Epson DFX-5000+ Service manual

EPSON
EPSON
EPSON France S.A.
DFX-5000+
SERVICE MANUAL
PRODUIT
EPSON TERM
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
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