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F Dl 165 Flexible Disk Drive Maintenance Manual NEC Inform ation System s. Inc. 819-000090-2001 10-82...
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LIABILITY DISCLAIMER Information Systems, Inc. products warranted accordance with the terms of the applicable NEC Information Systems, Inc. product specification. Product performance is affected by system configuration, software, the applica tion, customer data and operator control of the system among other factors.
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Although disk drives as subsystem type components do not require FCC rating, the following statement applies to the Model FD1165. This unit has been type tested and found to comply with the limits for a Class B computing device in accordance with the...
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Line isolation transformers Line filters Electro-magnetic shielding If necessary, the user should consult the dealer, NEC or an experienced radio/television technician for additional sug gestions. The user may find the following booklet prepared by the Federal Communications Commission to be helpful; "How...
CONTENTS Page CHAPTER 1 GENERAL INFORMATION DESCRIPTION........CONSTRUCTION AND FEATURES ..... 1.2.1 Base Frame......1.2.2 Spindle Assembly....1.2.3 Dc Direct Drive Spindle Motor..1.2.4 Carriage Read/Write Assembly Heads... 1.2.5 Stepping Motor ....... 1.2.6 Head Load Cam Assembly..1.2.7 Pop-Up Feature...... 1.2.8 Index Sensor......
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Busy Lamp On During Head Load..2-14 2.8.9.2 Busy Lamp On During Drive Select... 2-15 2.8.9.3 Busy Lamp On During In Use..2-15 OPERATING THE FD1165......2-15 2.9.1 Inserting a Flexible Disk... 2-15 2.9.2 Removing a Flexible Disk.... 2-16 2.10 DISPLAY LAMPS......
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CONTENTS (cont’d) Page CHAPTER 3 INTERFACE INFORMATION BASIC OPERATIONAL DESCRIPTION....ELECTRICAL INTERFACE......3.2.1 Signal Levels....... 3.2.2 Driver/Receiver Circuits.... 3.2.3 Interface Lines..... INPUT SIGNALS........ 3.3.1 Drive Select 1 Through 4 (DSX1 to 4). 3.3.2 Head Load (HDL) ...... 3.3.3 Step (STP)......3.3.4 Direction Select (DIR)....
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CONTENTS (cont’d) Page CHAPTER 4 MAINTENANCE PREVENTIVE MAINTENANCE......MAINTENANCE TOOLS......MAINTENANCE PARTS......REMOVAL AND REPLACEMENT PROCEDURES....4.4.1 PCB Removal....... 4.4.2 Collet Assembly Removal, Replacement, and Adjustment....4.4.3 Carriage Assembly Removal and Replacement......4.4.4 Head Load Cam Assembly and Head Load Cam Removal and Replacement...
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CONTENTS (cont’d) Page ADJUSTMENTS AND CHECKS USING THE ALIGNMENT FLEXIBLE DISK..... *....5.4.1 Head Radial Alignment Check or Adjustment......5.4.2 Azimuth Check....... 5.4<3 Index Alignment Check or Adjustment.. OTHER ADJUSTMENTS ......5.5.1 LED Assembly/Index Assembly Check and Adjustment..*....
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2-11 Terminator Resistors and Jumper Locations on the PCB......... 2-10 2-12 Parallel and Series Configurations..2-11 2-13 Closing the Door of the FD1165..... 2-15 2- 14 Unlocking the Door and Removing the Flexible Disk......2-16 3- 1 Driver/Receiver Circuits....
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Adjusting Head Radial Alignment.... Azimuth Waveform......Index Alignment Waveform....Waveforms at TP7 and TP10....Track 00 Signal......5- 8 Head Load Waveform......5-11 6- 1 FD1165 Flexible Disk Drive....G9NYF PCB Assembly......TABLES Table Title Page 1- 1 FD1165 Specifications......2- 1 Power Supply Specifications....
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LIST OF ABBREVIATIONS Ampere Direction Select Disk Change Door Lock Hold Drive Select Flexible Disk Drive Frequency Modulation File Unsafe Reset File Unsafe Head Load Integrated Circuit Index Input/Output 1000 Kilogram Light Emitting Diode Large-Scale Integration Low Write Current Milliampere Megabyte Modified Frequency Modulation Millisecond...
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With a dual-sided flexible disk and a double-density format, the maximum-storage capacity is 1.6 million bytes (MB). The most apparent features of the Model FD1165 are its small size and light weight. The disk drive measures 8.55 inches (217.2 mm) high, by 2.28...
CONSTRUCTION AND FEATURES This section describes the construction of the Model FD1165 and explains the features of the various assemblies. Figure 1-1 to identify the assemblies that are described in this section. Figure 1-1 FD1165 Flexible Disk Drive 1.2.1 Base Frame The base frame is the metal form that supports the sub- assemblies of the disk drive.
1.2.3 Dc Direct Drive Spindle Motor The dc direct drive motor (not shown) rotates the spindle assembly. This dc motor eliminates the problems that are associated with conventional ac motor drives. • The motor does not use drive pulleys or belts, elim inating the problems associated with these parts.
Index Sensor The index sensor is a combination LED and phototransistor that senses the index position of the flexible disk. Model FD1165 has a dual index sensor to detect both single sided and dual-sided flexible disks. 1.2.9 00 Track Sensor The 00 Track sensor detects when the read/write head is at the 00 track (track 0, side 0).
The door lock solenoid (not shown) makes it impossible to remove the flexible disk during certain drive operations, thereby preventing data loss physical damage flexible disk. SPECIFICATIONS Table lists specifications the Model FD1165 Flexible Disk Drive. Table 1-1 FD1165 Specifications...
Model FD1165. 2.2.1 Unpacking Procedure To unpack the Model FD1165, refer to Figure 2-1 and use the following procedure. Save all shipping materials for pos sible use in reshipment. Remove the tape band from around the shipping pack...
ENVIRONMENTAL REQUIREMENTS This section describes the required operating environment for the Model FD1165, gives space and weight data for the disk drive, and shows recommended mounting methods. 2.3.1 Operating Environment The disk drive can be installed in any clean, relatively dust-free environment with an ambient temperature of 50°F...
NOTE: AIR FLOW SHOWN BY BROKEN LINES PASSES THROUGH DISK DRIVES THROUGH HOLES IN THE COUPLING BRACKET Figure 2-6 Air Flow Requirements for Natural Air Cooling...
Model FD1165 . 2.4.1 Power Supply Specifications Because the Model FD1165 does not include a power supply, a separate power supply must be provided. This power supply must provide +24 Vdc and +5 Vdc. See Table 2-1 for complete specifications.
Figure 2-7 Power Connector Location 2.4.3 Power Connector Pin Assignments The pin assignments for the power connector are shown in Figure 2-8. Figure 2-8 Pin and Line Assignments for the Power Connector...
INTERFACE CONNECTION The data and control line interface connector (3M Part Num ber 3415-0001) connects to a 50-contact edge connector that is located on the edge of the PCB. At the edge connector, the odd-numbered contacts, 1 through 49, are located on the noncomponent side of the PCB;...
Data and Control Interface Contact Assignments TERMINATOR RESISTORS The Model FD1165 is shipped with terminator resistor arrays RN1 and RN2 installed as shown in Figure 2-11. Do not re move these resistors when only a single disk drive is used in a system.
The Model FD1165 is supplied with the DX jumper in the DX1 position. OPTION SELECTION The Model FD1165 can be tailored to fulfill specific system requirements by changing the positions of the option selec tion jumpers on the PCB. This section describes the options that are available by using the jumpers.
FR2 selected. 2*8.6 Door Lock Jumpers (DL, DR, DH) The Model FD1165 has three door lock jumpers which are used in different combinations with the In Use signal to deter mine the door lock condition.
Read Data signal, solder Pin 1 to the center pin. enable the Standardized Read Data signal (for the VFO op tion), solder Pin 2 to the center pin. The Model FD1165 is supplied with RD1 connected to the center pin. 2.8.9 Busy Lamp Jumpers (BU, BS) The busy lamp jumpers determine the conditions under which the busy lamp will be on.
Use this procedure to insert a flexible disk into the disk drive. Turn on the dc power supply. Insert a flexible disk into the FD1165 until flexible disk locks in place and close the door (see Figure 2-13). Figure 2-13 Closing the Door of the FD1165 2-15...
Unlocking the Door and Removing the Flexible Disk 2.10 DISPLAY LAMPS The FD1165 has two display lamps on the front panel, the ready lamp and the busy lamp. 2.10.1 Ready Lamp The ready lamp shows that the FD1165 is ready for use.
2.10.2 Busy Lamp selected, The busy lamp indicates that the disk drive is (depending use, or that the read/write heads are loaded 2.8.9). the position of the BU/BS jumpers; see Section...
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INTERFACE INFORMATION This chapter gives interface information Model FD1165. BASIC OPERATIONAL DESCRIPTION When a flexible disk is inserted into the Model FD1165 and the door handle is closed, the collet presses into center hole of the flexible disk centering the disk and clamping it in operating position on the spindle.
This section gives a description of the signal levels, the driver/receiver circuits, the interface lines of FD1165. 3.2.1 Signal Levels The input and output signals are at TTL levels and have the following electrical specifications. True = Logic 0 (low level), 0 to +0.4 Vdc False = Logic 1 (high level), +2.5 to +5.25 Vdc...
3.2.3 Interface Lines The interface lines for the FD1165 are shown in Figure 3-2. even-numbered lines (2 through 50) are signal lines. The odd-numbered lines (1 through grounds. lines are named for the input or output signals that they carry.
3.3.2 Head Load (HDL) When the disk drive is in the ready state, a Low on this line initiates loading of the read/write heads. 3.3.3 Step (STP) This pulse directs the stepping motor to move the read/write heads from track to track. The direction of movement determined Direction...
3.3.6 Write Gate (WGT) This signal selects the read or write operation. If the signal is Low, data is written to the disk. If the signal is High, data is read from the disk. During the Write operation, data is erased between adjacent tracks on the flexible disk for 560 ys after WGT goes High.
(see Section 2.8.6 and 218.7) . OUTPUT SIGNALS This section describes output signals the Model FD1165. 3.4.! Index (IPX) This signal occurs on the Index Line once for every rotation of the flexible disk. Figure 3-6 shows the IDX pulse. Figure 3-6 Index Signal Timing...
Low if the flexible disk is dual sided. If there is no flexible disk inserted, TSD stays High. 3.4.4 Ready (RDY) The Ready signal goes Low when the Model FD1165 is ready for use. The signal indicates that the following conditions exist.
3.4.6 Read Data (RDT) A signal on this line conditions the data that is sent from the disk drive to the host system. The line transmits the Read Data or the Standardized Read Data signal depending upon the position of the RD jumper (see Section 2.8.8).
Figure 3-8 Disk Change Signal Timing VFO INTERFACE SIGNALS optional interface signals are described in the following sections. 3.5.1 Modified Frequency Modulation Mode (MFM) The MFM signal is Low when MFM data is read or written. line is High when FM data is read or written. 3.5.2 VFO Synchronization (SYC) The SYC signal goes Low when read data is synchronized by...
This section describes the interface timing for the Model FD1165. 3.6.1 Power On Sequence The FD1165 processes valid I/O signals 700 ms after the door is closed. 3.6.2 Drive Select The disk drive processes valid I/O signals 500 ns after the Drive Select line (DX) goes Low.
3.6.4 Access Figure 3-11 shows the required time relationships between the Write Gate, Step, and Direction Select signals. Figure 3-11 Access Timing 3.6.5 Write Figure 3-12 shows the required time relationships of con troller signals during a Write operation. Figure 3-12 Write Timing 3-11...
CHAPTER 4 MAINTENANCE This chapter describes the maintenance procedures for the Model FD1165. If the disk drive proves defective in the field, it should be exchanged for another unit and the de fective unit should be sent to a depot repair facility for repair.
Table 4-2 Maintenance Parts REMOVAL AND REPLACEMENT PROCEDURES This section describes the part removal procedures for the Model FD1165. The replacement procedures are the reverse of the removal procedures, unless noted. Mechanical adjust ments are included with the removal and replacement proce...
4.4.2 Collet Assembly Removal, Replacement, and Adjustment Use the following procedure to remove the collet assembly. Remove the two screws that fasten the head unload spring to the spring plate and remove the head un load spring (see Figure 4-1). Remove the four screws that fasten the spring plate and the press plate to the base frame.
Insert a dummy flexible disk into the disk drive and gently close the door handle so that the collet fits into the spindle. Tighten the fours screws. Replace the head unload spring. The clearance be tween the arm on the head load cam and the head un load spring should be 0 to .008 inches (0 to 0.2 mm) (see Figure 4-2).
After the collet assembly is in place, check that there is no clearance between the head unload spring and the spring plate (see Figure 4-3). If there is clearance, replace collet assembly with a new one. Figure 4-3 Head Unload Spring in Relation to Spring Plate If the clearance between the head unload...
Open the door of the disk drive, insert a flexible disk, and close the door. Check on the stepping motor side of the disk drive that the spring plate does not contact the jacket of the flexible disk. If the specifications in Step c and Step e cannot be met, replace the collet assembly.
Figure 4-5 Carriage Assembly Position on the Base Frame Use the following procedure to replace the carriage assem bly. Fit the carriage assembly into the base frame. Hold the carriage assembly against the side of the base frame and measure the gap at points A and B in Figure 4-5.
Check that the three boss surfaces are in contact (see Figure 4-5). Perform the head radial alignment adjustment (see Section 5.4.1). 4.4.4 Head Load Cam Assembly and Head Load Cam Removal and Replacement the following procedure to remove the head load cam assembly.
To replace the head load cam assembly, Hold the head load cam assembly against the refer ence surface base frame install screws (see Figure 4-7). Run the wiring harness through the base frame and fasten it to the base frame with the appropriate clips.
Figure 4-8 Write Protect or Media-In Sensor Connections Use the following procedure to replace either sensor. Reverse the removal procedure, but do not tighten the screw. Push the sensor towards the front of the disk drive until the shaft of screw touches the rear of the elongated hole in the sensor (see Figure 4-9).
Slide the sensor out of the base frame, being care ful not to damage the encoder (see Figure 4-10). Remove the heat-shrinkable tubing from the sensor connections and unsolder the wires. Use the following procedure to replace the optical tachom eter sensor.
Remove the collet assembly. Separate the sensor cable connector from the PCB and slide the connector through the hole in the base frame. Remove the two screws that fasten the LED assembly to the base frame. From the PCB side of the disk drive, remove the single screw that fastens the index sensor to the...
Separate the connector to the 00 track sensor. Remove the heat-shrinkable tubing and unsolder the connections of the media-in sensor, the write pro tect sensor, and the optical tachometer sensor. Separate the sensor cable assembly from the base frame by spreading the clips that fasten the sensor cable to the base frame.
Use the following procedure to install the LED Assembly. Install the LED assembly so that the hole in the LED unit fits over the adjusting pin. Install the two screws that fasten the LED assembly to the base frame (see Figure 4-11). Remove the adjusting pin.
Use the following procedure to replace a carbon brush. Insert carbon brush with identification number facing upwards (see Figure 4-13). Insert the brush stopper. 4.4.9 Armature Removal Use the following procedure to remove the armature. Remove the PCB. Insert nonmagnetic screwdrivers between magnet cap and the motor flange as shown in Figure...
Pick up the magnet cap slowly and evenly (it is highly magnetized). carbon brushes installed, remove screws and B (see Figure 4-14) that hold motor flange, loosen screw C, and move the flange toward the front of the disk drive to take pressure off of the carbon brushes.
4.4.11 Front Panel Removal Use the following procedure to remove the front panel. Remove the two screws that fasten the front panel to the base frame (see Figure 4-16). Pinch the two panel latches (see Figure 4-16) remove the front panel. Figure 4-16 Removing the Front Panel 4.4.12...
Tighten the screw. Check the operation of the picker rod (see Section 4.4.15) . Figure 4-17 Adjusting the Picker Rod 4.4.13 Pop-Up Assembly Removal and Replacement Use the following procedure to remove the pop-up assembly. Remove the lever plate by removing the four screws that secure it to the lever plate hinges.
Use the following procedure to replace the pop-up assembly. Install pop-up assembly into base-frame, being careful not to damage the picker rod. Check operation pop-up assembly (see Section 4.4.15). 4.4.14 Guide Rail Removal Use the following procedure to remove the guide rail. Remove the lever plate by removing the four screws that secure it to the lever plate hinges.
Open the door and make sure that the disk drive ejects the flexible disk about 1/2-inch (13 mm). Insert a dummy flexible disk and close the door. Hold the disk in place by hand. Open and close the door about 10 times to insure that the door operates correctly.
To replace the door lock solenoid, reverse the removal pro cedure, then do the following. Lock the door and activate the solenoid by pushing in at the end of the solenoid that is opposite the shaft. Make sure that the clearance between the solenoid shaft and the lock lever is 0.02 +.006 inches (0.5 + 0.15 (see...
Model FD1165. DIAGNOSTIC TESTS This section describes the diagnostic tests for the Model FD1165. Diagnostic tests are performed using of diagnostic test pins T2 and T3 (see Figure 5-1) .
5.1,1 Auto Tap Test auto test consists a head load/head unload action. To initiate the auto tap test, use the following procedure. Turn off the power to the disk drive. Connect diagnostic pin T2 to the center pin. Select head load jumper position HL2 and connect HL2 to ground.
Media detect sensor output TP13 ADJUSTMENTS AND CHECKS USING THE ALIGNMENT FLEXIBLE DISK Table 5-2 lists the adjustments and checks using the NEC Alignment Flexible Disk (Part Number, 806-944184-0) and in dicates when the adjustments and checks should be performed. Table 5-2...
In addition to the usual care that should be taken with a flexible disk, take the following extra precautions with the alignment flexible disk. • Before making adjustments, acclimate flexible disk for one hour in the working environment. • Keep the disk drive in the "power-on" status for one hour.
Check the waveform (see Figure 5-2). The two lobes that are displayed should be within 70% of each other in amplitude. Figure 5-2 Head Radial Alignment Waveform If the ratio of the lobes of the waveform is not within specifications, loosen the two screws that fasten the carriage to the base frame and adjust the...
Figure 5-3 Adjusting Head Radial Alignment 5.4.2 Azimuth Check Carriage assembly replacement is usually required to correct Azimuth error. the oscilloscope settings Table 5-4, then use the following procedure to check for Azimuth error. Table 5-4 Head Azimuth Oscilloscope Settings...
Insert alignment flexible disk step carriage to track 76, Load the heads. Compare the waveform in Figure 5-4 with the waveform that is displayed on the oscilloscope. If the waveform is not within specifications, re place the carriage assembly. SPECIFICATION B>...
Insert an alignment flexible disk. Step the carriage to track 01. Load the heads. Observe the timing between the trailing edge of the index pulse and the first peak of the read waveforms (see Figure 5-5). It should be 200 ys + 200 ns. If ( the waveform does not meet this specification, adjust index...
When using a dual-sided flexible disk, measure the waveform at TP7 checking for a pulse width of 1 to 3 ms (see Figure 5-6). If the waveform does not meet this specification, adjust the index sensor as in Section 4.4.7. Figure 5-6 Waveforms at TP7 and TP10 5.5.2...
5.5.3 Write Protect Sensor Check or Adjustment After the write protect sensor is replaced, perform following check. Insert a flexible disk that has a write protect notch into the disk drive. Check that the voltage at TPll is less than 0.5 V. Move the jacket of the flexible disk to make sure that the voltage at TPll does not change.
Figure 5-8 Head Load Waveform TRIM POTS There are three trim pots on the PCB of the Model FD1165. RVl and RV2 determine the write current. They are adjusted at the factory and should never be adjusted in the field.
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The mechanical IPB is arranged in four columns. • Item - contains the item numbers referred to in the callouts on the exploded view. • Part Number - contains the NEC part number you use for ordering spares or replacement parts. • Description - contains a brief description of the part.
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The code is interpreted as follows, Head code. The symbol Q is replaced by one of the following codes to show the material type that is used. = Iron = Brass ST = Spring Steel Nominal diameter in mm. Length in mm. (Not used for nuts and washers.)