, Flat No. 4
BEARING, Follower Support
(Attaching Parts)
SCREW, Cap Socket Head, 4 - 40 x 1/4
WASHER, Flat No. 4
BUSHING, Ball
RUBBER, Neoprene, 1/8 x 1/4 x 5/8
. EASTMAN 910
LOCKTITE RETAINING COMPOUND 75
UNITS
VENDOR
PER
ASSY PART NO.
B61014
1
4
1
1
1
1
2
UPG1162802
UPG1162502
MAIN FRAME ASSEMBL'Y (CONT'D)
FIG.
INDEX PART
NO.
NUMBER
UNITS
DESCRIPTiON
1 2 3 4 5 6 7
PER
ASSY
00000476
00000470
·· ··
1
1
-117
-118
-119
-120
-121
-122
-123
-124
-125
-126
00000315
30006301
30008301
30006901
40006401
30046001
20065501
20057101
30046201
0000.0302
·· · ·
·
2
1
1
-127*
10158905
3.0014401
·
·
-128
-129*
00000344
20050301
···
-13.0
-131
-132
-133
-134
-135
-136
-137
-138
-139
-140
.0.00.00353
200386.01
20027502
20.027603
4.0.0764.01
4.0.075401
0.000.0.059
000.0.0058
3.0.0369.01
20017101
000.00657
-116
·•
·
·
··
·
CONNECTOR, AC Recessed (115 VAC. 60 Hz) (74545)
FILTER RFI. CoDlle~ 50 - 400 Hz 6A (05245)
(Attaching Parts)
SCREW. Machine. Pan Head 6 - 32 x 1/4
PLATE. Front Edge Frame
PLATE. Rear Edge T1"lm
ANGLE ASSEMBLY, Panel Mount .Bottom
SUBFRAME
ANGLE ASSEMBLY. Panel Mount Top
MOUNTING BRACKET, Hood
MOUNTING BRACKET, Hood
ANGLE ASSEMBLY. Panel Mount
SCREW. Machine Pan Head. 6 - 32 x 1/2
Output Connector Mounting
READ/LIGHT STATION ASSEMBLIES (Matched)
LIGHT STATION ASSEMBLY
(Attaching Parts)
SCREW, Machine, Flat Head 2 - 56 x 1/4
READ ARRAY ASSEMBLY
(Attaching Parte)
SCREW, Flat Head. 4 - 40 x 1/4
CABLE ASSEl\mLY. Hopper Empty Switch
CABLE ASSEMBLY, Circuit Breaker
CABLE ASSEMBLY, Relay
WIRING DIAGRAM, 23.0 VAG. 50 Hertz
WIRING DIAGRAM, 115 VAC, 60 Hertz
MOUNT, Cable Tie (06383)
TIE, Cable (.06383)
.,
CABLE ASSEl\-ffiLY, Output
CABLE ASSEMBLY, Solenoid DR
RUBBER, Foam
·
··
···
··
·
·
··
·
·
·
·
* Light Station Assembly and Read Array Alillembly must be
Part No. 1.0158905
ordered as a matched Set•••
M!,M ....'O
12-13g
V£NDOR
PARf NO.
'1~6
lEn
2
1
1
1
1
1
4
1
1
4
'1
2
1
1
AlB.
TA158C
S8TIM
~
I
I
I
I
I
,
I
I
I
0-'.
..
FIGURE 12-5 CONTROL PANEL ASSEMBLY
12-15
FIGURE 12-5 CONTROL PANEL ASflEMBLY
(
FIG.
INDEX PART
NO.
NUMBER
-1
-2
-3
-4
-5
-6
-7
-8
-9
-10
-11
30039002
30031001
00000106
00000101
00000097
00000094
00000098
00000099
00000102
00000lmJ
00000318
00000319
-12
00000321
-13
00000320
00000036
00000034
00000510
00000035
00000451
00000058
00000086
00000127
00000085
00000824
N/R
OOOOOISO
N/R
-14
-15
-16
-17
-18
-19
-20
-21
-22
-23
-24
~2S
-26
UNITS
PER
VENDOR
ASSY PART NO.
DESCRtPTION
1 23 4 56 7
CONTROL PANEL ASSEMBLY
lPANEL, Control
INDICATOR, White Barrier (72619)
CAP "Power" (72619)
CAP "Read Check", White Barrier (72619)
CAP "Pick Check", White Barrier (72619)
CAP "Stack Check", White Barrier (72619)
CAP "Hopper Check", White Barrier (72619)
CAP "Stop" (72619)
CAP "Reset" (72619)
BULB, Incande'scent 6V @ .2A (08806)
SWITCH, Alt Action, White Barrier (72619)
SWITCH, N. 0., SPST, White Barrier (72619)
SWITCH, N. 0., Snap Action, White Barrier (72619)
CONTACT, Connector Amp Leaf (00779)
CONTACT, Amp Leaf (00779)
CONTACT, Junction (08524)
CONTACT,. ~in (00779)
HOUSING, Pin (00779)
TIE, Cable (06383)
TUBING, Heatshrink, BLK 3/16 Dia. x 6" (92194)
TUBING, Heatshrlnk, BLK 1/8 Dia. X 3/4" (92194)
TUBING, Heatshrink, 1/4 Dia. x 8" (92194)
SLEEVING (92194)
WIRE, Elee. U8 AWG
WIRE,Bus f22 AWG, Solid
WIRE, Elee. *24 AWG
·
·
·
··
·
··
·
·
·
·
·
··
·
·
··
·
··
·
·
·
·
.....
.
\
I ...... ll. lilo
12-15a
1
"
¥,
1
1
1
1
1
1
1
7
1
1
1
t
2
1
1
1
5
1
2
1
'1
I" AlP.
A/'B.
AlB
533-1004
303-6375
114-0404-339
534-0404-339
514-0404-399
534-0404-339
303... 6361
301-6362
381
613-0410-004
613-0110-004
613-1810-004
42702-4LP
42717-4LP
1841-1-5616
60618-1
1480350-0
STIM-K
nT-tOG
Frr-10S
FIT-lOS
PVC-105119
1857/19
3818
1854/19
27
~",,---2'
~...--22
'
l
21
:
30
~24
I
23~
I
t-- 20
I
29~25~GI
19
I
,
31~
I I -'-y---I
,
II
,I
II
,
,
~I
-
39
'
'.
S.
i
--~~ -~-
"
-~
I
~~
e
I
"
" , "
~II
~-.. I~
I
10~
! "~ '-,34
~~
6~'G...
.... " "
r)rn
,
--~32,lIlI
,'
, " 35
Ie
~
lr
r«:.
I
4
®
-..
'>
1I~::-;'-7
~3
I
M3,M6, MIO
FIGURE 12-6 PICK SUPPORT ASSEMBLY
12-17
",
'(l/r'1il
.....
'U
~.
l
I
I
I I"
--
; :-:_-----
I
I
:u:
-"'
I
I
-
A
I
. III
14
_--oJ
...-21
~
"_'
-
e-
, - ----- ---1)-',.J,..
'-~ ~
~,..
_-~~,:-
jl-....
211'
I I I __ ...JI__ - -- __J- .0
,
-
,
41
I
~I I
I I I
,
r IF'
- ' ' ' - J %0
17
FIGURE 12-6 PICK SUPPORT ASSEMBLY
FIG.
INDEX PART
NO.
NUMBER
DESCRIPTION
1234567
UNITS
PER
VENDOR
ASSY PART NO.
40048201
PICK SUPPORT ASSEMBLY
-1
40001601
·
PICK SUPPORT
1
-2
20027701
00000096
10023501
20023401
-6
-7
00000272
00000062
SWITCH ASSEMBLY, Hopper Empty
(Attaching Parts)
SCREW, Machine, Button Head, 4 - 40 x 1/4
SWITCH (01963)
BRACKET, Switch
(A ttaching Parts)
SCREW, Machine, Pan Head, 4 - 40 x S/S
NUT, Plain, Hex, 4 - 40
1
-3
-4
-5
·
·
·
·
·
·
-S
30003701
·
-9
-10
-12
20101401
00000429
00000467
00000297
-13
··
··
2
1
1
··
··
2
2
SECTOR ASSEMBLY
(Attaching Parts)
SHAFT, Pick Assembly
BEARING (14927)
RING, Snap (79136)
SET SCREW, S - 32 x 3/16
1
··
·· ·
·
··
1
2
2
2
10004101
·
1
-14
-15
00000398
00000295
STOP, Pick
(Attaching Parts)
SCREW, Socket Head, 6 - 32 x 5/S
WASHER, Flat *6
··
··
2
2
-16
10004701
1
-17
-18
00000293
00000294
Pick
· BUMPER,
(Attaching. Parts)
Socket Head, 8 - 32 x 1/2
· · SCREW,
WASHER, Flat *8
··
-19
30023303
·
1
-20
00000391
··
-11
CAP, Rime Air
(Attaching Parts)
SCREW, Socket Head, 4 - 40 x 3/4
E21-S5HX
SFR1S8TTK25LGl
5100-25
2
2
2
DRIVE ROLLER, 2nd Pick Drive Assembly
-21
20005901
-22
-23
-24
-25
-26
00000292
00000432
10002201
00000429
00000467
.n
CAPSTAN
· (Attaching
Parts)
SETSCREW, Knurled 'Cup, 6 - 32 x 3/16
·
Bearing
··· SPACER,
SHAFT
(14927)
·· BEARING
RING SNAP (79136)
M6MIO
12-17a
2
2
2
2
"
2
982-28
8FR188TTK25LG1
5100-25
FIGURE 12-6 PICK SUPPORT ASSEMBLY (CONT'D)
FIG.
INDEX PART
NO.
NUMBER
DESCRIPTION
1234567
UNITS
PER
VENDOR
ASSY' PART NO.
00000292
00000432
10003003
00000429
STACK DRIVE, 1st Pick Drive Assembly
CAPSTAN
(Attaching Parts)
SETSCREW, Knurled CUp, 6 - 32 x 3/16
SPACER, Bearing
SHAFT
BEARING (14927)
·
· ·
··
1
2
-32
-33
-34
20012703
00000306
10000701
·
·
1
1
1
-35
00000564
DRUM, Spring
SPRING, Negator (80545)
SHA FT, Spring Drum
(Attaching Parts)
SET SCREW, 4 - 40 x 3/32
-36
20004801
·
1
-37
00000564
TUBE, Pick Vacuum
(Attaching Parts)
SET SCREW, 4 - 40 x 3/32
··
1
-38
20008101
1
-39
00000346
-40
20072801
-41
00000565
Card
· GUIDE,
(AttaChing Parts)
· · SCREW, Machine, Flat Head, 4 - 40 x 1/4
Pick Support
· INSERT,
(Attaching Parts)
· · SCREW, Machine, under cut Flat Head, 2 - 56 x 3/16
20005901
-27
-28
-29
-30
-31
-
·
·
··
Iotl,M6,IotI0
12-17b
2
2
2
1
2
2
2
SS2-28
SFR188TTK25LG1
SLGFZ4
44~~L
I
42
'I~
~_-"I~
p~~
~'47
41
26
43
I
'
I
....
45~
46/
"
1<
I
'~
34,35
~
/
1//
-<
I
M3,N6,MIO
FIGURE 12-7 STACK SUPPORT ASSEMBLY
12-19
32,33
FIGURE 12.-7 STACK SUPPORT ASSEMBLY
FIG.
INDEX PART
NO.
NUMBER
UNITS
VENDOR
PER
ASSY PART NO.
DESCRIPTION
1 2 3 456 7
40021205
STACK SUPPORT ASSEMBLY
1
-1
40048801
·
1
-2
-3
10003002
00000431
00000432
00000433
20001505
00000429
-4
-5
-6
-7
00000292
-8
-9
10003002
00000431
00000432
00000433
20001504
00000429
-10
-11
-12
-13
00000292
-14
-15
10003002
00000431
00000432
00000433
20001506
00000429
-16
-17
-18
-19
00000292
SUPPORT. Stack
FIRST STACK DRIVE ASSEMBLY
SHAFT. Stack Drive
SPACER. Bearing (29440)
SPACER. Bearing (29440)
SPACER. Bearing (29440)
ROLLER, Stack Drive
BEABING. (14927)
SAME AS ITEM-3
(Attaching Parts)
SCREW, Set Knurled CUp PT. 6 - ~2
·
·
·
1
A/R
AIR
AIR
2
2
·
·
·
·
··
x3/16
SS2-27
SS2-28
882-30
SFR188TT (3)
2
SECOND STACK DRIVE ASSEMBLY
SHAFT, Stack Drive
SPACER. Bearing (29440)
SPACER. Bearing (29440)
SPACER. Bearing (29440)
ROLLER, Stack Drive
BEABING (14927)
SAME AS ITEM -9
(Attaching Parts)
SCREW. Set Knurled CUp PT,6 - 32 x 3/16
·
···
·
·
·
··
1
AIR
AIR
A/R
2
2
882-27
882-28
882-30
SFR188TT (3)
2
THIRD STACK DRIVE ASSEMBLY
SHAFT, S~ck Drive
SPACER~ Bearing (29440)
SPACER,> Bearing (29440)
SPACER, Bearing (29440)
ROLLER. Stack Drive
BEARING (14927)
SAME AS ITEM -15 (Attaching Parts)
SCREW .. Set Knurled CUp PT. 6 - 32 x a/16
·
1
A/R
A/R
AIR
2
2
·
··
·
·
·
··
882-27
882-28
882-30
SFR188TT (3)
2
.
-20
-21
-22
10003002
00000431
00000432
00000433
20002101
FOURTH STACK DRIVE ASSEMBLY
SHAFT, Stack Drive
SPACER. Bearing (29440)
SPACER. Bearing (29440)
SPACER, Bearing (29440)
ROLLER, Stack Drive
·
·
·
M3, ... ·
12-19a
1
A/R
A/R
A/R
2
SS2-27
SS2-28
882-30
STACK SUPPORT ASSEMBLY (CONTID)
FIG.
INDEX PART
NO.
NUMBER
DESCRIPTION
1234567
-23
-24
00000430
·
·
-25
00000292
··
-26
-27
10003002
00000431
00000432
00000433
20002101
00000430
-28
-29
-30
BEARING. (14927)
SAME AS ITEM -21
(Attaching Parts)
SCREW. Set - Knurled Cup PT. 6 - 32 x 3/16
FIFTH STACK DRIVE ASSEMBLY
SHA FT. Stack Drive
SPACER, Bearing (29440)
SPACER, Bearing (29440)
SPACER, Bearing (29440)
ROLLER, Stack Drive
BEARING (14927)
SAME AS IT..!:M -27
(Attaching Parts)
SCREW. Set - Knurled Cup PT, 6 - 32 x 3/16
"
·
·
·
·
·
·
·
-31
00000292
-32
20038202
·
-33
00000292
-34
-35
-36
20012702
00000499
10000701
-37
00000292
-38
UNITS
VENDOR
PER
ASSY PART NO.
2
2
1
A/R
A/R
A/R
2
2
1
··
1
·
·
DRUM, Spring
SPRING, Negator (80545)
SHAFT, Spring Drum
(Attaching Parts)
SCREW. Set - Knurled Cup PT. 6 - 32 x 3/16
1
1
1
··
1
10075801
·
1
-39
00000305
THROAT. Pick
(Attaching Parts)
SCREW. Pan Head 4 - 40 x 1/4
··
1
-40
00000492
·
PIN. Dowel •• 25 Dia. x 1/2 Hardened Steel (70276)
1
-41
20021101
·
1
-42
-43
00000314
20012201
··
··
1
1
-44
-45
-46
-47
-48
00000369
00000725
00000425
00000305
00000059
···
2
2
2
2
1
-49
00000064
SWITCH ASSEMBLY. Stacker Full
(Attaching Parts)
SWITCH. Snap Action (01963)
BRACKET SWITCH
(Attaching Parts)
SCREW, Machine, Pan Head 2 - 56 x 1/2
WASHER. Split Lock #2
NUT. Hex #2 - 56
SCREW. Machine. Pan Head 4 - 40 x 1/4
CABLE TIE, Mount
(Attaching Parts)
SCREW. Machine. Pan Head 4 - 40 x S/S
·
·
·
·
·
··· ···
·
··
1113,"41
12-19b
552-27
SS2-28
SS2-30
SFR4TT (3)
2
STACK PHOTOCELL ASSEMBLY
(Attaching Parts)
SCREW, Set - Knurled Cup PT. 6 - 32 x 3/16
·
SFR4TT (3)
1
SL5E17
PINDOWl-4X1-2
' E630S0K
2
M3,M8
FIGURE 12-8 DRIVE MOTOR ASSEMBLY
12-21
FIGURE 12-8 DRIVE MOTOR ASSEMBLY
l
FIG. &
INDEX PART
NO.
NUMBER
DESCRIPTION
1234567
30016205
30016206
20001901
20001902
DRIVE MOTOR ASSEMBLY, 115 VAC. 60 Hertz
DRIVE MOTOR ASSEMBLY, 230 VAC, 50 Hertz
PLATE, Motor Mounting - 115 VAC, 60 Hertz
PLATE, Motor Mounting - 230 VAC. 50 Hertz
-2
00000774
·
-3
00000368
-4
20127008
20127006
-5
00000292
··
··
··
-8
-1
-8
00000295
00000610
00000526
-9
00000058
-10
00000059
00000375
-7
-11
·
·
MOTOR, (19070)
(Attaching Parts)
SCREW, Machine Pan Head, 10 - 32 x 3/8
SPROCKET, Timing Belt (15) - (115 VAC, 60 Hertz)
SPROCKET, Timing Belt (18) - (230 VAC, 50 Hertz)
(Attaching Parts)
SCREW, Set (Supplied With item 4)
CONNECTOR, Housing 6 Pos SKT (00779)
· CONTACT,
SKT CrJmp (00779)
· TIE, Cable Connector
(06383)
·· MOUNT, Cable Tie (06383)
(Attaching Parts)
Machine Pan Head 6 - 32 x 1/4
· · SCREW,
WASHER, Flat No. 6
··
(
Me M3
12-21 a
UNITS
PER
VENDOR
ASSY PART NO.
1
1
1
H34BBP-8
4
1
1
1
1
6
2
1
1
1
SSTIM
TA 158 C
r
•
r
~
'"
\0
I
~
I
I
I
L- ...... '
I
I
29 (FIG.12-11)
I
J
30,31,32,33
61,62,63
49, 50, 51,52,53
2 (FIG. 12-101
37,38,39,40
65
45,46,47,48
3
7
19
2 ,21,22,23
24
M6 M3
FIGURE 12-9 BASE PLATE ASSEMBLY
12-23
66
67
FIGURE 12-9 BASE PLATE ASSEMBLY
FIG. &
INDEX PART
NO.
NUMBER
DESCRIPTIO,.
1 2 3 4 5 6 7
UNITS
PER
VENDOR
ASSY PART NO.
40075115
40075116
BASE PLATE ASSEMBLY - 115 VAC, 60 Hertz
BASE PLATE ASSEMBLY - 230 VAC, 50 Hertz
-1
4000S001
40077401
·
·
PLATE, Bottom - 115 VAC, 60 Hertz
PLATE, Bottom - 230 VAC, 50 Hertz.
1
1
-2
40033304
40033307
·
VACUUM PUMP ASSEMBLY - 115 VAC, 60 Hz (FIg. 12-10)
VACUUM PUMP ASSEMBLY - 230 VAC, 50 Hz (Fig. 12-10)
(Attaching Parts)
SCREW, Machine, Pan Head #S - 32 x 1/2
1
1
·
-3
00000379
··
4
-4
-5
-6
-7
-S
-9
-10
-11
-12
-13
30010001
00000199
00000498
00000548
20010201
00000040
00000139
00000247
00000141
00000108
·
··
·
·
·
·
1
1
3
1
1
1
1
1
1
1
-14
-15
-16
00000064
00000062
00000065
-17
-18
-18A
00000368
00000444
00000236
-19
00000202
00000206
·
··
·
·
·
·
··
·
·
DRIVER ASSEMBLY, Solenoid
CAPACITOR, 6200 mf, 75 VDC (08806)
RIVET, (Pop)
BRACKET, Capacitor, Mounting (08806)
P.C. BOARD
DIODE (01295)
TRANSISTOR, NPN (94144)
RESISTOR, 270 ohms, ± 10%, 1/4W
TRANSISTOR, NPN, Power (01295)
COMPOUND, Heatsink (13103)
(Attaching Parts)
SCREW, Machine, Pan Head 4 - 40 x 3/S
NUT, Hex 4 - 40
WASHER, Flat No. 4
(Attaching Parts)
SCREW, Pan.Head, 10 - 32 x 3/S
WASHER, Lock, Internal tooth No. 10
RESISTOR, 10K, 1/2W
·
·· ·
·
··
··
··
··
··
···
···
···
··
·· ··
CAPACITOR, Vacuum Pump Motor Run, 17.5 ",£370 VAC
(115 VAC, 60 Hertz) (08S06)
CAPACITOR, Vacuum Pump Motor Run, 10 ",£ 200-365 VAC
(230 VAC, 50 Hertz) (08806)
CLAMP, Capacitor (Pair) (OSS06)
(Attaching Parts)
SCREW, Machine, Pan Head #6 - 32 x 1/2
NUT, Hex, #6 - 32
WASHER. Flat #6
'BOOT
S6F177M
SD44BS
94A734AB3
IN403
2N2102
RC07GF271K
T1P41C
6107B-14
1
1
1
2
4
1
RC20GF103K
1
45F279
1
1
45F170
302C920126
-20
00000290
·
-21
-22
-23
-24
00000302
00000301
00000295
00000472
··
·· ·
·
4
4
4
1
614A625P21
-25
00000109
·
·
1
724-11-159
1
733-12-150
00000474
-26
-27
-28
M6 M3
00000379
00000299
00000556
·
RELAY. Vacuum Pump and Drive Motor 20A
(115 VAC. 60 Hertz) (12617)
RELAY, VacuUJil Pump and Drive Motor SA
(230 VAC, 50 Hertz) (12617)
(Attaching Parts)
SCREW, Machine, Pan Head, 8 - 32 x 1/2
NUT, Hex #8 - 32
COMPOUND, Heatsink
--..
··
·· ··
'12-23 a
2
2
A/R
FIGURE 12-9 BASE PLATE ASSEMBLY (CONT'D)
FIG.
INDEX PART
NO.
NUMBER
-29
30029505
-30
-31
-32
-33
10015401
00000392
00000295
00000302
-34
00000200
-35
00000479
-36
00000498
-37
20015501
UNITS
PER
VENDOR
ASSY PART NO.
DESCRIPTION
1234567
·
·· ··
·· ··
POWER SUPPLY ASSEMBLY (Fig. 12-11)
(Attaching Parts)
STANDOFF
SCREW, Socket Head, *6 - 32 x 1/2
WASHER, Flat *6
SCREW, Machine, Pan Head, *6 - 32 x 1/2
4
4
4
LogIc Power Supply, 4600 mf 25 VDC
· CAPACITOR.
(08806)
(08806)
· CLAMP, Capacitor
Parts)
· · RIVET, (Pop)
1
1
86F119M
942A734AA1
3
SD44B5
(AttachlnlZ'
20074001
00000134
00000194.
-38
-39
-40
00000296
00000295·
00000301
-u
20015601
20073901
00000134
00000194.
ASSEMBLY • Solenoid Driver. 24V
· TRANSFORMER
(115 VAC, 50/60 Hertz)
ASSEMBLY, Solenoid Driver. 24V
· TRANSFORMER
(230 VAC, 50 Hertz)
(Stancor)
· · TRANSFORMER
CAPACITOR, .01 mf, 1000 VDC
· · (Attaching Parts)
·· ··
··
·
·
·· ··
··
-45
00000143
·
-4:6
-4:7
-4:8
00000272
00000065
00000062
·· ··
··
-4:9
00000205
·
·
·
··
00000289
-&1
00000296
,u ...
SCREW, Machine, Pan Head, 6 - 32 x 3/S
WASHER, Flat'6
NUT, Hex'6 - 32
1
1
1
2
P6377
5llK510
2
2
2
RECTIFIER, Diode Bridge, 100 VDC (04713)
(Attaching Parts)
SCREW, Machine, Pan Head. 4 - 40 x 5/S
WASHER, Flat *4
NUT, Hex 14 - 40
·2
KDA98o-2
2
2
2
CAPACITOR, Drive Motor Run, 3 "f. 370V (115 VAC, 60 Hz)
(08806)
CAPACITOR, Drive Motor BuD, 4 "f, 370V (230 VAC, 50 Hz)
(08806)
BRACKET, capacitor (08806)
(Attaching Parts)
SCREW, Machine, Pan Head. 6 - 32 x 3/8
I
12-23 b
P6377
5llK510
2
2
2
.. ·
··
00000296
00000295
00000301
-60
1
1
2
TRANSFORMER ASSEMBLY, Logic Power Supply 12V
(115 VAC, 50/60 Hertz)
TRANSFORMER ASSEMBLY, Logic Power Supply 12V
(230 VAC, 50 Hertz)
TRANSFORMER (Stancor)
CAPACITOR, .01 mf, 1000 VDC
(Attaching Parts)
SCREW, Machine, Pan Head, 6 - 32 x 3/S
WASHEl1, Flat *6
NtJII', Hex 16 - 32
-42
-43
-M
00000204
1
1
46F271
1
45F272
1
K987065P21
:I
"
BASE PLATE ASSEMBLY (CONTID)
FIG.
INDEX PART
NO.
NUMBER
DESCRIPTION
1234567
-52
-53
00000295
00000301
·· ·
·
-54
-55
00000147
00000133
·
·
-56
-57
-5~
00000302
00000295
00000301
I
-59
.. 1i0
,
2
2
WASHER, Flat #6
NUT, Hex, 6 - 32
1
1
313001
356001
FUSE, 1 amp Slo-Blo (75915)
MOUNT, Fuse (75915)
(Attaching Parts)
SCREW, Machine, Pan Head, 6 - 32 x 1/2
WASHER, Flat #6
NUT, Hex 6 - 32
·· ··
1
1
1
00000503
00000504
··
JUNCTION, Terminal (08524)
JUNCTION, Terminal (08524)
2
1
TJ1IA-0501
TJl1A-0502
-61
-62
00000487
00000132
·
·
1
1
M15570-16
101002
-63
00000498
TOOL, Insertion/Extraction (08524)
CLIP (7!J515)
(Attaching Parts)
RIVET, (Pop)
··
1
SD44BS
-64
00000428
4
SC405
-65
-66
-67
00000296
00000295
00000301
Rubber (83330)
· BUMPER,
(Attaching Parts)
Pan Head, #6 - 32 x 3/8
· ·· SCREW,
WASHER, Flat #6
·· NUT, Hex #6 - 32
·
-68
30075601
·
-69
-70
00000498
00000498
00000059
00000058
00000531
00000555
00000556
20027513
20027505
20091301
20027502
40075401
40076401
·· ·
I
I
I
UNITS
PER
VENDOR
ASSY PART NO.
-71
-72
-73
-74
-75
-76
-77
-78
-79
-80
· ·
·
·
·
·
·
·
··
···
FILTER ASSEMBLY
(Attaching Parts)
RIVET Pop
RIVET. Blind, Aluminum, 1/8 inch
MOUNT, Cable Tie . (06383)
TIE. Cable (06383)
LOCTITE, Grade C
ADHESIVE, Pliobond
COMPOUND, Heatsink (13103)
CABLE ASSEMBLY. FUse
CABLE ASSEMBLY
CABLE ASSEMBLY, Relay (230 VAC,50 Hertz)
CABLE ASSEMBLY
WIRING DIAGRAM· (115 VAC, 60 Hertz)
WIRING DIAGRAM (230 VAC. 50 Hertz)
M6 M5
12-230
4
4
4
1
2
2
5
11
A/R
A/R
A/R
1
1
1
.1
SD44BS
SD44BS
TA158C
SS1'11.1
60414-1
DO
/
3
15
-
18,19,20,21
6
(
22
24
23
10------
FIGURE 12-10 VACUUM PUMP ASSEMBLY
/
FIGURE 12-10 VACUUM PUMP ASSEMBLY
FIG.
INDEX PART
NO.
NUMBER
-1
40033304
40033307
00000539
00000540
UNITS
PER
VENDOR
ASSV PART NO.
DESCRIPTION
123 4 5 6 7
VACUUM PUMP ASSEMBLY, 115 VAC, 60 Hertz
VACUUM PUMP ASSEMBLY, 230 VAC, 50 Hertz
MOTOR, 60 Hz, 3350 rpm, 115 VAC, 60 Hertz (03597)
MOTOR, 50 Hz, 230 VAC, (03597)
(Attaching Parts)
SCREW, Machine, Pan Head, 8 - 32 x 1/2
·
·
·
1
1
1
1
-2
00000379
-3
00000541
·
-4
-5
00000441
00000855
··
·
3
3
-Ii
30031801
30076701
·
1
1
-7
-8
-9
00000381
00000294
00000505
00000291
10002004
00000064
00000062
-10
-11
-12
-13
-14
-15
00000519
00000520
20076101
20076102
00000591
·
·
·
·
·
·
·
·
·
PLATE, Blower - 115 VAC, 60 Hertz
PLATE, Blower - 230 VAC, 50 Hertz
(A ttaching Parts)
SCREW, Machine, Pan Head, 8 - 32 x 3/4
WASHER, Flat, No. 8 7/8 OD
MOUNT, Rubber (76005)
MOUNT, Rubber (76005)
STANDOFF
SCREW, Machine, Pan Head 4 - 40 x 3/8
NUT, Plain, Hex, No. 4 - 40
·
·
·
·
·
·
·
4
1
BLOWER (75511)
(A ttaching Parts)
WASHER, Flat #1/4
SCREW, Cap, Hex Head, 1/4 - 20 x 5/8
,
4
8
2
2
4
8
8
BELT - 115 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)
1
1
1
1
··
1
·
ADAPTER ASSEMBLY, Vacuum, 115 VAC, 60 Hertz
ADAPTER ASSEMBLY, Vacuum, 230 VAC, 60 Hertz
(Attaching Parts)
CLAMP (76599)
1
1
·
·
-16
20064701
20064702
-17
00000407
··
1
-18
20037901
·
1
-19
-20
-21
00000296
00000445
00000301
·· ·
·
··
1
1
1
-22
10002005
2
-23
-24
00000293
00000294
· STANDOFF
(Attaching Parts)
Cap, Socket Head, 8 - 32 x 1/2
· · SCREW,
WASHER, Flat #8
··
·
GROUND STRAP ASSEMBLY
(Attaching Parts)
SCREW, Pan Head, 6 - 32 x 3/8
WASHER, Lock, into tooth, #6
NUT, Hex, 6 - 32
M6,M311110
12-25 a
KCPMPG-190A
5KCl'19PG0222
2
2
60-115626
100PD2
100PD4
5 M 545
5 M 580
H - 24
VACUUM PUMP ASSEMBLY (CONTID)
FIG.
INDEX PART
NO.
NUMBER
-25
-26
-27
-28
-29
-30
-31
00000482
00000058
00000059
00000525
00000531
00000085
00000555,
UNITS
PER
VENDOR
ASSY PART NO.
DESCRIPTION
1234567
Grommet (06229)
·· STRIP.
TIE. Cable (06383)
TIE. Mount (06383)
·· CABLE
RECEPTACLE. Faston (2.50) (00779)
LOCTITE. Grade C
· TUBING
HEAT SHRINK, 1/4 x 1 1/4 (92194)
··
1
2
1
3
AIR
3
A/R
ADHESIVE. Pliobond
G55
SSTIM
TAJS8
60414-1
FIT -105
-
~
I
,
,
\
'-,
116113,1110
12-25 b
21'f
.
20~~
28"f
e
30~
22
.
26
I
17~
I
I
L---
I
I
I
I
_.-,
I
I
J
..
17
I
10,11
16
7
~22
~ .....
1112,1110."6,"3
FIGURE 12-11 POWER SUPPLY ASSEMBLY
12-27
FIGURE 12-11 POWER SUPPLY ASSEMBLY
•,
FIG. &
INDEX PART
NO.
NUMBER
30029505
UNITS
VENDOR
PER
"ASSY PART NO.
DESCRIPTION
1234567
POWER SUPPLY ASSEMBLY
,
-1
-2
-3
-4.
-5
-6
-7
-8
-9
-10
-11
-20
20032803
30032703
00000844
00000190
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
-31
00000569
00000445
00000491
-32
00000108
-12
-13
-14
-15
-16
-17
-18
-19
-SO
·
PC BOARD ASSEMBLY
PC BOARD
CAPACITOR, 10.0 UF, 12 VDC ± 10% (80183)
CAPACITOR, .1 UF, 100 VDC :!: 10% (80183)
CAPACITOR, .001 UF, 200 VDC (80183)
RESISTOR, Pree., 6. 81K:!: 1% 1W
RESISTOR, 100 ohm:!: 10% 1/4W
RESISTOR, • 10 ohm 2: 1% 3W
RESISTOR, 1K ohm:!: 10% 1/4W
TRANSISTOR, NPN (04713)
PAD, Transistor ~ount (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!2W
CONTACT, Electrical (.025 sq. MODU) (00779)
TERMINA L, Ring Tongue (00779)
HEAT SINK
TRANSISTOR, NPN, Power (.04713)
(Attaching Parts)
SCREW, Machine, Phillips Head 6 - 32 x 5/8
Nickle Brass Plate
WASHER, Lock internal tooth #6
WASHER, Shoulder, nylon (95987)
WASHER, ~ylon (95987)
NUT ,Plain, Hex 6 - 32. Nickel Brass Plate
WASHER, Insulating (13103)
··
··
·
··
··
··
· ··
·· ·
··
··
·· ··
··
··
··
· ··
·
··
··
· ··
·
··
··
·
··
·
·
···
··
··
··
·• ·
·
·
INTEGRATED CmCUIT, Regulator
(Attaching Parts)
SCREW, Machine, Phillips Head,6 - 32x 5/8
Nickle Brass Plate
NUT, Plain, Hex 6 - 32, Nickle Brass Plate
WASHER, Lock internal tooth #6
WASHER, Nylon (95987)
·
·
·
·
",
12-27 a
TE 1128
TG-P10
5HK-D10
RN60D6811F
RC07GF101K
RW79UR100F
RC07GF102K
2N706
7717-148
RC07GF
3-331677-6
RC07GF
3009P-1-103
RC2OGF752J
86094-2
32949
2
3
2
1
2
1
SW-6-NA
NW-6-312NA
1
MC 1469R
2
2
4
2
NW-6-3124NA
AIR
COMPOUND, Heatsfnk, (13103)
...... 1.11110 ... 12
1
1
1
2
1
1
1
1
1
1
1
4.
10
1
1
1
7
2
1
1
2N3771
43-03-04
--------~--------- ----------~~~~~F~]ILEASSEMBLY
FIGURE 12-12 CARD
.
(
FIGURE 12-12 CARD FILE ASSEMBLY
FIG.
INDEX PART
NO.
NUMBER
-1
-2
400612XX
30029401
40061903
40061906,
40061908
40061909
40061904
DESCRIPTION
1 2 3 4 5 6 1
CARD FILE ASSEMBLY
CARD CAGE WITH GUIDES
·
·
·
P. C.
P. C.
P. C.
P.C.
P. C.
·
·
·
ASSEMBLY,
ASSEMBLY,
ASSEMBLY,
ASSEMBLY,
ASSEMBLY,
Control
Control
Control
Control
Control
UNITS
PER
VENDOR
ASSY PART NO.
1
Card
Card
Card
Card
Card
(PT)
(PTRP)
(GTRP)
(PTOC)
(GTOC)
1
1
1
1
1
-3
40035301
·
P. C. ASSEMBLY, Sync Card
-4
40076507
40076509
40076504
40076510
40076508
··
··
P. C.
P.C.
P. C.
P.C.
P. C.
ASSEMBLY,
ASSEMBLY,
ASSEMBLY,
ASSEMBLY,
ASSEMBLY,
Clock
Clock
Clock
Clock
Clock
Card
Card
Card
Card
Card
(PT)
(PTRP)
(GTRP)
(PTOC)
(GTOC)
1
1
1
1
1
40061004
40061006
40061008
40061010
40061005
··
P. C.
P. C.
P.C.
P. C.
P. C.
ASSEMBLY,
ASSEMBLY,
ASSEMBLY,
ASSEMBLY,
ASSEMBLY,
Error
Error
Error
Error
Error
Card
Card
Card
Card
Card
(PT)
(PTRP)
(GTRP)
(PTOC)
(GTOC)
1
1
1
1
1
-5
·
·
··
1
HOUSING, Crimp, Snap-In (00779)
·· CONN
PLUG, Keyed (00779)
Retaining (00779)
· SPRING,
(Attaching Parts)
Machine, Pan Head, SSL 4 - 40 x 3/a
·· ·· SCREW,
WASHER, Lock, Internal Tooth *4
· · NUT, Plain, Hex Head *4 - 40
-6
-7
-8
00000029
00000030
00000061
-9
-10
-11
00000064
00000066
00000062
-12
-13
-14
00000032
00000702
20036201
-15
-16
-17
00000063
00000066
00000062
·
··
··
-18
-19
00000032
40032401
·
-20
-21
, -22
00000063
00000066
00000062
·
·
1
1
1
CONNECTOR, Tab, Solder Loaded (00779)
P. C. CARD, Motherboard
(Attaching Parts)
SCREW, Machine, Pan Head, SSL 4 - 40 x 1/2
WASHER, Lock, Internal Tooth *4
NUT, Plain, Hex '*4 - 40
4
1
·
·· ·
··
MJ
12-29a
1-582191-5
582501-5
42973-2
8
8
8
CONNECTOR, Single Row (00779)
CONTACT, Connector (00779)
BUS BAR, Connector
(Attaching Parts)
SCREW, Machine, Pan Head, SSL 4 - 40 x 1/2
WASHER, Lock, Internal Tooth '*4
NUT, Plain, Hex * 4 - 40
··
·
4
16
11
583302-1
583259-2
2
2
2
8
8
8
583334-1
FIGURE 12-12 CARD FILE ASSEMBLY (CONT'D)
FIG.
INDEX PART
NO.
NUMBER
-23
30033501
-24
00000114
-25
-26
-27
-28
20056609
N/R
20063601
40099401
DESCRIPTION
1 2 3 4 5 6 7
·
·
·
·
·
PLATE, Cover
(Attaching Parts)
SCREW, Machine Button Head BLK 6 - 32 x 1/4
JUMPER WIRE ASSEMBLY
WIRE, Elec. #20 AWG, BRN
CABLE ASSEMBLY, D.C. Power
WIRING DIAGRAM
M3, MI,
12-29b
UNITS
VENDOR
PER
ASSY PART NO.
1
4
1
A/R
1
1854/19
I
:
FIGURE 12-13 P. C. ASSEMBLY - Control Ca.rd
FIGURE 12-13 P. C. ASSEMBLY - Control Card
(
\
FIG. '
PART
INDEX
NUMBER
NO.
UNITS/ASSV
DESCRIPTION
1 2 3 456 7
L
III:
L
III:
L
"
... ... ... ...
L
"
Co)
Co)
~ ~
L
VENDOR
PART NO.
"
-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 :I
N7400A
N7474A
-22
-23
00000054
00000057
3
2
3 3 3 3
2 2 2 2
N828lADC
U6AL0459X
-24
-25
-26
-27
-28
00000050
00000083
00000020
00000198
00000124
·
·
·
12
1
1
1
9
1
1
1
-
-29
00000123
40065001
-30
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 ",f, 6V (03597)
CAPACITOR, Mylar, 0.1 ",f, 100V (03597)
CAPACITOR, O.Oll-'f, 100V (80813)
RESISTOR, 300 ohm, :t 10%, 1/4W
RESISTOR, lK ohm, :!: 10%, 1/4W
RESISTOR, 470 ohm, :!: 10%, 1/4W '
RESISTOR, 100 ohm, ! 10%, 1/4W
RESISTOR, 560 ohm, :t 5%, l/4:W
RESISTOR, 5.6K, ± 10%, 1/4W
INTEGRATED CIRCUIT, Hex Inverter (18324)
INTEGRA TED CIRCUIT, Quad 2 Input DTL gate
(07236)
INTEGRA TED CIRCUIT, 2 input (18324)
INTEGRATED CIRCUIT, Dual D Flip-Flop
(18324)
INTEGRATED CIRCUIT, 4 Bit Counter (18324)
INTEGRATED CIRCUIT, Low Pwr. Hex Inv.
(Fairchild)
INTEGRA TED CIRCUIT, Hex Inverter (18324)
SWITCH, SPDT PC Mount (09353)
WIRE, Bus 18 AWG 11/16"
,JUMPER, 0 ohm Resistor (Speer)
INTEGRA TED CIRCUIT, Hex Buffer NOD Inv.
(18324)
INTEGRA TED CIRCUIT. Hex Inverter (18324)
SCHEMATIC
·
·
·
·
··
·
·
·
·
·
·
··
·
·
·
·
·
·
·
M2 M3.M I,MIO MI2
12...31a
1
2
10
1
1
7
1
1
3
1
34
1
16
2
1
12
2
6
4
1
1
2
10
1
1
7
1
1
3
1
34
1
16
2
1
12
15
6
4
11
2 2
10 10
1 1
1 1
7 7
1 1
1 1
3 3
1 1
34 34
1 1
16 16
2 2
1 1
12 12
15 2
6 6
4: 4
8
1
1
1
4
-
9
1
1
1
-
1
1
10
1
1
7
1
1
3
1
34
1
16
2
1
12
2
6
4
8
1
1
1
4
-
3
3
1 1 1 1
S-203
21-030-F
IN5235
76F02CC200
BAI2AI04B
T6-S10
RC07GF331K
RC07GFI02K
RC07GF471K
RC07GFI01K
RC07GF561J
RC07GF562K
N7405A
USA994659X
N7404A
nOlA
Res. Jumper 0" 0 hm
N7417A
N741SA
3C
N
K
~
K
2
CI>
K
o
II:
NOEl
.
~
~
B
B
6
G
6
6
0 sGeB B G
~
S
~ 0 ~. B ~ ~ ~
EJ,,~
SeD ~ fJ ~
m
7
B
CD
CD
1
I
5
m
~
u 0 0 [3
CD
CD
0
0
d'
10
CD
t
3
FIGURE 12-14 P. C. ASSEMBLY - Sync Card
CD
CD
IT]
4
FIGURE 12-14 P. C. ASSEMBLY ~ Sync Card
FIG.
INDEX PART
NO.
NUMBER
-1
-2
-3
-4
-5
-6
-7
-8
-9
-10
-11
-12
-13
-14
-15
-16
-17
-18
-19
-20
-21
-22
-2S
-24
40035303
40060001
00000060
20031104
20031105
20031107
00000088
00000039
00000025
00000023
00000024
00000070
00000076
00000072
00000042
00000054
00000055
00000047
00000044
00000045
00000046
00000050
00000053
00000020
40094301
DESCRIPTION
1234567
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 ",r, 6V (03597)
CAPACITOR, .01 /oIf, 50V (56289)
CAPACITOR, Mylar, .I/o1f (03597)
RESISTOR, 1K ohm, :!: 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 ComparatorO. C. (18324)
INTEGRA TED CIRCUIT, Single 8 Input Gate (18324)
INTEGRA TED CIRCUIT, Dual D Flip-Flop (18324)
INTEGRA TED CIRCUIT, Dual 4 Input Buff (18324)
INTEGRATED 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
·
·
·
·
···
·
··
·
···
·
·
·
·
···
·
·
1112,M3 M ,MIO,III12
12-33a
UNITS
PER
VENDOR
ASSY PART NO.
1
2
9
8
1
1
1
1
25
2
6
3
1
1
8
2
4
6
~
2
3
2
1
S-203
21-030-F
IN5235
76F02CC200
TG-S10
BA12A104B
RC07GF102K
RC07GF471K
RC07GF221K
H6F22009XX
N8281ADC
N8242A
N7430A
N7474A
N7440A
N7400A
N7404A
N8280ADC
II:
N
II:
!fA
II:
•
2
. 11:
o
II:
iii
~--::---::---::--~~~~
'0
B
SSt]
tl
6
E
~ B~B:6~eD~D 0
G 0 D·G:G~[J ~
~ ~: 6 G8 6e[J [J B$ 08~
0
27
o
8
~
~
0
II
-LiD- DO
[jj]
-uo-8
-ill~
,.....-----'
5
3
•
..
.
I
FIGURE 12-15 P. C. ASSEMBLY - Clock Card
FIGURE 12-15 P. C. ASSEMBLY - Clock Card
\
FIG.
PART
INDEX NUMBER
NO.
-14
-15
-16
-17
-18
-19
-20
REF
40079901
40032201
40062601
00000060
20031104
20031105
20031107
00000088
00000039
00000025
00000024
00000022
00000023
00000077
00000070
00000073
00000080
00000225
00000056
00000053
00000046
00000048
-21
0000004'1
-22
-23
-24
00800045
00000044
00000123
-25
-26
-2'1
-28
00000050
00000124
00000087
00000198
00000020
40080001
40030801
40082'101
-1
-2
-3
-4
-I?
-6
-7
-8
-9
-10
-11
-12
-13
-29
-80
UNITS/ASSY
DESCRIPTION
1 2 3 4 561
P. C. ASSEMBLY, Clock Card
• PRINTED CIRCUIT BOARD
1
• PRINTED CIRCUIT BOARD
• PRINTED CIRCUIT BOARD
• HANDLE, Extractor with Roll Pins (18617)
,2
• BUS BAR, 4 Pin
I' 8
• BUS BAR, 5 Pin
5
• BUS BAR, 7 Pin
1
• BEAD, Ferritte
1
• DIODE, Zener 6.8V (04713)
1
• CAPACITOR, Electrolytic, 20llf, 6V (03597)
1
• CAPACITOR, Mylar, .1/Jf, 100V (03597)
1
• CAPACITOR,. 02 /Jf, 100V (56289)
1
• CAPACITOR,. 01 /Jf, 100V (56289)
16
1
• RESISTOR, 4.7K ± 10%, 1/4W
• RESISTOR, lK ± 10%, 1/4W
1
• RESISTOR, 2.2K:!: 10%, 1/4W
1
• RESISTOR, 5.6K:!: 10%, 1/4W
• RESISTOR, lOOK:!: 10%, 1/4W
• INTEGRA TED CIRCUIT. Comparator (07886)
1
• INTEGRATED CIRCt1IT. COIDlter Reg1ster·(18324) 1
• INTEGRA TED CIRCUIT. Quad 2 input gate (18324) 4
• . INTEGRA TED CIRCUIT, SiDgle 3 f,npat gate
2
(18324)
• INTEGRA TED CIRCUIT, SfDgle 8 input gate
5
(18324)
• INTEGRA TED CIRCUIT, Dual 4 input gate (18324) 1
•. INTEGRATED CIRCUIT. Dual D Flip Flop (18324) 12
• INTEGBA TED CIRCUIT. Hex Buff,lDv. o. c.
. (18324)
• JNTEGRA TED CIRCUIT. Hex Inverter (18324)
5
• INTEGRA TED CIRCUIT. Hex lSuff. Non Inv. O. C. • OSCILLATOR. Crystal 4.8 MHz (04713)
1
• RES18TOR. 0 ohm Jumper (Speer)
..
• WIRE. Bus AWG U8 11/16
1
• . SCHEMATIC
• SCHEMA TIC
1
• SCHEMATiC
-
(
M2 MS M ,MIO MIl
12-35a
VENDOR
PART NO.
11- 1
.. -
-
1
2 222
8-203
8 888
5 555
1 1. 1 1
111 1
1 1 1 1
3 3 - 3
21-03O-F
IN5235
76F02CC200
BA12AI04B
1 11-1
TG-S20
111 1
16 16 16 16 TG-SI0
RC07GF472K
1 1 1 1
'1 '1 6 7
RC07GFI02K
RC07GF222K
1 1 1 1
RC07GF562K
1 1 - ..
RC07GFI04K
1 1 - 1
LM311D
1 1 1 1
N8280ADC
111 1
4 4 4 4 N7400A
2 222
N7410A
555 5
N7430A
1 1 1 1
12 12 12 12
1 - - -
N7440A
N7474A
N7416A
5 555
- 111
111 1
1 1 .. 1
1 111
11- 1
N7404A
N7417A
KI035A00710
.. -
1 ..
24
3
4
~
FIGURE 12-16 P. C. ASSEMBLY - Error Card
I
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
-11
-12
-23
-14
-25
-28
-27
-28
-19
-aO
-11
REF
40081001
00000060
20031105
20031104
20031107
00000088
00000039
00000041
00000040
00000025
00000024
00000026
00000027
00000021
00000023
00000081
00000071
00000068
00000076
00000078
0000l070
00000074
00000080
20031103
00000051
00000044
00000046
00000047
00000050
00000048
-a2
00000052
0000042
-13
00000123
eM
00a00124
-I.
00000083
-SI
00000082
-17
00000198
. M000020
....1401
........
1111. . . . . .
UNITS/ASSY
DESCRIPTION
123 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, F~rrite (33062)
DIODE, Zener 6.8V (04713)
DIODE, Signal
DIODE
CAPACITOR, Electrolytic, 20/Jf, 6V (03597)
CAPACITOR, 0.1 /Jf, 100V (03597)
CAPACITOR, 400/Jf, 6V (03597)
CAPACITOR, 30 ",f, 12V (03597)
CJ. PA eITOR, • 22 /Jf, 25V (56289)
CAPACITOR, .01 /Jf, 100V (56289)
RESISTOR, 68 ohm, ± 10%, 1!2W
RESISTOR, 10K ohm, :t 10%, 1!4W
RESISTOR, 10 ohm, :!' 10%, 1!4W
RESISTOR, 470 ohm, ± 10%, 1/4W
RESISTOR, 1K ohm, :t 5%, 1/4W
RESISTOR, lK ohm, ± 10%, 1!4W
RESISTOR, 27K ohm, :!' 10%, 1I4W
RESISTOR, 5.6K ohm, :t 10%, 1/4W
BUS BAR, 3 Pin
INTEGRA TED CmCUIT, Dual Driver (01295)
INTEGRATED CmCUIT, Dual D Flip Flop (18324)
INTEGRA TED CIRCUIT, Quad 2 input gate (18324)
INTEGRA TED CIRCUIT, Single 8 input gate
(18324)
• . INTEGRATED cmCUIT, Hex Inverter (18324)
INTEGRA TED CIRCUIT, Triple 3 inplt gate
(18324)
INTEGRATED CIRCUIT, Delay Element (07263)
INTEGRATED CmCUIT. Quad 2 input DTL gate
(07263)
INTEGRATED CmCUIT. Hex Buff Inv. O.C.
(18324)
INTEGRA TED CmCUIT, Hex Buff. Non. Inv. O. C
(18324)
SWITCH. SPDT. P.C. Mount (09353)
SWITCH. SPDT. l'ush, P. C. Mount (09353)
JUMPER. 0 ohm, ReSistor (Speer)
WIRE, Bus 1MWG 18. 11/16
SCHEMATIC
·
·
·
·
..
·
··
·
·
··
·
·
·
·
·
·
·
··
··
··
·
Do
...
II:
" tL
II.
II:
...
"
~
II.
*
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
n~5235
1
1 1 1
2
IN914
2 2 2
IN4003
1
1 1 1
76F02CC200
1
1 1 1
BAI2AI04B
1
1 1 1
76F02CM401
1
1 1 1
76F02ED300
1 1 1
1
4
4 4 4 2C023224X0250A3
19 19 19 19 TG-S10
RC20GF680K
6 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
1
1 1 1 RC07GF273K
RC07GF562K
4
4
2
2 2 2
4
4 4 4
SN75450N
N7474A
5
5 5 5
5 5 5
N7400A
5
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
U6A9H659X
..
1
-
-
..
1 1 1
·
·
1
1
1
1
1
1
1
1
1
1
1
·
···
...,,~ 111111
12-37a·
1
2
6
8
1
1
1
2
1
1
1
1
1
4
19
6
1
1
1
1
8
1
-
1
--
1
1
1
1
.1
-
N7411A
N7417A
710lA
P8UIR
1 n.-Jumper 0 ohm
1
1
1
Source Exif Data:
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