Commodore Single Disk Drive Technical Manual Model 1540/1541 Cxcommodore COMPUTER PYN 990445,These documents are for repair service information only. Part numbers are for reference only. Only parts on current desler parts list are available, No license is given for any use by possession of these documents and may not be reproduced in any form without the written approval of Commodore Electronics LimitedCONTENTS Chapter 1 1.1 Scope 1,2. Unpacking 1.3 Protection against noise 1.4 Input-Output cable 1.5 DC power source 1.6 Initial inspection 1.7 Outline of functions 1.8 Read/Write Head 1.9 Track positioning mechanism 1,10 Spindle drive mechanism 1.11 Eject mechanism Chapter 2 2.1 Mechanism explanation 2.2 Functional explanation 2,3. Assembly proceedure Chapter 3 oe Operating proceedure 3.2 Media handling proceedure 3.3 Seek error 3.4 Write error 3.5 Read error 3.6 Head cleaning 3.7 Adjustment proceedure1.7 La Chapter one Scope In this chapter, a desciption is made of the proceedures necessary for servicing the Model 1540/1541 Floppy Disk Drive. Unpacking Special care should be exercised during unpacking not to damage the unit. Unpacking proceedures are as follows: a) Remove cardboard sleeve from styro-foam box b) Open 'styro-foam’ box and remove drive ¢) Check the drives front door for proper operation Prorertrrecers Aeeesteneeees Caution eee * * * Do Not Use Magnetized Tools * * Aeekeneeeeeeennenaesteeeeeenees Protection against noise A week signal from the media is detected in the head section of the drive. Hence, do not install the drive near a TV set or other areas where electromagnetic noise is generated. (i.e, motors, air- conditioners, ete) Input/Output Cable The length of the cable between the host and the drive (between the host and the last drive when the drives are daisy chained) should not exceed 5 meters (16 feet). DC power source The drive is powered by a internal power supply providing the drive with +12v and +5V. Initial inspection1.10 Tel) 1.12 1.13 1.14 The drive can be briefly inspected for its operation by the following proceedure. Install the drive, connect the power and I/O cables. Turn drive on and make sure the front panel power lamp is on. Proceed to step 2.2. Outline of functions The 1540/1541 Minifloppy Disk Drive mechanism is composed of the data read/write head, track positioning mechanism, spindle drive mechanism and eject mechanism. Read/Write Head The Read/Write head uses a glass-bonded, ferrite/ceramic head. Track-to-track erasing is accomplished by the straddle erase method. The surface of the Read/Write head is mirror-ground to minimize weear of the head and media. Also, the head is desighned in such a way that the maximum signal can be obtained from the media surface. Track positioning mechanism Positioning of the Read/Write Head is accomplished by a stepping motor and steel belt. The stepping motor rotates clockwise or counter-clockwise by two steps per track. The control circuit on the logic board selects the direction and number of step to the desired track. Spindle drive mechanism The spindle drive motor operates on 12 VDC and turns the spindle, through a belt drive, at 300 revolutions per minute. The speed of the drive motor is controtled by a feedback signal from a tachometer which is housed in the drive motor assembly. The feedback signal controls a servo amp that supplies the 12 VDC drive current. Eject mechanism When the media is inserted in the Disk Drive and the door is closed the media is clamped by the spindle and hub. At this time the ejector mechanism is loaded by the insertion of the disk and locked. When the door is opened, the ejector mechanism is unlocked and the media pops out of the door.2.3 2.3.1 2.3.2 Chapter Two Mechanism Explanation The 1540/1541 mechanism is installed in the system horizontally, however the drive will fuction if mounted vertically. Te mechanical parts of the drive include an aluminum chassis, a stepping motor, head positioning assembly, drive motor, a hub and spindle assembly for centering and retaining the media during operation. The magnetic head is of a glass ceramic construction. Function explanation The drive is itself an independent memory device. ‘The drive is composed of a media clamp rotating mechanism, ahead positioning mechanism and an eject mechanism. When the front door opens, the media can be inserted, All positioning operation excluding insertion and removal of the media are controlled by the internal guide mechanism. Closing the front door causes the media clamp mechanism to operate. Two operations are performed in the following order: a) The media is centered. b) The media is clamped and retained between the spindle and the hub. The spindle and hub rotate at 300 r.p.m. through a closed-loop control circuit employing a D.C. motor/tachometer. It is important that the relationship between the head and the media is maintained correctly during operation. For this purpose, a pressure pad is used to hold and press down the media(about 124) from the opposite side of the head, to maintain the correct contact with the head. This head assembly is coupled by a metal band to a four phase stepping motor the performs the track positioning. One step of the Stepping motor corresponds to a 1/2 track movement. Use of a high- speed stepping motor and metal band drive, this series of disk drives can perform access operations at a very high speed. Assembly Proceedure The housing assembly; install the eject pin and the spindle. The housing assembly; on the reverse side install the spindle pulley.2.3.3 PIG 1, The housing unit. Part Desciption 22 spindle 33 housing assembly. 53 eject pin2.3.4 The stepping motor assembly; install the stepping pulley. 2.3.5 PIG 2, The stepping motor unit Part Description 50 stepping motor assembly 55 confector housing stepper pulley 582.3.6 The D.C. motor assembly; instal] the motor pulley. 2.3.7 FIG 3, D.C, motor and control PCB Part Description 44 motor control PCB 43 D.C, motor 51 connector housing 89 D.C, motor pulleyFIG. 6 Description Description washer binder screw diskette guide eject spring diskette guide connector housingPart Description 15 binder screw 18 binder screw 24 tension pulley 25 guide shaft keeper ® 26 guide shaft 34 metal band 35 washer OB 36 head assembly 56 tension springFIG 9 Part Description Part Description 2 door assembly 13 hub support, 2 collar 14 hub frame 3 clamp spring 15 binder screw 5 thrust washer 16 spring washer 6 collet assembly 7 arm support assembly 7 hub spring 18 binder screw 8 hub 19 pad plate assembly 9 hub shaft 27 hinge spring 10 door spring 60 collet ul E-washer 61 collet bearing2.3.8 FIG. 4, Diskette guide, LED assembly and connector housing. Part 31 43 52 Description LED assenbly diskette guide connector housing2.3.9 2.3.10 2.3.11 2.3.12 2.3.13 2.3.14 2.3.15 2.3.16 2.3.17 2.3518 2.3.19 2.3.20 2aae2l 23822) 2.3.23 2.3.24 2.3.25 2.3.26 2.3.27 2.3.28 2.3.29 Secure the D.C. motor from the reverse side of the housing assembly with two screws. Put the motor control PCB into hole ‘A' and serure it with two screws, Secure the stepping motor with two screws. Secure the carraiage stopper with a screw. Install the connector housing '52' into the hole 'B' and remove through hole 'C' Sercure the two diskette guides '21' and '43' with two screws each. Install the LED holder in the front panel. Insert the LED assembly into the LED holder ring. Install the led into the LED holder, then push the LED holder ring onto the LED holder. Attach the front panel with four flush screws. Secure the eject plate with a screw. Wind the metal band around the tension pulley. Insert the guide shafts into the head assembly. Install the tension pullet as shown in figure & Secure the guide shaft keepers by two screws each. Wind the metal band around the stepper pulley and secure it with @ Screw to the stepper motor pulley. Hook the spring to the tension pulley and install unit in the slot in the housing assembly. Hook the opposite end of the spring to the housing assembly. Fasten cable ties to the cables. Secure the cable clamp with a screw as shown in FIG a. Secure the arm support assembly with a screw to the hub support. Insert the hub shaft into the hub, the hub spring, the collet assy, the thrust washer, the collar, the clamp spring and two collars. Insert the hub shaft into the frame and the hub support and fasten it at the E-washer. Set the door assembly and the door spring at the hub frame. Secure the pad plate assembly with a srew to the frame at the location shown in FIG 9 Secure the two hinge springs with two srews each. 19Part Description 1s binder screw 20 binder screw 37 washer 41 spring washer 42 carriage stopper 44 motor control PCB 50 stepping motor assembly2.3.36 Place the belt over the D.C. motor pulley and partially on the spindle pulley. 2.3.37 By turning the spindle pulley the rest ot the belt will seat completely on the pulley. 2.3.38 FIG 10 Part Description 12° drive belt3.3 Chapter Three Description Since the disk drive is placed under direct control of the interface and power supply, no special proceeedure is required for starting and operation Operating proceedure Make sure that the power supply and I/O connector are connected, then insert the disk in accordance with the following proceedure. Inserting the media a) Apply DC voltage to the drive. b) Open the front door. SS —y c) With the index hole and write protect notch being placed on the left side of the jacket, push the media in, when the media is fully inserted the loacking action can be felt. 4) Push the door downward and close the aoor so that it is locked firmly Extracting the media a) Open the front door. The media will pop out automatically to a position where you can extract it easily b) For protection of the recorded data, the media should always be stored in its envelope. c) Close th door of the drive. Media handling proceedure Since the media has been sudjected to awrite operation i naturally contains imformation, adequate attention must be paid to its handling. In order to extend the life of the media and eliminate the causes of errors, it is best to take the following steps 73.4 3.5 3.6 a) When writing something on the jacket label of the media, do not use a ball point pen or pencil, use felt-tipped pens. b) Do not hold the edges of the media with paper clips or the like. c) Do not touch the media exposed in the slot of the jacket. d) Do not attempt to clean the media. e) Do not keep the media in the areas where there is a strong magnetic field. £) The diskette should be kept in its jacket. g) Special care should be exercised so that the media is kept free from liquid, dust, metal particles, etc. h) Take care not to exceed the following environmental conditions: Temperature 10 to 51°C Relative humidity & to 80 % Seek error Few seek ertors will be experienced due to the low stepping rate, less than 12 msec/track, In case of a seek error, however, recalibration of track position can be performed. This can be done by repeatedly stepping the head towards track 0 untill track 0 status is detected. Write ercor In order to check the quality of the data, perform a read-after- write operation. When data can not be read, tewrite that track and sector once again. When data can not be read after four such operations track is defefective. Read error What happens quite often when performing a read operation is a soft error. A soft error is defined to be a read error which is recoverable by making ten or less read operations. However, in the event no recovery is made in ten operations, move one step from the track in the same direction as the previous step, then return one step. If this fails to read the data, this error is unrecoverable.3.9.1 Description Periodic maintenance is indispensable so that this type of peripherial equipment operates properly. It is particularly important to periodically clean the head and check the load pad. Repairs and adjustments should be made in accordance with the proceedures below. Head Cleaning Check for excessive dust or magnetic oxide on the load pad. With the door open (do not move upper arm greater that [Link] provided by opening the front door) clean head with lint free cotton cloth or 'Q-tip’ in 91/ isopropyl alcohol. Wipe the head carefully to remove any dust and/or oxide. Adjustment proceedure In case of a malfuction or parts replacement, make the following adjustments. In order to maintain the interchangability of the media between drives it is desirable check each drive against a master alignment diskette. Track adjustment (radial track) a) Connect I/0 cable an restore the head to track 00. b) Insert a 48tpi alignment diskette and close the door. ¢) Connect two oscilloscope probes to pin 1 and pin 14 of UH6 (592), set oscilloscope to angbraic add at SOmV/cm and 200 msec/div. 4) Load the head and allow it to seek to track 16, check for cats eye wave form, When the cats eye lobe ratio is 70/ or less, loosen the stepping motor mounting screws, turn the stepping motor to obtain the lobe ratio of 90/ or less. e) After allowing the head to track 34, return it to track 16 and recheck the cats eye. If the ratio is correct tighten the stepping motor screws. Cats eye lobe ratio3.9.2 Track 00 adjustment The drive is not provided with a track 00 sensor. 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