Documation_M 400L_Card_Reader_Technical_Manual_Feb1973 Documation M 400L Card Reader Technical Manual Feb1973
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TECHNICAL MANUAL IGODCODOGOGGIDDDDDIODOIDIII18Dlftftftft.Ill""II"""""""""".~Da ••• ".~ ilJ-a.cc L II I II II I I 1111 1 11111 11111 " • ZZZZZ2ZZZZZZlZZZZZZZZZ" 133111311333.113~··· 44U4" . 55 5 5 IIF .t 71;: I, L~"'D "'E~DE'" FEBRUARY 1973 1 \C:~ 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) •• ~ ,0/ ~ ~_ _.;;;;1;,;.;:2.:..:;41::.;7:..;;:1:..:.6_ __ ' (h t 2 ·f 2) . 0 r.. '\-'MODIFIED PER OPT 01 12'·'716 Schem a.t IC, S ee 0 • • • • •• • i;}' CY 0 ••••••.••••••• Sync Card Assembly ~ o. ~ ~ J.y • • • • • • • • • • • • • • • . Schemat~c, (sheet 1 of 3). o. ~~§ o. ~ Schematic, (sheet 2 of 3) o . ~ •.,-::. r.. •••••••• ., 0 0·~. Schematic, (sheet 3 of 3) •• tj!S' ,,-0$ ..•• Control Card Assembly o • • • s:; t>.~Ay . Schematic, (sheet 1 of 2) ••• ~ &4f4? .•.• 1241715 1241715 Schematic, (sheet 2 of 2) • • • •• .• 0 •• 0 0 0 ••• 0 • ••••••• 0 0 0 • • •••••• • • • • ••••••••• • 0 • • • • 0 0 • 1/ .. •• •• If •• • ••••••• ••• 0 • 0 0 ....... . 0 0 00 0 0 0 '.0 • 0 0 • •• .' ••• 0 • ......... D 00. 0 •• 0 0 0 0 • 0 0 0 • 0 ••••••. J.j.l- 0 ........ 0 • 0 0 •••• 0 ••••••• 0 0 . • 0 0 0 ••• 0 •••••••• 0 ••• 0 • •• 0 ••• 0 0 ••••• 0 • 0 •••• 0 0 ••• •••••••••••• 0 ••• • 0 Special Cards: •••• •••• 0 0 0 0 0 · ... ... -;- ·· .. .. .... ..... . ·...... . 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 (/2139101 C3 MOTOR .fl RU~ \ L UNE r cal su, CABU' AS5Y 102027521 1 W," 'OIITP"T 5 VOLT REGULATOR + INPUT CIRCUIT BREAKER I~ I I-' CABLE ASS 7 ~ _ J5-8 PICK I?TAl. J5- A PICK 5tJLEIJOfD ORIVE€ TO LIGHT STAT/OM , CAP.LE A&::' 82 CN.45S1S VACUUM MOTOR P C2 • I I ~ o ~5 MIT! :: r=L---',,'~!-' +SY :OFl~~D PowEA RTAI ~ n MOTHeRBOARD 1.'1-1' A:e". CABU .lOSSY 102027511 PIC/( /tTAl. 5C;L£AJOID j)IlJV£~ P,Ck: j5 • TO l/6HT sr~TlOAJ I CABLe ASSY fo-;df]5(H: (.J '-0'· ..... T8 Z o .....I >- CA8L( ASSY. 1112027'-02 B 7 t6 S CABLE A,SSY /02f)U702 ,"4 N{)T()/? ~: ..... ~ R.)L _____ cABLE ASSY' JOZoZ7S13 "-ti"~_E Po<;": IOz.C'313C r-~l~ -wu,,, I" J ~ wnf. 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'IN 8 0 ,0 c. ° l' t> ,0 DEUTSCH ?/N T..\\\"--OS-D\ ... FI,I.!)AMP '5I..o·eL.O otJ 1000 MODEL • r INPuT+ INPUT- I ~Rt.I + Bl..F\\9h\ I 1 C2H , 1 SINGLE f>O,,,,T GROIJND I I CI I o.\U~ I I I ¥;~I 3 I r. I> RI 10K U R2 7. SK. "2W!S~ I R; c.,Ste. I/4-Wil'fe. I Figure 10-5. 1 L_ UI • 1 yeL- R& · I au I &A•.t""N~ AI, , yn/",tfT '6/111/0.1 • .,. I _, I • ~_.L_ ,6 7 • ~UF -- - ~.: ",- I I \b I I lilt , U. [b. "I sv t I I ()UTPuT + "I Yf.L I I I I Ill. ~; .OOIUF II< '/~W!.\D% C4 lour OUT?\JT- S. VOLT POWER SUPPLY Schematic Diagram, 5V Power Supply, 115 VAC, 60 Hz (Dwg. No. 1040506) 'Jee ~o ~A.'RD j:,LE. MOTI-IE'R. o..:>A~D J I I • _174f""'tI _ _ _ ...J tp-. I I --1- -.J I _Row~ ~ . .... -_ -L_ ..',.._. --l ,'tz,o't> lOOn. .,. ReNO 5' ~ I I ~~ c.lG"r L. • 3 W_~CK.U,: 1 !9 w.. W1:,\OOJ',. · I .'R9"O jLV4W R" ~ I aI-I< ~CllI.1a to~ ' rJ RoI I,N I .IOJL 3W!\"'., I HEJo.T'5INK [19 ... I , RS I ZN~711 I " ,,!; I 1-----1 I I I I , i- - - - - - - Ii- - - - - - - - - - - - - - - - - - - ._- ----~ z. r. 1 I I P 0 -I I I I I I I Col 41.00U. 1'5'< 5 T"t.lCDR P-c;,~77 0, I ~ L - _.J L __ ....1 n,,"SmRw.e.. It' If£" · d- I I_ T~2. ~ll< I "'~ ~-----------, ~'''' , l'>R" ? llTN .... ~~JJ r - - - - - - - - - - - , --~~~----~~~------~:~----~~ i"~ RO~/t ~ If I. I> " a,S I F , I l ooA 1 n.r,,1J -----' _5: I:>--------1 I II I UI b ..... ,¥z I l. __ _ ~4A.'" t _________ _ j---- ---- ------- -- -----~ ------ --} I I I P/N I.'G~" I 'KInr.t 1 ~__~~~~U~_F~'~~~~__~____8§2~N~~Z(_) TIIZ Schematic Diagram~ 5V Power Supply~ 230 VAC~ 50 Hz (Dwg. No. 1041269) ! _ ~ tp RTN t-"\OTHeR e,oAR'O WHITE 'T~ DOT 48\1 TIWIISFORMI!" ASS'f I03030!I ______________ ~ ~ r.- - p os 40 DEUTSCH ~ II J ~~~D~ ____ ~ RECTIFIER DIODE 8RID&£ MOTOIIOLII PIN MI»I'!SO-l .OUI~ ,..!1!l~lC.~_+_ _-,l) 1600" ,3 !fill T JII"-()5-01 I ~ __ :J TIWI5FORIiIER 5TANC~ 1'-10311 p P i----te--p .. 2 p Q r' 05 -0 DEUTSCH TJII"'-05-01 PIN p WH1 I I SINE.LE (;1 (-) POINT 6~UNO 10K, Ifa vi ... ,1 C~ CRI IN 4003 TR"N5FORME.R SnNCDR 1'-1.311 c:..E. I1N 81i> Fill M CDZOO UI' lS \I~e. r>lEMSaNiC: ., --_..:..1_< I LI PI[I(.ER o;OlENOID L __ ..J G.t. TIP41C p RI ~10n. PltK 1 I I! , L 'I :: ________ J l '3OLENOIO ORIIIER ASSY 10'30100 Figure 10-6,. Schematic Diagram, Solenoid Driver, 115 VAC, 60 Hz (Dwg. No. 1341226) PICK R'HI WHITE T2. DOT 2.4 V A'S.SY Te3 TRA.N<;:'FO~ME~ RECT\I=\ER. DI005 e.l=I.lOGoE 102.0740 ~OTOROLA RED PiN MOAgeO-2 01', 10 0, 2.0 (0 '30 OS 40 + e\..1< OE'-'''5~H p PiN TJllA-O'=>-02 L __ -.J FI,II\,SI:> T'02 '--_R=E=O'+_ _ _f--_ _ _---1 TRANSl=ORMER STANCOR P- '"3"'-7 p oeo 10 ~ ~ 0-, 1:0 ~ 0 ~O 5 0:' "\0 ..... 0 I p oe'JTs,c.H I f'o/N TJIIA-O'5-01 1 ~ p wHi \..1 PICKER ,::>O\..ENO\O BRN "3 1 4 1 S,>..lGL.E POI>..l'TG;;2C>UND ca c'" n,,~ooa G..E. PIN B <;:.y J5-e I I I Figure 10-6A. c., (-) I I wH' R2. I I I I I , . WH..l -15- A 1 IO?OIOO Schematic Diagram, Solenoid Driver, 230 VAC, 50 Hz (Dwg. No. 1041268) ..... o ' J ~ Figure 10-7. Assembly Diagram, Clock Card (Dwg. No. 1040765) " .. 5~_ _ ~~2 74j)4 I 740"1 ii .. " C> " .. ---1.~12 __ t------------j-------j--- vee ~--~------ -'12'-____ ~ ----'"9...J~.~,--,~-_____'i51so--><,.,,----~ H8~ t/i;;04 1/7;" ~2~-3 741:1 ..... o I ex> R3 4.7K 1:6:, PICKUP AMPLIFlE:R '--"-h T ••__.:.:TS,,-T---'~-_i7--t---__ s .. TST RTR lCI9 .02UF 2 COl1f'ARATOR , '0 ••__~SH~!E~LO~_ _ _, 1 lM311D 09-11 RS 9{:-L.9C-13 LK 1B-LO.18-L9~---oVCC vcCo C9-]'\ 1m 1010 I·olUFI·oIUF 9 18-1.18-1 , i _ 1 ~_ 1 -, T 1 1 1 J.. 1'5 trHi ~C11 1"'C12 1[,1' TeG Tee Ie< T" T" . J J • t" • • • l • ~ 03 ::;:-"(9 CR, T~I~ IC LOCA~:O" : ,,~: 18.&C.1C.9C.60.70.90 AU_ CAPACITORS .OJUr Figure 10-8. Schematic Diagram, Clock Card (Sh. 1 of 3) (Dwg. No. 1040800) ~ NOCONNECTIONPjNS7&14 1-60-8 C> CD 13 ONE OARK 1'19-6 .1 74C14 s 50 7404 ~ POR GPR SYNC CONTROL 10 1160 L-.y·I(JC "8-11 ~O P . 1 c'---- HO-4 9 ~ ~D ~C "'-< 1-70-e 1 O~ 11 3-2D-l ~1~ , 5C 11 GPR 10 5C 1'1ll1 O~ 74*, ~ I ~DPl~ 12 ~ f-'O- ~ P 0 . IPl O~ 7~74 T5T2 9 I 1 01-"---- 7"'00 12 1 ~C 2 50 1 NOTES. '0 ~ ~ 2 M 6 5 71<10 Sse ~ RESET 5 S 5C .--k STORE CONTROL 12 ~"~" 1~ a 6C FOR CR cur LAND C-£ ADD JUMPER C-o. 7174 -4 7404 C Q:> O~ 1 Q:> 10 81CR 100 ""O 5 Dr!'- -CR POR-TSlR 3 13 1 P 0 1~74 ~ 13 %- 13 .~ ~11 , 'C '0 ~ C 7-40-4 ZERO E MO-' 9 " ~ T5TI ~ 12"~ '-511-8 Coo 5 " '0 I CD 1 ,!-C 01-"---- 7104 ~C ....0 P 0 DC ~O MB ... ~ ' 7400 7404 C 1ST SYNC CONTROL 1-90-9 , 1~ 7~ 7~ 2 SO CL P " 7A ~ FBI 6B 5 12 '0 P 10 9 "" :=E ~O - P OFFSET CONTROL 1~ FF --h ~D 3D -- 5 PIS PR elK ~' -4 10 Me-IS 710Cl 7401 7110 , -'--- ~c 71~ H8-4 ~C Cl Dr!'-- 71~ I 1 ~C Cl "~ 7~ I • 5 ~~1~ 12 D P 'C 10 ~O P 1~ ,. - .0 ~c 1-70-6 Cl 7A-13 8C 1 80-2 7A-28C .... SD-3 7A-3 8C-I0 :g:g 4C-230-1 4C-330-I3 4C-13 -40-1 ~ vee lK R1 ~ lK vee '0 ll~ * 7<17.11 13 as ClIC S ~ STllB 11 C 0 , r 13 OSR 12 III 9 OSU cue 7",1(1 RESET-+P~R I NUI1BERS USED LAST NO. RU Ie LOCATION 'Oh) 7104 H.:)' *' 747'" 5C USED THIS SHEET R6,R? ?A,6B,'IC-6C,8C.30-8D Figure 10-9. Schematic Diagram, Clock Card (Sh. 2 of 3) I> 3-;;A-I3 -~ _L L~5 "e 1'1'6-"7 T RESEr.,.. POR .;.. GPR 2~(.,~8 "" Q"'" k~Q~ IZ 0 p L: 'D A?. "e Q S I~QfL I2..D P A3 QB ~ '3 Q'- "e CL. 1 l~~ lie T . 1]:>. rOIl,Y400 E4CR 2. Cz. ct.Jri..AND~ J-J:.. ,0·2. "'DD ,JUMPERS .1-L,G!5, ~02 /VI 5(){) CU.T"lANDS F-e;. J-k:, A+N. T-Y. ADIJ JUMPEIZS F-.... J-L M-P,T-W. ~'!.-D ' CQI...LJ\'t"IN I Figure 10-10. i ,; Schematic Diagram, Clock Card, (Sh. 3 of 3) ":;OL.N-:"'';R 18 AkJ7C' (t:>4'M t.a!E~ _TN A:rS'l~ ='f:ll~~=;:: L-....\----+-+--~ ...."M''''. [p~~::/~t::~--.------f .!It/IfIIINIVIC·P. Figure 10-11. Assembly Diagra.m, Error Card .' (Dwg. No. 1040610) F ::( -r---:.~j MI5-~ 2-\3",,-\ 2-6.:0-2 M8-/3 MB-5 O/'O STAc:r: C !J D4 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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