NCR 7156 User manual

NCR 7156 Thermal Receipt and

Impact Slip Printer:

Service Guide

BD20-1437-A

Issue B

September 1997

September 1998ii

Disclaimer

Information in this document is subject to change without notice. Therefore, before using this

document, consult your NCR sales representative for information that is applicable and current.

NCR reserves the right to improve products as new technology, components, software, and

firmware become available.

No part of this document may be reproduced or transmitted in any form or by any means, electronic

or mechanical, for any purpose without the express written permission of NCR.

Copyright

Dayton, Ohio

Printed in USA

Confidential, Unpublished

Property of NCR Corporation

Trademarks

NCR is the registered trademark of NCR Corporation. Other trademarks and registered trademarks

are the property of their respective holders.

September 1998 iii

Important Information to the User

In order to ensure compliance with the Product Safety, FCC and CE marking requirements, you

must use the power supply, power cord, and interface cable which were shipped with this product

or which meet the following parameters:

Power Supply

UL Listed (QQGQ), Class 2 power supply with SELV (Secondary Extra Low Voltage), non-energy

hazard output, limited energy source, input rated 100-240 Vac, 1.5/0.8 A, 50/60 Hz, output rated 24

Vdc, 2.3 A.

Use of this product with a power supply other than the NCR power supply will require you to test

this power supply and NCR printer for FCC and CE mark certification.

Interface Cable

A shielded (360 degree) interface cable must be used with this product. The shield must be

connected to the frame or earth ground connection or earth ground reference at EACH end of the

cable.

Use of a cable other than described here will require that you test this cable with the NCR printer

and your system for FCC and CE mark certification.

Power Cord

A UL listed, detachable power cord must be used for this product. For applications where the power

supply module may be mounted on the floor, a power cord with Type SJT marking must be used.

For applications outside the US, power cords which meet the particular country’s certification and

application requirements should be used.

Use of a power cord other than described here may result in a violation of safety certifications which

are in force in the country of use.

September 1998iv

Federal Communications Commission (FCC)

Radio Frequency Interference Statement

Warning

Changes or modifications to this unit not expressly approved by the party responsible for

compliance could void the user’s authority to operate the equipment.

Note

This equipment has been tested and found to comply with the limits for a Class A digital device,

pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection

against harmful interference when the equipment is operated in a commercial environment. This

equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in

accordance with the instruction manual, may cause harmful interference to radio communications.

Operation of this equipment in a residential area is likely to cause harmful interference in which case

the user will be required to correct the interference at his own expense.

Communication Cables

Shielded communication cables must be used with this unit to ensure compliance with the Class A

FCC limits.

Information to User

This equipment must be installed and used in strict accordance with the manufacturer's instructions.

However, there is no guarantee that interference to radio communications will not occur in a

particular commercial installation. If this equipment does cause interference, which can be

determined by turning the equipment off and on, the user is encouraged to contact NCR

immediately.

The NCR company is not responsible for any radio or television interference caused by

unauthorized modification of this equipment or the substitution or attachment of connecting cables

and equipment other than those specified by NCR. The correction of interferences caused by such

unauthorized modification, substitution or attachment will be the responsibility of the user.

Industry Canada (IC)

Radio Frequency Interference Statement

This Class A digital apparatus meets all requirements of the Canadian Interference-Causing

Equipment Regulations.

Cet appareil numérique de la classe A respecte toutes les exigences du Règlement sur le matériel brouilleur du

Canada.

September 1998 v

Quick Reference

This Quick Reference will direct you to key areas of the Service Guide. For a complete

listing of topics, consult the Table of Contents or the Index.

Setting Up the Printer page 7

Basic requirements for unpacking and installation, connecting the printer, turning

it on, and running the print test.

Checking and Adjusting the MICR Check Reader pages 27, 30

Instructions for adjusting the Magnetic Ink Character Recognition (MICR) check

reader for the common PC board and the MICR amplifier board (on older

LCSIO—RS-485 models).

Running the Data Scope Mode page 35

Instructions for running the data scope mode.

Troubleshooting page 43

Information on correcting problems with the printer.

Adjusting the Platen Gap page 55

Instructions for adjusting the platen gap on the print mechanism.

Replacing the Thermal Printhead page 72

Instructions for replacing the thermal printhead on the thermal mechanism.

Replacing the Knife Assembly page 74

Instructions for replacing the knife assembly on the thermal mechanism.

September 1998vi

How to Use this Book

Use this book as a general and technical reference manual and as a guide when replacing

parts on the printer. The service guide is intended as a guide for service representatives,

field engineers, and those who will be installing and learning about the 7156 printer. It can

also be used as a reference for service courses.

See the Quick Reference page, the Contents, or the Index for detailed listings of what is

contained in this book.

Who Should Use this Book?

You must be a trained service representative to service the 7156 Thermal Receipt and

Impact printer.

How to Obtain More Information

For more information see the following documents:

•

7156 Thermal Receipt and Impact Slip Printer: Owner’s Guide (BD20-1436-A)

•

7156 Thermal Receipt and Impact Slip Printer: Setup and User’s Guide (BD20-1435-A)

For this and additional copies of the Service Guide, contact your sales representative.

Revision Record

Issue Date Remarks

A September 97 First printing

B September 98 Second printing, including

minor revisions

7156 Service Guide Contents

September 1998 vii

Contents

Section One: Printer Information and Setup 1

Chapter 1: About the 7156 Printer 3

Features ......................................................................................................................................4

Receipt Station....................................................................................................................4

Slip Station..........................................................................................................................4

Both Stations.......................................................................................................................4

General Features ................................................................................................................5

Options....................................................................................................................................... 5

Chapter 2: Setting Up the Printer 7

What Is in the Box? ................................................................................................................... 7

Removing the Packing Material....................................................................................... 8

Repacking the Printer........................................................................................................9

Choosing a Location ............................................................................................................... 10

Setting DIP Switches............................................................................................................... 11

Connecting the Cables............................................................................................................12

RS-232C Models (Remote) .............................................................................................. 12

LCSIO (RS-485) Models (Integrated)............................................................................. 14

Turning On the Printer...........................................................................................................15

Testing the Printer................................................................................................................... 15

Running the Print Test by Power Cycling the Printer................................................. 16

Running the Print Test by Opening and Closing the Cover....................................... 16

Sample Print Test for RS-232C Models ......................................................................... 17

Sample Print Test for LCSIO (RS-485) Models............................................................. 18

Cleaning the Printer................................................................................................................ 19

Cleaning the Cabinet ....................................................................................................... 19

Cleaning the Thermal Printhead.................................................................................... 19

Chapter 3: Diagnostics 21

Level 0 Diagnostics ................................................................................................................. 21

Level 1 Diagnostics ................................................................................................................. 22

Setting Printhead Resistance ..........................................................................................23

Setting Partial Cut Distance............................................................................................ 24

Setting Data Error and Data Buffer Options (RS-232C Models Only) ...................... 25

Ignoring/Using the Carriage Return............................................................................. 26

Checking and Adjusting the MICR Check Reader (Common Board and RS-232C

Models).........................................................................................................................27

Checking and Adjusting the MICR Check Reader (LCSIO—RS-485 MICR

Amplifier Board)......................................................................................................... 30

Contents 7156 Owner’s Guide

September 1998viii

Verifying Read of MICR Characters..............................................................................34

Running the Data Scope Mode.......................................................................................35

Testing the Slip and Receipt Stations.............................................................................36

Level 2 Diagnostics..................................................................................................................39

Level 3 Diagnostics..................................................................................................................39

Print Test ..................................................................................................................................39

Running the Print Test by Power Cycling the Printer.................................................40

Running the Print Test by Opening and Closing the Cover.......................................40

Sample Print Test for RS-232C Models..........................................................................41

Sample Print Test for LCSIO (RS-485) Models.............................................................42

Chapter 4: Troubleshooting 43

Test Points................................................................................................................................43

Field Effect Transistors (FETs)...............................................................................................44

Common PC Board (Newer Printer Models) ...............................................................44

RS-232C PC Board (Older Models)................................................................................45

LCSIO (RS-485) PC Board (Older Models) ...................................................................46

Mechanical Problems..............................................................................................................47

Printing Problems....................................................................................................................49

Forms Feeding Problems........................................................................................................50

Electronic Problems ................................................................................................................51

Chapter 5: Adjustments 53

Adjusting the Paper Low Sensor...........................................................................................53

Adjusting the Platen Gap.......................................................................................................55

Section Two: Thermal Receipt Mechanism 57

Chapter 6: Removing the Thermal Receipt Mechanism 59

Tools..........................................................................................................................................59

Removing the Receipt Cover.................................................................................................60

Disassembling and Reassembling the Receipt Cover.........................................................62

Removing the Platen (Non-Knife Models)....................................................................62

Replacing the Platen (Non-Knife Models)....................................................................62

Removing the Top Cover .......................................................................................................63

Disconnecting Cables from the Common PC Board...........................................................64

Disconnecting Cables from the Older RS-232C PC Board ................................................. 66

Disconnecting Cables from the Older LCSIO (RS-485) PC Board.....................................68

Removing the Thermal Receipt Mechanism........................................................................70

7156 Service Guide Contents

September 1998 ix

Chapter 7: Disassembling and Reassembling the Thermal Receipt Mechanism 71

Tools.......................................................................................................................................... 71

Thermal Printhead.................................................................................................................. 72

Removing the Printhead ................................................................................................. 72

Replacing the Printhead..................................................................................................73

Knife Assembly ....................................................................................................................... 74

Removing the Knife Assembly....................................................................................... 74

Replacing the Knife Assembly ....................................................................................... 75

Knife Motor.............................................................................................................................. 76

Removing the Knife Motor............................................................................................. 76

Replacing the Knife Motor.............................................................................................. 76

Switches....................................................................................................................................77

Removing the Switches................................................................................................... 77

Replacing the Switches.................................................................................................... 78

Paper Low Sensor.................................................................................................................... 79

Removing the Paper Low Sensor................................................................................... 79

Replacing the Paper Low Sensor....................................................................................79

Paper Feed Motor.................................................................................................................... 80

Removing the Paper Feed Motor................................................................................... 80

Replacing the Paper Feed Motor.................................................................................... 80

Chapter 8: Replacing the Thermal Receipt Mechanism 81

Tools.......................................................................................................................................... 81

Replacing the Thermal Receipt Mechanism ........................................................................ 82

Reconnecting Cables to the Common PC Board................................................................. 84

Reconnecting Cables to the Older RS-232C PC Board........................................................ 86

Reconnecting Cables to the Older LCSIO (RS-485) PC Board........................................... 88

Replacing the Top Cover........................................................................................................ 90

Replacing the Receipt Cover.................................................................................................. 91

Section Three: Print Mechanism 93

Chapter 9: Removing the Print Mechanism 95

Tools.......................................................................................................................................... 95

Preparation............................................................................................................................... 96

Removing the Sensor Bracket................................................................................................ 97

Removing the PC Board......................................................................................................... 98

Removing the Thermal Mount............................................................................................ 100

Removing the Hinge Arm Assembly ................................................................................. 101

Removing the MICR Amplifier Board: LCSIO (RS-485) Models.................................... 102

Removing the Print Mechanism.......................................................................................... 104

Contents 7156 Owner’s Guide

September 1998x

Chapter 10: Hinge Arm Assembly and Sensor Bracket 105

Tools........................................................................................................................................105

Disassembling the Hinge Arm Assembly.......................................................................... 106

Reassembling the Hinge Arm Assembly ...........................................................................107

Disassembling the Sensor Bracket.......................................................................................108

Reassembling the Sensor Bracket........................................................................................ 108

Chapter 11: MICR Assembly 109

Tools........................................................................................................................................109

Removing the MICR Assembly from the Print Mechanism............................................110

Removing the MICR Bracket Assembly......................................................................111

Removing the Buck Coil Assembly .............................................................................111

Replacing the MICR Assembly on the Print Mechanism................................................. 112

Replacing the Buck Coil Assembly..............................................................................112

Replacing the MICR Bracket Assembly ......................................................................112

Chapter 12: Carriage Assembly 113

Tools........................................................................................................................................113

Removing the Carriage Assembly from the Print Mechanism........................................114

Disassembling the Carriage Assembly............................................................................... 115

Reassembling the Carriage Assembly ................................................................................ 116

Replacing the Carriage Assembly on the Print Mechanism............................................117

Chapter 13: Drive Plate Assembly 119

Tools........................................................................................................................................119

Removing the Drive Plate Assembly from the Print Mechanism...................................120

Disassembling the Drive Plate Assembly...........................................................................121

Reassembling the Drive Plate Assembly............................................................................123

Replacing the Drive Plate Assembly on the Print Mechanism........................................ 124

Chapter 14: Replacing the Print Mechanism 125

Tools........................................................................................................................................125

Replacing the Print Mechanism........................................................................................... 126

Replacing the MICR Amplifier Board: LCSIO (RS-485) Models..................................... 128

Replacing the Hinge Arm Assembly..................................................................................130

Replacing the Thermal Mount.............................................................................................131

Replacing the PC Board........................................................................................................ 132

Enhanced Common PC Board Connectors.................................................................134

RS-232C PC Board Connectors..................................................................................... 135

LCSIO (RS-485) PC Board Connectors ........................................................................136

Adjusting the Platen Gap.....................................................................................................137

Adjusting the MICR Check Reader.....................................................................................138

Replacing the Remaining Items...........................................................................................138

7156 Service Guide Contents

September 1998 xi

Section Four: Base Feed Assembly 139

Chapter 15: Removing the Base/Feed Mechanism 141

Tools........................................................................................................................................ 141

Preparation............................................................................................................................. 142

Separating Mechanisms from the Base/Feed Mechanism............................................... 143

Chapter 16: Forms Compensation Arm Assembly 145

Tools........................................................................................................................................ 145

Removing the Forms Compensation Arm Assembly....................................................... 146

Disassembling the Forms Compensation Arm Assembly............................................... 147

Reassembling the Forms Compensation Arm Assembly................................................. 148

Replacing the Forms Compensation Arm Assembly in the Base.................................... 149

Chapter 17: Forms Guide Assembly 151

Tools........................................................................................................................................ 151

Removing the Forms Guide Assembly............................................................................... 152

Disassembling the Forms Guide Assembly....................................................................... 153

Reassembling the Forms Guide Assembly ........................................................................ 153

Replacing the Forms Guide Assembly in the Base........................................................... 154

Chapter 18: Solenoid and Pivot Arm Assemblies 155

Tools........................................................................................................................................ 155

Removing the Solenoid and the Pivot Arm Assembly..................................................... 156

Removing the Solenoid ................................................................................................. 156

Disassembling the Pivot Arm Assembly .................................................................... 157

Replacing the Solenoid and the Pivot Arm Assembly..................................................... 157

Replacing the Solenoid.................................................................................................. 157

Reassembling the Pivot Arm Assembly...................................................................... 157

Chapter 19: Paper Feed Motor Assembly 159

Tools........................................................................................................................................ 159

Removing the Paper Feed Motor Assembly...................................................................... 160

Replacing the Paper Feed Motor Assembly....................................................................... 160

Chapter 20: Replacing Mechanisms in the Base/Feed Mechanism 161

Tools........................................................................................................................................ 161

Reassembling Mechanisms in the Base Assembly............................................................ 162

Finishing................................................................................................................................. 162

Contents 7156 Owner’s Guide

September 1998xii

Section Five: Appendixes 163

Appendix A: Printer Specifications 165

Print Specifications: Both Stations....................................................................................... 165

Slip Station Specifications .................................................................................................... 166

General Information.......................................................................................................166

Slips/Forms Print Zone.................................................................................................166

Power Requirements.............................................................................................................166

Power from Host............................................................................................................166

Power from Power Supply............................................................................................167

Environmental Requirements..............................................................................................167

Reliability................................................................................................................................167

Dimensions and Weight....................................................................................................... 168

Density of Receipt Print Lines ............................................................................................. 168

Duty Cycle Restrictions (Printing Solid Blocks)................................................................ 168

Appendix B: Communication Information 169

RS-232C Connectors.............................................................................................................. 169

RS-232C Power Cable Connector.................................................................................169

Cash Drawer Connector and Pin Assignments.......................................................... 169

RS-232C Communication Connector Pin Assignments............................................. 170

RS-232C 25-Pin to 9-Pin Cable Diagram......................................................................170

RS-232C 9-Pin to 9-Pin Cable Diagram........................................................................ 171

LCSIO (RS-485) Connector and Pin Assignments.............................................................171

DIP Switch Settings...............................................................................................................172

RS-232C Switch Settings................................................................................................ 172

LCSIO (RS-485) Switch Settings...................................................................................173

Commands............................................................................................................................. 174

Printer Function Commands ........................................................................................174

Print Characteristics Commands..................................................................................176

Station Select Commands..............................................................................................176

Graphics Commands.....................................................................................................177

Printer Status Commands.............................................................................................177

Real Time Commands ...................................................................................................177

Bar Code Commands.....................................................................................................178

MICR Check Reader Commands.................................................................................178

7156 Service Guide Contents

September 1998 xiii

Appendix C: Common PC Board and Extender Cables 179

Appendix D: Ordering Paper and Supplies 181

Ordering Thermal Receipt Paper........................................................................................ 181

Ordering Forms..................................................................................................................... 181

Ordering Ribbon Cassettes .................................................................................................. 182

Ordering Other Supplies...................................................................................................... 182

Ordering Documentation..................................................................................................... 183

Index 185

Contents 7156 Owner’s Guide

September 1998xiv

Revision Record

Issue Date Remarks

A September 97 First printing

B September 98 Second printing, including

minor revisions

7156 Service Guide Section One: Printer Information and Setup

September 1998 1

Section One: Printer Information and Setup

•

Chapter 1: About the 7156 Printer

•

Features

•

Options

•

Chapter 2: Setting Up the Printer

•

What Is in the Box

•

Choosing a Location

•

Setting DIP Switches

•

Connecting the Cables

•

Turning On the Printer

•

Testing the Printer

•

Cleaning the Printer

•

Chapter 3: Diagnostics

•

Level 0 Diagnostics

•

Level 1 Diagnostics

•

Level 2 Diagnostics

•

Level 3 Diagnostics

•

Print Test

•

Chapter 4: Troubleshooting

•

Test Points

•

Field Effect Transistors (FETs)

•

Mechanical Problems

•

Printing Problems

•

Forms Feeding Problems

•

Electronic Problems

•

Chapter 5: Adjustments

•

Adjusting the Paper Low Sensor

• Adjusting the Platen Gap

7156 Service Guide Chapter 1: About the 7156 Printer

September 1998 3

Chapter 1: About the 7156 Printer

Receipt

Cover

Receipt

Paper Feed

Button

Front

Cover

LED

Extended

Slip Table

Slip or

Check

On Line Button

Paper Status

Red Led

On Line

Green LED

Note: Some 7156 models may appear slightly different from what is shown in the

illustration. The procedures are the same for all models unless otherwise noted.

The 7156 printer is a fast, quiet, relatively small and very reliable multiple- function

printer. It prints receipts, validates and prints checks, and prints on a variety of single- or

multiple-part forms. There is no journal as it is kept electronically by the host computer.

Chapter 1: About the 7156 Printer 7156 Service Guide

September 19984

Features

The 7156 printer comes with several features and options.

Receipt Station

•

Thermal printing

•

Standard pitch (host selectable): 15.2 characters per inch, 44 columns

•

Compressed pitch (host selectable): 19.0 characters per inch, 56 columns

•

Resident bar codes

•

Code 39

•

Code 128

•

UPC-A

•

UPC-E

•

JAN8 (EAN)

•

JAN13 (EAN)

•

Interleaved 2 of 5

•

Codabar

•

Drop-in paper loading requiring no spindle or threading paper

•

Paper low indicator

•

Paper exhaust

Slip Station

•

Bi-directional, impact printing

•

Standard pitch (host selectable): 13.9 characters per inch, 66 columns

•

Compressed pitch (host selectable): 17.1 characters per inch, 80 columns

•

Printing of forms up to five plies

•

Front insertion of forms with forms stop

•

Side insertion of forms with override of forms stop

•

Automatic and manual insertion of forms

•

Form alignment sensors and Slip In LED indicator

•

Horizontal flat-bed slip table with optional extension (standard with MICR check

reader)

•

Snap-on ribbon cassette

Both Stations

• Variety of print modes: double high (receipt station only), double strike (slip station

only), double wide, upside down, and rotated

• Two resident character sets:

• PC Code Page 437 (US)

• PC Code Page 850 (Multilingual)

• 16K RAM for downloaded character sets or bit-mapped graphics (such as logos)

7156 Service Guide Chapter 1: About the 7156 Printer

September 1998 5

General Features

•

Cover open sensors

•

Industry standard RS-232C communication interface

•

History EEROM for custom settings

•

Power and communication support for a remote 2x20 pass-through display

•

Audible tone (controlled by application)

Note: The 7156 does not use a paper journal. The journal is kept electronically by the host

computer.

Options

•

Magnetic Ink Character Recognition (MICR) check reader built into the slip station for

verifying checks (includes custom MICR field parsing)

•

Extended slip table for handling large forms (standard with MICR check reader)

•

Paper cutter (receipt station)

•

Remote power supply

•

Two cash drawer drivers

•

Communication cable

Chapter 1: About the 7156 Printer 7156 Service Guide

September 19986

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