Epson DFX-5000+ Service manual

EPSON

EPSON

EPSON France S.A.

DFX-5000+

SERVICE MANUAL

PRODUIT

EPSON TERM

NAL PR

NTER

DFX-5000+

SERVICE MANUAL

EPSON

NOTICE

All rights reserved. Reproduction of any part of this manual in any form whatsoever without
SEIKO EPSON’s express written permission is forbidden.

The contents of this manual are subjects to change without notice.

All efforts have been made to ensure the accuracy of the contents of this manual. However, should
any errors be detected, SEIKO EPSON would greatly appreciate being informed of them.

The above notwithstanding SEIKO EPSON can assume no responsibility for any errors in this
manual or the consequence thereof.

Centronics is a registered trademark of Centronics Data Computer Corporation.
Epson and

Epson

ESC/P are registered trademark of Seiko Epson Corporation.

@Copyright 1994 by SEIKO EPSON CORPORATION Nagano, Japan

-iv-

PRECAUTIONS

Precautionary notations
damage to equipment.

DANGER

WARNING

The precautionary measures itemized below should always be observed when performing repair/
maintenance procedures.

ALWAYS DISCONNECT THE PRODUCT FROM BOTH THE POWER SOURCE AND

1.
PERIPHERAL DEVICES PERFORMING ANY MAINTENANCE OR REPAIR PROCE­DURE.

NO WORK SHOULD BE PERFORMED ON THE UNIT BY PERSONS UNFAMILIAR WITH

2.
BASIC SAFETY MEASURES AS DICTATED FOR ALL ELECTRONICS TECHNICIANS IN
THEIR LINE OF WORK.

3.

WHEN PERFORMING TESTING AS DICTATED WITHIN THIS MANUAL, DO NOT
CONNECT THE UNIT TO A POWER SOURCE UNTIL INSTRUCTED TO DO SO. WHEN
THE POWER SUPPLY CABLE MUST BE CONNECTED, USE EXTREME CAUTION IN
WORKING ON POWER SUPPLY AND OTHER ELECTRONIC COMPONENTS.

Signals a precaution which, if ignored, could result in serious or fatal personal injury.
Great caution should be exercised in performing procedures preceded by DANGER
Headings.

Signals a precaution which, if ignored, could result in damage to equipment.

throughout the text are categorized relative to

1)

personal injury and 2)

REPAIRS ON EPSON PRODUCT SHOULD BE PERFORMED ONLY BY AN EPSON

1.

CERTIFIED REPAIR TECHNICIAN.

MAKE CERTAIN THAT THE SOURCE VOLTAGE IS THE SAME AS THE RATED VOLT-

2.
AGE, LISTED ON THE SERIAL NUMBER/RATING PLATE. IF THE EPSON PRODUCT
HAS A PRIMARY AC RATING DIFFERENT FROM AVAILABLE POWER SOURCE, DO
NOT CONNECT IT TO THE POWER SOURCE.

ALWAYS VERIFY THAT THE EPSON PRODUCT HAS BEEN DISCONNECTED FROM

3.
THE POWER SOURCE BEFORE REMOVING OR REPLACING PRINTED CIRCUIT
BOARDS AND/OR INDIVIDUAL CHIPS.

4.

IN ORDER TO PROTECT SENSITIVE MICROPROCESSORS AND CIRCUITRY, USE
STATIC DISCHARGE EQUIPMENT, SUCH AS ANTI-STATIC WRIST STRAPS, WHEN
ACCESSING INTERNAL COMPONENTS.

REPLACE MALFUNCTIONING COMPONENTS ONLY WITH THOSE COMPONENTS

5.
BY THE MANUFACTURE; INTRODUCTION OF SECOND-SOURCE ICS OR OTHER
NON APPROVED COMPONENTS MAY DAMAGE THE PRODUCT AND VOID ANY
APPLICABLE EPSON WARRANTY.

- ii -.

PREFACE

This manual describes functions, theory of electrical and mechanical operations, maintenance, and repair
of DFX-5000+.
The instructions and procedures included herein are intended for the experience repair technician, and
attention should be given to the precautions on the preceding page. The chapters are organized as
follows:

CHAPTER 1. GENERAL DESCRIPTION

Provides a general product overview, lists specifications, and illustrates the main components of the printer.

CHAPTER 2. OPERATING PRINCIPLES

Describes the theory of printer operation.

CHAPTER 3. DISASSEMBLY AND ASSEMBLY

Includes a step-by-step guide for product disassembly and assembly.

CHAPTER 4. ADJUSTMENTS

Includes a step-by-step guide for adjustment.

CHAPTER 5. TROUBLESHOOTING

Provides Epson-approved techniques for adjustment.

CHAPTER 6. MAINTENANCE AND LUBRICATION

Describes preventive maintenance techniques and lists Lubricants and adhesives required to service the equipment.

APPENDIX

Describes connector pin assignments, circuit diagrams, circuit board component layout and exploded diagram.

The contents of this, manual are subject to change without notice.

- iv -

REVISION SHEET

Rev.-A

/

Rev.-B

Rev.-C

Rev.-D

I

Rev.-E

Revision

Issue Data

February 9, 1994

1

April 20, 1994

November 22, 1994

,

December 15, 1994

i

March 7, 1995

Revision Page

1 st issue

/

Page 4-10: Addition the notes
Page 4-1 1: Addition the notes

Page 4-4 to 4-7: Change the explanation

1

Whole Revise of the Chap.4

I

Page 4-12: Change the explanation
Page 4-12: Addition the notes

TABLE OF CONTENTS

CHAPTER 1.
CHAPTER 2.
CHAPTER 3.
CHAPTER
CHAPTER 5.
CHAPTER 6.
APPENDIX

4.

GENERAL DESCRIPTION

OPERATING PRINCIPLES
DISASSEMBLY AND ASSEMBLY
ADJUSTMENTS
TROUBLESHOOTING
MAINTENANCE AND LUBRICATION

-

vi -

CHAPTER

1 Product Description

Table of Contents

GENERAL FEATURES

1.1

1.2 SPECIFICATIONS

1.2.1

1.2.2

1.2.3

1.2.4

1.2.5

1.2.6

1.2.7

1.2.8

1.2.9

1.3 INTERFACE SPECIFICATIONS

1.3.1 Parallel Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

1.3.2 RS-232C Serial interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

1.4 PRINTER OPERATION

1.4.1

1.4.2

1.4.3

1.4.4

1.4.5

1.4.6

1.4.7

1.4.8

1.4.9

1.4.10

1.4.11

1.4.12

1.4.13

1.4.14

1.4.15

Printer Capabilities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l-3

Paper Handling Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l-3

Paper Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Ribbon Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

Environmental Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

Electrical Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

Reliability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

Safety Approvals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

Physical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

Control Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17

Self-test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18

Hexadecimal Dump Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18

Paper Out Detection Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18

Cover Open Detection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18

Paper Width Detection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19

Automatic PaperThickness Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 1-19

Paper Memory Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19

1.4.8.1 Using the Paper Memory Function . . . . . . . . . . . . . . . . . . . . . . 1-20

1.4.8.2 Saving Paper Format and Thickness Information.. . . . . . . . . . 1-20

Automatic Tear Off Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21

PaperJam Detection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... 1-21

Automatic Interface Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21

Thermal Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21

Skip Binding Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22

Printer Initialization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22

Buzzer Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .......... 1-22

1-1

1-3

1-14

1-17

.-

1.5 DIP SWITCH SETTINGS

1.6 MAIN COMPONENTS

1.6.1 M-3C11 Printer Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27

1.6.2

1.6.3

1.6.4

1.6.5

Main Control Board (Cl 17 MAIN Board Assembly). . . . . . . . . . . . . . . . 1-28

Power Supply Circuit (C117 PSB/PSE Board Assembly) . . . . . . . . . . . 1-28

Control Panel Board (C117 PNL Board Assembly). . . . . . . . . . . . . . . . 1-29

Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-29

1-23
1-26

List of Figures

. .

Figure 1-1.
Figure 1-2.
Figure 1-3.
Figure 1-4.

Figure 1-5.

Figure 1-6. Perforation Pitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Figure l-7. Paper Edge at a Horizontal Perforation . . . . . . . . . . . . . . . . . . . . . . 1-7

Figure l-8. Perforation Intersections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Figure l-9. Raised Portion at aPerforation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Figure

Figure 1-11. Aligned Sprocket Holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Figure 1-12. Incorrectly Folded Paper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Figure 1-13. Printable Area, Overlapping Multi-part Forms. . . . . . . . . . . . . . . . 1-8

Figure 1-14. Dotted Paste Positions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Figure 1-15. Stapled Area 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Figure 1-16. Stapled Area 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Figure 1-17. Stapled Area 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Figure 1-18. Correct Multi-part Form Binding. . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Figure 1-19. Printable Area for Fanfold Paper with a Label. . . . . . . . . . . . . . . 1-10

Figure 1-20. Printable Area for Labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

Figure 1-21. Label and Carrier. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

Figure 1-22. Data Transmission Timing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

Figure 1-23. Control Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17

Figure 1-24. Multi-part Forms with a Label. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19

Figure 1-25. overlapping Multi-part Forms. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19

Figure 1-26. Main Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26

Figure 1-27. M-3C11 Printer Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27

Figure 1-28. C117 MAIN Board Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28

Figure 1-29. C117 PSB/PSE Board Assembly. . . . . . . . . . . . . . . . . . . . . . . . . 1-28

Figure 1-30. C117 PNL Board Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29

Figure 1-31. Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29

Exterior View

Pin Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Printable Area

Unsuitable Paper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Form Override

1-10. Sprocket Holes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

of the

DFX-5000+. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

for Fanfold Paper. . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Area. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

List of Tables

Table 1-1. Options and Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Table 1-2. Character Size and Pitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Table 1-3. Printing Speeds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Table 1-4. Character Tables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Table 1-5. Acceptable Environmental Conditions. . . . . . . . . . . . . . . . . . . . . . . 1-12

Table 1-6. Rated Electrical Ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

Table 1-7. Parallel lnterface Signals and Connector Pin Assignments. . . . . . . 1-15

Table 1-8. Serial Interface Signals and Connector Pin Assignments . . . . . . . 1-16

Table 1-9. Selecting the Paper Memory Area . . . . . . . . . . . . . . . . . . . . . . . . . 1-20

Table 1-10. Setting the Page Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20

Table 1-11. Setting the Paper Type.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21

Table 1-12. DIP Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23

Table 1-13. IBM Mode Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23

Table 1-14. ESC/P Mode Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24

Table 1-15. Interface Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25

Table 1-16. Baud Rate Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25

Table 1-17. Page Length Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25

DFX-5000+ Service Manual

Product Description

1.1 GENERAL FEATURES

The DFX-5000+ is a 9-pin, serial, dot matrix printer with a maximum speed of 560 characters per

second (cps). It is designed for business use and provides high-speed, high-volume printing and

continuous-sheet handling. The main features of the printer are:

Cl

Maximum printing speeds:

560 cps (high-speed draft mode)
504 cps (draft elite mode)
420 cps (draft pica mode)

Cl

Advanced paper handling:

-10 inches per second (ips) paper feeding

- Paper jam detection

- Paper width detection

- Front and rear two-way push tractors

- Automatic paper back-out and loading from another paper path and paper park

- Automatic platen gap adjustment for paper thickness

- Automatic tear off

- Paper memory function

- Automatic paper path changing

Cl

Eight-bit parallel interface and RS-232C serial interface standard

Cl

Epson ESC/P-83 (ESC/P version 83) printer driver (compatible with the FX-870/1170 and

DFX-5000)

D

9 character tables in the standard version

21 character tables in the NLSP (National Language Support) version

Cl

Upgraded data handling:

- 20KB input buffer

- Automatic interface selection

- Type B optional I/F cards

The figure below shows the DFX-5000+.

“’”’”’””

control panel

‘NV’

too cover

poper separator

----,

.-n”.fltnr f-flue,

~“p=,

>Gpu,..

-,

~orallel

a”$

----

interface

rial interface

e cover for

I

interface

Rev. A

Figure 1-1. Exterior View of the DFX-5000+

1-1

Product Description

DFX-5000+

Service Manual

Table 1-1.

I

Model

#8309

#8766

#8767

t
I

C82305* I Serial I/Fcard, simple serial interface** (SSi), inch screw

C82306*

I

C82307’

I

C82308*
C8231O*
C82312*
C82313*
C82314*

i
I

C82315* I Twinax I/F card

C82324*

I

‘The

●

*A

the card.

I

Pull tractor unit
Ribbon cartridge
Ribbon pack

,

Serial I/F card, SSI, mm screw

1

I

32KB intelligent serial l/F card (inch screw)

32KB intelligent serial I/F card (mm screw)
32KB intelligent parallel l/F card
LocalTalk l/F card
32KB IEEE-488 I/F card
Coax l/F card

I

Ethernet I/Fcard

digit

indicated by an asterisk (*) vanes by country.

simple

serial interface card has no CPU; the printer processes the data from

Options and Consumables

Description

1-2

Rev. A

DFX-5000+ Service Manual

1.2 SPECIFICATIONS

This section provides detailed information about the DFX-5000+.

1.2.1 Printer Capabilities

Printing method:
Pin configuration:

Serial impact dot matrix
9 wires

Product Description

Pin diameter:

Dot matrix:

0.29 mm (0.01 inches)

I

8/72”

o
o
0
0
0

L3-

Figure 1-2. Pin Configuration

9 x 7 (high-speed draft mode)

9 x 9 (draft

18x

mode)

23 (NLQ mode)

mm (1/72”)

Printing direction:

Text mode

Bit image mode

Built-in fonts:

Type of Letters

Pica (1 O cpi)
Elite (12 cpi)

15 cpi
Condensed (17.1 cpi)
Condensed elite (20 cpi)

Bidirectional with logic seeking
(Unidirectional mode can be selected using the ESC U command.)
Unidirectional

Draft
NLQ Roman
NLQ Saris Serif

Table 1-2. Character Size and Pitch

Width in

(inches) (inches)

2.12 (0.08)

1.69 (0.07)

1.41 (0.06) 3.1 (0.12)

1.06 (0.04) 3.1 (0.12)

0.85 (0.03)

mm

Height in mm

3.1 (0.12)

3.1 (0.12)

3.1 (0.12)

Pitch in mm printable Columns

(inches)

2.54 (0.10)

2.12 (0.08)

1.69 (0.07)

1.48 (0.06)

1.27 (0.05)

136

163

204
233
272

I

Rev. A

1-3

Product Description

Table 1-3. Printing Speeds

DFX5000+

Service Manuai

Type of Letters Print Speed (cps)

High-speed draft
Draft pica 10@
Draft elite 12 cpi
Draft 15 cpi
Draft condensed pica
Draft emphasized pica 20cpi
NLQ pica
NLQ elite

Input data buffer:

control codes:

17 Cpi

20KB or O bytes (selectable by DIP switch 2-2)

ESC/P-83 mode

Table 1-4. Character Tables

Character Tables

Italic

PC437 (U. S., Standard Europe)

PC850 (Multilingual)
PC860 (Portuguese)
PC863 (Canadian-French)
PC865 (Norwegian)
PC861 (Iceland)

BRASCII

Abicornp

PC853(Turkish)
PC857(Turkish)
ISO Latin IT (Turkish)

PC437 (Greak)
PC869 (Greek)
ISO 8859-7 (Greek)
PC855 (Cy
PC866 (Russian)

PC852
MAZOWIA (Polish)

Code MJK (Czecho, Slovak)

Bulgaria (Bulgaria)

rillic)

(East

Europe)

0: supported

x: Not supported

High Duty (cps)

420

420

210

84

101

standard

Version

o

o 0 0
o
o 0
o

o
o

o 0

NLSP* Version IBM Mode

0

0

0

0 0

0

o 0

x

x o

x
x
x
x
x
x
x
x
x
x

o

o
o
o
o

o
o
o
o
o
o

533
400

400

200

80

96

x

x

x

x

x

x
x

x

x
x
x

x
x

x

x

x
x
x
x

*: Nationa/Language Support

1-4

Rev. A

DFX-5000+ Service Manual

1.2.2 Paper Handling Specifications

Product Description

Feeding methods:

Paper size:

Fanfold paper
Single sheet paper Not available
Roll paper

Line spacing:

Feeding speed

(1/6-inch per line):

Continuous

Intermittent

Note: The

1.2.3 Paper Specifications

Fanfold Paper

Quality:
Width:
Copy capability:

Front
Rear

feeding speed (10 ips) is reduced to 6 ips when the optional pull tractor is installed.

Push tractor feed (front and rear)

Push-pull feed with the optional pull tractor (front or rear)

101

-406 mm (4

Not available
1/6- or l/8-inch feed or progra

minimum increment

17 ins/line (10 inches per second)
26 ins/line

Plain paper
101

-406 mm (4 - 16inches)

6 sheets (1 original + 5 carbonless copies)
4 sheets (1 original + 3 carbonless copies)

- 16 inches) wide

mmable with a l/216-inch

Total thickness:

Front
Rear

Weight:

Single

Multi-part

Up to 0.46 mm (0.018 inches)
Up to 0.30 mm (0.012 inches)

45-70 kg(14- 22 lb)
35-48 kg (11 - 15 lb) x n (n < 8), up to the total thickness

13-31

mm

o

o

ABCD

r

o
0

I

II

o
0

I

E

m

>

g

s

H

O~BCD

0

— - — --- — ----- —-------

~~BcD

01

A

More than 13mm

~

.————

wxY~

-————

WXYZJ

- — - —w---

A

o

~

I

0
0

I

0
0

‘o

0

:

I

/0

Rev. A

Figure 1-3. Printable Area for Fanfold Paper

1-5

Product Description

Notes:

1. Horizontal alignment maybe irregular in the top 75 mm (3 inches) of the first page.

2. When using the optional pull tractor, the top 120 mm (4.8 inches) of the first page are
unprintable.

3. Use clean paper with no folds, creases, or tears (especially for multi-part paper). Figure 1-4
shows paper you should not use.

DFX-5000+ Service Manual

creases

Figure 1-4. Unsuitable Paper

4.

Form override printing is available for 20 lines after the paper end. The paper feeding pitch is
not guaranteed. The end of the printable area is 15 mm (0.60 inches) above the bottom edge of
the paper.

E

In

A

:p6D—

0’
0
o

‘

o

L%D—. —-

END OF PAPER

-

A

— -–

~lo

w)(wJ

o

o
0

I
10

10

‘o

E

1$

s

,~

il

V

If?

,

Figure 1-5. Form override Area

5.

Weak horizontal and vertical perforations cause paper jams.

The pitch of perforations (the ratio of the cut part to the uncut part) must be less than

6.

cut

_f&__t?t-

VE!?L

Figure 1-6. Perforation pitch

1-6

5:1.

Rev. A

DFX-5000+ Service Manual

7.

Horizontal perforations must have uncut parts on both edges of the paper.

Uncut

Product Description

[

Paper

edge

-’/

Figure

At the intersection of a horizontal and vertical perforation, the perforation cuts must not cross

8.
each other. Figure 1-8 shows examples of correct perforation intersections.

1-7. Paper

I
I

-——.

Edge at a Horizontal Perforation

———

———

l_-

I
I

cut

I
I

——

I

I

I

Figure 1-8. Perforation Intersections

The raised portion at a perforation (fold) must be less than 1 mm (0.04 inches) from the flat

9.

part, and the bottom layer must be kept flat by force.

Perforations

I

Figure 1-9. Raised Portion

10. Sprocket holes must be circular and may have teeth.

at a Perforation

OC3

Figure 1-10. Sprocket Holes

11. The sprocket holes of each paper layer must be properly aligned.

U
0

II

Figure

o

NG

-b

3

1-11. Aligned Sprocket Holes

Rev. A

1-7

Product Description

12. Any pieces of paper remaining in the sprocket holes must be removed.

13. The paper should be fanfolded at the horizontal perforations. Never use incorrectly folded
paper, such as the paper shown below.

Figure 1-12. Incorrectly Folded Paper

14. Make sure there are no holes in the printable area.

15. The paper must be tom off cleanly along a perforation.

Overlapping Mutti-part Forms

DFX-50oo+ Service Manual

NG

Paper path:
Quality:
Width:
Copy capability:

Overlap length:
Total thickness:

Print area

Overlap area

Weight:

Multi-part
Carrier

Front only
Plain paper
101-406 mm (4 -16 inches)

5 sheets (1 original + 4 carbonless copies), excluding the bottom
carrier

10 mm (0.394 inches) maximum

0.46 mm (0.018 inches) maximum

0.70 mm (0.028 inches) maximum, including the bottom carrier

35-48 kg (11 ­45- 70kg (14- 221b)

13-31mm

4-

T

r

o
0

./

———

Ma)

15 lb), up to the total thickness

More than

13mm

--D

Perforations

/

-------------­—..—

——.

—

z

o

.1

Carrier

7

o

0

-.

0

0

0

0

0

-.

0
0

0

0

-.

5

—

o

o

A

Figure 1-13. Printable Area, Overlapping Multi-part Forms

0

—

DFX-5000+ Service Manual Product Description

r,

Ii

When using overlapping multi-part forms, do not use the paper select (change tractors) or tear

offfunction; to avoid a paper jam, it is important not to feed overlapping multi-part forms

backward.

Notes:

Rough multi-part form binding causes paper jams.

1.

2. The

multi-part form sheets should be bound together with spot gluing (dotted paste), paper
stapling (mechanical staking), or tape stitching. Forms joined with spot gluing are
recommended for the best printing quality.

3.

For multi-part forms joined with dotted paste, the form sheets can be joined on either a single

side or both sides. Figure 1-14 shows the recommended paste positions.

Surface

o“

a

o

-------------------

0 0

Ea

0

0

m

0
0

mB-

0

0

0

-------------------

m

0
0

W

0

0

m

0

o

m

0

m

0

0

Figure 1-14. Dotted Paste Positions

4. The

pasted areas must be pressed flat. There must be no creases in the paper.

5.

Paper stapling must be applied from the front, and the paper must be flat. Figure 1-15 shows a

cross section of the stapled area.

a: Less than paper thickness

Figure 1-15. Stapled Area 1

6. Paper stapling must be applied for both feeding directions. Figure 1-16 shows a cross section of
the stapled area.

Paper feeding direction

Rev.

Figure 1-16. Stapled Area 2

A

1-9

Pfvduct Descfiptkm

7.

The binding area must be fiat. Figure 1-17 shows a cross section of the stapled area.

NG

DEMO(M+

Servke

hisnual

Figure 1-17. Stapled Area 3

Never use forms joined with metal staples.

8.
The binding (dots of paste or paper staples) must be outside the printable area.

9.

10.

Overlapping multi-part forms must be bound at the top side by spot gluing. The binding must

giue.

be secure and there should be no spilled
binding method.

11.

Multi-part
be too large.

firm

sheets should be securely bound to each other, and the binding area must not

Figure 1-18 shows the correct multi-part form

Paate

Figure 1-18. Correct

Fanfold Paper with a

Paper path:
Quality:
Width:
Total thickness:
Weight:

Single
Multi-part

Muiti-part

Labal

Front only
Plain paper
101-406 mm (4 - 16 inches)

0.46 mm (0.018 inches)

45- 70kg(14-
35- 48kg (11 -15 lb) x n (n < 8), up

‘w

rruximum

221b)

No

Form Binding

tothe

pmling area

13nml

total thickness

\

..-,.

~‘ t

c’

-,

1-1o

Figure 1-19.

01

A

Printabie

Area for

A

Fanfoid

10

Paper with a

Labei

Rev.

A

DFX-5000+

Labels

Service Manual

Product Description

Paper path:
Label size (W x H):

Bottom carrier:

Width

Length

Total thickness:

Label examples:

Front only

2%x

15/16 inches
4 x 15/16 inches
4 x 17/16 inches

4- 16 inches

3.5 inches minimum

0.19 mm (0.0075 inches) maximum
Differences in thickness must be less than 0.12 mm (0.0047 inches).

Avery continuous form labels
Avery mini-line labels

r-lr-l

0

II II

o

0

I

01

I

0

L.-----H---J

0

r-l~-l!o

0

0

II

II

II

II

I

10

I

I 10

10

10

“
o

o

0

H

Inside of each. label

11

A

Figure 1-20. Printable Area for Labels

0

When using labels, do not use the paper select (change tractors) or tear

paper jam, it is important not to feed

Notes:

Load label forms only onto the front tractor. The paper select function must not be used.

1.

2.

Feed label forms only in the forward direction, using the forward-feeding MICRO FEED
button

may cause a paper jam, or the labels may come off the backing and stick to the printer.)
When using label forms, do not use the TOF (top of form) function.

3.

4.

Do not use easy-peel labels.
Label comers must be rounded.

5.
The labels and the bottom carrier should have no folds or creases.

6.
Labels must be on carrier paper, and there should be carrier paper between the labels. (The

7.
labels should not touch each other.)

The label surface must be flat.

8.

(A).

Do not feed label forms in the reverse direction. (Feeding label forms backward

label

forms backward.

oflfinction;

to avoid a

Rev.

A

1-11

Product Description

DEX-50(W+

Service

hWw81

r

o

[-

---------------------------

0’

r--

O,

~

10;

r-l

0 ~

~

-----------------------------

0(

1.2.4 Ribbon Specifications

Ribbon cartridge:
Ribbon pack:
Ribbon pack exchanges:

Ribbon color:
Dimensions:

Cartridge
Ribbon

Life:

-

\

~w

Figure 1-21. Label and Carrier

#8766
#8767
4 times per cartridge maximum

Black

506 (W)

13 mm x 70 m (0.52 inches x 231.0
15 million characters (14 dots/character)

4-16”

A

A

H

r

‘T

‘k’ j i ‘*e’ j

r‘7

bb’ i i ‘ab’ j,

v

X

H

23

(H) X 140(D) mm (20.24X 0.92 x5.60 inches)

o

A

I

o

J

.-

0

0
o

o

H

r

tit),

endless

1.2.5 Environmental Conditions

Table 1-5. Acceptable Environmental Conditions

Condition

Temperature
Humidity
Shock resistance

Vibration resistance

●

’:

7hese

●

2:

conditions are acceptable when

wjj~mnsationm

5- 35°C (41” -

10-

1 G (within 1

0.25 G, 55 Hz maximum

Operating

95”F)

WY.

RH

q

msec.)

theprinterisin itssh@ping mntainer.

-30-

80”C

5- 85% RH

2 G (within 2

0.50 G, 55 Hz maximum

storage

(-22 -

maec.)”

140”F)
““v

“’

1-12

Rev. A

.?..,

..

.

‘{

.4

. ...~

c

DFX-5000+

Service Manual Product

1.2.6 Electrical Specifications
Table 1-6. Rated Electrical Ranges

120

V

Version

DescriMion

220-240 V Version

Rated voltage
Input voltage range
Rated frequency range
Input frequency range
Rated current

Power consumption

Insulation resistance

Dielectric strength

1.2.7 Reliability

MTBF:
MCBF:
Printhead

life:

120

VAC

103.5- 132 V

50-60

49.5 -60.5

Approx. 115 W

(self-test in 10

10 MQ minimum 10

(applying 500

1000

1200

(between AC line and chassis)

VDC

and chassis)

VAC

rms -1 minute or

VAC rrns

8000 power-on hours
24 million lines (excluding the
300 million characters (14 dots/character)

HZ

Hz

5.0 A

cpi

draft mode)

between AC line (applying

-1 second

I

I

I

(self-test in 10

(between AC line and chassis)

(POH)

220-240

198-264 V

50-60

49.5 -60.5

Approx.110 W

MQ,

500

and chassis)

VAC rrns

1500

at a duty cycle of

printhead

VAC

tiz

tiz

3.0 A

cpi

draft mode)

minimum

VDC

between AC

-1 minute

and ribbon)

zs~o

IHw

1.2.8 Safety Approvals

Safety standards:

Radio frequency interference

(RFI):

1.2.9 Physical Specifications

Size (W x D x H):
Weight:

U.S. version:

European version:

U.S. version:
European version:

700 x 382x 369 mm (27.6 x 15.0 x 14.5 inches)
29 kg (63.8 lb)

UL1950 with D3

CSA22.2

EN 60950
NEMKO, SETI)

FCC part 15 sub-part B class B

Vfg
CISPR

#950 with D3

~,

SEMKO,

243 (VDE 0878 part 3)

Pub 22 class B

DEMKO,

Rev.

A

1-13

Product Description

1.3 INTERFACE SPECIFICATIONS

1.3.1 Parallel Interface

LKMO#+

Serukw Mwd

Data

forrmt:

Synchronization:
Handshaking:
Signal level:
Connector:

ACKNLG

DATA

8-bit parallel
By STROBE

By BUSY and
TT’compatible level
%-pm 57-30360

Pllk Sy’dWXWa

ACKNLG

(Amphenol)

L

&

“ tion

SigdS

or equivalent

0.5uS(Min.)
O.SuS(Min.)

0.5uS(Min.)

.,

‘,$

‘. .>..

,:,

6!’!?

Figure 1-22. Data Transmission Timing

Note:

The BUSY signal is active (HIGH) under the following conditions:

The ERROR signal is active (LOW) under the following conditions:

The PE signal is active (HIGH) when a paper out error occurs.

The transition time (the rise and fall time) of each input signal must be less than 0.2

- During data reception (See Figure 1-22.)

- When the ~t buffer is

- When the INIT’ input signal is active

- During initialization

- When the ERROR or PE signal is active

- During the self-test

-

II-I

paper memory setting mode

-

IrI

pause mode

- When a fatal error occurs

- When a paper out error occurs

- When a paper jam error occurs

- When a fatal

error

occurs

full

ILS.

1-14

Rev.

A

DFX-5000+ Service Manual

Table 1-7 shows the signal functions and connector pin assignments for the 8-bit parallel interface.

Product Description

Table 1-7. Parallel Interface Signals and Connector Pin Assignments

Pin No.

1

2-9

10

11

12

13

14

Signal Name

STROBE

DATA 1- DATA 8

ACKNLG 28

BUSY

PE

SLCT

AFXT

Return

Pin No.

19

20-27

29

30

I/o’

STROBE pulse to read the input data. The

I

pulse width must exceed 0.5 @. Input data is
latched after the falling edge of this signal.

Parallel input data to the printer.

I

HIGH level means data 1.
LOW level means data O.

This pulse indicates data has been received

and the printer is ready to accept the next data.

0

The pulse width is approximately 12 p.s.
HIGH indicates the printer cannot accept the

0

next data.

HIGH indicates paper out. This signal is

0

effective only when the ERROR signal is LOW.
Always HIGH output. (Pulled up to +5 V

o

through a 3.3 KQ resistor.)

If the signal is LOW when the printer is

I

initialized, a line feed is automatically

performed when a CR code is input (auto

Description

LF).

15,34

18,35

19-30

31

32
33
36

*The

NC

16
17

Ov

FG
+5

v

GND

INIT

ERROR

GND
SLCTIN

1/0

column indicates the direction of the signal as viewed from the printer.

-

No connection (not used).
Signal ground level.
Chassis ground. In the printer, chassis ground

and signal ground are short circuited.
Pulled up to +5 V through a 3.3 KQ resistor.
Ground for twisted-pair return signal.
Pulse input (width: 50

I

LOW) for printer initialization.
LOW indicates that some error has occurred in

o

the printer.

Signal ground.

If the signal is LOW when the printer is

I

initialized,

DC1/DC3

p.s

minimum, active

control is disabled.

Rev.

A

1-15

Product

Lkscription

DEX401W+

Servka

Mm&#

1.3.2

Data format:

Synchronization:

Handshaking:

Word length:

Bit rate:
Logic level:

Connector:

Table 1-8 shows the signal

RS-232C

Start bit

Data bit
Parity bit

Stop bit

MARK (logical 1)

SPACE (logical O)

Serial Interface

RS-232C

Asynchronous
By

1 bit
8 bits
Odd, even, or no parity

1 bit
300,1200,9600, or 19200 bps (selectable by DIP switches 2-7 and 2-8)

-3 to –27 V
+3 to +27 V

EIA standard 25-pin

functions

serial

DTR

signal or X-ON/X-OFF protocol

or more

cmnector

and connector

pin

assignments for the serial interface.

Table 1-8. Serial Interface Signals and Connector Pin Assignments

Pin No.

1

2

3

7

Signal Name

I

r

I

FG

TXD

RXD

SG

I/o*

I

I
I O I TmllSmt*tafOrx-Ow-OFF

I

.

I

Chassis ground.

[

I

.

Receive data.
Signal ground.

Description

hndShake. I

I

I

11,20

4-6,8-10,

12-19.21-25

●

The PO column indicates the data flow as

I

DTR

NC

o

.

I

tiewed fmm

Indicates whether the printer is ready to receive
data. If the printer is not ready, the
becomes MARK.

No connection (not used).

the printer.

DTR

signal

P

j

1-16

Rev.

.>,;,,,

,,,’;

.;.,,,

0

A

DFX-5000+ Service Manual

Product Description

1.4 PRINTER OPERATION

This section describes the basic operation of the printer.

1.4.1 Control Panel

The printer’s control panel contains eight non-lock type push buttons and twelve LED indicators

for easy use of the various printer functions.

Cl

POWER PAUSE

n

PAPER

OUT

Buttons

PAUSE:

LF/FF

LOAD:

TEAR OFF:

MICRO FEED:

TOP OF FORM:

PITCH:

LFIFF

LOAO

cl

a

m

TEAR OFF MICRO FEEO

m

A

in

a

(e)

TOP OF

ORM

‘

(A) (B)

PITCH

0

‘

o 12

0

PAPER SELECT

g m

~o

B

FRONT/REAR

(c)

Figure 1-23. Control Panel

Stops or starts printing, if any print data exists in the input buffer. (Turns
pause mode on or off.)

Advances the paper line by line according to the set line spacing while the
printer is ready to print or paused by the PAUSE button. Holding down the
button for about one second advances the paper to the next top of form

(TOF)

position. This button is also used to load the paper from the push

tractor of the selected paper path when the printer is in the paper-out state.
Enables tear off mode and advances the paper to the tear off position. This

button functions only when the printer is in pause mode. The tear off
position can be adjusted using the MICRO FEED buttons. The adjusted value
is stored in the EEPROM on the main board when the printer is turned off.

Adjusts the paper position, including the top of form
positions. The forward MICRO FEED button

(A)

advances the paper in 1/216

inch increments and the backward MICRO FEED button (v) feeds the paper

backward in 1 /216 inch increments.

Enables top of form

(TOF)

setting mode, so that the

adjusted using the MICRO FEED buttons. This button functions only when

paper is loaded into the printer using the
printer is in pause mode. In

TOF

LED blinks.

TOF

setting mode, the PAUSE LED is lit and the

LF/FF

Selects a character pitch of 10,12, or 17 cpi.

(TOF)

and tear off

TOF

position can be

LOAD button and the

PAPER SELECT:

Rev.

A

Selects the front or rear paper path. If there is paper in the current path and
the printer is in pause mode, the paper is fed backward to the tractor. Then,
the selected paper from the other tractor is fed to the

TOF

position. If all the
paper in the current path is not fed backward to the tractor by the single
22-inch (55.9-cm) backward feeding sequence, make sure your previous
print job is tom off and press the PAPER SELECT button again until the
current path is empty.

1-17

Product Descrhtion

LED Indicators

DFX-5009+ Servkm MwnuJ

POWER (green):
PAPER OUT (red):

PAUSE (orange):
TEAR OFF (orange):
TOP OF FORM (green):
PITCH (3) (green):
FRONT (2) (green):

(red):

REAR (2) (green):

(red):

Lit when the printer is turned on.
Lit when the printer is out of paper.

Flashes when there is a paper jam.
Lit when the printer is in pause mode.
Lit when the printer is in tear off mode.

Lit when the printer is in TOF mode.
The lit PITCH LED indicates the selected pitch.
Lit when the front paper path is selected with paper loaded onto the

front tractor.
Lit when the front paper path is selected with no paper
the front tractor.

Lit when the rear paper path is selected with paper loaded onto the
rear tractor.
Lit when the rear paper path is selected with no paper loaded onto
the rear tractor.

1.4.2 Self-test

The printer’s self-test (self printing) function checks the following

- Control arcuit
Printer mechanism
Print quality

loaded

onto

To run the self-test in draft* mode, hold down the
run the self-test in

The self-test can be interrupted by pressing the PAUSE button. To end the self-test, press the

PAUSE button and then turn off the printer.

The self-test prints the following:

- Program ROM version number

– Built-in characters
To print the current DIP switch settings,
* The printer does not print the self-test in draft mode if

DIP switch 1-3.

NLQ

mode, hold down the TEAR OFF button and

hold down the

LF/FF

LOAD button and turn on the printer. To

tmm

on the printer.

PAUSE button and turn on the printer.

NLQ

mode is selected using

1.4.3 Hexadecimal Dump Function

The hexadecimal dump function prints the data the printer receives in hexadecimal format. To

print a hexadecimal dump, hold down
printer. “HEX DUMP MODE” is printed on the first line. Then 16 bytes an? printed in

on each line, and the ASCII character correspondkg to each byte is printed on the right side. “.” is
printed if there is no corresponding ASCII character
bytes remain, they can be printed by pressing the PAUSE button. To cancel hexadecimal dump
mode, turn off the printer.

the

LF/FF

LOAD and

(such

as, for a control code). If less than 16

TEAR

OFF

buttons and turn on the

hexadedmal

1.4.4 Paper Out Detection Function

When the paper out sensor detects the printer is out of paper, the printer automatically enters

pause mode. Load new paper properly, and then press the PAUSE button to turn off pause mode

so the printer is ready to print.

1.4.5 Cover Open Detection

When the printer cover is opened, the printer stops
intervals, and enters pause mode. Close the printer cover and press the PAUSE button to turn off
pause mode so the printer is ready to print.

1-18

printin&

beeps 4 times with 0.1 second

Rev.

A

DFX-5000+

Service Manual

Product Description

1.4.6 Paper Width Detection

The printer detects the right paper edge and determines the right end of the printable area. This

disables printing in areas where there is no paper.

1.4.7 Automatic Paper Thickness Adjustment

The printer measures the paper thickness each time paper is loaded. The distance between the
printhead and the platen is automatically adjusted to match the paper’s thickness and obtain the
best print quality.

1.4.8 Paper Memory Function

The paper memory function allows the printer to print properly when different areas of the same
form vary in thickness. For the best print quality when using forms with a label or overlapping
forms, use the paper memory function.
information using the DIP switches and the control panel buttons. The paper memory function is
available only for forms loaded on the front tractor.

Cl

Forms with a label

Multi-part forms that vary in thickness include forms with a label; the label area is thicker
than the rest of the form.

It allows you to save paper format and thickness

0

0

Figure 1-24. Multi-part Forms with a Label

Q

Multi-part forms that partly overlap the next page

Multi-part forms that vary in thickness include forms that overlap slightly where they are

glued together; the overlap area is twice as thick as the rest of the form.

Figure 1-25. Overlapping Multi-part Forms

Set the information about the label and overlap areas before printing. The printer works according

to this information.
Note:

Rev.

The tear off and paper select functions are not available when the paper memory function
is used.

A

1-19

Product Description

1.4.8.1 Using the Paper Memory Function

To use the paper memory function, you must first save paper format and thickness information for
up to two different types of paper as described in

fktion

1.4.8.2, below.

DFX-5000+

Servke

Manual

To turn on the paper
hold down one of the buttons below and turn on the printer.

MICRO FEED (A)

MICRO FEED (v)

To turn off the paper
button and turn on the printer.

Notes: Cl A

1.4.8.2 Saving Paper Format and Thickness Information

To save paper format and thickness information for overlapping forms, forms with a label, or

overlapping forms with a label, follow these steps:

1. Turn off the printer.

2. Use DIP switch 3-4 to select the memory area where you want the printer to store the paper
format and thickness information. Memory area 1 is

is the printer’s default setting. To select memory area 2, turn on the switch.

l-inch skip over perforation area is automatically included for overlapping forms.

Ct ESC

C (set page length) is valid when using the paper memory function.

O ESC

N (set skip over perforation) is valid when using the paper memory function;
however, if the skip
overlapping forms.

Q

ESC

O

with overlapping forms.

Q

When using overlapping forms, the loading position must be adjusted each time you

load paper.

memo~ function after saving your paper format and thickness information,

Recalls the paper format and thickness information stored
in memory area 1.

RecaIls

the paper format and thickness information stored

in memory area 2.

memory function

length

(reset skip over perforation) is valid when using the paper memory function

and use normal paper, hold down the PAPER SELECT

is less than

1 inch, the setting is ignored when using

sekcted

when DIP switch 3-4 is off.

This

Table

3. Use DIP switches 3-1 and 3-2 or

1-9.

Selecting the Paper Memory Area

Paper Memory Area

Table 1-10.

Page Length (inches)

11
12

8.5

70/6

DIP SW 3-4

1

2 ON

softwareco

Setting the Page

rnmands to set the page length.

DIP SW 3-1 DIP SW 3-2

OFF
OFF ON

ON

ON

OFF

Length

OFF

OFF

ON

1-20

Rev. A

.,.

,.,.

...

:,

...

o

DFX-5000+ Service Manual

4.

Use DIP switches 3-5 and 3-6 to set the paper type.

Table 1-11. Setting the Paper Type

Product Description

Paper Type

Normal paper

Forms with a label
Overlapping forms ON
Overlapping forms with a label

5.

Hold down both MICRO FEED buttons and turn on the printer.

6.

If you are using forms with a label, indicate the label’s position by following these steps:

Sw

3-5

OFF
OFF

I

ON [ ON

Sw

OFF

ON

OFF

34

(1) Open the printer cover.
(2) Align the pointer on the ribbon mask with one of the label’s comers.

– To feed the paper up or down, press the appropriate MICRO FEED button.
– To move the pointer right or left, move the

printhead

by hand.
(3) Press the TOP OF FORM button.
(4) Move the pointer to the comer of the label diagonally opposite the first comer.
(5) Press the TOP OF FORM button.
(6) Close the printer cover.

7. Use the printer beeps to confirm that the paper format and thickness information has been
saved properly. If the printer beeps once or twice, the information has been saved correctly

1

or

memory area

2. If the printer beeps 10 times, the information has not been saved; carefully

in

follow steps 1 through 7 in this section again.

1.4.9 Automatic Tear Off Function

Use DIP switch 3-8 to enable or disable the automatic tear off function. When the tear off function is
enabled, the printer automatically feeds fanfold paper until its perforation reaches the tear off
position of the printer cover under these conditions:

Cl

The paper is advanced to the

Q

The printer receives an FFcode and then no other codes or characters for at least3 seconds. (The

TOFposition

after a print job.

printer has finished a print job.)

Ll

The pull tractor is not being used.

D

The paper memory function is not being used.

Then, if the printer receives more data, it automatically feeds the paper backward to the original
position and printing starts.

1.4.10 Paper Jam Detection

When a paper jam is detected, the printer beeps, stops feeding the paper, and enters pause mode.
The PAPER OUT indicator flashes. Remove the paper and load new paper properly. Then press the
PAUSE button to turn off pause mode so the printer is ready to print.

1.4.11 Automatic Interface Selection

When the printer does not receive any data
the parallel

interfam,

serial

interfam,

and optional

The standby time can beset to 10 seconds or30 seconds using DIP switches 24,2-5, and

tbr

the set time over

interfam,

and selects the

the

currently selected interface, it checks

intert%ce

that receives data

fit.

245.

Note:

The built-in serial interface and Type B simple serial interface card cannot be used at the
same time. The simple serial interface card takes precedence over the built-in serial

interface.

1.4.12 Thermal Protection

The

printhead

the pnnthead or cooling fan is too hot, the printer stops printing while it cools.

Rev. A

has a thermistor inside it, and the

printhead

cooling fan also has a thermistor. When

1-21

Product

Dascrfption

1.4.13 Skip Binding Function

DEW(W)+

Service Mmual

The skip binding
the

printhead

binding during paper feeding to avoid paper jams. Use DIP switch
binding function; when it is enabled, throughput is

function is used

for printing on multi-part forms with binding that could scratch

during paper feeding. When

this

function is

reducwl.

used, the

3-7

1.4.14 Printer Initialization

The printer is initialized in the following cases:

Lt

When

il men

Initialization performs the following functions:

The top of form

~

Printer

Li ESC/P
~

Page length command

2

IBM top-of-form setting command

thep@er

the

NIT

Returns the

is turned on.

signal is input through the parallel rnterface.

printhead

to

th~

far left position (carriage home).
Puts the printer in ready mode, so it is ready to print.
Clears the print buffer and input data buffer.
Clears download characters (CG ROM copy in IBM mode).
Sets the line spacing to 1/6 inch.
Sets the page length according to the DIP switch settings.
Clears all vertical tab positions.
Sets the horizontal tab position to every 8 columns.

Sets the print mode according to the DIP switch settings and non-volatile

(T’OF)

position is reset by the following:

initializ.ation

software reset command

(ESC @)

(ESCC)

(ESC4)

head parks away from the

to enable or disable the skip

memory.

1.4.15 Buzzer Operation

The buzzer sounds for approximately 0.1 second when a

indicate printer status, as shown below. Each asterisk (*) represents one 0.1 second beep.

The

ESC BEL

command

(07H)

is input.

A carnage error is detected due to:

-

CRlockup.

Low insulation resistance (less than 1

IQ.

A paper out or paper jam is detected.
(The printer runs out of paper or a paper jam

occurs during paper feeding or printing.)

Another paper error is detected:

Incomplete

back+ut.

(The previous print
job is not tom off.)
Empty during operation. (The paper is out
at power on.)

An abnormal voltage is detected.
RAM error is detected.
A cover open is detected:

The

cover open sensor detects that the
cover is open.
The interlock switch detects that the
cover is open.

A short circuited

printhead

is detected.

(The head driver FETs are bad.)

A short circuited

An

illegal paper memory setting is detected.

printhead

fan is detected.

A micro adjust limit is detected.
A platen gap adjust error is detected.

Note:

** 0.1 second interval

* *0.3 sWmd

interval

1-22

BEL

code

(07H)

is input. Buzzer beeps

*(1

beep)

“**

“w

(2 sets of 3

● *** ‘* *-*‘~ ****(5

*“*

(3 beeps)

*

**•”

(sbeepswi~ a w= ~

** w ** **
***

* * *

~?

(4 beeps)

*

● ● * * ●

~ -

**

●

● *

**** W-* @
***-**-**...

*** *** ***

beepa)

*

(5

SPJS

of z beeps)

* (II)

- ** ** (B *S
*S,

(continuom

(3* of 3

&P ~~ a Pam

*)

sek

of 4 beeps)

of 2

beeps)

tween

each beep)

between each

~)

Rev.

c’”

beep)

A

DFX-5000+

Service Manual

Product Description

1.5 DIP SWITCH

This section describes the functions of the DIP switches. After
turn on the printer to put your settings into effect.

SEITINGS

Table 1-12. DIP Switch Settings

SW No. Function

1-1

1-2
1-3
1-4

1-5
1-6
1-7

1-8
2-1
2-2 Input buffer
2-3 Automatic LF bv CR
2-4

2-5
2-6

Emulation mode

Drafl

speed

Character quality

IBM mode

ESC/P

mode

Shape of zero

Interface

ON

See Table 1-13.
See Table 1-14.

E

See Table 1-15.

settimz

one or more DIP switches,

OFF

I

Factory

Setting

OFF
OFF
OFF
OFF

OFF
OFF
OFF

OFF

OFF
OFF
OFF
OFF

OFF

OFF

2-7
2-8

3-1
3-2

3-3
3-4
3-5
3-6
3-7

3-8 Automatic tear off

* IBM mode indicates IBM ProPrinter emulation mode.
** These DIP switches are used

Serial bit rate

Page length See Table 1-17.
Skip over perforation

Paper memory area**
Overlapping forms**
Forms with a label**
Skip binding

forpaper

Valid
Valid
Valid
Valid

memory function settings.

See Table 1-16.

Valid (1”)
2

Table 1-13. IBM Mode Selection

J

I

ON

Invalid

t

SW No.

1-4

1-5

I

Function

Automatic CR by LF,

Reserved OFF

ESC

OFF

OFF

OFF

OFF
Invalid
1

Invalid
Invalid
Invalid

I

Invalid OFF

I

OFF

Valid

OFF
OFF

OFF

OFF

OFF

I

Factory

Setting

OFF

Rev. A

1-6

1-7
1-8

Codes 80-9FH
Reserved

Character table

Characters

PC865

Commands

PC437

OFF

OFF

OFF

1-23

Product Description

DEW50tM+ Swvke

Manual

Table 1-14.

Character Table

Standard

Italic

Italh

France

Italk

Germany OFF OFF

Itzk

Italic Denmark

Italic Sweden

Italic Italy

Italii Spain OFF
PC437 PC437
PC850
PC860 PC860
PC863

NLSP

Us.

U.K. OFF

PC850

PC863

ESC/P

Sw 1-4

OFF OFF

OFF

OFF
OFF
OFF
OFF

Mode Selection

Sw l-a

OFF
OFF

OFF

OFF OFF
OFF

OFF

OFF
OFF
OFF

ON

ON
ON
ON

Sw

l-e

Sw

OFF
OFF
OFF

ON
ON
ON ON

ON
OFF
OFF
OFF

OFF

1-7

Sw

OFF OFF
OFF

ON
ON

OFF OFF

OFF ON

ON ON
OFF OFF
OFF

ON
ON ON

ON

OFF

ON

OFF

ON

OFF

14

PC865 PC865
PC861 PC861
BRASCII
Abicomp

BRASCII
Abicomp
PC437
PC869
1s0

8859-7

PC853 ON OFF
PC857 ON

ISO Latin IT

PC865
PC866 ON

PC852 ON ON
MAZOWIA

Code MJK
Bulgaria ON ON

Greek

OFF
OFF
OFF
OFF

ON
ON
ON

ON
ON

ON
ON

ON

ON
ON
ON

OFF OFF
OFF OFF
OFF

OFF
OFF
OFF
OFF

ON
ON

ON

ON
ON
ON

OFF
OFF

ON

ON
ON

ON
OFF
OFF
OFF

OFF

OFF OFF
OFF

ON

ON
OFF OFF
OFF

ON

ON ON

OFF
OFF

ON

ON ON
OFF OFF
OFF

ON
ON ON

ON

OFF

ON

ON

OFF

OFF

ON

OFF

ON

OFF

1-24

Rev.

A

DFX-5000+ Service Manual

Product Description

Table 1-15. Interface Selection

Interface

Automatic selection, serial interface, odd parity (30 seconds*)
Automatic selection, serial interface, odd parity (10 seconds*)
Automatic selection, serial interface, no parity (30 seconds*)
Automatic selection, serial interface, no parity (10 seconds*)

Parallel interface
Serial interface, odd parity
Serial interface, even parity
Serial interface, no parity

*This is the standby time. See Section 1.4.11, ‘Automatic Interface Selection.”

Sw 2-4

OFF OFF
OFF
OFF
OFF

ON
ON
ON
ON

Table 1-16. Baud Rate Selection

Bit Rate (bps)

19,200

9,600

1,200

SW 2-7

OFF OFF

OFF

ON

Sw 2-8

ON

OFF

SW 2-5

OFF

ON

ON
OFF
OFF

ON

ON

Sw 2-6

OFF

ON

OFF

ON

OFF

ON

OFF

ON

300

ON ON

Table 1-17. Page Length Selection

Page Length Sw 3-1

11 inches
12 inches

8.5

70/6

inches

inches

I

I

OFF OFF
OFF

I

ON I OFF

ON ON

SW 3-2

ON

Rev.

~

A

1-25

Pfvduct

Dwcription

1.6 MAIN COMPONENTS

DEX4i’W+ Swvice Msnusl

The main components of the

main components are:

Printer mechanism
Main control board
Power supply board (
Control panel
Housing

(M-3C11)

(C117

MAIN board assembly)

C117 PSB/PSE

(C117

PNL board assembly)

DFX-5000+

board assembly)

are designed fix easy removal and replacement. These

Connector Junction Board

e

@

,.’ .+.

,,.. ..,;,

Y

c

Figure 1-26. Main Components

1-26

Rev.

A

DFX-5000+

Service Manual

Product Description

1.6.1

The

DFX-5000+.

and durable when compared with existing terminal printer mechanisms. Its paper feeding
mechanism uses fanfold paper, and an automatic mechanism is included to provide enhanced
paper handling.

The structural differences between the

U

Ll

Cl
U

LI

Cl

El

M-3CI

M-3C11

The

DFX-5000+

The

DFX-5000+

To prevent paper jams, the
The

DFX-5000+

The detection method of the carriage encoder sensor has been changed. In the

encoder plate was attached to the rotor of the CR motor, while the
encoder.

In the

changed to reduce noise.

In the DFX-5000+, the ribbon guide is not attached to the ribbon mask; the ribbon mask is

attached to the pnnthead carriage.

1 Printer Mechanism

printer mechanism is a 9-pin, serial, dot matrix printer mechanism developed for the

It is designed to provide high-speed, high-volume printing, and is especially heavy

includes a CR motor isolation resistance sensor.

includes a paper jam sensor.

does not include a carriage home position sensor.

DFX-5000+,

DFX-5000+

DFX-5000+

the angle between the printhead and the surface of the platen has been

includes a tractor wire at the front and rear tractors.

and the

DFX-5000

are:

DFX-5000+

DFX-5000,

uses a belt-type

the

Rev. A

Figure 1-27.

M-3C11

Printer Mechanism

1-27

Product

~퀕°ÿ€•\•••üà€•œ•¥•pE•Œ`õ€•••¥•(•¥•€Ô¤•µ

LA9ecriotkn

DEX-45000+

Service

Manual

1.6.2 Main Control Board

The

C117

MAIN board assembly

PROM (2 megabit including the CG ROM), a PS-RAM (256K), an

paper feed motor, an SLA5007 for the

interface control circuits.

CN7

CN9

\

+

t

1’

:

g-lc;-$:,,RAM,

,1

000

0

000

nno

o

I

CN1O

\

-41,

(C117

&

,-E,

II

~

W?

MAIN Board Assembly)

cxmsists ofi

a

TA4P96C14

CR

motor, each driver’s

u

~

m

CN3

i

I

S,22,10,13,16,i4,16,20,21(dnv.r

I

zlJGJca+--

for PRINTHEAD)

8-bit CPU, an E05A87 gate array, a

n

:

a

EEPROM, an SLA7026M

IC,

and the parallel and serial

IC1(CPU:TMPWC14)
lC2fEEPROM 9SC46)

tcqM51966
lC31PST5910 for

for +36V qotnn road)

IWC sptam mwt)

Db-witches

for the

L

Q28

031(dnvor for MOTOR, RF)

figure 1-28.

1.6.3 Power Supply Circuit

The

C117 PSB/PSE tmrd

mechanism drive circuit with
lower case constant and cools the
see Table 2-1 for

irhrrnation

assembly power supply circuit supplies the control circuit and printer

on the input voltage and fuse ratings of your printer’s board.

(C117 PSB/PSE

power.

CR

C117

MAIN Board Assembly

Board Assembly)

The

fan motor on this board keeps the temperature in the

motor. The printer contains one of two power supply boards;

~

T101

Trsnsformr

Clol

o

f

z“

0101

o

s

RI

r

k

F1

4-

ml

,..

,..

4

.. .,-

c

,,

1-28

L.

Figure 1-29.

CC3MPAMTER

T201

Ttansforrnsr

C117 PSWPSE

~a?ol

\

‘%3

Board Assembly

101

Rev.

A

DFX-5000+

1.6.4 Control Panel Board (C117 PNL Board Assembly)

The

LEDs, and buzzer.

1.6.5 Housing

The housing consists of many parts. The lower case is the main frame which holds the printer

mechanism and circuits. These components are covered by the upper case, bottom plate, and two
side covers, each of which has various covers. The housing has large openings in the front and rear
for the paper entrances and exits. It also has a cover on the bottom plate to provide easy access to
the PROM on the main board.

Service Manual

C117

PNL

Product Description

board assembly is the operator control panel. It contains the buttons, indicator

9
10

5

RA1

Figure 1-30. C117 PNL Board Assembly

—

—

—

—

—

—

—

c-)

‘\”

‘=”

\

——

Rev.

Figure 1-31. Housing

A

1-29

CHAPTER 2 Operating Principles

Table of Contents

2.1 OVERVIEW OF PRINTER MECHANISM OPERATION

2.1.1

Printhead

2.1.2

Carriage Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

2.1.3 Platen Gap Adjustment Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

2.1.4 Paper Feed Mechanism. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

2.1.4.1 Tractor Wire Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

2.1.5 Ribbon Feed and Tractor Select Mechanism. . . . . . . . . . . . . . . . . . . . . . 2-9

2.1.6 Plunger Mechanism. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

2.2 POWER SUPPLY OPERATION

2.2.1 PowerSupplyOverview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2.2 +5

2.2.3 +35

2.2.4 +/-12 VDC Half-wave Rectifier Smoothing Circuit. . . . . . . . . . . . . . . . . 2-16

VDCLine

VDCLine

RegulatorCircuk. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RegulatorCircuti. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3 CONTROL CIRCUIT

2.3.1

2.3.2

2.3.3

2.3.4

2.3.5

2.3.6

2.3.7

2.3.8

2.3.9

Control Circuit Operation Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

Reset Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Sensor Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CR Motor Driver Cimufi. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25

PF Motor Driver

RF Motor Driver Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PG

Motor Driver Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32

Plunger Driver Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Printhead

Driver Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cimuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1

2-11

2-12

2-12
2-14
2-15

2-17

2-21
2-Z

2-30

2-31

2-33
2-33

c)

-.”

.,,
.-.
*..

62

List of Figures

Figure 2-1.
Figure 2-2.
Figure 2-3.
Figure 2-4.
Figure 2-5.
Figure 2-6.
Figure 2-7.
Figure 2-8.
Figure 2-9.

Mode13Cll

Printer Mechanism. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Printer Mechanism Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Printer Mechanism Operation 2. . . . . . . . . . . . . . . . . . . . ........2-3

Printhead Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. ....2-3

Carriage Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. ....2-4

Platen GapAdjustment Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Tension Roller and PF Roller Operation . . . . . . . . . . . . . . . . . . . . . 2-6

Front Tractor Assembly Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

RearTractorAssembly Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Figure 2-10. Tractor Wire Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

Figure2-ll. Ribbon Feed Mechanism. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Figure 2-12.

TractorSelect Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

Figure 2-13. Plunger Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Figure 2-14. PowerSupplyBoard Block Diagram . . . . . . . . . . . . . . . . . . . . . . 2-12

Figure2-15.

+5VDC

Line RegulatorCircuit. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

Figure2-16. +35VDC Line Regulator Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

Figure 2-17. Half-wave Rectifier Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

Figure 2-18. Control Circuit Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

Figure2-19. Data Flow from the Parallel Interface . . . . . . . . . . . . . . . . . . . . . . 2-19

Figure2-20. Reset Circuit Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

Figure 2-21.

SensorCircuit Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

Figure 2-22. CRMotor Internal Circuit.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25

Figure 2-23. CR Motor Driver Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25

Figure 2-24. Acceleration Control

Cutve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27

Figure 2-25. Deceleration Control Curve.... . . . . . . . . . . . . . . . . . . . . . . . . . 2-28

Figure 2-26. Measurement Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30

Figure 2-27. PFMotor Driver Circuit,
Figure 2-28. RF Motor Driver Circuit
Figure 2-29. PG Motor Driver Circuit
Figure 2-30. Plunger Driver Circuit.,
Figure 2-31.

Printhead DriverCircuit

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-30

2’31

2-32
2-33
2-34

List of Tables

Table 2-1

Table 2-2
Table 2-3

Table 2-4. CR Motor Drive Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 2-5. CR Motor Drive Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27

Table 2-6.
Table 2-7. RF
Table 2-8.
Table 2-9.

PowerSupplyBoards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

DC Voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

IC

Main

PF

Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

2-26

Motor Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31

MotorSpecifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31

PG

MotorSpecifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32

PlungerSwitching Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33

DFx-5tW(h Sewka Manual Oparathg Prfncipka

2.1 OVERVIEW OF PRINTER MECHANISM OPERATION

This section describes the Model
Model
printer mechanism is the main component of the printer and is supported by the other
(the power supply and control

TIMING

Connector

Junction

Board

3C11

Plunger

BEL

printer mechanism features a 9-pin, impact dot

PAPER

\

3C11

printer mechanism and explains how the printer works. The

printhead

arcuits).

PLATEN GAP ADJUSTMENT MOTOR

Figure 2-1 shows the Model

BA~L

ASSEMBLY

3C11

TRACTOR ASSEMBLY (FRONT)

D MOTOR

for serial printing.

mmponents

printer mechanism.

The

Figure 2-1. Model

The printer mechanism consists of the following main components:

22 Printhead

The

printhead

performed by striking the pins (arranged in a vertical line) against the surface of the paper and the
ribbon. A character is printed by repeating this printing operation in the horizontal direction (as the

printhead

has a thermistor. When the

(Refer to Section 1.4.12,

L1

Carnage mechanism

The carriage mechanism moves the
carriage, with the
The CR motor is closed-loop controlled. Because the CR motor is driven at a very high speed, it
includes an isolation resistance sensor to detect abnormal resistance. The sensor detects an error if

the resistance is less than 1
Cl Interlock switch

Because the carnage moves at a very high speed, it would be dangerous if a hand or finger were
inserted inside the printer mechanism during printing. Therefore, as a safety measure, when the
top cover is opened, the interlock switch cuts the drive voltage to the CR motor to slow down the
carriage speed and prevent
(Refer to Section 2.3.4.,

is the component that actually pMts characters (dot matrix patterns). Printing is

moves).

The printhead

Themud

printhead

CR Motor Dine Circuit.)

includes a head fan and temperature sensor.

printhead

Probation.)

printhead

on it. The CR sensor detects the CR motor speed and carriage position.

I@.

acadents.

or fan is too hot, the printer stops printing until it cools.

A control circuit

3C11

Printer Mechanism

The

head fan also

in the horizontal direction. The CR motor drives the

controIs

Printing resumes when the top cover is closed.

CR motor driver deceleration.

LI

Auto platen gap adjustment mechanism

The printer mechanism has an automatic platen gap adjustment function that measures the
thickness of the paper and provides the appropriate gap between the platen and
platen gap is adjusted by moving the carriage (and
the front and rear carriage guide shafts which hold the
the carriage moves as the PC motor rotates the shafts. The PG

movement (= gap) to the control circuit.

Rev.

A

printhead)

@rriage

either forward or backward. Because

are purposely mounted off-center,

sensor transmits the amount of

printhead. The

2-1

Operating Principles

Cl

Ribbon feed mechanism

DFX-5000+

Service Manual

The printer’s ribbon cartridge contains an endless ribbon. The ribbon feed mechanism takes up the

ribbon so that the portion hit by the pins is constantly changing. The RF motor drives the ribbon
feed mechanism. Figures 2-2 and 2-3 show the operation of the ribbon feed mechanism.

SHAFT, CR, GUIDE, REAR

PLATEN

GAP

ADJUSTMENT MOTOR

Inter Lock Switch

PRINTHEAD

CARRIAGE

MOTOR

L

,

I

&

1

I

I

11

I

I

I

I

I

2JJJJU

9

Platen

6

1,

II I

/

I

Gap Home Position

4

,

[

I

I

I

I

\

I

Carriage Encoder Belt

DETECTOR, CR

Sensor

Figure 2-2.

Cl

Paper feed mechanism

The CR motor controls printing in the horizontal direction, and the paper feed mechanism controls

movement in the vertical direction (line feeding and form feeding). The paper feed mechanism
feeds paper vertically. The PF motor drives the paper feed mechanism.

Printer Mechanism Operation 1

The front, rear, and top PE sensors detect whether paper is present in the paper path, and stop the

printer from printing when there is no paper. The printer is equipped with three PE sensors: the
front

PE

sensor at the front tractor, the rear PE sensor at the rear tractor, and the top PE sensor at
the paper bail. The pull tractor sensor detects whether the optional pull tractor is installed. The
printer is also equipped with a paper jam sensor. The control circuit reads the signals from the
sensors and indicates when an error occurs.

D

Tractor select mechanism

The printer mechanism has two paper entrances: one at the front tractor and one at the rear tractor.
By controlling the RF motor, the

txactor

select mechanism chooses which tractor to use, and power
from the PF motor is conveyed via a series of gears. The tractor select sensor detects the selected
tractor and signals that information to the control circuit.

D

Plunger mechanism

During printing, the paper bail assembly holds the paper under tension so that it is fed smoothly.
When paper is loaded or ejected or when the tear off function is executed, the paper bail assembly
needs to move up to prevent a paper jam. The plunger moves the paper bail assembly up. Figure

2-3 shows this operation.

2-2

Rev.

A

DEX-4XXW

Service

Manual

Opating Princ@ha

PRINTHEAD

SENSOR

Front Tractor

ASSY.,

PE,

FRONT

Sprocket

\.fi-

(

Paper

-SENSOR

TRASCOTR SELECT SENSOR

TRACTOR

ASSY.,

RIBBON FEED MOTOR

ASSY.,

SENSOR

PAPER JAM

SENSOR

Rear Tractor Sprocket

PAPER FEED MOTOR

PULL

ASSY., PE,

ASSY., PE,

UPPER

REAR

,..

:..,’;

.

.

c

‘1

Figure 2-3. Printer Mechanism Operation 2

2.1.1 Printhead Mechanism

The

printhead

is attached to the actuating spring at point A. It is pulled back (left in the figure) by magnetic
when power is applied and during standby. The magnetic force holds back the actuating spring.
When current flows through the
actuating spring ejects the dot wire fix-ward against the ink

+35VDCo

GNDo

Iron Core

is a charge-type, impact dot

/

. .

.

:

—

/////

Head Drive Coil

-——J

——-

/

A

/

./

\-

\

-+

A

LJ

pnnthead. 13gure 24

coil,

a

countermagnetic

shows its operation. The dot wire

field is

ribbcm,

MASK HOLDER (Cutting)

Ribbon

rnduced

printing a dot on the paper.

in the coil.

Then,

PLATEN

form

the

ASSY.

. . . .

(J

.,

Rev. A

Figure 24

Printhead

Operation

2-3

Operating Principles

DFX4000+ Service Manual

2.1.2 Carriage Mechanism

Figure 2-5 shows the carriage mechanism. The front and rear carriage guide shafts support the
carriage. The rotation of the CR motor is transmitted to the carnage timing belt through the
carriage belt pulleys at the right and left sides. The
attached to the carriage timing belt and moves horizontally.

The printer does not have a carriage home position sensor; the home position is detected using
disordered pulses of the CR motor and CR sensor (linear, belt-type). A gum pad is attached to the

left side of the frame. When the carriage hits the pad, the CR motor pulse is disordered by this
obstacle. The control circuit monitors the CR motor’s pulse; when it is disordered, the control
circuit recognizes the carriage home position.

The CR motor is equipped with an encoder unit which generates pulses. The encoder belt has
equally pitched slits and is mounted under the timing belt. A photo interrupter (encoder)
surrounds the encoder belt and converts the carriage movement into a pulse train.

HEAD DAMPER (LEFT) .

printhead

is mounted on the carriage, which is

SHAFT, CR, GUIDE, FRONT /

Carriage Encoder Belt

Figure 2-5. Carriage Mechanism

-’&ZZ.=

TIMING B~} CR~

9

2-4

Rev.

A

DEX-5Uk Servic@

2.1.3 Platen Gap Adjustment Mechanism

Man(ml

Oparathg Prlnclpks

Figure 2-6 shows the platen gap adjustment mechanism. The front and rear
supporting the carriage have a vertical

rear carriage guide shaft through the gears. Counterclockwise rotation of the motor expands the

platen gap and clockwise rotation reduces it.

The encoder plate with equally pitched slits is attached
rotates, the PG sensor detects it and outputs the pulses. Each pulse corresponds to detection of a

0.015 mm resolution (horizontal distance). The system range is O to 0.7 mm.

Mask less Holder

PLATEN

‘:ENASSEMBL%23P.-’.

wtion. The

rotation of the PG motor is transmitted to the

coaxially

to the motor axis. When the motor

SHAFT, CR,

carriage guide shafts

GUIDE,

REAR

PLATEN GAP

AJ’”

ADJUSTMENT MOTOR

Figure 2-6. Platen Gap Adjustment Mechanism

Platen Gap Encoder Plate

ON GEAR

NSOR

*

c=

Cw

Ccw

f--”

J

Rev.

A

24

Operating Principles

2.1.4

Paper Feed Mechanism

Figures 2-7, 2-8, and 2-9 show the paper feed mechanism. After you load paper, it is fed by the
tension roller, PF roller, and front or rear tractor assembly. The PF motor rotates the tension roller
and tractor select gear (Figure 2-7) and moves either the front or rear tractor assembly. The rotation
of the paper feed transmission gear rotates the tractor select gear, which can engage either tractor
train. The tractor select mechanism alternates the engagement of the rear tractor assembly gear
train and front tractor assembly gear train. (Refer to Section 2.1.5,

Mechanisms,

The front and rear PE sensors are incorporated in the tractor sprocket. When paper is loaded, the
paper pushes the leaf spring and blocks the photo interrupter. When no paper is loaded, the photo
interrupter is not blocked. The top PE sensor is attached to the upper paper guide and is used with
the reflection plate on the paper bail assembly. When paper is loaded, the paper surface reflects the
beam; when there is no paper, the beam is absorbed (not reflected). The pull tractor sensor
monitors whether the pull tractor is installed.

for more information.)

DFX-5000+

Ribbon

Feed

Service Manual

and

Tractor Select

SENSOR
TRACTOR

SENSOR
PE, UPPER

ASSY.,

Figure 2-7. Tension Roller and PF Roller Operation

ASSY.,

‘KG

M–

~D

ol~l

-1’

(’

@=-4/

(

w

. .

\

, ,

“)

1

APER BAIL LEVER

TIMING BELT,

TRACTOR SELECT

TRANSMISSION GEAR

PAPER FEED MOTOR

Pinicon Gear

PF

24

Rev.

A

Paper

TENSION ROLLER

TRACTOR SELECT
TRANSMISSION GEAR

PAPER FEED MOTOR
Pinion Gear

Figure 2-8. Front Tractor Assembly Operation

PAPER BAIL LEVER

SENSOR

ASSY., PE,

Tractor Sprocket (Front)

FRONT

TENSION ROLLER

SENSOR

ASSY., PE,

I

Tractor Sprocket (Rear)

, Paper

\

PAPER BAIL LEVER

FRONT ~ \ TRACTOR SELECT GEAR

k-i-l U.!!xtw”

~’”~y

t@j-)@;E:

/1

FEED MOTOR

. .

Rev.

Figure 2-9. Rear Tractor

A

Assembiy

Operation

2-7

Operating Principles

DFX-5000+

Service Manual

2.1.4.1 Tractor Wire Operation

The printer is equipped with a tractor wire (white line) to prevent paper jams when continuous
paper is loaded from the front or rear entrance. The tractor tension spring on the right side frame
pulls the wire and releases the stress on the continuous paper being fed. Figure 2-10 shows how the
tractor wire operates.

The front left tractor sprocket or rear right tractor sprocket is fixed in position by the shape of the
bottom frame of the printer mechanism, while the other sprocket (the front right sprocket or rear

left sprocket) can move along the tractor shafts. When the tractor release lever is released, the

sprocket can move smoothly side to side along the tractor shafts. When the tractor release lever is
engaged, the sprocket can move along the tractor shafts, but it cannot move smoothly, because the
tractor wire tension is valid.

In the Figure 2-10, point A shows the movement range of the left tractor sprocket when the tractor
release lever is released. Point B shows the movement range of the right tractor sprocket when the
release lever is engaged or released.

If the paper in the printer becomes bubbled, you can pull the tractor wire to the right to stabilize

the paper tension between the left and right tractor sprockets.

-1

A

—
.

(In case of Front Entrance)

B

Figure 2-10. Tractor Wire Operation

Tractor Wire

Tension Spring

>

nsion

24

Rev. A

DEX-5000+

Service Manual

2.1.5 Ribbon Feed and Tractor Select Mechanisms

operating

#%’fnclphe

@

.J&
,,

The RF motor supplies power to both the ribbon feed and tractor select mechanisms.
of the RF motor pinion swings the ribbon feed select gear like a pendulum, using the lever axis as
support point.
motor pinion gear rotates counterclockwise, the motor rotates the ribbon feed mechanism; when
rotates clockwise, the motor rotates the tractor select mechanism.

Figure 2-11 shows the ribbon feed mechanism.
Counterclockwise
ribbon &d select gear and ribbon feed transmission gear. The ribbon feed gear engages the

winding roller on the ribbon cartridge to feed the ribbon.

The

rotation of the RF motor is transmitted after the gears are engaged. When the RF

7he

ribbon is fed in only one direction.

rotatkm

of the RF motor is transmitted to the ribbon feed gear through the

The rotaticm

a

it

RIBBON

Iv

GEAR

N GEAR

Figure 2-11. Ribbon Feed Mechanism

;?5

. .

0

.

Rev.

A

24

Operating Principles

Figure 2-12 shows the operation of the tractor select mechanism. Clockwise rotation of the RF
motor is transmitted
transmission gear, and rotates the tractor select cam clockwise. The tractor select lever contacts the
inside curve of the cam due to the spring force; when the cam rotates, the tractor select lever moves
horizontally along the curve.

When the tractor select lever is set to the left, the tractor select gear engages the rear tractor
assembly train, and the PF motor rotates the rear tractor assembly. When the tractor select lever is

set to the right, the tractor select gear engages the front tractor assembly. The tractor select sensor

contacts the cam and closes when it reaches the convex portion.

to the tractor select

cam through the ribbon feed select gear and tractor select

DFX4000+ Service Manual

TRACTOR DRIVE
GEAR

---1
*EI*

—TRACTOR SELECT

TRANSMISSION GEAR

TRACTOR SELECT GEAR

HOLDER

–TRACTOR SELECT

LEVER LOWER

TRACTOR

SELECT

SENSOR

RIBBON FEED SELECT
GEAR

RIBBON FEED

MOTOR~

-TRACTOR SELECT
LEVER UPPER

[

=

-TRACTOR SELECT CAM

,

2-1o

\

Figure 2-12. Tractor Select Mechanism

Rev.

A

DFX-5LXXI+

2.1.6 Plunger Mechanism

Service Manual

Operating

Prfnc@laa

Figure 2-13 shows the plunger mechanism. The paper bail assembly is attached to the
plunger’s iron core. The paper bail assembly axis is connected to the frame. When the plunger coil
is energized, the force of the paper bail spring returns the paper bail assembly to ik original
position.

PAPER BAIL LEVER

I
I

tmd

of the

\’

Figure 2-13. Plunger Mechanism

.,,

0

Rev.

A

2-11

Omratinf7

Principles

2.2 POWER SUPPLY OPERATION

DEW5000+

Service Manual

The printer can be powered by either of two power supply boards: the 120 V

assembly or the 220/240 V

PSE C117

board assembly. The only difference in the operation of these

C117 PSB

board

two boards is in the primary circuitry. They supply power to the printer in the same way. The

power supply board outputs the DC current required to drive the control circuits and printer drive

mechanis-rn.

Table 2-1 shows the input voltages and fuse ratings of the boards.

Table 2-1. Power Supply Boards

Board

Cl

17

PSB

board assembly

Cl 17 PSE board assembly

Input Voltage

100-120

220-240

VAC

VAC

Fuse Ratings

6.3

A1250

VAC

12 A/125

VAC

2.2.1 Power Supply Overview

Figure 2-14 shows a block diagram of the power supply board.

—

—

—

Surga-cut

Circuil

o

1

t

}

Recfifiar

circuit

Smoothing

circuit

a

~

swhching

t

swtching

r

Smoothing

Circuit

Smoothing

Circuit

a

Main

Circuit (1)

Main

Circuit (2)

rll

Transfosrmar

Figure 2-14. Power Supply Board Block Diagram

+3SV

a

a

Drop

Circuil

A

—

rnontor

a

T

+3SV

Over

Protection

\

Circuil

r

)

.

J

vdtqa

‘+’”

VPC signal

O

O

~ CLIMIT

signal

+3SV

GP

or 13V

&

)

DRERR

)+

S@’ld

2-12

Rev.

A

DFX-5000+ Sendee Mama!

The

power supply board converts the AC voltage to the DC voltages required to operate the

printer. The AC voltage is input to the AC inlet, and is supplied to the

e

assembly via the power switch and fuse.
to the three DC voltages (+35 V,

The

power supply board contains two +35
two sections.) One +35
and 9); the other +35
and to the motors.

These switching regulator circuits perform voltage control and over-current limiting for each

voltage. They supply or cut the DC voltage based on the

C117

MAIN board assembly, and output the

exceeded its duty cycle (the
The

Cl17

power supply board assembly includes a cooling km that is driven by the +35
fan lowers the temperature of the circuit components, and is located under the carnage motor so
that it also lowers the carriage motor temperature.

VDC

VDC

+5

line supplies power to six of the nine

line supplies power to three of the nine

printhead

l’hree

switching regulator circuits convert the AC voltage

V, and +/-12 V) required to operate the printer.

VDC

creation circuits.

CLIMIT

temperature is too high).

(Power Down) signal when the printer has

DRERR

(Ike

printhead

printhead

(Driver Error) signal from the

O~atfng Princi@aa

C117

power supply board

+35

VDC

line is divided into

pins (pins 1,3,5, 7,8,

pins (pins 2,4, and 6)

VDC. The

m

%i;’

To prevent a surge in the current, the power supply board cannot recover for approximately
minutes after the power is turned off. Therefore, after the printer is turned off, wait three minutes
before you turn it back on.

The specifications for the

C117 MB

Before using a different AC power supply, replace the fuse and power cord.

or 220/240 V

Voltage Rated Current

+35

V

(CN2)

+35

V

(CN4)

+5 V

(CN3)

C117

power supply board assembly depend on the board type (120 V

C117 PSE).

Table

2A

2A

1.0 A

2-2. DC Voltages

Q Printhead

Q

CR motor drive

Q

PF motor drive

Q PG

Q

RF motor drive

Q

Plunger drive

Q

Head fan motor drive

Cl Fan power for

O

All

assembly and Cl 17 PNL
operating voltages)

Q

CR motor hold voltage

Cl

~U~W

Q i%
0

Power for ail the sensors

drive

motor

motor hold voltage

drive

Iogio

systems (Cl 17 MAIN board

hold

Application

coding

the CR motor

vda~

bad

~w

thee

.:.

-

,.,

.*

,

,,

c)

Note:

Rev. A

+12 V

(CN3)

-12 V

(CN3)

Before the power supply board outputs +35
drivers on the

printhead

C117

damage.

0.1 A

0.1 A

MAIN board assembly. ‘This procedure is a driver check to prevent

Cl Cl

17 MAIN board assembly operating
voltage (serial interface conversion and
Type

D F~

VDC,

B optional

trigger for

it outputs +13

interface voltage supply)

printhead

firing

VDC

to the

printhead

2-13

Operating Principles

2.2.2 +5 VDC Line Regulator Circuit

The

+5

VDC

line regulator circuit uses a ringing choke coil

DFX-5000+

(RCC)

system DC/DC converter.

Service Manual

-

A

IC151

(TL494)

C2 cl

+12

+11

1

Zk

PRIMERY

CIRCUIT

Figure 2-15. +5

The rectified and smoothed DC voltage turns on the +5
When the +35

The power supply board uses a 2-step rise method. When the printer is turned on, the +35
line outputs
drivers on the

If

a

printhead

VDC

line becomes +13 V, switching regulator IC

+13 VDC

C117

for 140

ms.

The first rising voltage

MAIN board assembly.

driver is damaged, the control board outputs the error signal (HIGH

VDC

Line Regulator Circuit

VDC

line first.

TL494 (IC151)

(+13 VDC)

is used to check the

+35VIX
b

C,,

I’.,.

+3VUL,

)-P

-

ZD153

HZS7B-2

RIM

is a starting resistor.

creates a +5 V line.

printhead

DRERR

VDC

signal)
to the power supply board. When the power supply board receives this signal, the photo-coupler is
turned on and it cuts off the voltage of the primary side. This prevents

printhead
VPC

rises to +35

driver is damaged. If the

printhead

drivers are normal, the control board outputs the

signal to the power supply board. When the power supply board receives this signal, the line

VDC

after 140

ms.

printhead

damage when a

me

+5

VDC

regulator circuit includes the following:

D

+5

VDC

line over-voltage protection circuit

If the +5

phot~coupler (PC2)

common circuit with the

D

+5

IC151 (TL494)

comparator is used for over-voltage control.

VDC

line exceeds +7

VDC,

the current flows to

is turned on, and the voltage of the primary side is cut off. This circuit is a

DRERR

VDC

line over-voltage control/over-current control circuit

includes this control circuit.

signal feedback circuit on the

IC151

contains two internal comparators. One

Pin

16

(+12)

ZD153.

Then Q155 is turned on, the

C117

MAIN board assembly.

monitors the +5

VDC

line. If this voltage
exceeds +5 V (pin 15), internal comparator 1 outputs a HIGH signal. The other comparator controls
the +5 V

Iine

over-current. Pin 1

(+11)

monitors the current of the +5 V line. If the current exceeds

the set value (pin 2), the voltage becomes HIGH and comparator 2 outputs a HIGH signal.
Both the comparator 1 signal and comparator 2 signal are tied by the wired OR. If the output signal

is HIGH from either comparator, the output signal is HIGH. This switching procedure monitors the
Cl and C2 ports. These switching waveforms are controlled by PWM (Pulse Width Modulation),
which changes the level of the inverse terminal of comparator

Cl Printhead

This circuit prevents
turned on, the
the

printhead

If a

printhead
C117

signal, it stops creating +35
board

driver detection circuit

printhead

C117

MAIN board assembly tells the

damage when a

drivers are normal.

driver is damaged, the

C117

MAIN board assembly sends the

power supply board assembly. When the

VDC

assembIy

sends the

and +5

VPC

signal to the

VDC.

C117

If the

printhead

C117

C117

power supply board assembly receives this

printhead

power supply board assembly. When the

power supply board assembly receives this signal, it creates +35

1

and comparator 2.

driver is damaged. When the printer is

power supply board assembly whether

DRERR

drivers are normal, the

signal to the

C117

MAIN

C117

VDC.

2-14

Rev.

A

DFX-5000+

Service Manual

operating

Principbe

,,p:..

,

“:.>..

(“

2.2.3 +35

When the printer is turned on and the

VDC

line rises from +13 V to +35 V. The +35
AC input switching power circuit. This system uses few parts and a small transformer, and is
used when a small power supply is required.

Figure 2-16 shows the +35
flows to the gate of switching FET

D251

on the secondary side of T1 and T2 prevent current flow in the
turned on, the primary side of transformer coil
voltage in windings
side of the transformer coil.

VDC

Line Regulator Circuit

C117 MAIN

VDC

W-4

and ‘12-3. When

o

o

Main

sWching

Circuif

(1)

Filter

Clrcuk

Smmthing

Clrcuif

main switching circuit. When power is applied, drive current

line

(Q101)

via starting resistor

Surge-cul

Circuit

H

a

board assembly

VDC

line arcuit uses a ringing choke

T2-3

receives an

Q101

is turned off, the

R9ctifbr “

arcuit

H

a

smoothing

C&wit

H

sends

R118.

Diodes

secondary side. When

rnput

currmt

h

a

--0 +35
O

the WC signal, the +35

mnvertor (RCC)

ok

D157, D156, D151,

voltage, which induces

flows to the

and

QIOl

wamdary

I

al%

T

VDc

GP

-

OREFIRS@d

is

. .

.

.

.

{

. . .

c’

Over Current
Protection
Circuit (IC101,2O1)

Main switching

Transformer

Figure 2-16. +35

Smcdhing

Cimllit

+/-13

v

(ZD151,181 / ZD1S2-1S5)

+35 WC Drop Monitor
ckcuii

(NJM2903)

VDC

Creatial

a

Line Regulator Circuit

0--0

+35V

O/er Volmga
Prokxiorl

(91s3,0353)

Ck4it

0-

+35

VDc

o

GP

O ~ CI.MT signal

WC

Sigrui

c

)

Rev.

A

2-15

Operating Principles

Dl%Y4iOOO+

Service Manual

The +35

D

IC101 and
the current does not flow into the shunt regulator. When the over-current flows to the input
voltage line, the shunt regulator is turned on,

Q101 (Q201)

Q

If the +35

turns on
time, the delay timing creation circuit (CR circuit) consisting of

timing.

circuit; if it is operated during the
turned on. The CR circuit has approximately a one-second delay timing.

Cl

When the +35

printhead

1.3

two +35

Cl +13

When the printer is turned on, the
the
assembly sends the
power supply board assembly. If the
is turned on, and Q181 is turned off. Therefore, six
motor driver check, the VPC signal is LOW. When this signal is LOW, Q182 stays off, the base of

Q182

VDC

regulator circuit includes the following:

Input voltage line over-current protection arcuit (primary side)

IC201

detect the input voltage of the primary circuit. When the input voltage is normal,

Q103 (Q203)

is turned off.

+35

VDC

line over-current protection circuit

VDC

line drops to +13

Q153 (Q253). Q154

When the printer is turned on, the delay timing creation circuit cannot start this protection

+35

VDC

powerdown detection circuit

VDC

temperature is too high), the voltage of PC101 approaches O

VDC, IC152

VDC

printhead

stays HIGH, and then two Zener diodes

outputs a HIGH

VDC

line creation circuits.

creation circuit

drivers on the

is turned on, PC2 is turned on, and then the input voltage is cut. At this

line drops (such as, when the printer has exceeded its duty cycle and the

DRERR

VDC,

the sensor circuit consisting of

printhead

CLIMIT

C117

C117

MAIN board assembly. After 140 ms, the

(driver error) or the VPC (+35

printhead

driver check, the power supply board cannot be

signal to the base of transistor

power supply board assembly creates +13

drivers are normal, the VPC signal is HIGH,

Zener

(ZD151

and

and

Q102 (Q202)

R172 (R272)

C157 and

VDC.

VDC

permission) signal to the C117

diodes create the +35

ZD181)

output +13

are turned on, and

R174

If the voltage drops to

Q187. IC152

C117

VDC.

and

R173 (R273)

makes the delay

monitors the

VDC

to check

MAIN board

VDC.

During the

Q182

2.2.4

The power from the half-wave rectifier smoothing circuit is mainly supplied to the RS-232C
interface on the standard or optional board and uses the
and -12

C182

+/-12 VDC

VDC

and

Over Current
Protection

Cimuif

(ICI01,201)

Half-wave Rectifier Smoothing Circuit

printhead

lines have a half-wave rectifier circuit. This smoothing circuit consists of capacitors

C181.

Two Zener diodes stabilize the *12

o
o

4

)

Main switching

Circuit (1)

FMer

I

TF

Transfmxmer

Circuit

Smoothing Circuit

+

I

–

surge-cut

Circuit Circuit

(C181,182)

:

VDC

line.

Rectifier Smoothing

+

DerM3dvoltage

Conttd arcut

==

ZD187,1SS

=

❑

fire trigger. Both the

C+

Icuit

I

J

-12VDC Cteation

ci!:~=l~)

+12VDC

Creation

Circut

“

(QIS3,184)

~

+12 VDC

Smoothing Circuit

(C1SA3,161)

+

o

o

+12

-12

VDC

WC

2-16

Figure 2-17. Half-wave Rectifier Circuit

Rev.

A

L,,,,

DEX-5000+ Servics

Manual

2.3 CONTROL CIRCUIT

@wating

*“ncipba

~....,

..

c\

,..

%

Figure 2-18 shows a block diagram of the control arcuit with the

center.

2.3.1 Control Circuit Operation Overview

The core of the control circuit is the
external clock
external PROM
external device

memories. The CPU also
as the tear off position, while the printer is turned off. The CPU controls all the printer operations
via the peripheral
ports. The CPU controls the
Input/Output).

The main functions of the

decodina printhead driver control, carriage driver control, encoder pulse arcuit control, PG and

fan motor phase signal creation, interface control, CR and

control, reset signal creation, control signal creation for the power supply board, control of the

LEDs

on the Cl 17 PNL board assembly, and reading the DIP switch settings.

Signals, such as DRERR, VPC, and
board assembly to provide back-up control of the non-volatile memory (when the printer is turned
off) and control of the power supply voltage. When the
power has been turned off (or that the power supply voltage has dropped), the CPU turns off the
power supply voltage from the
signal.

(CRU1).

(IC4).

The CPU executes programs stored in the internal mask ROM and IM

The CPU starts executing a program upon

(IC8, IC9).

ICS

The CPU accesses the internal RAM and external

contTols

and controls the printer

E05A87

E05A87

TMP96C14

the non-volatile memory

gate array

gate array are: ~ (Chip Select) signal creation, address

CLIMIT

C117

power supply board assembly by outputting the

CPU

(IC1).

mechanism

(IC7)

via the address bus

(power down), are

CLJMIT

C117

MAIN board assembly at the

This CPU is driven using a 14.74 MHz

r-iving

(IC2)

used to store the parameters, such

and interfaces by writing directly to the

PF

motor driver abnormal sensor

comected

signal informs the CPU that the

the reset signal from an

P$RAM (256K)

(MMIO:

to the

Memory Mapped

arcuit

C117

power supply

CLIMIT

The reset circuit outputs the reset signal when the printer is turned on or off, the voltage level
drops, or a reset signal is input from an external device. It resets the control circuit for a certain
period directly or via the

E05A87

gate array.

L

.

.

. . .

Rev.

A

2-17

Operating Principles

DEX4000+ Service Manual

P-ROM

(IC4)

I

m

~

Address Bus

=

Data Bus

CPU

TM

P96CI

41

(lCl)

,

Q28 - Q31

-’l

I

1 1

SLA7026M

-’i

m

(Icll)

L

Each Sensors Circuit

1.PE(top)

4. Paper Jam

6.PuII

8. Cover Open 9. Paper Wide

10.Fan

11

12. Head Temperature

13.MOTOR,PF

14.Drop

(from BOARD ASSEMBLY, C117PS)

2.
Tractor 7. Tractor Select
Temperature

.MOTOR,

Error Signal Detection

t--

1

t-

PE(front)

5.PG

CR isolation

Watch Dog Timer

MOTOR, RF

MOTOR,

3.

PE(rear)

Home position

PF

Standard/Optional

Interface

I

BOARD ASSEMBLY,
Cl 17 PNL

I

SDC03(QM2)

-1

Q17,Q18

ZICR

I

1

k

-

I

I Each Sensors Circuit

1

A

Q26,22,10,13,16,

14,18,20,21

1.PG encorder sensor

2.CR encorder

3.

PRINTHEAD

1

FAN

P

sensor

thermistor sensor

MOTOR,PG

PLUNGER

Interlock

itch

L

------+ PRINTHEAD

1

I

2-18

Figure 2-18. Control Circuit Block Diagram

Rev.

A

DFX-5000+ Servics Mimml

Figure 2-19 shows the data flow for data input via the parallel interface. Although various circuits
perform data processing, the control core
In this circuit, the gate array

and the CPU, and all data processing is performed by read/write operations to

Mapped Input/Output).

IC (IC7)

is

the CPU and all operations are executed via the CPU.

provides the interface between the external heat computer

0per8thg Ffinchl&e

MMIO

(Memory

, .:

$

a

Data from the host computer is latched by

1. Upon receiving the STROBE signal,
signal to HIGH.

2. The CPU reads the latched data from the
command (CR code), and stores it in the input data buffer if it is not.

3. After checking the data, the CPU makes
signal, via the
becomes full, the CPU sets the BUSY signal to HIGH and executes printing.

STROBE

DATA .: DATA

BUSY or

m

IACK

w

MMIO

E05A87

1

40

. . . . . . . . . . . . . . . . .

accesses. When either a CR code is received or the input data buffer

(IC7)

.

.

,..

-:

+

+r-,

‘*A

I

repeating

IC7

latches the data into ports

IC7

CPU

(ICI)

2

o

CR command ?

e

Yes

..+---------

‘u(lCl)

.

.

.

..

.

.

.

.

..

.

.

Command

Analyzer

steps 1 through 3 below.

MMIO pcx%

clear the BUSY signal and output the

0

DATA

‘)

. . . . . . . . . . . . . .

I

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

4

checks whether the data is a print

PS-RAM

Buffer Full.

Yes

o

L

d

DIOO

- 7and sets the BUSY

(IC3)

Input

Data

Buffer

ACKNLG

AHribute

el-

Character Generator

Printer Mechanism

Driver

8

T

Figure 2-19.

4.

The

CP[J reads the data from the input data
is a character or a co
character codes and 2-byte attributes. Character data is stored as character codes and
commands or character types are stored as attributes.

remand, and converts it to print data. The print data consists of l-byte

D8tti

flow

o

I

from the Parallel Interface

buftkr,

I

analyzes

+

. . . . . . . . . . . . . . . .

Down Load

eacii

byte to determine whether it

““;

Image Buffer

I

?1

I

Rev.

A

2-19

Operating Principles

DEX4000+

Service

Manual

5. The

6.

print data is stored in the line buffer in units of one line of data.

The CPU reads the print data stored in the line buffer byte by byte, accesses the CG (Character

Generator), and expands the data in the image buffer (in the case of download characters, in
the download

CG).

A row of expanded data is output to the

printhead

control circuit as head

data.

7. When data is expanded to an italic or super/subscript character, the CPU uses
via

MMIO.

IC7

to expand it

8. The CPU controls the CR motor by calculating the control data for each line from the print data

in the line buffer. When a paper feed command is sent after one line is printed, the CPU
executes paper feeding.

For NLQ characters, printing one line consists of two passes; the printer performs steps 6 through 8
twice. When the CPU expands the data from the CG in the image buffer, it uses the 24-bit shift
register in
interrupt-to-fetch operation.

IC7.

The CPU is always ready to fetch data so printing can be viewed as an

Whenever the input data buffer is not full between printing

operations, data is fetched. Table 2-3 describes the functions of the main printer components.

Note:

The data flow from the serial interface is the same as the data flow from the parallel
interface, described above, except the signal names and data access method differ.

Table 2-3. Main IC Functions

IC

Name

Location

Functions

TMP96C141

(CPU)

E05A87

PROM

PS-RAM

SLA7026

Icl

IC7

IC4

IC3

ICI

1

Receives data from the host computer via the gate array,
loads the data to the input buffer in

PS-RAM,

and converts the

image data to print data.

Th&main E05A87
Q CS

(Chip Select) signal creation

D

Address decoding

Q

Address latching

Cl

Clock pulse creation (divided from the CPU clock)

Q Printhead
D

CR motor driver control

LI

CR and PG motor pulse encoder l/O (input/output)

Q

Encoder pulse

Q

Phase signal creation for the motors

Q

i/O port control

Q

Interface control

Q

Abnormal CR and PF motor detection

Q

RESET signal creation

Q

Control signal creation for the power supply

features are:

driver control

1/0

board

PROM
Contains the program that runs the CPU.
Holds the CPU working area and buffers

(input, line, and image buffers).

Drives the RF motor and controls the constant current.

SDC03 QM2

NJM2903

SLA5007

2-20

Iclo

QM1

Drives the PG motor.
Detects the current in the CR motor driver and feeds it back to

the gate

away.

Drives the CR motor.

Rev.

A

OEX-5000+ %rvica

2.3.2

Reset Circuit

hfimual

Optuating Prfncipka

This section describes the hardware reset circuit. When the hardware reset signal is input, all

the control circuit are reset, and the CPU executes the program from the starting address. Figure

2-20 shows the reset arcuit block diagram.
The printer is equipped with two reset

M51955

Cl

Reset IC

VDC,

gate array outputs the RESET signal to the reset port of the CPU and
the delay control arcuit (CR circuit). The delay
the reset timing for the CPU and Type B interface card.

Cl

Reset
approximately 1.7
the 22.9 V to 30.0 V range.

If this voltage
port. When the printer is turned off, this circuit operates and

is used for resetting the +35

+5

VDC

reset

arcuit

PTS591D

the reset IC outputs a LOW signal to the CPU, gate array, and optional interface board.

+35

VDC

IC M51955

monitors the +5

reset circuit

monitors the +35

VDC

level

drops to +125

VDC

to pin 2. When the detection

VDC,

r!

I

ICS: PTS591D

VDC

line. These reset

VDC

line on the

line. Normally, the dividing resistors (R27 and

the RESET signal (LOW level) is output to the CPU’s

R2a

-r

Cn

777-

is used for resetting the + 5

ICS

are described below.

C117

MAIN board assembly. If it drops to 42

also to the

cxmtrol

circuit cmsists of

level

is 1.7

VDC,

the +35

manages writing to the

gate array itself, via

R26

and C72 and

VDC

i

VDC

line drops into

EEPROM.

ICS

line and

l’he

controis

R28)

input

NMI

in

R2S

21

I

n

2

mEsin

INMI

’

CPU

TMP96C141

(ICI)

Figure 2-20. Reset Circuit Biock Diagram

i

.-

Rev.

A

2-21

Operating Principles

DFX-5000+

Service Manual

2.3.3 Sensor Circuits

Figure 2-21 shows the sensor circuits in block diagram form. The printer is equipped with the
following sensors:

Front and rear PE sensors (use a photo interrupter)

1.
Top PE sensor (to detect the TOF position, uses a photo interrupter)

2.

Paper jam sensor (uses a magnetic transistor)

3.

Tractor select sensor (uses a micro mechanical switch)

4.

Pull tractor sensor (uses a micro mechanical switch)

5.

Cover open sensor (uses a micro mechanical switch)

6.

7.

CR encoder sensor (uses an LED and photo diode)

PG

8.

9.

10.

11

12.

13.

14.

sensor (uses a photo interrupter)

PG

home sensor (uses a micro mechanical switch)

+35 VDC voltage drop sensor (signal interface)
Head temperature sensor (uses a thermistor)
Fan temperature sensor (uses a thermistor)

PW sensor (uses a photo reflector)
Carriage motor isolation resistance sensor (monitored by the analog port of the CPU)

CPU

TMP96C141

(lCl)

71

47

48.6850,

(

1

n

-3
n
)
3

72

LJ

67

32,

65

51

84 18

T

76

26,

>>>

Zzz

Iv- 0

753<74

19/

73

2-22

Figure 2-21.

Sensor Circuit

Block Diagram

Rev.

A

DEX-5000+ Setvice

Manual

Each sensor is described below.

1. Front and rear paper end sensors

L1

Detection form:

Q

output form:

LI

Input circuit:

Cl

Logical:

Photo interrupter
Open collector (pulled up to 10
CR filter circuit (10

Paper present: LOW
Paper out: HIGH

Kfil

and 39

Kfi2

resistance)

pF)

C)pmWng Pn”nc@&a

2. Top paper end sensor (to

Cl &?te&ion
c1

output form:

form:

Cl Input circuit:

0

Logical:

Photo reflector
Open collector

CR filter circuit (10
Paper present LOW
Paper out: HIGH

3. Paper jam sensor

~

Detection form:
c1 output form:

D

Input arcuit:

Ct

Logical:

Magnetic transistor
Rectangle wave (1 channel, TTL level)
Resistance for latch up prevention (10
Paper feed: Level changes continuously.
Paper jam: Level remains the same.

LI

Supplement:

The magnetic transistor is attached to the tension roller on the paper tension

unit.

4. Tractor select sensor

D

Detection

Cl

Input circuit:

tirm:

Micro mechanical switch
Resistance for latch up prevention (10

Pulled up to 390

a

Logical:

Front tractor: LOW (closed)
Rear tractor: HIGH (open)

5. Pull tractor sensor

Lt

Detection form:

Ct

Input arcuit:

Micro mechanical switch
Resistance for latch up prevention (10
Pulled up to 390 f2 resistance

L1

Logical:

Pull tractor installed: LOW (closed)
Pull tractor not installed: HIGH (open)

detcd

the TOF position)

Kf2

and 39

f2

resistance

pF)

KQ)

Kf2

I@)

)

6. Cover open sensor

O

Detection firm:

Q

Input arcuit:

u

Logical:

7.

Carnage encoder sensor

Cl

Detection form:

Ct

Input arcuit:

LI

Transaction:

Micro mechanical switch
CR filter arcuit (10 KQ and 0.01

I@

Pulled up to 390 Q resistance
Cover closed: LOW
Cover open: HIGH

LED and photo diode

Rectangle wave (2-phase,
CR filter
Pulled up to 10

arcuit (10

Kf2

resistance

Kf2

and 390

Tll

level)

pF)

The carriage encoder outputs two pulses (A or B) to the gate array and the

gate array tells the CPU which signal it receives.

Rev.

A

2-23

Operating Principles

8.

Paper thickness sensor

D

Detection form:

Cl

Input circuit:

Photo interrupter
Rectangle wave (2 channels, TTL level)
CR filter circuit (10 KQ and 390

Cl PG

ability:

D

Sensing range:

9.

Platen gap home position sensor

D

Detection form:

Ct

Input circuit:

0.015 mm/pulse
O to 0.7 mm

Micro mechanical switch
Resistance for latch up prevention (10

Pulled up to 390 ~ resistance

pF)

KCt)

DFX-5000+

Service Manual

10. +35

VDC

voltage drop sensor (signal interface)
When the +35

CLIMIT

signal to the

VDC

line voltages drop, the

C117

MAIN board assembly.

C117

power supply board assembly sends a HIGH

11. Head temperature sensor (uses a thermistor)

Cl

Input circuit:

12. Fan temperature

Cl

Input circuit:

Pulled up to 3.32
CR filter circuit (1

sensor (uses a thermistor)

Pulled up to 3.32
CR filter circuit (1

KCl

resistance

KKt

and 0.1

Kf2

resistance

K$i2

and 0.1

pF)

p.F)

13. Paper width sensor

Cl

Detection form:

D

Output form:

Cl

Input circuit:

D

Judgement:

Photo reflector
Emitter follower

CR filter circuit (10

KLt

and 0.01

pF)

No paper present: Standard voltage level.
Paper present: The voltage level is double the standard voltage level.

14.

Carnage motor isolation

To provide information about the carnage motor life, the analog port

resistance sensor (monitored by port

ANO

of the CPU)

(ANO)

of the CPU checks
the isolation resistance every time the printer is turned on. If the isolation resistance is less than

1QKC2,

a

carriage

error is detected and the printer beeps. (Refer to Section 1.4.15,

lluzza

Operation.)

2-24

Rev.

A

DEX-5000+ Sawka

2.3.4

CR Motor Driver Circuit

Manual

Opwatfng

Prh@aa

Figure
the CR motor driver circuit. An SLA5007 bipolar driver IC drives the CR motor. It has built-in
bipolar switching transistors and a current limiter. A

current in the CR motor driver

the gate array

transistors
When the printer is turned on, CPU analog port

motor at once. If the isolation resistance is less than 1
If the printer cover is open at power on, the CR motor driver power is cut. The

the carriage encoder outputs is input to general purpose port

ENC-B pulse that the carriage enmder outputs is input to general purpose port

array. The gate array
and direction of motor rotation.

Table 2-4 lists the CR motor drive modes. The printer has three deceleration control modes.
degree of deceleration is determined by how the carriage motor transistors are driven.
describes how the transistors are driven for each mode.

2-22

shows the internal circuit for the CR motor, and Figure

comparator IC

(E05A87),

(Q4,

Q7, and Q8).

IC (SLA5007). If

and then the gate array outputs the

munts

these pulses using the internal

al

the current exceeds the set value, it is &i back to

ANO

measures the isolation resistance in the CR

IQ

the CPU sounds the buzzer.

signal

ENCA

munter

2-23

shows

a block diagram

(NJM

2903) monitors the

for the current setting

ENC-A pulse

of the gate array, and the

ENCB

of the gate

and determines the amount

TabIe

fir

that

lhe

2-5

04

,

,

Figure 2-22. CR Motor Internal Circuit

Intwloek

E05M7

(IC7)

gm
o g

CR

A

‘

. . . . . . . . . . . . . .

~r-

=

-0

L

I

m CR B

.

9-7=

VP

+-

SLA5007(0Ml)

PB

1

Ps 1

-

B

PB2

Ps 2 “

AiN-

1

+s

+

1

AIN+

k(--l

w

Cmlqo

●

ncodor

smwor

~

CRA

Cmiago

CRA
CRB
CRB

v

motif

D

E

&-

L’

QP

CPU TMP96C141

(ICI)

ANO

i

,

Rev.

Figure

A

2-23.

N

CR Motor Driver Block Diagram

2-25

Omwatina

Principles

DEWOOO+

Table 2-4. CR Motor Drive Modes

Service Manual

Division

Carriage
moves with
printing.

Note 2

Drive Mode

Super draft
Super drafi-HD
Draft

Draft-HD

Bit image 1

Bit image 1–HD
Bit image 2
Bit image 2–HD

M%!or

~r~me

1680

1600

1260

1200

1050

1000

945

900
Bit image 3 840
Bit image 3–HD

800
NLQ

NLQ-HD

Bit image 4

600

525

Acceleration/Deceleration

Control Curve

Acceleration or deceleration
control

cutve.

Acceleration control curve
only. Deceleration mode 3
controls deceleration.

Note 1

Constan

Speed

Control

PI control

Bit image 4–HD 500
Home position

Carriage
moves without
printing.

Note 3

seek
Pa er width

de~ction

seek
Logical seek 1
Logical seek 2

Note 1:

Table 2-5 describes Deceleration mode 3.

Note 2: This division applies to all printing modes. PI control oversees

315

m

630

1260

theconstant

speed.

(Refer to page 2-32 for more information on PI control.) For increased throughput, this

division allows printing during acceleration and deceleration.

Note 3: This division increases throughput when the carnage is moving and the printer is not

printing.

Note 4: Carriage motor internal coil resistance: 6.2 G? *0.45

~

2-26

Rev. A

DFX-5000+

Service Manual

Table 2-5. CR Motor Drive Sequence

Operating

Pdncipbs

(

..-.

“

Carria#~T~;sfer

Driving Mode

Driver (Refer to Figure 2-22.)

Q1

Q2

Q3

Acceleration On

Left -+ Right

Deceleration 1

on

Deceleration 2

on
On

On

Right + Left

Deceleration 3
Acceleration
Deceleration 1

on
On

Deceleration 2

LI

PI control

Deceleration 3

on on

PI control keeps the carriage motor speed constant using the following steps:

1. CN1O outputs two encoder pulses (ENC-A and

2.

Thegate

3.

The

4.

CR ports A, B, and C output the drive signal for the CR motor.

Q

Acceleration control

array selects

CPU outputs the

speed to the

PWM

oneofthe twopulses

PWM

(pulse width modulation) signal according to the carriage motor

and sends the signal tothe CPU

port of the gate array and determines the duty of the carriage drive timing.

ENC–B)

to

thegatearray.

INIT4

04
On

on

on

port.

Until the carriage speed reaches the constant speed set by PI control, acceleration control

determines the speed of the carriage. The printer can print while the carriage is accelerating.

The

carriage speed moves to constant control speed smoothly to prevent the CR motor from exceeding
the constant control speed. ‘l’he

E05A87

gate array controls the motor driver

(SLA5007),

which

performs the current chopping. Figure 2-24 shows the acceleration control curve.

SFlet

, .

t

\

. .

s%?

SPl

o

MYxleratiofl

B

decderaiion

r

2

Figure

2-24. Acceleration Control

Cuwe

Note:

Rev.

In Figure 2-24, the acceleration curve is labeled A and the driving modes are labeled B.

A

2-27

Operating Principle

DFX-5000+

Service

Manuai

SpeeciO

1.

2.

SP1

1.

-

SP1

It causes the carriage to accelerate.
Because the control circuit measures time periods with the encoder signal, when the carriage

speed reaches

-

SP2

The

DFX-5000+

SP1,

it changes to the next sequence

(SP1

-

SP2).

printer has a table programmed into its main program ROM to determine the
duration of the acceleration pulses. This table is called the duty data table. Duty data is divided
into ten sections, plus
duty data for acceleration control. Pulse width modulation

Dutymin.

Section 1 is the largest, and

Dutyti

(PWM)

represents the minimum

determines each section
number. For each section, the carriage motor driver is turned on part of the time and off part of
the time.

2.

When the carriage speed reaches

SP1,

the printer uses the acceleration driving mode, based on

the duty data, and the rest of the time, it uses Deceleration driving mode 2. (Refer to Table 2-5.)

3.

During this time the control circuit measures time periods using the encoder signal, and

controls the following:

Cl

When duty data becomes

carnage speed reaches

D

When the carriage speed reaches

(SP2-)

takes effect.

SP2

-

Duty~ti

SP2,

before the carriage speed reaches

the next sequence

SP2

before duty data becomes

(SP2-)

takes effect.

SP2.

Then, when the

Dutyfi, the

next sequence

When the carriage speed reaches

D

Deceleration control

SP2,

PI control oversees the carriage speed.

Deceleration control provides smooth deceleration and prevents rapid vibration.

; ;
~ ;
,,
;;

: :
: :
: :
! :

: :

Decalaratica

3

B

4

Deceieratbn
Dacalf%on

2

1

:

1

1

msec

PWM parcdic

time

Note:

2-28

Figure 2-25. Deceleration Control Curve

In

Figure 2-25, the deceleration curve is labeled A and the driving modes are labeled B.

1,2, and 3 indicate the

PWM

control section number.

Rev.

A

Current speed -

SP3

1. The

duty data for deceleration control is determined for each printing mode beforehand and

programmed into a table in the main program ROM.

Duty data is divided into 19 sections, plus
represents the minimum duty data for deceleration amtml. Pulse width modulation

Dutytil.

Section 1 is the

largest,

and

Dutytil

(PWM)

determines each section number. For each section, the carriage motor driver is turned on part
of the time and off part of the time.

2. The printer uses Deceleration driving mode 2, based on the dutydata, and the rest of the time,
it uses Deceleration driving mode 1. (Refer to Table 2-5.)

3. During this time the control circuit measures time periods using the

controls the

Cl

When duty data becomes

Q men

(SP3

SP3

-

Speedo

1. When the carriage speed reaches
method is the inve

2. During this time, the control
rising edge of next pulse is not detected after

effect and the control

Q

High temperature detection sequence

followirqy

the

arriage

-

SpeedO)

Dutytil betbre

speed reaches

takes effect.

rse-continuity

arcuit measures time periods

arcuit

controls short-break.

the carriage speed reaches

Sp3

befire duty

SP3,

Deceleration driving mode 3 takes effect. This control

data kmes ~tytil, me next sequ~

break method.

usrng

the encoder signal. When the

seconds,

13

Deceleratkm

enmder

signal, and

SP3.

driving mode 1 takes

The software supports a high temperature detection sequence, which consists of the

tbllowing

steps:

A unit of one section is 72.5

1.

ms.

Every 72.5

ms,

the

sotlware monitors

the number of carriage

movements and saves this number.

2. The printer calculates the total number of movements for the eight most recent sections.

3. When the printer is in the normal drive sequence, and

tie

total number of carriage movements
is more than 3250, the printer assumes high CR motor temperature and changes to the high
temperature drive sequence.

4. When the printer is in the high temperature drive

sequena?,

and the total number of carriage

movements is less than 2000, the printer changes back to the normal drive sequence.

Ct

Measurement sequence

Because printer mechanisms differ, the acceleration and deceleration curves also

diftkr. ‘Ihe

measurement sequence control adjusts for these variations so that the carriage accelerates and

decelerates smoothly.

During

The printer saves the values

printin&

1.

The

2.

l%e

3. The number of encoder pulses until the carriage speed reaches SP2. (See

Acce/eYation

printer software monitors the following items:
time between the last 40 encoder pukes and the stopping point.
number of encoder pulses from the established speed to the stopping point.

Figure

Control

Curcv,

for

SP2.)

fir

each of the items listed above

and

uses it for every column.

2-24,

This

procedure compensates for individual variations in the printer mechanism. Tkre!bre, carriage

operation control for column n is determined by the data in

cdumri

n-l.

Figure 2-26 illustrates the measurement sequence.

Rev.

A

2-29

Operating Principles

Carrige

transfer direction

DEX-5000+

Carrige

transfer direction

[

Right

~

Left

Service Manual

3

t

1

““””””””””-””””- SP2

t

1

Figure 2-26. Measurement Sequence

2.3.5 PF Motor Driver Circuit

Stepping motor driver
circuit block diagram, and Table 2-6 provides the

SLA7026 (IC1l)

Gate Array
E05A87

(IC7)

drives the PF motor. Figure 2-27 shows the PF motor driver

PF

PFI

PFA

Ref. voltage
setting circuit

I

(Q23)

3

‘“---””””””--””” SP2

motor specifications.

I

r+

&

4.7 VDc

CPU

TMP96C141
(ICI)

PGOO

I

\

‘GO’~

‘“3t-----

A

SLA7026

(ICI 1)

ANA
/lN-A

ANB

IN-B

<<

cnoY

*a

A~

I

-A

B

-B PF D

1=

I

-.J

PFA

PF B

PFC

=P

Figure 2-27. PF Motor Driver Circuit

The motor pulse switching signals are transmitted from CPU ports

controlled using open-loop phase switching based on the specified time data, and the phase
driving method is 1-2 phase excitation. (When the PF motor is held, the phase driving method is 2
phase excitation.) The CPU selects the most suitable driving mode from the modes below
according to conditions such as the paper feed step number and the pull tractor condition.

D

Micro feed (adjust) mode

LI

Normal speed mode

Q

Middle speed mode

Each phase switching FET in driver
HIGH, the motor is turned on. The
PF motor and checks whether it is operating normally. The

IC1l

is an open collector. When the phase switching data is

PFA

port of the gate array monitors the phase A signal of the

PFA

dog timer). If PF motor operation is abnormal, the gate array outputs the
signal to the CPU and the +5 V system reset

IC (IC9).

PGOO

to

PG03.

The PF motor is

port is used as the WDT (watch

RSTOUT

(reset request)

2-30

Rev.

A

DEX-5000+ Sarvice

Manual

Table 2-6. PF Motor Specifications

Oparatfng Phc@ba

e

Specification

Form

b

Supply voltage

Internal coil resistance

Frequency

Current consumption

I

*

HB = Hybrid

* pps

= pulses per second

** ips

= inches per second

4-phase, 200-pole, HB* pulse motor

35 VDC t

1

I

2.65 f2
4274

2610
Driving: 1.95 Aj 0.20A per phase (average)

Holding: 0.26 A, 0.02A per phase (average)

6%

(applied to the driver

+0.32 Llperphaseat 25°C (77°F)

pps~

(normal mode, constant driving): 9.9

pps

(middle speed mode, constant driving): 6

tkaaoription

circuit)

I

I

ipe””

ips

I

2.3.6 RF Motor Driver Circuit

Figure 2-28 shows a block diagram of the RF motor driver circuit, and Table 2-7 provides the RF
motor specifications. The RF motor is a stepping motor.
phase switching control according to the timing data for acceleration
deceleration. CPU ports
method is not equipped with a hold circuit for changing the motor phase. ‘The RF motor rotates
when the carriage moves.

PG1O

to

PG13

output the motor phase switching signals. The control

The

control circuit

perlbrms

mnstant

w

open-loop

speed, and

TMP96C141

(lCl)

PG1O

PG 11

PG12

PG 13

➤

“

➤

➤

,

+

~

PNP

Transistor x4

CN;

Figure 2-28. RF Motor Driver Circuit

Table 2-7. RF Motor Specifications

I

Specification

Form

Supply voltage 35 VDC * 6%

Internal coil resistance

Cunent

consumption
Frequency
Driving method Constant voltage driving, 2-2 phase drive only

I

I

4-phase,

1

150 Q f 13 Q per phase at

Driving: 0.10 A (average)

I

720

!

”s

46-poie,

~

PM pulse motor

(apptied

Description

to the driver circuit)

25°C (77°F)

i

I

I
I

I

I

I

I

,.. ,.

(“J

Rev.

A

2-31

Operating Principles

DFX4000+ Service Manual

2.3.7 PG Motor Driver Circuit

Figure 2-29 shows a block diagram of the PG motor driver circuit, and Table 2-8 provides PG motor
specifications. The motor phase switching signals are output from the

PGBN

port of the gate array. The motor common voltage

(+35

VDC)

driver IC

and hold mode (+5

(QM2)

is turned on when the motor pulse switching data is LOW.

VDC)

using the pulses from port

(PGCOM)

PGA

port and input to the

alternates between drive mode

PGI

of the gate array. The phase

The phase A output pulse from the platen gap encoder

ENCA

of the gate array and the phase B output pulse from the platen gap encoder

to general purpose port

ENCB

of the gate array. The gate array counts these pulses using the

(ENCA)

is input to general purpose port

(ENCB)

internal counter and determines the amount and direction of motor rotation.

VP or +5

E05A67

(IC7)

~

Zz
c-) (-l

>Cu

PGI

PGA
PGB

PGAN

‘“T”[

PGBN

Plsten

gap .
encoder
(on the CARRIAGE)

SDC03(QM2)

➤

B1

➤

B2

➤

B3

+

B4

15,16
13,14
11,12
9,10

v

v

MOTOR,PG

Q1,Q15

,

v

—

w

is input

Figure 2-29. PG Motor Driver Circuit

Table 2-9. PG Motor Specifications

Specification

Form

Supply voltage

Internal coil resistanceI

Current consumption

Frequency

Drivina

method

I

Description

4-phase, 48-pole, PM pulse motor

I

35

VDC *

I

250Qt

60/0 (applied to the driver circuit)

18 Qperphaseat25°C

(77°F)

Driving: 0.20 A (average)
Holding: 0.02 A * 0.5

333 pps

I
I

Constant

voltaae drivin~,2-2

mA

Phase

dflveonly

2-32

Rev.

A

DEX-5000+ Servb Manual

Dperating

Ptinciphs

2.3.8 Plunger Driver Circuit

Figure 2-30 shows a block diagram of the plunger driver arcuit, and Table 2-9 provides the plunger
switching pattern. The plunger is driven using three switching patterns. Gate array general
purpose ports

data in the gate array. When the

transistor

switching transistor

into the plunger coil using general purpose port

PLP

and

PLN

output the plunger coil drive signals. The CPU latches the switching

PNP

port of the gate array turns off switching transistor

Q17

is turned on and the supply voltage (VP) flows into the plunger coil. When

Q19

is turned on, transistor

Q17

is turned off and the hold voltage (+5 V) flows

PLN

of the gate array.

VP

Q19,

EOSA87 (IC7)

-0

1-

Z

)
(

I

Tabie

Suspension Roller

closed
Closed + open
Closed with hold

PLP

B

Q27

●

Figure 2-30.

2-10.

Piunger

Ststus Q17

vottage

PNP

Q19

●

B

+5
A

-

E

~

Piunger

-c B

Driver Circuit

*

Switching Pattern

off off
On
off

NPN

Q17

T

-

E

~

-U

0

c)

0

=

GP

Q27

off
On

@>

c~’

. .

;:..

,:.-..

!.

,..

c)

2.3.9

Figure 2-31 shows a
when they are LOW, but the invertor ICS
HD1 to HD8 of
flows through the

the
charges into the head
Zener diodes D4 to D6. (This prevents a large current from suddenly flowing into the head driving
coil.) Two +35 VDC lines

HD3, HD5, HD7, HD8, and HD9 are supplied by the VH

10). Pins HD2, HD4, and HD6 are supplied by the VP
The CPU monitors the head temperature and head fan temperature. When the temperature rises

abnormally, printing stops at once until the temperature cools. The CPU also monitors the
driver status. If the head driver IC shorts, CPU port
the
supply board assembly receives this signal, it stops the output voltage and the printer beeps.

Rev.

Printhead

printhead

DRERR

(Driver

A

Driver Circuit

printhead

IC7

go LOW, the FET gates are biased, and the FETs are turned on so that current

printhead

coil current is cut. The trigger power of these FETs is +12 VDC. If extra

mil

Emor)

driver arcuit block diagram.

(IC6

and

IC7)

coil. When the HD port of

(more than 62

(VH

and VP) assign the common voltage for the

signal to the

VDC),

the extra current escapes to the +35 VDC line using

C117

power supply board assembly. When the C117 power

lhe

print data lines from

convert these signals to HIGH. When ports

IC7

goes HIGH, the FETs are turned off and

(HDCOM2)

(HDCOM1)

P34

detects a LOW level and the CPU sends

line (CN6 pins 11,12, and 14).

.

IC7

are active

curnmt

pnnthead coil.

line (CN6 pins 5,6,7,8, and

Pins

HDl,

@d

2-33

Operating Principle

m
0

0-l
g

-1

FANA

FANAN

DEHOOO+

r

m
>

0

n

>

z

Service Manual

J

+

(/)
T

0

a

I

>

z

L--

+’

—

@

co’”’

HEAD FAN

thermistor data

HEAD

thermistor data

x

w

1

x

(0

-1

➤

0

Zz

00

-N

-1”1
::

-z-x

00

u-lo)

2-34

Figure 2-31. Printhead Driver Circuit

Rev.

A

CHAPTER 3 Disassembly and Assembly

Table of Contents

c

“ ‘4

,. f

3.1 BEFORE STARTING

3.1.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

3.1.2 Small Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

3.2 DISASSEMBLY AND ASSEMBLY

3.2.1 Replacing the

3.2.2 Replacing the ROM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

3.2.3 Removing the Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

3.2.3.1 Removing theTopCover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

3.2.3.2 Removing the Left, Right, and Front Covers and

Replacing the Fuse. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2.3.3 Removing the Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

3.2.3.4 Removing the Upper Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

3.2.3.5 Removing theCoverOpen Sensor . . . . . . . . . . . . . . . . . . . . . . 3-14

3.2.4 Removing

3.2.4.1 Removing the Bottom Panel Assembly. . . . . . . . . . . . . . . . . . . 3-15

3.2.4.2 Removing the Cooling Fan and

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2.4.3 Removing the Cl 17 MAIN Board Assembly. . . . . . . . . . . . . . . 3-18

3.2.4.4 Removing the AC Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2.4.5 Removing the

3.2.5 Removing the Interlock Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . 3-21

3.2.6 Removing the Printer Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

3.2.7 Printer Mechanism

3.2.7.1

3.2.7.2

3.2.7.3

3.2.7.4

3.2.7.5

3.2.7.6

3.2.7.7

3.2.7.8

3.2.7.9

3.2.7.10 Removifig the Pull Tractor Sensor . . . . . . . . . . . . . . . . . . . . . 3-35

3.2.7.11 Removing the Paper Width

3.2.7.12 Removing the PG Home Sensor. . . . . . . . . . . . . . . . . . . . . . . 3-36

3.2.7.13 Removing the PF Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37

3.2.7.14 Removing the Left Side Frame Gears. . . . . . . . . . . . . . . . . . . 3-38

,3.2.7.15 Removing the Front Tractor Assembly . . . . . . . . . . . . . . . . . . 3-39

3.2.7.16 Removing the Rear Tractor Assembly . . . . . . . . . . . . . . . . . . 3-40

3.2.7.17 Removing the CR Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41

3.2.7.18 Removing the CR (Carriage Encoder) Sensor . . . . . . . . . . . . 3-42

3.2.7.19 Disassembling the Carriage Mechanism . . . . . . . . . . . . . . . . 3-43

3.2.7.20 Removing the Paper Guide

3.2.7.21 Removing the Platen Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45

Removing the Front/Rear Tractor Select Lever Assembly . . . . 3-24

Disassembling the Front/Rear Tractor Select Lever

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25

Removing the Connector Junction Board Assembly and

FPC Board Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27

Removing the PG Sensor and PG Motor . . . . . . . . . . . . . . . . . 3-28

Removing the Plunger and Paper Bail Assembly. . . . . . . . . . . 3-29

Removing the Upper Paper Guide and Top PE Sensor , . . . . . 3-31

Removing the Tension Roller Shaft. . . . . . . . . . . . . . . . . . . . . .

Removing the Platen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing the Paper Jam Sensor. . . . . . . . . . . . . . . . . . . . . . .

Printhead

theCircuitBoards.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

C117

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

C117 Power Supply Board

PNL

Board Assembly. . . . . . . . . . . . . . . . 3-20

(PW)

Sensor . . . . . . . . . . . . . . . . 3-35

Suppoft Plate . . . . . . . . . . . . . . . 3-45

3-1

3-7

3-11

3-18
3-19

3-24

3-31
3-33
3-34

List of Figures

Figure 3-1. Attaching the Packing Materials . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Figure 3-2. Packing the

Figure3-3. Dial Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Figure3-4. Dial Gauge Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Figure3-5. Dial Gauge Master . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Figure 3-6. Thickness Gauge . . . . . . . . . . . . . . . . . . . . . .................3-5

Figure3-7.

Figure 3-8. Removing the Printhead . . . . . . . . . . . . . . . . . . . . . ............3-8

Figure 3-9. Replacing the ROM . . . . . . . . . . . . . . . . . . . . . ...............3-9

Figure3-10. Removing theTopCover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Figure3-11. Removing the Left and Right Side Covers . . . . . . . . . . . . . . . . . 3-11

Figure3-12. Connecting the

Figure3-13. Removingthe Fuse. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Figure3-14. Removing the Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Figure3-15. Removingthe Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

Figure3-16. Removing the Uppercase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

Figure3-17. Removing theCoverOpen Sensor . . . . . . . . . . . . . . . . . . . . . . . 3-14

Figure3-18. Removing the lnterfaceCover . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

Figure3-19. RemovingtheBottom

Figure 3-20. Removing the Connector and Earth Cable . . . . . . . . . . . . . . . . . 3-16

Figure 3-21. Removing the Bottom Panel Assembly2 . . . . . . . . . . . . . . . . . . 3-17

Figure 3-22. Removing the Cl 17 Power Supply Board Assembly . . . . .....3-18

Figure 3-23. Removing the Cl 17 MAIN Board Assembly. . . . . . . . . . . . . . . . 3-18

Figure 3-24. Removing the Earth Plate . . . . . . . . . . . . . . . . . . . . . . . . .....3-19

Figure 3-25. Removing the AC Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . .....3-19

Figure 3-26. Removing the

Figure 3-27. Removing the Interlock Switch Assembly. . . . . . . . . . . . . . . . . . 3-21

Figure 3-28. Removing the Printer Mechanism. . . . . . . . . . . . . . . . . . . . . . . . 3-22

Figure 3-29. Lifting the Printer Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

Figure 3-30. Connecting the Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

Figure 3-31. Removing the Tractor Select Lever

Figure 3-32. Removing the Tractor Select Lever2 . . . . . . . . . . . . . . . . . . . . . 3-24

Figure 3-33. Disassembling the Tractor Select Lever. . . . . . . . . . . . . . . . . . . 3-25

Figure 3-34. Tractor Select Lever Mounting Position . . . . . . . . . . . . . . . . . . . 3-26

Figure 3-35. Removing the Connector Junction Board . . . . . . . . . . . . . . . . . . 3-27

Figure 3-36. Removing the PG Sensor and PG Motor . . . . . . . . . . . . . . . . . . 3-28

Figure 3-37. Removing the Plunger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

Figure 3-38. Removing the Paper Bail Assembly . . . . . . . . . . . . . . . . . . . . . . 3-30

Figure 3-39. Removing the Top PE Sensor. . . . . . . . . . . . . . . . . . .’. . . . . . . . . 3-31

Figure 3-40. Removing the Tension Roller Gear . . . . . . . . . . . . . . . . . . . . . . 3-31

Figure 3-41. Removing the Shaft Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32

Figure 3-42. Removing the Tension Roller Shaft . . . . . . . . . . . . . . . . . . . . . . 3-32

Figure 3-43. Removing the Platen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33

Figure 3-44. Removing the Left Part of Lower Paper Guide . . . . . . . . . . . . . . 3-34

Figure 3-45. Removing the Paper Jam Sensor. . . . . . . . . . . . . . . . . . . . . . . . 3-34

Figure 3-46. Removing the Pull Tractor Sensor . . . . . . . . . . . . . . . . . . . . . . . 3-35

Figure 3-47. Removing the PWSensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35

Figure 3-48. Removing the Carriage Guide Shaft Gear . . . . . . . . . . . . . . . . . 3-36

Figure 3-49. Removing the PG Home Sensor. . . . . . . . . . . . . . . . . . . . . . . . . 3-36

Figure 3-50. Removing the PF Motor . . . . . . . . . . . . . . . . . . . . ... , . . . . . . . 3-37

Removingthe FPC Cover and theConnectors . . . . . . . . . . . . . . . 3-7

DFX-5000+ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Cablestothe

PanelAssemblyl

C117 PNL Board Assembly. . . . . . . . . . . . . . . . . 3-20

Main Switch . . . . . . . . . . . . . . . . . 3-11

. . . . . . . . . . . . . . . . . . 3-16

1

. . . . . . . . . . . . . . . . . . . . . 3-24

Figure 3-51. Removing the Left Side Frame Gears . . . . . . . . . . . . . . . . . . . . 3-38

:

Figure 3-52. Removing the Front Tractor Assembly. . . . . . . . . .

Figure 3-53. Removing the Rear Tractor Assembly . . . . . . . . . . . . . . . . . . . . 3-40

Figure 3-54. Removing the Timing Belt Holder. . . . . . . . . . . . . . . . . . . . . . . . 3-41

Figure 3-55. Removing the CR Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41

Figure 3-56. Removing the CR Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42

Figure 3-57. Removing the Belt Pulley. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43

Figure 3-58. Removing the Front Carriage Guide Shaft. . . . . . . . . . . . . . . . . 3-43

Figure 3-59. Removing the Right Side Frame . . . . . . . . . . . . . . . . . . . . . . . . 3-44

. . . . . . . . . 3-39

List of Tables

Table 3-1. Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Table 3-2. Abbreviations for Small Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Table 3-3. Screw Names and Illustrations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

LKX-5000+ Servica

Manual

LXsassembly

and

3.1 BEFORE STARTING

Read this section before you disassemble, assemble, or transport the printer.

Assembty

Because the

printers, you must be carefil when handling it.
persons must carry it, supporting
cover, because it may come

Before transporting the printer, remove the paper and ribbon cartridge. Then attach the following
packing materials, as shown in Figure 3-1:

LI

Transport locking bracket

Cl Carriage guide shaft support bar

Ll

Printhead protector

LI

Foam packing for paper bail

DFX-5000+

weighs 29.0 kg (63.8

itfrom the

o#.

lb)

botiom.

and is much larger and heavier than most

Whenever it needs to be moved, two or more

Never

lifi

the printer by holding the front

~.

,.

,.

c.”’

..-,.

,., . .

0

Rev.

Figure 3-1. Attaching the Packing Materials

A

3-1

Disassembly and Assembly

After attaching the packing materials, pack the printer in its container as shown in Figure 3-2. If
you do not pack the printer properly, it may be damaged during transportation.

DFX-5000+

Service Manual

Figure 3-2. Packing the

Before disassembling the printer, turn it off and
and the wall outlet.
ribbon cartridge.

Because you may need to turn the printer while you disassemble or assemble it, place it on a
clean, thick cloth, such as a blanket, before starting.

Before assembling the printer, lubricate it as described @Chapter 6,

Lubrication.

Also, be sure to clean the printer as described in Chapter 6.

(A substantial amount of oil maybe removed during maintenance or repair work.)

Discomect

the printer

from the

DFX-5000+

discomect

computer, and then remove the paper and

the power cord from the printer

Mainfenunce and

3-2

Rev.

A

DFX-5000+

Service Manual

3.1.1 Tools

Disassembly and Assembly

This section describes the tools required for assembling

Note:

Refer to Chapter 4 for adjustment tools, Chapter 5 for troubleshooting tools, and
Chapter 6

for

tools for

m&ntenance,

lubrication, and adhesives.

Table 3-1. Tools

Tool Name Type

Phillips screwdriver No. 2
Phillips screwdriver No. 1

Box driver
(7

mm or .28 inches across)

E-ring holder No. 3
E-ring holder No. 6
Round nose pliers
Diagonal wire cutters

Tweezers

Electric soldering

imn

0

0

o
o

I

o

I

o

I

o

I

o

I I

o

disassembling

class

A
A

A

I
I

I
I

A
A
A

A

A

A

or adjusting the printer.

-

Part No.

B743800200

B7438OO1OO

B741700200

B740800500

I

B740800800

I

B7404OO1OO

I

B7405OO1OO

I

B641OOO1OO

I

B7402OO1OO

(.

.

.

Tension gauge (4000 g)
Tension gauge (2000 g)
Tension gauge (200 g)

Lift

habctles

Dial gauges

Dial gauge base #F611
Dial gauge master

‘

Thickness gauge #F616
Motor screwdriver

(Phillips head,

O:

Commeraally

E: EPSON exclusive

A:

Mandatory

B: Recommended

#E656

#F610

toque

#F612

adjustable)

available

o
o
o

E

E

E

I

E
E

0

I

A
A
A

A

A

A

A
A 1020471

B

B747700300
B7477OO1OO
6765114601

B7651 11001

1019466

1019467

I

1019468

—

f.....

‘

Rev. C

34

Disassembly andilsaembly

DEX-51UW+ Seffice Manual

Part number:

Catalog number:

Part number:
Catalog number:

B1019466OO
Dial gauges

#F610

Figure 3-3. Dial Gauges

B1019467OO
Dial gauge base

v

#F611

. . . . .

0

-

[

1

Part number:

Catalog number:

Figure 34 Dial Gauge Base

B1019468OO

Dial gauge master

.

.

::

::

::

::

::

. .

::

::

::

::

. .

::

::

::

::

. .

. .

Figure 3-5. Dial Gauge Master

#F612

3-4

Rev.

A

Part number:
Catalog

number

B102O47NXI

l’hickness

I

gauge

Figure 3-6. Thickness Gauge

#F616

●

3.1.2

Smail

Abbreviation

CBB

CBS (0)

CBS

(SP)

CFS

CP

(SP)

CP

(Ps)
CPB
CPB

(0)

CPS
CPS

(P)

CPS (SP)

CPN

Parts

Tabie

3-2. Abbreviations for

Part Name

Cross-Bind head, B-tight screw

Cress-Bind head, S-tight screw with Outside-toothed lock washer
Cross-Bind
Cross-Flat head, S-tight screw
Cross-Pan head

C--Pan

Cross-Pan head, B-tight screw

Cms-Pan head, B-tight screw with Outside toothed lock washer
Crose-Pan

Cress-Pan head, S-tight screw with Plain washer
Cross-Pan head, S-tight screw with Spring lock washer + Plain washer
Cress-Pan head screw

head, S-tight screw with Spring lock

with Spring

head with Plane washer + Spring lock washer

head, S-tight screw

lock

washer + Plane washer

Smaii

washer +

Parts

Plane washer

,,

c)

CPN

(0)

CPN (SP) Cross-Pan head screw with Spring lock washer + Plain washer
CPT

(0)

Cross-Pan head screw with Outside toothed lock washer

Cross-Pan head Tapping screw with Outside

toohed

lock washer

Rev. A

3-s

Disassembly and Assembly

Table 3-3. Screw Names and Illustrations

DFX-5000+

Service Manual

Top

1. Cross-recessed
head

@

Head

1. Bind

(with

2. Pan

3. Flat

Ul=

P

0

b

Side

fjotch)

—

Body

1. Normal

2. S-tight

I \ \,

i.

mo

3. B-tight

m~

I

‘Ii

4. Tapping

‘0

Washer

1. Plain washer

@@

\

2. Outside toothed

lock washer

Q!=

3. Spring washer

Ob

ma

3-s

Rev.

A

DEX-5iWO+ Samica

Manual

3.2 DISASSEMBLY AND ASSEMBLY

Disassamhiy

and

blssainbly

Before you

disassemble or assemble the printer, be sure to read and follow the

instmctions

in

Section 3.1, “BEFORE STARTING.”

This section describes how to disassemble the printer. See the Appendix for an exploded diagram
of the printer. Use this diagram for simple disasse

the printer, follow the disassembly

instructkms

mbly

procedures not

dewribed

here. To assemble

in this chapter in reverse. Any extra information

you need to assemble printer components is provided in notes labeled “Assembly Note.”

Adjustments required before assembly are described in notes labeled “Adjustment Required.” Be

sure to follow the instructions in these notes.

3.2.1 Replacing the

You can replace the

Q

When you remove

Ct

When you remove

Printhead

printhead

without disassembling the printer.

theconnectorcover,
theprinthead

cable

becarefil not to break the tabs.

hohier, becarejid

not to break

thepn”ntheadcabi%

holder latch. Use a slotted screwdriver ifnecessay.

Remove the top cover.

1.

2. Pry up the 2 hooks for the head cable cover and remove it from the carnage.
Discomect the white

3.

comector

4.

Release the harness

from the connector junction board on the carriage.

FPC

cable,

from the carriage hook and

4pin

white harness comector, and

4pin red

harness

remove the CP (SP) (M3 x 6) screw.

SHA~;

REAR

SHAH

cOVE

#

~R&D~oNT

,!

~

....-s<

~

/P

CP (SP) (M3x6)

(for Carriage Encoder

/PRINTHEAD

““ ~rpApZRVWXH

(for FAN Drive

Head Cable

Conn@or Junction

Signal and

SkYaO

(FPC)

Board

Thermistor

signal)

Signal)

Rev.

Figure 3-7. Removing the

A

FPC

Cover and the Connector

3-7

Disassembly and Assembly

DFX-5000+

Service Manual

5. Remove the 2 CPN
mechanism.

6. Remove the 2
and remove the

the

printhead

Ribbon Fee

FPC printhead

2

with the PW sensor and the masldess holder.

BOARD

(M3

x 8) screws securing the

cables from the connector junction board on the bottom plate

CP (PS) (M4

x 7) screws securing the pnnthead to the carriage. Disengage

FPC

cover to the bottom plate of the printer

TRACTOR ASSEMBLY

(REAR)

Figure 3-8. Removing the

Q

When you install the

Cl

Tighten the screws while pulling the

printhead,

torque the screws to 8

printhead

Printhead

kglcm (44 lblinch).

backward to secure the

printheadjirmly.

When you install the

printhead,

described in Section 4.1.7.

3-8

perform the platen gap motor value (platen gap) adjustment

Rev.

A

DFX-5000+

3.2.2 Replacing the ROM

Service Manual

~“sassambly

and

Assembiy

.<

.,.,

.,

c

You can

il Zt is

~

~
~
~

1. Tilt back the printer and lay it on its back. Hold the top cover closed if it is not removed.

2.

Remove the

-———

7’

replace the ROM without disassembling the printer.

best to remove the top cover before you tilt back

below. Refer to Section

If you tilt back the printer with the top cover attached, be

weight on the top cover or any other

Spread a thick,
Remove the
Before you install a new ROM, check the

oriented correctly.

ROM using the ROM holder.

—
—

—

—

—
—

—

sofl

ROMcarejidly

CBB

(M3 x 10) screw securing the ROM cover, remove the cover, and replace the

I

I

3.2.3.lfor instructions on

ptinter

cloth under

Insert

the ROM care filly to avoid

theprz”nter

to avoid

before you follow the steps below.

damagn”ng

ZNDEXmark

components.

the board.

theprz”nter

remooing

the top cover.

carejid

on the socket to be sure the ROMis

damafl”ng

as described in the steps

not to put too much

the

ROMp”ns

and the board.

\

(

-.,

1

-.-’

—
—

—
—

IEll

I

!

I

‘— CBB(M3X1 o)

Figure 3-9. Replacing the ROM

Rev.

A

3-9

Disassembly and Assembly

DFX-5000+

Service Manual

3.2.3 Removing the Housing

This section describes how to remove the housing.

3.2.3.1 Removing the Top Cover

Two people are required to remove the top cover; one person must hold the top cover while the
other person removes the screws. If the top cover is not supported while the screws are removed,

the weight of the top cover may damage the rear hinges.

1. Open the top cover.

2.

While someone supports the top cover, remove the4 screws

securing the top cover to the hinges and remove the cover.

/\

\

\–

~\—

(2

on therightand 2 on the left)

I

3-1o

Figure 3-10. Removing the Top Cover

Rev.

A

DEX-&MO+

Service Manual

Disassamb@

and

Assambly

3.2.3.2

1. Remove

2. Remove the right side cover in the same way as you removed the left side cover. Also remove

Removing the Left, Right, and Front Covers and Replacing the

the

4

CBB (M4 x

the 4 cables from the main switch on the right side cover.

16)

screws securing the left side cover and remove the cover.

Fuse

Figure 3-11. Removing the Left and Right Side Covers

c’

~

‘.,

When you attach the right side cover, connect the
supply board assembly and the cable from the AC inlet to the main
cover, as shown below.

F%Wrse

sided

the

side

cover

(R)

AC

Cl

17

pxer

rnlet set

wpplybosfd

CNI

L.ight browI able

?

E

Light

I 1

1’

browr

11 12

11~

24 25

cablej%om

cebie

n

connector

,

I

1-

Mains~

.. ---=

I

d-----

sun”tch

rns@ficstkm

CNI

on the Cl17power

on the right side

,

.

c

‘1

/

Rev. A

Figure 3-12. Connecting the Cables to the Main Switch

3-11

Disassembly and Assembly

DEX-5000+

Service Manual

3. After you remove the right side cover, you can replace the input fuse for the
supply board assembly.

Make sure the new fuse meets the printer’s AC power specifications.

-1

,CARRIAGE

Grounding Harries

MOTOR

C117

power

(RIGHT Side)

Figure 3-13. Removing the Fuse

4. Remove the 3

Then remove the screws on the right side and remove the front cover with the 2 hinges.

CBB

(M4 x

10)

screws securing the left side of the front cover to the lower cover.

CB

3-12

Figure 3-14. Removing the Front Cover

Rev.

A

DFX-5000+

Service Manml

Dkassamb(y

andAssamb&

3.2.3.3

1.

2. Open the top rover and disconnect connector

3. Remove the2

Removing the Front Panel

Remove the left and right side covers. (Refer to Section 3.23.2)

CN8

(the control panel

CBB (M4

PNL board assembly and its cable.

x 16) screws from the front panel and rernovethe panel with the Cl17

00

1111111111111

mnnector).

WI

4

:,.,

(2

CBB ~M4x16)

Figure 3-15. Removing the Front Panel

3.2.3.4

1.

2. Disconnect connector

3. Remove the 6

Removing the Upper Case

Remove the front panel. (Refer to Section 3.2.3.3)

CN7

(the cover open sensor connector) from the

assembly.

CBB (M4

remove the upper case with the cover open sensor.

CBB

(M4x1

x 16) screws, and 2

“, ,“,

J

r.h~

1

1

1

CPS (M3

L

C117

MAIN board

x

8) screws from the upper case, and

then

Rev.

W-..-_L

CPS

(M3x8)

figure

A

3-16. Removing the Upper

Caae

3-13

Disassembly and Assembly

3.2.3.5 Removing the Cover Open Sensor

1. Remove the uppercase. (Refer to Section 3.2.3.4)

2. Tum over
remove the sensor.

tie upper

case. Remove the 2 CPB (M2

x 8) screws

DFX-5000+ Sarvice

from the case

op~

sensor and

Manual

UPPER

CASE

(reverse

CASE OPEN SENSOR

Figure 3-17. Removing the Cover Open Sensor

side)

3-14

Rev.

A

DEX-5tNW+ Sarvica

Manual

3.2.4 Removing the Circuit Boards

This section describes how to remove the circuit boards.

Disassembly and

blssambly

3.2.4.1 Removing the Bottom

Q It

is

best to remove the top cover before you tilt back the~”nter as

below.

Q

If you tilt back

weight on the top cover or any other printer components.

2 Spreada
~

When you attach the

between the lower case and bottom panel.

1.

Remove theleftand right side covers. (Refer to Section 3.232)

2. Open the rear cover. Remove the4CPB
securing the interface cover and remove the cover.

3. Remove the 2 CPT (0)
cover.

Refo

to Section 3.2.3.1 for instructions on removing the top cover.

thepn”nterwith

thick, soft cloth under

bottompanel,

(M3

x 12) screws securing the optional interfa~ cover and remove the

CPT (0)

Panel

Assembly

the

topcoverattached, becamfidnot toputtoo

theprinterbefore youjbllow

make sure

(M3x12)

theparallel

(M3

x

12) screws and 2

interface cable latch is not caught

describedin

the steps below.

CPT(0) (IWI

,11

Ill

II /

thesteps

much

x

12)screws

,.

o

REAR

COVER

Figure 3-18. Removing the Interface Cover

CPB

(M3x12)

Rev.

A

3-15

Disassembly and Assembly

4.

While supporting the top cover to protect it from scratches, tilt back the printer and lay it on

its back.

5. Remove the 8 CPB (M4
printer to its upright position before you remove the screws for the bottom panel assembly.
Then remove the rear cover.

x 16) screws securing the bottom panel assembly. Slowly return the

CPB

(M4x16)

DFX-5000+

Service Manual

Figure 3-19. Removing the Bottom Panel Assembly

6.

From the left side, remove the 2 CPB

cable between the bottom plate of the printer mechanism and the earth plate on the bottom
panel assembly.

7. Disconnect connectors

8. Since comector
connector (not labeled with a CN number) between the interlock switch and connector
on the

C117

CN9

MAIN board assembly.

CN1O, CN6,

is fixed to the

(0)

(M4

x 8) screws securing the green and yellow earth

CN7,

and CN8.

C117

MAIN board assembly, remove the junction

1

CN9

Junction

Connector
(for

CN9)

-

Connector Junction Board

CN6

(Mechanism Drive)

BOARD ASSY.,C117 MAIN

CN1O

CFJ8

(Control

Panel)

~CN7

CN9

(DETECTOR, CR)

(CASE OPEN SENSOR)

(Inter Lock Switch)

3-16

CPB

(0)

(M4x8)

(LEFT Side)

Figure 3-20. Removing the Connector and Earth Cable

Rev.

A

DFX-5000+ Sarvica

9. On the right side of the printer mechanism, remove the green and yellow earth cable from the
earth plate on the bottom panel assembly. Then slowly lift up the bottom panel assembly.

10. Remove the CBS (0) (M4 x 8) screw securing earth plate.

Manual

Disasaam6/y and Assamb/y

I

Earth Cable

CBS(O)

‘M4X8)

BO

Po

Figure 3-21. Removing the Bottom

Psnel

Assembly 2

Disassembly and Assembly

DFX-5000+

Service Manual

3.2.4.2

1.

2. If you need to remove the cooling fan, remove the 4

Removing the Cooling Fan and

CI17

Power Supply Board Assembly

Remove the bottom panel assembly. (Refer to Section 3.2.4.1)

CCN (M3

remove the fan.

3. Disconnect comectors CN2,

4.

Remove

the G CpB (M3

x

CN3,

11)

screws and

and CN4.

CPN

(0)

(M3

x 8) screw securing the CI17 power

supply board assembly and remove the board.

CPB(M3x11)

InOr

//

/

\

I

\,

,

,“~

7?irE?’’RsuppLy

-“LC

(--+.

CPN

/

(0)

(M3x8)

AC INLET

SET’

CCN (M3x30)

//’1°’1

r+_L——————

v

x 30) screws securing it and

cy3

I

4

ARD ASSY.,

Cl

17 MAIN

Figure 3-22.

3.2.4.3

1.

2. Disconnect connectors

3. Remove the 5

Removing the C117 MAIN Board Assembly

Remove the bottom panel assembly. (Refer to Section 3.2.4.1)

CPB (M3

Removing the Cl 17 Power Supply

CN1

and

CN3.

x 11) screws and 2

CPN

(0)

(M3

x8) screws securing the Cl17MAIN

board assembly and remove the board.

CPN

(0)

MAIN Board Assembly

BOARD
POWER SUPPLY

ASSY.,

C

117

CN1

Figure 3-23. Removing the

CN3

CPB(M3x11)

CI17

Board Assembly

(M3x8)

ASSY.,

ARD

Cl 17 MAIN

When you install the

Q

Platen gap motor value (platen gap) adjustment (described in Section

D Bidirectionalprinting

C117MAIN

board assembly, perform the

follorw”ng

adjustment (described in Section 4.1.8)

3-18

adjustments:

4.1.7)

Rev.

A

DFX-5000+ Sarvica Mamml

3.2.4.4 Removing the AC Inlet

Disassembly and

Assemb&

. . .

->

.., , ,,-<

Remove the

1.

2. Remove the Cl17MAINboard assembly.

3. Remove the 3
the bottom panel assembly and remove the earth plate.

CPB

(M4x

C117

power supply board assembly. (Refer to Section 3.2.4.2)

(RAertoSection3 Q.43)

CPS(M3

AC

x8) screws and 1

INLET SET

CPB

(0)

(M4

x5) screw securing the earth plate to

.

c“

.

4. Remove

CFS (M3x12)

the

AC inlet.

2

CFS (M3

Figure 3-24. Removing the Earth Plate

x 12) screws securing the AC inlet to the earth plate and remove the

AC

INLET SET

——

C3

Eafih

Plate

Figure 3-25. Removing the AC Inlet

Rev.

A

3-19

Disassembly and Assembly

DFX-5000+

Service Manual

3.2.4.5 Removing the

Remove the front panel. (Refer to Section 3.2.3.3)

1.

Discomect

2.

3. Remove the

remove the board.

connectors

CPB

(M4 x 9) screw securing the

CI17

PNL Board Assembly

CN1

and

CN2

on the

C117 PNL

C117 PNL

board assembly.
board assembly to the front cover and

,,

FRONT

,

c117 PNL

Figure 3-26. Removing the

PANEL

C117 PNL Board Assembly

3-20

Rev.

A

/-’=3

(_

DFX-5tWO+ Sarvica Marwal

3.2.5 Removing the Interlock Switch Assembly

Remove the upper case. (Refer to Section 3.23.4)

1.

2. Di

SCQMeCt

board assembly.

3. Remove the
remove the interlock switch assembly.

the interlock assembly cable

CBB

(M4 x 10) screw securing the interlock switch assembly to the lower case and

from junction

comector

D/aaaaambly

CN9

on the C117 MAIN

and Asaambly

,.

c)

Rev.

Figure 3-27. Removing the Interlock Switch Assembly

A

3-21

Disassembly and Assembly

DFX-5000+

Service Manual

3.2.6 Removing the Printer Mechanism

This section describes how to remove the printer mechanism.

Because the printer mechanism is large and heavy, you must be careful when you remove it.
When you lift or lower the printer mechanism, follow these precautions:

Ll

Two people are required to remove or install the printer mechanism.

Q

Use the lift handles

printer mechanism when you remove or install it.

U

To avoid straining your waist, hands, or feet, place the printer on a low table before

following the steps below.

Remove the interlock switch assembly. (Refer to Section 3.2.5)

1.

2.

I&move

3. Disconnect the cables from connectors CN1O, CN7, and CN6 on the left side of the

4. Remove the 4 screws securing the printer mechanism to the lower case.

the

3

CBS (0)

plate. There are two screws on the left and one on the right.

MAIN board assembly.

(#E656,

part number B765111OO1) designed for

(M4 x 8) screws securing the green and yellow earth cables to the earth

lifling

or

lowen”ng

the

C117

CBS (0)
SCREWS

2

SCREWS

CBS (0)
SCREWS

(M4x8)

(M4x8)

((((

‘t-lfl, ,,

I

1!21

I

pl

,,

Figure 3-28. Removing the Printer Mechanism

In

,Vm

CBS (0)
SCREW

2 SCREWS

(M4x8)

3-22

Rev.

A

DFX-5000+ Sarvica Manual

Disassembly and

Assambly

5. Install the lift handles from the inside of the printer mechanism. Insert each handle through
the 2 holes in the side frames of the printer mechanism. Then slowly lift the printer
mechanism using the handles and remove it from the lowercase.

SM

ER

Figure 3-29. Lifting the Printer Mechanism

When you install the printer mechanism, route the cables as shown in Figure 3-30. Make sure
the cables do not get caught between the

Inte

1

I

I
I

I

I

I

I

c

CN9 (Fixed)

(LEFT Side)

SHILD

PLATE

ptinter

mechanism and lowercase.

R

/-/”

‘ ------ –---- —-- —------

11 /’

q

/

I

PRINTER MECHANISM

I
U -

HEAD\I

I

1

I
I

I

I

‘2’

y:~

SM

--—--—-

SHILD

(RIGHT Side)

-– ,

t

PLATE

-_J-.

-—

J’

)

I

I

/

I

/

\

J

(

/

!

Figure 3-30. Connecting the Cables

When you install the printer mechanism,

~

Platen gap motor

Q

Bidirectional printing adjustment (described in Section 4.1.8)

Rev.

A

value

(platen gap) adjustment (described in Section 4.1.7)

perjorm

the

follom”ng

adjustments:

3-23