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26 Pin Connector Cable
Connects stepper driver board to interface board.
40/50 Pin Cable
Information is transferred back and forth between the control unit and the TRS-80 through the 40/50 cable. The 40-pin connector is plugged into the interface board, and the 50-pin connector plugged into the TRS-80. Do not bend or crimp this cable. Make sure all other electrical cables and cords do not touch are cross this ribbon cable.
Accessory Kit
An assortment of spare parts and tools that came with the System 1.
Air Blow Off
Small copper tube near the spindle used to keep engraving chips from building up around the spindle nosecone. This tube is connected to the air cylinder, and air flow though it is controlled by the air blow off value located at the back right side of the engraving table.
Air Blow Off Value
Air Cylinder
Regulates down speed on the Z-axis.
Adjustment Valve
Valve to regulate the flow of air to the air cylinder. Located on the back right side of the engraving table. Excessive air flow causes the cutter or graver to "slap" the engraving surface.
Air Cylinder Clamping Screw
Use to adjust the clearance between the engraving table and spindle.
Air Solenoid Value
Air Solenoid Port
Connects air solenoid/cutter (Z-axis) and Stepper Driver Board.
Ball Slide
Located behind the cutter spindle, the vertical movement of the cutter, from the up position to the down position on the surface is dependent on proper pre-load of the ball slide mechanism. The ball slide pre-load must be adjusted properly to insure high quality of the final engraved character. (Show Drawing - page 50/1 of original Brown manual
Blow Off Tube
See Air Blow Off Tube
Bridge Rectifier
This diode bridge does rectification to change the fluctuation of positive and negative voltage received from the transformer to only positive voltage
Bristol Spline Wrench
Cutter wrench used to adjust screw in cutter knob.
Calligraphy Kit
An accessory used for engraving on metal. Includes an assortment of engraving tips which are inserted in place of your diamond tip in your diamond graver. Works best when used with calligraphic style fonts. Kit includes 4 jewelry gravers, 4 chisel gravers. Requires Diamond Kit.
Capacitor (Big Blue One)
Filters the flow of current from the bridge rectifier so that it is even and constant. From screw to screw 32 Volts. If no voltage or low, bridge rectifier or no AC voltage. The big blue one; 3 inch diameter x 5.75 tall
Capacitor Connector Board
On earlier versions of Blue Style Stepper boards. Instead of a single blue 25 volt capacitor, there was dual 25V capacitors with a circuit board on top.
Card Cage
Houses CPU, RAM, Interface, and EPROM Boards, inside control unit.
Carriage Assembly
Major assembly which travels along the X-axis bridge. Components include the carriage base and v-wheels
Carriage Base Plate
The flat metal base to which the v-wheels are connected. Travels along rails on X-axis bridge.
Clamping Return Springs
The "door" springs under the engraving table that apply pressure for holding the engraving plate in place.
Continuous Air Blow Off Value
Control Unit
Information is transferred back and forth between the control unit and the TRS-80 through the 50/50 cable. Information concerning jobs to be engraved are entered into the TRS-80, and all job information such as table parameters, font condensation and scaling, etc. are computed, then sent to the control unit. The font width table is loaded from the control unit into the TRS-80 during the initialization process.
Coupler
See Helical Coupling.
CPU Board
(Central Processing Unit) This is an 8080 microprocessor, and is the second computer used to operate the System one. It is configured by the system program EPROM's located on the number one EPROM board, as to what its function is. Information is transmitted from the TRS-80 through the 40/50 cable and interface board, to this microprocessor, and stored in the ram board. Information is received at a rate faster than it can operate at, is sent to the ram board for storage, and retrieved at a rate at which it can operate. System CPU Board 8080 processor 8212 - decode & drive CPU F symbols into the S100 Bus
Cutter Down Speed
The speed of the downward motion of the spindle. The rate is regulated by the adjustment value for the air cylinder. This value is one of the two located on the right rear of the engraving table. Excessive speed causes dimples in metal plates when using the Diamond Graver. Many operators confuse the air controlled down speed with engraving pressure.
Delay
Feed Rate & Delay do not function in Slew Mode
Delrin
Brand of material used for the engraving table and most nose 'plastic' nosecones.
Demo Mode
A procedure used in the diagnostics of a System 1 that will not initialize. It can also be used to run the System One Engraving Program without the necessity of having the TRS-80 hooked up to the Control Unit.
Diamond Kit
An option for scratch, drag engraving on metal. It includes the holder (similar to a rotating spindle, but solid) and a special diamond tipped tool called a Diamond Graver.
Engraving Controls
Engraving Motor
Engraving Motor Belt
Flat belts that go from Carter motor to engraving spindle
Engraving Pressure
The downward pressure of the diamond graver, or the nosecone of the rotating spindle, against the engraving surface. This is controlled by the pressure exerted on the Engraving Pressure Adjustment Spring by the Engraving Pressure Adjustment Ring. Don't confuse engraving pressure with Cutter Down Speed. Excessive pressure when burnishing will damage the cutting tool as well as the engraving plate. Insufficient pressure while using a rotating cutter can cause uneven line depths.
Engraving Pressure Adjustment Ring
The large thread ring on the lower part of the pneumatic cylinder. It is used to adjust the Engraving Pressure Adjustment Spring to increase the Engraving Pressure.
EPROM Board
Up to 3 EPROM Boards may be used in the system, with switch positions on the board indicating in which order they are to be read. The number one board contains the System Program EPROM's, which configure the microprocessor on the CPU board with its functions. Additional EPROM's following the system program EPROM's are font EPROM's. These contain all the information required for the engraving of letters in different styles.
EPROM Board Dip Switch Positions
Board with 8 positions
EPROM board #1 - All switches off
EPROM board #2 - All switches off (except 6 ) A14 on
EPROM board #3 - All switches off (except 5) A15 on
Board with 7 positions
EPROM board #1 - All switches off
EPROM board #2 - All switches off (except 5)
EPROM board #3 - All switches off (except 4)
The font boards can be inserted in any of the available slots (except the interface slot), and in any sequence, and they will still be properly recognized.
There are normally three EPROM/font boards with 16 chip slots on each. Although there is an slot on the mother board when 3 fonts boards are installed, the maximum number allowed in the System 1 control unit is 3 font boards. The first seven slots on the first board are reserved for the System Program EPROM's. The remaining 41 chip slots are for THE 2708(1K) fonts & logo EPROM's.
Nine fonts, numbered 0-8 in the software, is the maximum number of allowable on-line fonts in the control unit. Each font, depending on # of lines, or complexity of the letter, varies in size. Avant Garde and Futura require 3 chips each, while Helvetica 6-line takes 14K. If all the fonts you normally used were 3K each, you could have 8 fonts (the maximum number) with 17 blank spaces unused. If all the fonts you normally used were 14K each, you could only have 2 fonts in your control unit. Three of the 14K fonts would equal 42, one more than the maximum. Look in your card cage (see manual) and see if you have three font boards. If you have less than 9 fonts (0 - 8) and have extra blank sockets on the boards, you can add more on-line fonts.
Refer to main font chart for the number of chips for each chip.
Brands of EPROM's for fonts chips
Texas Instrument's TMS 2708JL-45 (humpback)
Motorola MCM2708C
Intel '75 D2608
EPROM Board 907 chips - won't talk, no initialize ; can cause front panel to not work.
907 control slew speed & speed between cutter down
Can only have up to 3 EPROM boards
Fan
Mounting screws (8) 8-32 x 3/4 button head, and 8-32 nut w/locking washers Fan cord same as Wizzard power cord.
Feed Rate
Feed Rate & Delay do not function in Slew Mode
Filename
Acceptable names normally start with A-Z, no numbers with TRS80 Systems.
File extensions FT9, LGO, DIG, JOB, LAY, FNT
Font Disk
A floppy diskette especially designed for storage of fonts and logos for the Dahlgren Engraving System. Early factory specifications for font and logo files was a maximum of 14,500 bytes. Currently 16,000 bytes work on most System 1’s.
The maximum size of a logo that can be used on a System 1 is approximately 16K. Early Dahlgren service bulletins listed the maximum at 14,500 bytes, but most control units can work with 16K.
The memory of the System 1, System 2, or any other Dahlgren Control Unit CANNOT be upgraded as of this date. I do not see any changes in this restriction. The new SCU’s allow the use of multiple fonts on a single layout, but they are still restricted to a limit of 32K for each font or logo.
Up until recently, there was no alternative to this limit. However, LogoStar of Corpus Christi, Texas has an alternative to buying a new control unit. Their program will automatically break up a logo into pre- determined segments which allows an almost unlimited size of logo that a Dahlgren control unit can handle.
Fuse Holder
Check cap also, especially when replacing fuse.
Helical Coupling
Cylindrical coupler between stepper motor and leadscrew.
Interface Cable 40/50 pin
(Interface Board To Stepper Board Ribbon cable from interface board to stepper board; red or #1 towards back of control unit. (Same for both styles of stepper boards in Sys.1 CU.)
Interface Board SYS.1 Driver chips are on Interface board
Having a bi-directional handshake port, information is sent back and forth between the Interface board and the TRS-80. Information for the 2 stepper motors and the air solenoid (Z-axis) is transmitted out the 3 output ports, through the 26 pin cable, to the steeper driver board. A timer chip controls the rate of the stepper motors and the cutter delay. This information is read directly from the front control panel by the position or status of the switches and potentiometers (i.e., cutter delay knob).
Pin missing on interface board, system 1 ok.
Green Board - To slew change to C2; regular position is C1.
Leadscrews
Threaded rod attached to the stepper motor which moves the X and Y-axis
Leadscrew Coupling
Connects the respective assembly to the leadscrews.
Line Filter
From power supply cord - filters voltage coming from Power Cord
Motor Belt
Motor Belt Tension Spring
Motor Brushes
Control current to the engraving motor.
Motor Cord Support Rod
Potentiometer
Small square shaped electrical component on the newer Stepper Board. Used to adjust for different voltage stepper motors.
Power Saver Switch
This switch be left in the ‘POWER SAVER’, or up position. Leaving it in the ‘ON’ position will cause the motors to overheat, and the stepper board/resistor banks to fail.
Power Switch
The ‘on/off’ power switch for the Control Unit.
Pneumatic Cylinder Adjustment Value
Quick Disconnect Air Fitting
Black fitting used on end of air hose for quick disconnect
Quick Lock Vice
Used on T-slot table models. hold plates ups to 8.5 x 14
Rails
Guides the movement of the V-wheel of the carriage assembly and the engraving table.
RAM Board (Random Access Memory)
This is a 16K RAM board, used by the CPU board for temporary storage of job definitions or strings, and down loaded fonts or logos from disk (when using a font 9). All stored information is lost when a power-down occurs. The System program EPROM's are found on the RAM Board, and configure the microprocessor.
System 1 Ram Board - One of several styles used
Older style board - maybe original
System 1 RAM board CompuPro from Godbout ir Bodboue Electronics RAM14 16K x 8, older style may be original, Dip settings on S1 All off, and on s2 1,2,7,8 off - 3,4,5,6 on
Used National Semiconductor 051B/mm2147J RAM chips (32 chips)
Old Style Blue Board Ram Chips - MM2114N-2L - 4 banks of 8
RAM BOARDS Ram Boards are all 16 K
RAM Boards with LEd’s have no meaning
CompuPro Ram Boards - dip switch settings
Sys. 1 retro has problems with CompuPro ram boards - will get intermittent resets
Reset Button
Small red switch on the rear of the Control Unit. Clears Ram Board of Job storage and fonts loaded, but system remains initialized.
Resistors
Found on the stepper drive board, they cut down or limit the flow of current received from the capacitor, and extra current is given off in the form of heat.
Resistor Bank - System 1, CLAROSTAT, VJ-100-N-5(Omega Symbol)-411 8346
Resistor Bank
Four resistors which cut down or limit the flow of current received from the interface board into high current signals to drive the stepper motors.
Resistor Bank Check
Disconnect each of the 4 wires from the Stepper Driver board to the resistors. Hold a probe from you ohm meter to an exposed section of the wire that shorts all 4 resistors together across the bottom of the bank. Insert the other probe into the connect of each resistor in succession.
On a 5 ohm (for 4.6 amp motor) resistor bank each resistor should measure 4.5 to 6 ohms individually.
On a 10 ohm (for 2.9amp motor) resistor bank should measure 9-11 ohms individually.
Riser Blocks
An option available on some engraving tables that increase the height of the X-axis bridge. Dahl Riser Blocks - increase spindle clearance by raising the carriage assembly a full 1 1/2.
Rubber Work Piece Clamps
Holds jobs secure on table - rubber strips.
S-100 Power Supply
Error code (TRS80) with (2 dots over A) as status symbol, probably bad power supply
System 1 - S-100 provides power to blue stepper board for Y-axis and left side power supply provides power for X & Y axis.
Fuse F1- Slow Blow, 5Amp, 250 V, Type 313 - Allied #845-4062
Fuse F2 - Fast Acting Fuse, 3 AMP, 250 v, Type 312 - Allied #845-4013
Fuse F3 - Fast Acting Fuses, 10 AMP, 125 V, Type 312 - Allied #
On s100 from factory that had new stepper board, yellow wire added to fuse, and several of the traces were modified
4700 MFD ELECTROLYTIC CAPACITOR 35WVDC max. Radio shack #272-1022 For System 1, S-100 power supply, 2 required..
Slew Test
This procedure will test all three axis (X Y Z) of a system, by moving all three axis. The spindle will move diagonally to the bottom right hand corner, the spindle will go up and down, and the spindle will return diagonally to the upper left hand corner. This test is very useful in diagnosing mechanical failures. (Also called the DEMO mode).
Slew Procedure
Turn off the power on the machine and un-plug.
Take the cover off the Control Unit.
Locate the red box with the white dip switch on the interface board in the upper right hand corner.
The normal running position for this dip switch is with the flat side pointed toward "C2".
To place the Control Unit in the slew mode, flip this dip switch so that the flat side is pointed towards "C1". Is this backwards?
Plug the machine back in and turn on the power, and make sure all switches are in the run position.
By pushing the engrave switch to single, the table will slew once, and then stop. By pushing the engrave switch to continuous, the machine will continue to slew until stopped.
Feed Rate & Delay do not function in Slew Mode
TRS80 - can slew without computer attached. In SP has to start SP program & switches comes up.
Solenoid Value
Rear of Table
Speed Controller
SYS.1/ - USES 8AMP SLOW BLOW FUSE
Limit Switch - Unimax 2LMW-E, 5A, 250V, Screws - 2 x 56 - 3/8 long - button head socket cap screw
Also found this limit switch- McGill, 4605-1100, 15A, 1/2 hp, 125/250 - Screws 4-40 x 1/2 Socket cap screw (non-rounded). Holes were re-drilled. Didn’t match standard for placement.
Spindle Travel Adjustment Knob
Small split ring screw under the Air Cylinder Adjustment Sprint. Used to adjust the spindle and table clearance.
Status Character
Status Character D - ‘DEAD’. Computer not talking with timing chip on interface board. (clean and reseat sometimes helps.)
E-engrave - (flowing F- like symbol for character format Frame) Bad TRS80
T-transferring
S-switch/slewing
S-bad cable
W - Had SP CPU board instead of old style CPU Board
* then E - Interface Board U3 Timing Chip
R-Ready
A (with two dots above) - font problem
Bad S-100 power supply
Bad TRS80; intermittent
Dip Switch Settings Set not set for board 1
Multiple Status Character (rapidly kept changing while engraving - pinched cable
V - seen (unknown)
Stepper Driver Board
Translates low current microprocessor signals received from the interface board into high current signals to drive the stepper motors. There have been three versions, the original brown, the problematic green, and the current blue board. Check with your service department if you have the green stepper board.
Original "Brown" System 1 Stepper Driver Board
(Used in conjunction with Resistor Bank)
Brown Style - Dahlgren Part #39-16811 $695 - Discontinued
Fuses
F1- 5 AMP, Fast, 250 Volt, Type 312, Allied Stock #845-4016
F2- 5 AMP, Fast, 250 Volt
F3- 5 AMP, Fast, 250 Volt
F4- 5 AMP, Fast, 250 Volt
F5-1 AMP, 250 Volt
Resistor type VK100N 5
System 1 "Green Board" Discontinued-Similar to Current "Blue Board", What was problem - why was it removed.
Blue Board Stepper fuses
F1 & F2 - !2 amp Fast Fuses
Stepper Driver Power Supply- big transformer
Stepper Motors
Electronic signals or pulses received from the stepper driver board charge its coils with a magnetic charge, causing the Stepper Motors to rotate. There are 400 steps per revolution. Two different amp motors have been used on Systems 1’s. The change for the amp difference can be made on the Potentiometer of the blue Stepper Driver Board.
AMP5056 Cable - from Stepper Motor to Control Unit
Motors From SOS 05/31/94
A - empty
B - Red
C - Empty
D - Green
E - White
F - White/Green Stripe
G - Black
H - White/Red Stripe
Stepper Motor Superior Electric, BLUE MOTOR (Old System 1 Grey CU), Type MO63-FC09, Spec BM101025, 200 Steps Per Rev, 60 HZ, 2.25V
Wiring Diagram From Motor -> CONTROL UNIT
White - White
Red - Red
Green - Green
Black - Black
White/Red - Blue
White/Green - Orange
Brown from connector is not used (rolled back tubing and found this wire coming from connector)
Cable from Stepper Motor is an Alpha 5056C - 6 wire Unshielded cable
System Disk
A 5-1/4 inch floppy disk which contains all of the programs for operating the Dahlgren Engraving System on the TRS-80. The programs use the NEWDOS80 disk operating system.
System Program EPROM's
The number one board contains the System Program EPROM's, which configure the microprocessor on the CPU board with its functions.
Different System chips include - LT, RTOC, 900, 901,907, 83-91907 (SuperPro).
907 System Chips replaced by 83-90908 - chips on System 1 TRS80- LT
SuperPro Chips are 83-91907; 3/94 the latest version was 1.40.
Table Grooves
metal piece for solid fit when doing seals - .115 x .30 x 11 inches long
Table Position Gauge
A small brass plate used in aligning home position. It was included in the Accessory Kit. (See also quick way of aligning home).
Thompson Bearings
System 1 & newer tables have Thompson bearings - problem with letter quality (add to diagnostics)
Thumb Screws
Used to tighten plates on engraving table.
Transformer
Transforms the 110 voltage received to only the required amount of voltage to the bridge rectifier. TRANSFORMER Transforms the 110 voltage received to only the required amount of voltage. (Is this the same as the Stepper Driver Power Supply - the big transformer?)
Upper Adjusting Knob
Large black threaded rod on top of the air cylinder used to restrict the downward travel of the spindle.
Vacuum Chip Removal Kit
An accessory for eliminating engraving chips. A pickup foot screws on to the bottom of your spindle in place of your nose cone retainer. A plastic hose connects the foot with a vacuum cleaner. This option, available from Dahlgren and other suppliers, is recommended for engravers who primarily do plastics engraving.
VERSA clamp/Quick Lock Vice
Used on T-slot table models. hold plates ups to 8.5 x 14. System One plate vice - fits onto System 1 table in place of the Delrin slotted table clamps. Screw down claming bar. Alum.
X-axis Port
Connector between the X-axis stepper motor and the Stepper Driver Board.
Y-axis Port
Connector between the Y-axis stepper motor and the Stepper Driver Board.
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