Oki MICROLINE 520, MICROLINE 521 Service Handbook

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Microline 520/521

Service Handbook

P/N 59257803

Microline 520/521

Service Handbook

This document may not be reproduced without the written permission of the Okidata Technical Training Group. Every effort has been made to ensure the accuracy of the information contained in this training course. Okidata is not responsible for errors beyond its control.

First Edition February, 1993 P/N 59257801 Second Edition September, 1993 P/N 59257802 Third Edition December, 1994 P/N 59257803 Written and produced by the Okidata Technical Training Group Please address any comments on this publication to:

Technical Train ing Group Okidata 532 Fellowship Road Mount Laurel, NJ 08054-3499 Fax Number: (609) 235-2600, ext. 7034 Okilink Login Name : Technica l Trai nin g

OKIDATA is a registered trademark of Oki Electric Industry Company, Ltd.; marques deposee de Oki Electric Industry Company, Ltd.; marca registrada, Oki Electric Industry Company, Ltd.

MICROLINE is a registered trademark of Oki Electric Industry Company, Ltd.; marque depose de Oki Electric Industry Company, Ltd.

OkiSmart Paper Handling is a trademark of Oki Electric Industry Company, Inc. PLUG ’n PRINT is a registered trademark of Oki America, Inc.; marque deposee de Oki America, Inc. Bitstream is a registered trademark of Bitstream Incorporated. Epson is a registered trademark of Seiko Epson Corporation. IBM is a registered trademark of International Business Machine Corporation. MS-DOS is a registered trademark of Microsoft Corporation. PC is a registered trademark of International Business Machine Corporation. Proprinter is a registered trademark of International Business Machine Corporation.

Windows is a trademark of Microsoft Corporation

Table of Contents

COURSE ADMINISTRATION:

OVERVIEW.................................................................................................................................i-1

RECOMMENDATIONS. ............................................................................................................. i-2

INFORMATION UPDATES........................................................................................................ i-3

NOTICES......................................................................................................................................i-3

WHERE TO SEND TESTING MATERIALS.............................................................................i-4

MISSING ITEMS OR MISSING PAGES....................................................................................i-5

COURSE PATH ...........................................................................................................................i-6

SERVICE TRAINING............................................................................... .............................. .....i-7

SERVICE AUTHORIZATION..................................................................................................i-11

General Info rma ti o n............... ... ............ ............ ............ ............ ............ ... ............ ...........i-11

Answer Sheet: Microlin e 520/52 1.......... ...... ... ...... ...... ... ...... ...... ... ...... ...... ... ...... ...... ... ..i-13

Course Critique: Microline 520/521..............................................................................i-14

Certification Test: Microline 520/521............................................................................i-16

SECTION ONE: SPECIFICATIONS

1.1 OVERVIEW....................................................................................................................1-1

1.1.01 General Information..........................................................................................1-1

1.2 PHYSICAL SPECIFICATIONS.....................................................................................1-2

1.2.01 Dimensions .......................................................................................................1-2

1.2.02 Printer Weight...................................................................................................1-2

1.3 POWER REQUIREMENTS...................... ... ... ...... ... ... ...... ... ... ...... ... ... ...... ... ... ...... ... ... .... 1- 3

1.3.01 Input Powe r......................... ..................... ..................... ............ ..................... ...1-3

1.3.02 Power Consumption..........................................................................................1-3

1.3.03 Power Frequency ..............................................................................................1-3

1.4 ENVIRONMENTAL CONDITIONS.............................................................................. 1-4

1.4.01 Acoustic Rating.................................................................................................1-4

1.4.01 Altitude .............................................................................................................1-4

1.4.03 Ambie nt Temp erature and Re la tive Humid it y (RH).... ... ............ .....................1-4

1.5 AGENCY APPROVALS................................................................................................. 1-5

1.5.01 Listings..............................................................................................................1-5

1.6 OPERATIONAL SPECIFICATIONS.............................................................................1-6

1.6.01 Charact er Mat r i x Siz es.......................... ..................... ..................... ..................1-6

Table of Print Speed and Character Matrix......... ............ ............ ............ ............ ......1-6

1.6.02 Characters Per Line...........................................................................................1-6

Microline 520.............................................................................................................1-6

Microline 521.............................................................................................................1-6

1.6.03 Character Pitches..............................................................................................1-6

1.6.04 Character Sets...................................................................................................1-7

1.6.05 Emulations........................................................................................................1-7

1.6.06 Fonts..................................................................................................................1-8

Near Letter Quality ....................................................................................................1-8

Utility.........................................................................................................................1-8

High Speed Draft.......................................................................................................1-8

Bar Code....................................................................................................................1-8

1.6.07 Front Panel Switches.........................................................................................1-8

1.6.08 Graphics Resolution............................................. ......... ...... ......... ...... ......... ......1 -8

1.6.09 Interface ....................................... ......... ...... ......... ...... ......... ...... ......... ...... .........1 -8

Standa rd... ............ ....................................... .............................. .................................1-8

Optional......................................................................................................................1-8

1.6.10 Line Feed Increments........................................................................................1-9

Fixed ..........................................................................................................................1-9

Variable......................................................................................................................1-9

1.6.11 Line Feed Ti me............................ ..................... ..................... ..................... ......1-9

1.6.12 Menu Mode .......................................................................................................1-9

1.6.13 Paper Feed Methods........................................................................................1-10

Standard ...................................................................................................................1-10

Optional....................................................................................................................1-10

1.6.14 Paper Feed Paths.............................................................................................1-10

1.6.15 Paper Loading.................................................................................................1-10

1.6.16 Paper Out Detection........................................................................................1-10

1.6.17 Paper Tear Capabilities...................................................................................1-10

1.6.18 Print Method...................................................................................................1-11

Printhead Type.........................................................................................................1-11

General Info rma ti o n............... ............ ............ ............ ............ ............ ............ ....1-11

Overheat Protection ...........................................................................................1-11

Printhead Gap Information.......................................................................................1-12

1.6.19 Print Modes.....................................................................................................1-14

1.6.20 Print Speed......................................................................................................1-14

Table of Print Speed and Character Matrix.................. ............ ............ ............ .......1-14

1.7 PAPER SPECIFICATIONS .......................................................................................... 1-15

1.7.01 Types...............................................................................................................1-15

Card Stock................................................................................................................1-15

Continuous Form.....................................................................................................1-15

Cut Sheet..................................................................................................................1-16

Envelopes.................................................................................................................1-16

Labels.......................................................................................................................1-17

Transparency............................................................................................................1-17

1.7.02 Length.............................................................................................................1-18

1.7.03 Number of Copies...........................................................................................1-18

1.7.04 Thickness ........................................................................................................1-18

1.7.05 Weight.............................................................................................................1-19

1.7.06 Width...............................................................................................................1-19

Paper ........................................................................................................................1-19

Printing Area............................................................................................................1-19

1.8 MEMORY SPECIFICATIONS.....................................................................................1-20

1.8.01 EEPROM........................................................................................................1-20

1.8.02 EPROM...........................................................................................................1-20

1.8.03 RAM ...............................................................................................................1-20

1.9 CONSUMABLES.......................................................................................................... 1-21

1.9.01 Ribbon.............................................................................................................1-21

1.10 OPTIONS.......................................................................................................................1-22

1.10.01 Cut Sheet Feeders ...........................................................................................1-22

Single Bin.................................................................................................................1-22

Dual Bin...................................................................................................................1-22

1.10.02 Pull Tract or Kit ........................ ............ ..................... ............ ..................... ....1-23

1.10.04 Bottom Push Tractor Kit ............. ... ... ............ ............ ... ............ ............ ..........1-23

1.10.05 Serial Interface................................................................................................1-23

1.10.06 Roll Paper St an d............................. ..................... ..................... ..................... .1-24

1.10.08 OKISmart Typer Utility.. ................................................................................ 1-24

1.10.09 OKISmart Panel Utility................................................................................... 1-24

1.11 RELIABILITY............................................................................................................... 1-25

1.11.01 Mean Time Before Failure (MTBF) ...............................................................1-25

1.11.02 Mean Time To Repair (MTTR)......................................................................1-25

1.11.03 Printer Life......................................................................................................1-25

1.11.04 Printhead Life..................................................................................................1-25

1.11.05 Ribbon Life ....................................................................................................1-25

iii

1.11.06 Warranty (Limited)...................... ... ...... ...... ... ...... ...... ... ...... ...... ... ...... ...... ... ....1-25

1.11.07 Service.. ............ ....................................... .............................. ..........................1-25

SECTION TWO: PRINCIP LES OF OPERAT IO N

2.1 ELECTRICAL OPERATION.. ........................................................................................2-1

2.1.01 Main Cont rol Board.................................... ..................... ..................... ............2-2

Block Diagram...........................................................................................................2-3

Program ROM............................................................................................................2-4

RAM ..........................................................................................................................2-4

LSI..............................................................................................................................2-5

Electrically Erasable Programmable Read Only Memory (EEPROM).....................2-5

2.1.02 Initialization......................................................................................................2-6

2.1.03 Parallel Interface Control..................................................................................2-7

2.1.04 Print Control......................................................................................................2-8

LSI/Printhead Interface..............................................................................................2-8

Gap Adjust Control....................................................................................................2-9

Print Compensation Control....................................................................................... 2-9

2.1.05 Space and Line Feed (SP/LF) Motor Control........................ ...... ... ...... ...... ... .2-10

Line Feed Motor Control.........................................................................................2-10

Space Motor Control ................................................................................................2-11

Encoder Disk............................................................................................................2-11

2.1.06 Operation Panel...............................................................................................2-12

2.1.07 Alarm Circuit..................................................................................................2-14

Driver Circuit Alarm Processing..............................................................................2-14

Low Motor Drive Voltage Alarm............................................................................2-14

Head Drive Time.. ............ ..................... ..................... ..................... ..................... ....2-15

Print Speed...............................................................................................................2-15

Head Overheat Alarm Processing........................... ............ ............ ............ ............ .2-15

2.1.08 Power Supply Circuit......................................................................................2-16

Table of Out put Vo l ta ge s............. ... ..................... ..................... ..................... ..........2-16

2.2 MECHANICAL OPERATION.....................................................................................2-17

2.2.01 Printhead Mechanism......................................................................................2-17

Printhead Gap Information.......................................................................................2-18

Interconnect Diagram: Control Board to Printhead................................................2-20

Line Feed Motor Resistance ..............................................................................2-21

Space Motor Resistance.....................................................................................2-21

Printhead Operation.................................................................................................2-22

Printhead Temperature.............................................................................................2-22

2.2.02 Spacing Mechanism........................................................................................2-24

Spacing Operation.................. ..................... ..................... ..................... ...................2-24

2.2.03 Head Gap Mechanism.....................................................................................2-26

Head Gap Setting Operation....................................................................................2-26

2.2.04 Ribbon Drive Mechanism...............................................................................2-29

Ribbon Drive Operation...........................................................................................2-29

2.2.05 Line Feed Me chanism..................... ..................... ..................... ..................... .2-30

Change Lev er (Pap er Path Sele ction Lever )........... ............ ............ ............ ............ .2-30

Paper Clam p Me chanism....... ... ............ ..................... ..................... ..................... ....2-30

Cut Sheet/Continuous Sheet Switching Mechanism................................................2-31

Top Feed (for cut sheet paper)........................................................................... 2-31

Rear/Bot t om Feed (for co nt i nuo us feed pap er)............. ............ ............ ... ..........2-31

Cut Sheet Paper Feed Operation..............................................................................2-32

Continuous Paper Feed (Rear Tractor Mechanism).................................................2-32

Continuous Paper Feed (Pull Tractor Mechanism) .................................................2-32

Continuous Paper Feed (Bottom Tractor Feed Mechanism) ..................................2-33

Continuous Paper Feed (Push/Pull Tractor Mechanism).........................................2-33

2.2.06 Paper Detection Mechanism ..........................................................................2-34

Top Feed Paper Detection........................................................................................2-34

Rear Feed Dete ct io n...... ... ... ..................... ..................... ..................... ..................... .2-34

Bottom Feed Det ection............. ... ... ..................... ..................... ..................... ..........2-34

2.2.07 Support Protector Mechanism.........................................................................2-35

2.2.08 Automatic Paper Load....................................................................................2-36

Cut Sheet Paper........................................................................................................2-36

Continuous Feed Paper............................................................................................2-37

2.2.09 Paper Park ......................................................................................................2-38

Paper Park Operat i on................ ............ ............ ............ ............ ............ ............ .......2-38

SECTION THREE: MAINTENANCE

3.1 OVERVIEW....................................................................................................................3-1

3.1.01 General Information..........................................................................................3-1

3.1.02 Maint en an ce To ol s.................... ..................... ............ ..................... ............ ......3-1

3.1.03 Mainten an ce Precautions.......... ............ ..................... ..................... ............ ......3-2

3.2 DISASSEMBLY/ASSEMBLY PROCEDUR ES............................................................ 3-3

General Info rma ti o n............... ... ............ ............ ............ ............ ............ ... ............ ......3-3

3.2.01 Preliminary Items..............................................................................................3-4

3.2.02 Printhead Assembly..........................................................................................3-6

3.2.03 Ribbon Protector...............................................................................................3-8

3.2.04 Gear Case Assembly............................. ...... ......... ...... ......... ...... ......... ...... .......3-10

3.2.05 Pull-up Roller Assembly.................................................................................3-12

3.2.06 Upper Cover, Access C over, and Sheet Guide Assem bli es........................ ... .3-14

3.2.07 C ontrol Board (FJIM)................................... ......... ......... ...... ......... ......... ...... .. 3-16

3.2.08 Power Supply Assembly.................................................................................3-18

3.2.09 Operator Panel PCB (LEOP) ..........................................................................3-20

3.2.10 PC Connect o r.......... ... ..................... ..................... ..................... ..................... .3-22

3.2.11 Space Motor and Roller Guide Assembl ie s.............................. ...... ... ...... ...... .3-24

3.2.12 Carriage Cable ................................................................................................3-26

3.2.13 Space Rack................. ..................... ..................... ..................... ..................... .3-28

3.2.14 Roller/Holder Backup Assembly....................................................................3-30

3.2.15 Guide Rail and Adjust Cam............................................................................3-32

3.2.16 Left Ground Plate............................................................................................3-34

3.2.17 Right Ground Plate .........................................................................................3-36

3.2.18 Rear and Cut She et Paper Feed Sensor Levers................ ............ ............ .......3-38

3.2.19 Platen Assembly............ ...... ... ...... ...... ... ...... ...... ... ...... ...... ... ...... ...... ... ...... ...... .3-40

3.2.20 Paper Chute Assembly....................................................................................3-42

3.2.21 Line Feed Motor Assembly ........................... ...... ...... ... ...... ...... ... ...... ...... ... ....3-44

3.2.22 Reset Spring....................................................................................................3-46

3.2.23 Idle Gear and Change Lever................. ...... ... ... ... ...... ... ... ... ...... ... ... ... ...... ... ... .3-48

3.2.24 Pressure Spring...............................................................................................3-50

3.2.25 Carriage Shaft.................................................................................................3-52

3.2.26 Leaf Spring......................................................................................................3-54

3.2.27 Bottom Paper Sensor Lev er s................. ..................... ..................... ............ ....3-56

3.2.28 Front Pressure Roller Assembly .....................................................................3-58

3.2.29 Tractor Assembly............................................................................................3-60

3.2.30 Main Frame.....................................................................................................3-62

3.3 PRINTER ADJUSTMENTS .........................................................................................3-65

3.3.01 General Information........................................................................................3-65

3.3.02 Printhead Gap Adjustment..............................................................................3-66

General Info rma ti o n............... ... ............ ............ ............ ............ ............ ... ............ ....3-66

Procedu r e............. ... ... ............ ..................... ..................... ..................... ...................3-68

Setup Phase............. ... ............ ..................... ..................... ............ ..................... .3-68

Printhead Gap Modification Phase ....................................................................3-68

Parallel Adjustment Phase .................................................................................3-68

Verification Phase..............................................................................................3-68

3.3.03 Key Combinations ..........................................................................................3-70

3.3.04 Menu Operation..............................................................................................3-71

General Info rma ti o n............... ............ ............ ............ ............ ............ ............ ..........3-71

Menu Mode............. ............ ..................... ..................... ............ ..................... ..........3-71

Printing the Menu ....................................................................................................3-72

Sample Me nu....... ... ............ ..................... ..................... ..................... ..................... .3-73

Reset Menu to Facto ry Defaults .......................... ............ ............ ............ ............ ....3-75

Limited Operation....................................................................................................3-76

General Info rma ti o n............... ............ ............ ............ ............ ............ ............ ....3-76

Procedu r e............. ... ............ ..................... .............................. ..................... .......3-77

Menu Setti n gs............ ... ............ ............ ..................... ..................... ..................... ....3-78

3.3.05 Top of Form................................................... ......... ...... ......... ...... ......... ...... ....3-82

General Info rma ti o n............... ... ............ ............ ............ ............ ............ ... ............ ....3-82

Setting Top of Form.................................................................................................3-82

Reset the Top of Form to Factory Default...............................................................3-82

3.3.06 Paper Park.......................................................................................................3-83

General Info rma ti o n............... ... ............ ............ ............ ............ ............ ... ............ ....3-83

Procedure: Continuous Feed to Single Sheet..........................................................3-83

Procedu re: Single Sheet to Con ti n uou s Feed........................ ..................... ............ .3-83

3.3.07 Tear Feature....................................................................................................3-84

General Info rma ti o n............... ... ............ ............ ............ ............ ............ ... ............ ....3-84

3.3.08 Forms Tear Off ...............................................................................................3-85

General Info rma ti o n............... ... ............ ............ ............ ............ ............ ... ............ ....3-85

Vertical Line Spacing Problems ..............................................................................3-86

Setting......................................................................................................................3-87

Using........................................................................................................................3-87

Checking Top of Form with Form Tear Off Activated............................................3-87

3.3.09 Resets..............................................................................................................3-88

Reset Menu to Facto ry Defaults .......................... ............ ............ ............ ............ ....3-88

Reset the Top of Form to Factory Default...............................................................3-88

3.4 CLEANING...................................................................................................................3-89

3.4.01 General Information........................................................................................3-89

3.4.02 Cleani n g Sch ed ul e........ ... ... ... ..................... ..................... ............ ...................3-89

3.4.03 Cleani n g To ol s........... ............ ..................... ............ ..................... ............ .......3-89

3.4.04 Areas to be Cleaned..................... ... ...... ...... ... ...... ...... ... ...... ...... ... ...... ...... ... ....3-89

3.5 LUBRICATION ............................................................................................................ 3-90

3.5.01 General Information........................................................................................3-90

3.5.02 Lubrica tion Sched ul e.......... ... ... ... ..................... ..................... ............ .............3-90

3.5.03 Lubrica tion Type s............... ... ... ..................... ..................... ............ ................3-90

3.5.04 Lubrica tion Amoun t s............. ..................... ..................... ............ ...................3-90

3.5.05 Lubrica tion Table.......... ... ... ..................... ............ ..................... ............ ..........3-91

3.5.06 Areas Not Lubricated...................... ...... ... ...... ...... ... ...... ...... ... ...... ...... ... ...... ....3-91

3.6 SHIPPING INSTRUCTIONS........................................................................................ 3-92

3.6.01 Return for Service...........................................................................................3-92

3.6.02 All Other Returns............................................................................................3-93

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SECTION FOUR: FAILURE ANALYS IS

4.1 OVERVIEW....................................................................................................................4-1

4.1.01 Introdu ction............. ....................................... ....................................... ............4-1

4.1.02 Printer Serial Number Identification.................................................................4-3

4.1.03 Firmware Revision Identifica tio n................................................... ......... ...... ...4-3

Header....................................... .............................. ....................................... ............4-3

4.2 REPORTING PROBLEMS............................................................................................. 4-4

4.2.01 General Information..........................................................................................4-4

4.2.02 Problem Li sts.......... ............ ............ ..................... ..................... ............ ............4-4

4.2.03 Reporting Methods............................................................................................4-5

Okili nk II........................................................... .........................................................4-5

Course Crit iq u e....... ... ... ..................... ..................... ..................... ..................... .........4-5

Fax Number ...............................................................................................................4-5

Mailing Address.........................................................................................................4-5

Information Provided.................................................................................................4-5

4.3 TROUBLESHOOTING UPDATES................................................................................ 4-6

4.3.01 General Information..........................................................................................4-6

4.3.02 Okilin k II........................................................... ................................................4-6

4.3.03 Faxable Facts ....................................................................................................4-6

4.3.04 Technical Service Bulletins ..............................................................................4-6

4.4 TROUBLESHOOTING TIPS.......................................................................................... 4-7

4.4.01 Preliminary Checks...........................................................................................4-7

4.4.02 Problem Ca te go ri es.................................. ..................... ..................... ...............4-8

ALARM Lamp Blinks (Fatal Errors)......................................................................... 4-8

Operational Errors......................................................................................................4-8

ALARM Lamp Lights (Paper End/Jam Conditions)................................................. 4-8

4.4.03 START HERE Flowchart .................................................................................4-9

4.4.04 Tips for Preventi n g Imag e Prob l ems................... ............ ............ ............ .......4-10

4.4.05 Common Problems..........................................................................................4-11

4.5 ABNORMAL OUTPUT................................................................................................ 4-14

4.5.01 Output Samples...............................................................................................4-14

Light Pri n t on the Ent i re Pa ge......... ..................... ..................... ..................... ....4-15

Uneven Print Density.........................................................................................4-15

Smeared Print.....................................................................................................4-15

Inconsistent Line Feed.......................................................................................4-15

Drifti n g Ma rgi n....... ... ... ..................... ..................... ..................... ..................... .4-15

Left Margin Dri fti n g Prob l em......... ... ... ............ ............ ............ ............ ............ .4-17

viii

4.6 FAULT ALARMS......................................................................................................... 4-18

4.6.01 General Information........................................................................................4-18

4.6.02 ALARM/LED Display Troubleshooting Table Index .................................... 4-19

4.6.03 ALARM/LED Display Troubleshooting Tables............................................. 4-20

4.7 REPAIR ANALYSIS PROCEDURES (RAPs)............................................................. 4-22

4.7.01 Using the RAPs...............................................................................................4-22

4.7.02 RAP Index.................. ...... ... ... ... ...... ... ... ... ...... ... ... ... ...... ... ... ... ...... ... ... ... ...... ... .4-23

RAP 01 No Power Suppl ie d to Pri nter........ ... ... ............ ............ ............ ... ............ ....4-24

RAP 02 No Spacing Operation................................................................................4-26

RAP 03 Printhead Homing Error.............................................................................4-28

RAP 04 Paper Jam During Paper Loading ..............................................................4-30

RAP 05 Printhe ad Pins Not Firing........... ... ............ ............ ............ ............ ... ..........4-31

RAP 06 Poor Print Quality.......................................................................................4-32

RAP 07 Ribbo n Fee d Prob l em........ ............ ..................... ............ ..................... .......4-33

RAP 08 Line Fee d Prob le m............... ... ... ..................... ..................... ............ ..........4-34

RAP 09 Operat io n Panel Malfunc ti o n............................. ............ ..................... .......4-37

RAP 10 Parallel Interface Problem..........................................................................4-38

RAP 11 Serial Interface Problem.............................................................................4-40

4.8 PRINTER TESTS......................................... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 4- 43

4.8.01 General Information........................................................................................4-43

4.8.02 Rolling ASCII Test ............................... ...... ......... ...... ......... ...... ......... ...... .......4-44

General Info rma ti o n............... ... ............ ............ ............ ............ ............ ... ............ ....4-44

Procedu r e............. ... ... ............ ..................... ..................... ..................... ...................4-44

Sample... ..................... ..................... ..................... ..................... ..................... ..........4-45

4.8.03 Font Test .........................................................................................................4-46

General Info rma ti o n............... ............ ............ ............ ............ ............ ............ ..........4-46

Procedu r e............. ... ............ ..................... .............................. ..................... .............4-46

Sample............ ..................... ..................... ..................... .............................. .............4-47

4.8.04 Serial Interface Loopback Test.......................................................................4-48

Loopbac k Co n ne ct or Co nfiguratio n ................................ ............ ..................... .......4-49

Serial Cable Information..........................................................................................4-50

Serial Interface Signal Requirements.......................................................................4-50

Commonly Used Serial Cable Configurations.........................................................4-51

IBM 25-Pin Cable Co nfiguratio n....... ..................... ............ ..................... ..........4-51

IBM 9-Pin Cable Configuration.........................................................................4-51

4.8.05 Hexadeci mal Dump Mod e.............. ............ ..................... ..................... ..........4-52

General Info rma ti o n............... ............ ............ ............ ............ ............ ............ ..........4-52

Exampl e............... ..................... .............................. ..................... ..................... .......4-52

Procedu r e............. ... ............ ..................... .............................. ..................... .............4-52

Sample............ ..................... ..................... ..................... .............................. .............4-53

4.9 RESISTANCE CHECKS.............................. ... ... .............................. ... .......................... 4-54

4.9.01 General Description........................................................................................4-54

Layout Dia gra m......... ... ... ............ ..................... ............ ..................... ..................... .4-55

4.9.02 Printhe ad............................. ............ ..................... ..................... ............ ..........4-56

Interconnect Diagram: Control Board to Printhead................................................4-56

4.9.03 Line Feed Mot or Resistance................................ ............ ..................... ..........4-57

4.9.04 Space Motor Resistance............ ... ............ ............ ..................... ............ ..........4-57

APPENDIX A: BOARD DIAGRAMS

A.1 OVERVIEW................................................................................................................... A-1

A.1.01 General Information.........................................................................................A-1

A.2 INDEX TO CHARTS..................................................................................................... A-2

A.2.01 Main Controller Board (FJIM).........................................................................A-4

A.2.02 Operator Panel Board (LEOP)......................................................................... A-6

A.2.03 Power Supply Assembly.................................................................................. A-8

A.2.04 Space Mot or Bo ard....... ... ... ..................... ..................... ..................... ............A-10

A.2.05 RS232-C Serial Interface Board - Option (LXHI)........................................ A-12

APPENDIX B: ILLUSTRATED PARTS LISTING

B.1 OVERVIEW ....................................................................................................................B-1

B.1.01 General Information..........................................................................................B-1

Format........................................................................................................................B-2

Current Part Numbers ................................................................................................B-3

B.1.02 Definition of Terms...........................................................................................B-4

Assemblies.................................................................................................................B-4

Blank . .........................................................................................................................B-4

Consumable................................................................................................................B-4

Document...................................................................................................................B-4

Drivers........................................................................................................................B-4

Firmware. ...................................................................................................................B-4

Option........................................................................................................................B-4

Option RSPL....................................................................... ............... ............... .........B-4

RSPL........... .............................. ....................................... ....................................... ... B-4

Technica l Service Bulletins ..................... ..................... ............ ..................... ............B - 5

520..............................................................................................................................B-5

521..............................................................................................................................B-5

Both............................................................................................................................B-5

B.1.03 Parts Ordering Information...............................................................................B-6

Service Cent er Re feren ce Guide....................... ... ............ ............ ............ ............ ... ...B - 6

Placing a Parts Order .............................................. ......... ...... ......... ...... ......... ...... ......B-7

B.2 CHARTS..........................................................................................................................B-8

B.2.01 Printer............. ..................... ....................................... .............................. .......B-10

B.2.02 Upper Cover Assembly......................... ............ ............ ............ ............ ..........B-1 2

B.2.03 Printer General Assembly...............................................................................B-14

B.2.04 Printer Unit......................................................................................................B-16

B.2.05 Printer Unit......................................................................................................B-18

B.2.06 Printer Unit......................................................................................................B-20

B.2.07 Carriage Assembly..........................................................................................B-22

B.2.08 Options............................................................................................................B-24

B.2.09 Option Parts ....................................................................................................B-26

B.2.10 Consumables...................................................................................................B-28

B.2.11 Packing Materials............................................................................................B-30

B.2.12 Documentation................................................................................................B-32

B.2.13 Service Training Kit Revision List.................................................................B-34

This page was intentionally l eft blan k.

xii

COURSE ADMINI STRATION

OVERVIEW

Okidata develo ped this cou rse in ord er to prov i de the informa ti o n necessa ry to in sta ll and maintain the Microline 520 and Microl i ne 521 pri nters. Upon successful compl et ion of this training course , yo u will be able to do the foll owing.

Install and operate the produc t Locate the major assemblies of the product Identify fault indications Perform corrective and prev entiv e mainten ance

The Service Handbook is the primary reference manual for this course. You cannot, however, successfully complete this course by referring only to this manual. Take the time to familiarize yourself with all of the docume nt ati on in the trai ni ng kit . This additio nal info rma tio n wil l greatly simpl ify working with the prod uct.

Okidata’s Techni cal Trai nin g Program is design ed to buil d a knowled g eabl e and efficie nt service and sup port group for Okida ta prod u ct s.

One step in becoming an Authorized Okidata Service Center is obtaining a training kit for the appropri ate pro duct . Thi s acqui sit i on allo ws the Deale rshi p to have referen ce materials available during service jobs. Having, and using, these reference materials will minimize the time and money spent on repairs.

Technician s com plet e Ce rti fi cat ion Test s as part of Oki dat a’s Aut hor i zati on process. Testin g familiarizes th e tech nici an wit h the pro duc t and refere nce mat eri al s.

This training course provides assembly level repair informat ion to the field technician. N o attempt is made to provide basic training in being a technician. This kit strives to train a technician to service the product. Okid at a views servi ce techn ic ians as re pre sen ta tiv es of Okidata. Through this course, Okidata seeks to provide the means and the motivation that will make good service a reality.

Remember

Compone nt lev el servic in g is prov id ed only at Okida t a Servi ce Rep a ir Dep ot s !

Microline 520/521 Service Handbook i - 1 Course Administration P/N 59257803

RECOMMENDATIONS

Prerequisites

Before begi nni ng this co urse , yo u shou ld know th e fol l owi n g conc ep ts.

Have an understanding of basic electronics Be familiar with electrostatic principles Be familiar with dot matrix technology and protocol Be familiar wit h the proper procedures for handlin g circui t board s, Re ad Only

Memory (ROM), and Random Access Memory (RAM) Be able to use basic tools Be able to use a digital multimeter (DMM)

Equipment

The followi ng equi p men t is recom men ded for the succe ssful com plet i on of th is tra ini ng course.

Microline 520 or Microline 521 (optional) Tools (optional - refer to Module Three of the Service Handbook) Personal Computer (for Okilink II connection) Modem (for Okilink II connection) Communicatio ns Soft ware (for Okili nk II connecti on) Telephone (for Faxable Facts connection) Facsimile Machin e (for Faxab le Facts connec ti on) Video Cassette Player (for viewing videotape) Video Monitor (for viewing videotape)

Documentation

You should hav e acc ess to the foll owing documenta ti o n whi le com pl et i ng th is co urse .

Okidata Servic e Cent er Refe rence Guide Service Handbo ok Printer Handbook Service Video tap e

Course Administration i - 2 Microline 520/521 Service Handbook

P/N 59257803

INFORMATION UPDATE S

Every effort has been made to ensure the accuracy of the information contained in this training course. Okidata is not respo nsi b le for errors beyo nd it s contro l .

Technical updates are made available to authorized Service Centers through the Technical Service Bulleti ns (TSBs / Oki data ’s Mont hly Techni ca l Mail). The TSBs are dist ri but ed via Okidata’s Bulle tin Board, Okil ink II.

Addition s and correc tio ns to th e train ing mate ria ls are av aila bl e in the Trai ni ng Sect i on of Okilink II. Please sign on and check this section before beginning this course.

For informati on on using Okili nk II, pl ease refer to the Servic e Cent er Refe ren ce Gui d e.

NOTICES

Pay attention to all not ices th at appear th ro ugh out this trai n ing course. They are for your safet y ! Here are the definitions of the notices.

NOTE:

This notice refers to sup p le men ta l inf o rmat i on.

CAUTION:

Deviation from the li st ed proc ed ure s may resul t in dama ge to the pro d uct.

WARNING:

Deviation from the listed pro cedur es ma y result in personal injury.

Microline 520/521 Service Handbook i - 3 Course Administration P/N 59257803

WHERE TO SEND TESTING MATE RIAL S

Refer to the Okidata Servi ce Ce nter Re feren ce Guid e for whe re to send the test mate ria ls. The Okidata Service Center Reference Guide is sent to your dealership along with the Okidata

Service Contra ct mate ria ls. It is availab le fro m Oki dat a Deal er Service. It is also available through Okilink II.

Course Administration i - 4 Microline 520/521 Service Handbook

P/N 59257803

MISSING ITEMS OR MISSING PAGE S

Missing Items When you receive the training kit, you MUST verify that the kit contains the items listed on the

Read Me First sheet. If any items are missin g, pl ease con ta ct Okidat a Logistics at the app ro pri at e nu mb er li st ed below.

Facsimile 1-609-424-7 423 Voice 1-800-72 7-8654

You must prov id e the fol l owi n g info rmation.

• Okidata Auth ori zati on Num ber (Deale r Number)

• Okidata Customer Number

• Order Acknowledgment Number (on the invoice)

• Part Number of kit

Missing Pages

If you find that pages are missi ng from any item in this ki t, please co ntac t Oki dat a Techn ical Training.

Please FAX your request or use Okilink II.

Fax Number: (609) 235-2600, ext. 7034 Okilink Login Name : Technica l Trai nin g

You must prov id e the fol l owi n g info rmation.

• Okidata Auth ori zati on Num ber (Deale r Number)

• Part Number of docu me nt wit h missin g pages

• Name of document with missing pages

• Page numbers of mi ssin g pages

If it is the Service Han dbo ok, be sure to speci fy the secti on (i, 1, 2, 3, 4, a, or b).

• Your facsimi l e numb er (wit h area code )

Microline 520/521 Service Handbook i - 5 Course Administration P/N 59257803

COURSE PATH

This Course Admini stra tio n direc ts you throu gh the trai nin g packag e. Each section covers a different part of th e train i ng. Tasks wit h in each sect ion dire ct you to the porti on s of the trai nin g materials th at cover th e sub j ect you are stu d yin g.

When you have co mp le ted one section, move on to the next. Yo u must achieve a score of 80% or greater on your Certi fi cation Test to successfu l ly com pl ete th is cou rse.

You must return your co mp le te d Certi fi cat i on Test Answer Sh eet an d Course Cr i tiq ue to Okidata within 30 days after the kit is receive d by your Deal ersh i p. If multi ple tech nici an s are training at your De alership, only one techni cian must com plet e the te sti n g duri ng th e 30 days.

DO NOT STAPLE THE ANSWER SHEET TO THE COURSE CRITIQUE!

Be sure to make a copy of the Answer Sheet for your record s. Your Answer Sheet will be corrected wit hin two days after it is received by Okidat a. If you

achieve a score of 80% or higher, you will receive a Certificate of Training. The Dealership you work for will become an Aut hori zed Servi ce Cente r fo r the prod u cts cov ered in this trai n in g packag e.

Service Auth ori za tio n is appro v ed once Oki data proc esses the Answe r Sheet . The Certi fi cat e of Training will be mail ed to you afte r the Answer Shee t is correct ed .

You and your Dealership are responsible for returnin g the Answer Sheet and Course Crit i que within 30 days after receiving the training kit. Okidata strongly urges you to keep track of the date you return your Answer Sheet and Course Critique. Certification and Authorization are processed within two days after Okidata receives the testing materials. A certificate for successful completion of the training program will be sent to you within 21 days. If authorization is not updat ed withi n two days or a certi fi cat e rece iv ed wit hi n 21 days, con ta ct Okidata Dealer Serv ic e.

Proceed through each section and perform the assigned tasks.

Learn from the Course and Good Luck!

Course Administration i - 6 Microline 520/521 Service Handbook

P/N 59257803

SERVICE TRAINI NG

Requirements

You will need the following items.

Service Center Re feren ce Guide Service Handbo ok User’s Documentation Service Video tap e Video Cassette Play er and Moni tor

Service Train in g is div ide d int o the fol l owing six section s.

General Descriptio n Installation Principles of Operation Failure Analysis Appendices Maintenance

Disassembly/Assembly Adjustments and Service Checks Cleaning Lubrication Shipping Instructions

Microline 520/521 Service Handbook i - 7 Course Administration P/N 59257803

General Description

This section describe s the featu res and spe ci fic atio ns of the prin t ers.

Assigned Tasks

Read Section 1 of the Service Handbook. Read Appendix A in the Printer Handbook.

Installation

In this section, you will install the unit. You will also perform various tests.

Assigned Tasks

Review the Printer Handbook Read the Introdu ct ion ; Chap t ers 1, 2, 3, 4, and 5; and Appen di ces B, C, D, E, and F

in the Printer Handbook. If a product is availab le , perform th e tests li st ed below. Refer to Sect ion 4 of the

Service Handbook.

Rolling ASCII Font Test

Principles of Operation

This section describe s the func ti on of the maj or asse mbli es from an elect ric al and mech anic al perspecti ve .

Assigned Tasks

Read Section 2 of the Service Handbook.

Course Administration i - 8 Microline 520/521 Service Handbook

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Failure Analysis

This section covers the methods used to identify and correct problems with the unit.

Assigned Tasks

Read Section 4 of the Service Handbook. Read Chapter 6 of the Printer Handbook. Study the Board Diagrams in Appendix A of the Service Handbook. Check Okilink II for addit ion al troub le shoo tin g info rmat i on. Refer to the Servi ce

Center Reference Guide for information on accessing Okilink II.

Appendices A and B

Appendices A and B contain charts, illustrations, and an illustrated parts list to support you in servicing the product.

Appendix A

Appendix A contains inform atio n about the print ed circ uit boards (PCBs). This appendix includes reference charts which present data regarding function, firmware, fuses, jumpers, sensors, switches, and test points. An illustration of each board is also included.

Appendix B

Assigned Tasks

Look through Appendix A and Appendix B in the Service Handbook.

Appendix B is an illu stra ted pa rts list in g of the produ ct . This list ing is cross-referenced to Sectio n 3 of the Service Handb ook.

Microline 520/521 Service Handbook i - 9 Course Administration P/N 59257803

Maintenance

Disassembly / Assembly

Assigned Tasks

Read Section 3.2 of the Service Handbook. View th e videotape.

CAUTION:

Okidata does not reco mmen d perfo rming the disassembl y / assembl y pro cedu res on a product whi ch is opera ti n g norma ll y. Therefo re, you are no t requi red to perf orm the disassembly / assembly procedures to complete this training.

Adjustments and Service Checks

This section explain s the adjust me nts perfo rmed after parts replaceme nt. Hardware repl ace men t may require adjustments to firmware set ti ngs. This section also explai ns vi ewi ng and reset t ing counters.

Assigned Tasks

Read Section 3.3 of the Service Handbook. Perform the procedures li st ed in Secti on 3.3 of the Servi ce Hand book.

Cleaning

Assigned Tasks

Read Section 3.4 of the Service Handbook.

Lubrication

Assigned Tasks

Read Section 3.5 of the Service Handbook.

Shipping Instructions

Assigned Tasks

Read Section 3.6 of the Service Handbook.

Course Administra ti on i - 10 Microline 520/ 521 Servi ce Handboo k

P/N 59257803

SERVICE AUTHORIZATION

General Information

Read throug h the instructions for co mp le ti n g the te sti n g proce ss before you begin. This section contain s the Answer Shee t, Certification Test, and Course Cri ti q ue for this service

training pa ckag e. These are the only copie s of t hese it ems yo u wi ll re cei v e.

DO NOT WRITE ON THESE ITEMS!

PHOTOCOPY EACH ITEM!

Use the photocopies to comp lete the test ing process. Photo co py the Cert ific at ion Test, Answer Sheet, and Cou rse Cri ti que as required for e ach techn i cian being train ed .

The informati on provi ded on the Answer Sheet and Course Crit i que is use d to update your Dealership’s Okid at a Servic e Warran ty Profile and to process your Certi fic ate of Trai ni ng. The critique information is used to respond to your questions regarding this training package.

MAKE YOUR RESPONSES COMPLETE AND LEGIBLE!

Feel free to reference the trai nin g materi al as you answer the test questi o ns. Every attempt has been made to test your knowledge of the product and your ability to use the

reference materi als in this kit. No attempt has been made to write "tri ck quest ion s". If you have a question abou t a specific test question or answe r, pl ease brin g it to the att en t ion of

Okidata Techni cal Trai ni ng. Refer to the Service Cent er Refe ren ce Gui de for in form at ion on contacting Okidata Technical Training.

In order to improv e the qualit y of future tra in i ng courses, Okidat a wel comes you r eval uat ion of this training prog ram . Please comp le te the course c rit iqu e for thi s trai nin g course .

Before returning your completed testing materials, photocopy your completed Answer Sheet for your records.

DO NOT ATTACH ANYTHING TO THE ANSWER SHEET!

Microline 520/521 Servi ce Han dbo ok i - 11 Course Administra ti on P/N 59257803

Certificati on Tes t

Requirements

You must achiev e a score of 80% or greater on your Ce rti fi cat i on Test to suc cessfu l ly com plet e this course.

You will need the following items.

Service Handbo ok User’s Documentation #2 Lead Penci l

Assigned Tasks

Read through all instructions BEFORE comp le ting the testi n g pro cess. Photocopy the Certi fic at ion Test and Answe r Sheet pro vid ed in thi s kit. Use the

photocopies to complete the testing process. Complete the top secti on of the Answe r Sheet. Make your resp onses le gib le . Answer the Certification Test Questions by filling in th e appro pri at e blo ck on the

Answer Sheet. Use a Number 2 pencil and compl et ely fil l in the selected block.

DO NOT ATTACH ANYTHING TO THE ANSWER SHEET!

Make a copy of the complete d Answe r Sheet for your reco rds.

Course Critique

Requirements

You will need the following items.

Your photocop y of the Cou rse Cri ti q ue

Assigned Tasks

Complete the Course Cri ti q ue. Return the Answer She et and Course Cri t iq ue to Okidat a Deal er Serv ic e.

DO NOT ATTACH ANYTHING TO THE ANSWER SHEET!

DATE ITEMS RETURNED TO OKIDATA: __________________________

Course Administra ti on i - 12 Microline 520/ 521 Servi ce Handboo k

P/N 59257803

Answer Sheet: Microline 520/521

Section 1

Dealer Code:

Today’s Date: Technician’s Name: Company: Company’s Address:

City: State/Province: Zip/Po sta l Co d e: Country: Phone #: Fax #: If your Dealership uses Okil ink II, please pro vid e your Deal ersh i p’s Lo gin Name. First:

Last:

Section 2

ABCD ABCD

1. 11.

2. 12.

3. 13.

4. 14.

5. 15.

6. 16.

7. 17.

8. 18.

9. 19.

10. 20.

Microline 520/521 Servi ce Han dbo ok i - 13 Course Administra ti on P/N 59257803

Course Critique: Microline 520/521

Deal er Code:

Today’s Date: Technician’s Name: Company: Company’s Address:

City: State/Province: Zip/Posta l Code: Country: Phone #: Fax #:

1. Have you completed other Oki da ta Self-St ud y Servi ce Trai nin g packag es?

Yes

2. Please rate this course.

Excellent Above Averag e Poor Average

3. Does your Dealership use Okilink II?

Yes If yes, please provid e your Deal ersh i p’s Lo gi n Name. First Name: Last Name:

Below Average

Course Administra ti o n i - 14 Microline 520/5 21 Servi ce Handbo ok

P/N 59257803

4. Comments

Microline 520/521 Servi ce Han dbo ok i - 15 Course Administra ti on P/N 59257803

Certification Test: Microline 520/521

1. After install ing the space mot or, Okid at a reco mm en ds th at you check the printhead gap.

A. True

B. False

Correct Answer: A Pages 3-2 and 3-26, Servi ce Handbook, Rev 01 and 02 Pages 3-2, 3-2 4, and 3-66, Servi ce Handbook, Rev 03

2. Refer to RAP 01. You have pressed the AC power switch to ON, but the unit does not

power ON. The next step is to

A. replace the fuse.

B. check if the AC ca ble is connected properly.

C. replace the space motor assemb l y.

D. remove the printhead.

Correct Answer: B Page 4-10, Service Handbook, Rev 01 and 02 Page 4-24, Service Handbook, Rev 03

3. The + 40 vdc needed for the printhead and space motor drive can be verified at

__________ on the main control (FJIM) board.

A. CN1 Pins 8 and 9

B. CN3 Pins 1 and 2

C. CN7 Pins 29 and 31

D. CN6 Pins 1 and 2

Correct Answer: C Page A-4, Service Handbook, Rev 01 and 02 Page A-4, Service Han dbo ok, Re v 03

Course Administra ti o n i - 16 Microline 520/5 21 Servi ce Handbo ok

P/N 59257803

4. According to Appen dix A of the Servic e Handb oo k, on e funct io n of the main cont rol

board is to regulate the AC voltages from the power suppl y (transfo rme r).

A. True

B. False

Correct Answer: A Page A-4, Service Handbook, Rev 01 and 02 Page A-4, Service Han dbo ok, Re v 03

5. You are using RAP 11 to trou bleshoot a printer. The uni t cann ot recei v e seria l

communicat ion from the host. You have verified that the cable has the prop er configuration of pins. No ALARM LEDs are blinking. Your next step should be to

A. replace the transfo rmer.

B. replace the RS 232-C serial board.

C. check your serial interface parameters.

D. replace the main control board (FJIM).

Correct Answer: C Page 4-26, Service Handbook, Rev 01 and 02 Page 4-40, Service Handbook, Rev 03

Microline 520/521 Servi ce Han dbo ok i - 17 Course Administra ti on P/N 59257803

6. The printer is processing a head overhe at alarm . When the printhead temp erature exceeds

110 degrees Celsius, the printer switches to unidirectional print. When the printhead temperatu re excee ds 11 8 deg rees Celsius, the printer wil l

A. need a new space motor.

B. continue unidirectional print.

C. alternate between unidirectional print and bidirectional print.

D. stop printing.

Correct Answer: D Pages 2-21, 2-28, and 4-31, Service Handbook, Rev 01 and 02 Pages 1-11, 2-15, 2-32, and 4-21, Service Handbook, Rev 03

7. Before you begin troubleshooti ng an ALARM / LED display, you should always

A. replace the power supply.

B. check that all of the connectors of the prin ter are makin g goo d contac t.

C. replace the main control board.

D. replace the operator panel.

Correct Answer: B Page 4-30, Service Handb ook , Rev 01 and 02 Page 4-20, Service Handbook, Rev 03

Course Administra ti on i - 18 Microline 520/ 521 Servi ce Handboo k

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8. According to the Printer Handb ook or Sectio n Three of thi s Servi ce Han dbo ok, whi ch of

the following settings is NOT a default menu setti n g of the serial interfa ce configuration?

A. Parity - Even

B. Serial Data - 8 bits

C. Protocol - Ready/Busy

D. Baud Rate - 9600 bps

Correct Answer: A Page 90, Printer Manual User’s Docum enta tio n, Rev 01 and 02 Page 3-81, Service Handbook, Rev 03

9. The ALARM lamp is flashing. The PROP and 10 cpi lamps are lit. Which alarm is th e

printer experiencing?

A. Printhead Data Transfer Ala rm

B. Printhead Type Alarm

C. Paper End Alarm

D. Space Motor Ala r m

Correct Answer: B Page 4-29 and 4-30, Service Handbook, Rev 01 and 02 Pages 4-19 and 4-20 , Serv ice Hand b ook , Rev 03

Microline 520/521 Servi ce Han dbo ok i - 19 Course Administration P/N 59257803

10. You insta ll a new control board in the printer. What are the indic at ion s of an inco rrect l y

posit ione d cut sheet / continuous s ensor lever?

A. The unit will not power-ON.

B. All lamps on the operator panel light.

C. The ALARM lamp lights and F1 on the control board blows.

D. The ALARM lamp lights and the unit will NOT auto mat ical ly load paper.

Correct Answer: D Pages i-7 and i-8, Service Handbook, Rev 01 and 02 OLD QUESTION Page 3-16, Service Handbook, Rev 03 NEW QUESTION

11. What is the recomm en ded amb ien t temp erat u re and rela tiv e humi dit y (RH) for the pri nte r

whil e operating?

A. 41°F to 104°F, 20% to 80% (RH)

B. 41°F to 104°F, 10% to 70% (RH)

C. 41°F to 104°F, 20% to 50% (RH)

D. 41°F to 104°F, 20% to 90% (RH)

Correct Answer: A Page 1-2, Servic e Handb ook , Rev 01 and 02 Page 1-4, Servic e Handb ook , Rev 03

12. The Microli ne 520 and Micro l ine 521 prin ters all o w you to prin t up to eight differe nt bar

codes.

A. True

B. False

Correct Answer: A Pages 84, Print er Man ual and 1-8, Servi ce Han dbo ok , Rev 01 and 02 Page 1-7 and 1-8, Service Handbook, Rev 03

Course Administra ti on i - 20 Microline 520/ 521 Servi ce Handboo k

P/N 59257803

13. The Micro lin e 520 and Microline 521 print ers come wit h ____ ___ ___ ___ Kbyte of

resident RAM.

A. 32

B. 64

C. 128

D. 256

Correct Answer: C Page 1-4, Servic e Handb ook , Rev 01 and 02 Page 1-20, Service Handbook, Rev 03

14. Refer to RAP 02. The carriage is jammed. The ribbon is not jammed. What do you do

next?

A. Install a new space motor.

B. Power OFF the printer, then power ON.

C. Remove the space motor assem bly and insp ec t the te et h on the spac e rack and

space motor gear.

D. Replace fuse F1 on the main controller board.

Correct Answer: C Page 4-12, Service Handbook, Rev 01 and 02 Page 4-26, Service Handbook, Rev 03

15. You must replace the line feed motor. The disassembly procedure also tells you to

remove the li n e fe ed idle ge a r.

A. True

B. False

Correct Answer: B Page 3-54, Service Handbook, Rev 01 and 02 Page 3-46, Service Handbook, Rev 03

Microline 520/521 Servi ce Han dbo ok i - 21 Course Administra ti on P/N 59257803

16. Three items factor into printhead gap information.

1. Printhead Gap Adjustment (performed by a service technician)

2. Printhead Gap Adjust (set in the prin t er menu, under the Set -up Grou p)

3. Gap Control (set in the printer menu, under each [Paper Feed] Group)

A. True

B. False

Correct Answer: A Page C-1, Service Handbook, Rev 01 and 02 OLD QUESTION Pages 1-12 and 2-18, Service Handbook, Rev 03 NEW QUESTION

17. Which of th e follo wi ng areas of the pri nte r shou l d NOT be lubricated?

1. Tractor pins

2. Pressure roller (Rubber Face)

3. Platen assembly (Rubber Face)

4. Teeth of gears in the gear case assembly

A. 1

B. 1 and 2

C. 1, 2, and 3

D. 1, 2, 3, and 4

Correct Answer: D Page 3-88 and 3-89, Service Handbook, Rev 01 and 02 Page 3-91, Service Handbook, Rev 03

Course Administra ti on i - 22 Microline 520/ 521 Servi ce Handboo k

P/N 59257803

18. You are performing the printhea d gap adju st men t . The printh ead gap is changed by

turning th e adju sti n g screw, locat ed on the spa ce mo to r assemb l y. Turn in g the adjusting screw coun ter-cl oc kwi se wil l increase the gap. Turnin g it clockw i se will decrease the gap.

A. True

B. False

Correct Answer: B Page 3-68, Service Handbook, Rev 01 and 02 Page 3-68, Service Handbook, Rev 03

19. The ALARM lam p is flashi n g. The 15 cpi LED is lit. Which of the fol lowing should be

replaced fi rst ?

A. Printhead

B. Line feed motor

C. Space motor

D. Main cont rol boa rd and / or ROM

Correct Answer: D Page 4-30, Service Handb ook , Rev 01 and 02 Page 4-20, Service Handbook, Rev 03

Microline 520/521 Servi ce Han dbo ok i - 23 Course Administra ti on P/N 59257803

20. Before rese tti ng a printer men u to facto ry set ti n gs, Okidat a reco mmends that you

A. run a self test.

B. perform the hex dump test.

C. power OFF the printer, then press and hold the LINE FEED while powering

ON the printer.

D. print the menu.

Correct Answer: D Pages 47, User’s Documentati on and 3-81, Servi ce Handbo ok, Rev 01 and 02 Page 3-75, Service Handbook, Rev 03

Course Administra ti on i - 24 Microline 520/ 521 Servi ce Handboo k

P/N 59257803

SECTION ONE

SPECIFICATIONS

1.1 OVERVIEW

1.1.01 Gene ral Infor mati on

The Microline 520 and Microline 521 are letter quality, nine-pin, dot-matrix printers which utilize OKI

SMART paper handling. Patented Okidata technology does away with the manual

head gap adjustment. The printer actually "reads and learns" the print medium being used, then automat ical ly adju sts th e head gap to the opt im um dist an ce . This auto gap pi n g proce ss lead s to longer printhead life.

Options incl ude the Bott om Feed Push Tract or , Cut-Sh ee t Feed er, Pull Tract or and Serial Interface Board.

The Microline 520 is an 80 column printer. The Microline 521 is a 132 column printer. Okidata’s one year limi te d warrant y cove rs the part s, labo r and prin t head on both prin ters. The following items are available for the printer.

OKI

SMART Typer - software which provid es the fle xib ili ty for th e Micro li ne 590/ 521 to

function like a typewriter on checks, labels and envelopes.

NOTE:

OKI

SMART Panel - a utility program that lets yo u contro l sel ect ed pri nter fun ct i ons fro m

your personal computer. Scalable Fonts - 14 scalable fonts, available on diskette.

The OkiSmart software includes three programs.

1. OkiSmart Control

2. OkiSmart Panel Emulator

3. OkiSmart Setup

Refer to the Printer Handbook for more information.

Microline 520/ 521 Servi ce Han dbo ok 1 - 1 Specificat ion s P/N 59257803

1.2 PHYSICAL SPECIFICATIONS

1.2.01 Dimensions

NOTE:

Dimensions INCLUDE the platen knob, acoustic cover, and paper separator.

Microline 520

Width: 16.9 inches (43 centimeters) Depth: 14.9 inches (37.8 centimeters) Height: 6.5 inches (16.5 centimeters)

Microline 521

Width: 23 inches (58.4 centimeters) Depth: 14.9 inches (37.8 centimeters) Height: 6.5 inches (16.5 centimeters)

1.2.02 Printer Weight

Microline 520

17.6 pounds (8.0 kilograms)

Microline 521

23.1 pounds (10.5 kilograms)

Specificati ons 1 - 2 Microline 520/52 1 Serv ice Handb ook

P/N 59257803

1.3 POWER REQUIREME NTS

1.3.01 Input Power

120 VAC: +5.5 / -15% 230/240 VAC: +10 / -14%

1.3.02 Power Consum pti on

Operating: 110 VA Idle: 40 VA Local Test : 70 VA

1.3.03 Po wer Fre quency

120 VAC: 60 Hz +/- 2% 230/240 VAC: 50/60 Hz +/- 2%

Microline 520/ 521 Servi ce Han dbo ok 1 - 3 Specificat ion s P/N 59257803

1.4 ENVIRONMENTAL CONDI TIONS

1.4.01 Acoustic Rating

Near Letter Quality Mode

Microline 520 54. 9 dBA Microline 521 54. 4 dBA

Utility Mode

Microline 520 57. 2 dBA Microline 521 56. 9 dBA

Quie t Mode

Microline 520 52. 5 dBA Microline 521 52. 3 dBA

1.4.01 Altitude

10,000 feet (3,050 meters)

1.4.03 Ambi ent Tempe ra ture and Rel ati ve Humi di ty (RH)

While operati ng: 41 to 104 degrees Fah renheit (5 to 40 degrees Celsius)

Operating humidity: 20% to 80% RH

While in storage: 14 to 122 degrees Fahrenheit ( - 10 to 50 degrees Celsius)

Storage humidity: 5% to 95% RH

Specificati ons 1 - 4 Microline 520/52 1 Serv ice Handb ook

P/N 59257803

1.5 AGENCY APPROVAL S

1.5.01 Listings

UL No: UL Standard No. 1950 D3 CSA No: CSA Standard 22.2-950 D3 FCC: FCC Certifie d per Part 15, Subje ct J, Class B IEC: IEC 950 VDE: VDE 0805 VDE 0875 Class B BS: BS 7002

Microline 520/ 521 Service Handbook 1 - 5 Specifications P/N 59257803

1.6 OPERATIONAL SPECIFICAT IO NS

1.6.01 Char ac ter Matr ix Size s

Table of Print Speed and Character Matrix

Mode Near Letter

Speed 80 (12 cpi) 320 (12 cpi) 427 (12 cpi)

Matrix (H x V) 17 x 13 9 x 7 7 x 7

1.6.02 Char ac ters Per Line

Microline 520

Characters Per Line Characters Per Inch

Microline 521

Characters Per Line Characters Per Inch

Utility High Speed

Quality

80 10

96 12 120 15 137 17.1 160 20

136 10 163 12 204 15 233 17.1 272 20

Draft

1.6.03 Char acter Pi tches

5, 6, 8.5, 10, 12, 15, 17.1, 20

Specificati ons 1 - 6 Microline 520/52 1 Serv ice Handb ook

P/N 59257803

1.6.04 Charac ter Sets

Standard ASCII EPSON Character Set I & II IBM Character Set I, II & All Characters Foreign Character Substitution International Character Sets Code Page 850, 860, 863, 865 and 437 Line Graphics Bar Code

Code 39 UPC A UPC E EAN 8 EAN 13 Interleaved 2 of 5 Code 128 (A, B, C) Postnet

1.6.05 Emulations

NOTE:

The emulati o ns are co-resid en t

Epson F X IBM Proprinter Microline Standard

Microline 520/ 521 Servi ce Han dbo ok 1 - 7 Specificat ion s P/N 59257803

1.6.06 Fonts

Near Letter Quality

Courier

Utility

Gothic

High Speed Draft

Gothic

Bar Code

Code 39 UPC A UPC E EAN 8 EAN 13 Interleaved 2 of 5 Code 128 (A, B, C) Postnet

1.6.07 Front Panel Switches

SELECT / Menu Micro Feed Up / Down Shift Paper Park Line Feed Pitch Selection FORM FEED / Load Print Quality Selection Top of Form Tear Quiet Reset

1.6.08 Graphics Resolution

Graphics Resolution: 288 (horizon tal) x 144 (vert ical) dots per inch (DPI) maximu m

1.6.09 Interface

Standard

Centronics Parallel

Optional

RS232C Serial

Specificati ons 1 - 8 Microline 520/52 1 Serv ice Handb ook

P/N 59257803

1.6.10 Line Fee d Increm ents

Fixed

6 lines per inch (lpi) [0.167 inch (4.23 millimeters)] 8 lines per inch (lpi) [0.125 inch (3.175 millimeters)]

Variable

n/60 inch n/72 inch n/14 4 inch n/21 6 inch

1.6.11 Line Feed Time

65 milliseco nds 6 lines per inch (lpi) 6 milliseconds 8 lines per inch (lpi) 1 second 5.0 inches (Continuous paper feed rate)

1.6.12 Menu Mode

Switch Action

Paper Park Prints the entire menu. Line Feed / Reverse Selects Group Function FORM FEED / Load Selects Item

Tear Selects Item Value

SEL / Menu Exits Menu Mode, Enters Select

Microline 520/ 521 Servi ce Han dbo ok 1 - 9 Specificat ion s P/N 59257803

1.6.13 Paper Fee d Methods

Standard

Friction Feed (Top) Rear Push Tractor (R ear)

Optional

Pull Tractor (Bottom) Bottom Push Tractor Feed (Bottom) Single-Bin Cu t Sheet Feede r (Top)

CSF 5000 - Narrow CSF 5001 - Wide

1.6.14 Paper Feed Paths

Top Feed (Standard) Rear Feed (Standard ) Bottom Feed (by using an Optional feed mechanism) Special Features

Paper Park Automatic Paper Loading Forms Tear Off

1.6.15 Pa per Loa ding

Auto Loading (To p Feed ) Press FORM FEED / Load switch to feed paper to defau lt posit i on

1.6.16 Paper Out Detecti on

Distance from end of paper

Rear Feed: 0.5 inches (12.7 mm ) Bottom Feed: 0.5 inches (12.7 mm) Top Feed: 0.5 inches (12.7 mm)

1.6.17 Paper Tear Capabi l iti es

Forms Tear-0ff (sharp edge on access cover) Metal Tear Bar (with optional bottom feed tractor unit)

Specificati ons 1 - 10 Microline 520/52 1 Serv ice Handb ook

P/N 59257803

1.6.18 Print Method

Printhead Type

General Information

Impact: Dot Matrix 9 pin printhead .0134 inch (0.34 milli met er) di am eter pi ns

Overheat Protection

When print head temp era tu re ex cee ds 11 0 deg rees Ce lsi u s, the printer stops bi-d i rect i on al printing. Uni-directional printing begins.

If the temperature exceeds 118 degrees Celsius, printing stops. Printing wil l resume when the printhead temperature drops be low 11 8 degre es Cel si us.

NOTE:

Refer to Section Two for more information on printhead operation.

Microline 520/ 521 Servi ce Han dbo ok 1 - 11 Specificat io ns P/N 59257803

Printhead Gap Information

Three items factor int o prin thea d gap info rmat i on.

1. Printhead Gap Adjustment This is a SERVICE ADJUSTMENT made by a technician. It is covered in Sectio n 3.3 of thi s Servi ce Han dbo ok. The Adjustmen t measure s 0.0 14, +/- 0.0 01 inch es (0.3 5, +/- 0.03 mm).

2. Printhead Gap Adjust This is a MENU ITEM in the SET-UP Group. It fine tunes the auto m atic setting o f the prin thead ga p. The settings are 0, 1, and -1. 0 is the factory default. Use 1 to darken print (if output is co nsistently light). Use - 1 to lighten print (if output is consist ently da rk ).

3. Gap Control This is a MENU ITEM in each [Paper Feed] Group. The Groups are REAR FEED, BOTTOM FEED, and TOP FEED. Gap Control de termines how the pri n thea d ga p is set . The settings are li st ed bel ow.

Auto Gap, Semi Auto Gap, 1, 2, 3, 4, 5, 6, 7, 8, 9

An explanati o n of eac h setti n g fol l ows.

Specificati ons 1 - 12 Microline 520/52 1 Serv ice Handb ook

P/N 59257803

Auto Gap

This is the factory default. Automatically determines paper thickness of the first page. During single-sheet feed, each page’s thickness is checked while a job is

printing.

Semi Auto Gap

Similar to Auto Gap. Automatically determines paper thickness of the first page. During single-sheet feed, each page’s thickness IS NOT checked "while"

a job is printing.

1, 2, 3, 4, 5, 6, 7, 8, 9

Used when the same paper is used ALL of the time. Bypasses the automatic head gap adjustment. 1 is the narrowest gap setting. 9 is the widest gap setting.

1-7-01.tif

Microline 520/ 521 Servi ce Han dbo ok 1 - 13 Specificat io ns P/N 59257803

1.6.19 Print Modes

Near Letter Quality Utility High Speed Draft

1.6.20 Print Speed

Table of Print Speed and Character Matrix

Mode Near Letter

Quality

Speed 80 (12 cpi) 320 (12 cpi) 427 (12 cpi)

Matrix (H x V) 17 x 13 9 x 7 7 x 7

Utility High Speed

Draft

Specificati ons 1 - 14 Microline 520/52 1 Serv ice Handb ook

P/N 59257803

1.7 PAPER SPECIFICATIONS

CAUTION:

Use Bottom Feed and/ or opt ion al Pull Tract or for card stock and label s.

1.7.01 Types

Card Stock

Weight: 120 lbs. (450 g/m2) Maximum Width: Microline 520 5 to 8 inches (12.7 to 20.3 centimeters)

Microline 521 5 to 14 inches (12.7 to 35.6 centimeters) Length: 3 to 17 inches (7.62 to 43.18 centimeters) Thickness: .01 7 inches (0. 44 mill imeters) Paper Feed Path: Bottom Printhead Gap

Information: Refer to the Printhead Gap Information, Section 1.6

Continuous Form

Weight:

Single Pa r t 12 - 24 lb. (45 to 90 g/m

)

Multi-Part, Carbonless 9 - 11 lb. (35 to 40 g/m

)

Multi-Part, Interleaf Paper 10 - 12 lb. (38 to 45 g/m Carbo n 9 lb. (35 g/m

)

Width: Microline 520 3.5 to 10.5 inches (8.8 to 26.6 centimeters)

Microline 521 3.5 to 16.5 inches (8.8 to 41.9 centimeters) Length: 3 to 17 inches (7.62 to 43.18 centimeters) Thickness: 0.014 inches (0.36 millimeters) Rear Feed

0.017 inches (0.44 millime te r s) Bottom Feed Paper Feed Path: Rear or Bottom Printhead Gap

Information: Refer to the Printhead Gap Information, Section 1.6

Microline 520/ 521 Servi ce Han dbo ok 1 - 15 Specificat io ns P/N 59257803

Cut Sheet

Weight: 12 to 24 lbs. (45 to 90 g/m2) Width: 7.2 to 14.3 inches (18.3 to 36.3 centimeters) Width: Microline 520 7.2 to 8.5 inches (18.2 to 21.5 centimeters)

Length: 3 to 17 inches (7.62 to 43.18 centimeters) Thickness: 0.014 inches (0.325 millimeters) Maximum Paper Feed Path: Top Printhead Gap

Information: Refer to the Printhead Gap Information, Section 1.6.

Envelopes

Weight: 24 lbs. (90 g/m2) Maximum Size:

Microline 521 7.2 to 14.3 inches (18.2 to 36.3 centimeters)

Single Feed

Minimum: 6.5 x 3.6 inches (16.5 x 9.1 centimeters) Maximum: 9.5 x 4.1 inches (24.1 x 10.4 centimeters)

Continuous

Non-overlap type

Thickness: .01 4 inches (.325 millimeters) Maximum Paper Feed Path: Bottom Printhead Gap

Information: Refer to the Printhead Gap Information, Section 1.6.

Specificati ons 1 - 16 Microline 520/52 1 Serv ice Handb ook

P/N 59257803

Labels

Weight: N/A Width: Microline 520 3.5 to 10.5 inches (8.8 to 26.6 centimeters)

Length: 3 to 17 inches (7.62 to 43.18 centimeters) Thickness: .011 inches (0.28 mm) Maximum (including backing) Paper Feed Path: Bottom Printhead Gap

Information: Refer to the Printhead Gap Information, Section 1.6.

CAUTION:

Use Bottom Feed and/ or opt ion al Pull Tract or for card stock and label s.

Transparency

NOTE:

Roller marks may mar the tra n spa rency under high temperat ure / high humidi ty conditions.

Microline 521 3.5 to 16.5 inches (8.8 to 41.9 centimeters)

Weight: 12 to 24 lbs. (45 to 90 g/m

)

Width: Microline 520 7.2 to 8.5 inches (18.2 to 21.5 centimeters)

Microline 521 7.2 to 14.3 inches (18.2 to 36.3 centimeters) Length: 3 to 17 inches (7.62 to 43.18 centimeters) Thickness: 0.1 4 inches (0. 36 mill imeters) Paper Feed Path: Top Printhead Gap

Information: Refer to the Printhead Gap Information, Section 1.6.

Microline 520/ 521 Servi ce Han dbo ok 1 - 17 Specificat io ns P/N 59257803

1.7.02 Length

NOTE:

The re co mmen ded le ngt h is spe cifi c to pape r typ e.

Rear Feed

Minimum 3 inches (7.62 centimeters) Maximum 17 inches (43.18 centimeters)

Bottom Feed

Minimum 3 inches (7.62 centimeters) Maximum 17 inches (43.18 centimeters)

Top Feed

Minimum 3 inches (7.62 centimeters) Maximum 17 inches (43.18 centimeters)

1.7.03 Number of Copies

Original + 4 Interleaf Original + 4 Carbonless Original Cut Sheet

1.7.04 Thickness

0.014 inches / 0.36 mm Maximum Thickness, Rear Feed

0.017 inches / 0.44 mm Maximum Thickness, Bottom Feed

Specificati ons 1 - 18 Microline 520/52 1 Serv ice Hand boo k

P/N 59257803

1.7.05 Weight

NOTE:

The re co mmen ded we igh t is spe ci fic to pa per typ e.

Mini mu m : 9 lb . (3 5 g/ m Maximum: 120 lb. (90 g/m

1.7.06 Width

NOTE:

The recommended width is specific to paper type.

Paper

Microline 520

Minimum: 3.5 inches ( 8.8 centimeters) Maximum: 10.5 inches (26.6 centimeters)

)

Microline 521

Minimum: 3.5 inches ( 8.8 centimeters) Maximum: 16.5 inches (41.9 centimeters)

Printing Area

Microline 520 8 inche s Maximum Microline 521 13.6 in ches Maximum

Microline 520/ 521 Servi ce Han dbo ok 1 - 19 Specificat io ns P/N 59257803

1.8 MEMORY SPECIFICATIONS

1.8.01 EEPROM

1 Kbit serial EEPROM (used to store Menu data)

1.8.02 EPROM

1 MBit EPROM (Printer Contro l Progra m - Fonts)

1.8.03 RAM

128 K by te Total Resident RAM

Used as

Receive Buffer

Receive Buffer Size is selected through the Menu.

Settings are: 64 K, 32 K, 1 line Print Buffer DLL Buffer Scratch Pad

Specificati ons 1 - 20 Microline 520/52 1 Serv ice Handb ook

P/N 59257803

1.9 CONSUMABLES

1.9.01 Ribbon

CAUTION:

Using a non-Okidata ribbon may damage the printhead and void any warranties.

Material

Nylon fabric, cartridge type, re-i nki ng

Type

Black Ribbon

Life (On average, at 10 characters per in ch, Uti l ity Mode)

4 million characters

Microline 520/ 521 Service Handbook 1 - 21 Specification s P/N 59257803

1.10 OPTIONS

1.10.01 Cut Sheet Feeders

Single Bin

The CSF-5000 is a narrow feeder for the Microline 520.

Single Bin with envelope capability Paper Width: 7.2" to 8.5" (18.3 cm to 36.3 cm) Paper Length: 10.1" to 14" (25.6 cm to 35.6 cm) Capacity: 170 sheets (16 lb.), 100 sheets (20 lb.)

The CSF-5001 is a wide feeder for the Microline 521.

Single Bin with envelope capability

Paper Width: 7.2" to 14.3" (18.3 cm to 36.3 cm) Paper Length: 10.1" to 14" (25.6 cm to 35.6 cm) Capacity: 170 sheets (16 lb.), 100 sheets (20 lb.)

1-1-01.pcx

Dual Bin

P/N 70022601 is a narrow feeder for the Microline 520.

P/N 70022801 is a wide feeder for the Microline 521.

Dual Bin with envelope capability Paper Width: 7.2" to 8.5" (18.3 cm to 36.3 cm) Paper Length: 10.1" to 14" (25.6 cm to 35.6 cm) Capacity: 170 sheets (16 lb.), 100 sheets (20 lb.)

Dual Bin with envelope capability Paper Width: 7.2" to 14.3" (18.3 cm to 36.3 cm) Paper Length: 10.1" to 14" (25.6 cm to 35.6 cm) Capacity: 170 sheets (16 lb.), 100 sheets (20 lb.)

Specificati ons 1 - 22 Microline 520/52 1 Serv ice Handb ook

P/N 59257803

1.10.02 Pull Tractor Kit

NOTE:

The Pull Tractor Kit (P/N 70023001) is a narrow feeder for the Microline 520.

The Pull Tractor Kit (P/N 70023201) is a wide feeder for the Microline 521.

Bottom Feed Rear Feed (For Push/Pull Operation)

Paper Types: Contin uous Fee d and Labels

1.10.04 Bottom Push Tractor Kit

NOTE:

1-1-02.pcx

The Bottom Push Tractor Kit (P/N 70022901) is a narrow feeder for the Microline 520.

The Bottom Push Tractor Kit (P/N 70023101) is a wide feeder for the Microline 521.

Bottom Feed Paper Type: Continuous Feed Includes: Stand and Metal Tear Bar

1.10.05 Serial Interface

Super-Speed 19.2K RS-232C Ready/Busy/X-On/X-Off Protocols Can be configured through the Menu or OKISmart Utility Program

1-1-03.pcx

Microline 520/ 521 Servi ce Han dbo ok 1 - 23 Specificat io ns P/N 59257803

1.10.06 Roll Paper Stand

Adapts printer for use with roll-type paper (Model 520 only) Includes: Stand, Support, Cord and DIN plug for connection

to printer

1.10.08 OKISmart Typer Utility

Obtained via BRC (Business Reply Card) packaged with printer Includes: Typewriter Mode, Form Creation Utility and Barcode Utility

1.10.09 OKISmart Panel Utility

1-1-05.pcx

NOTE:

Obtained via BRC (Business Reply Card) packaged with printer Includes: Fron t Panel Cont rol Utili t y and Drivers for Win d ows 3.0 & 3.1

The OKISmart software includes three programs.

1. OKISmart Con tro l

2. OKISmart Panel Emu lat or

3. OKISmart Setup

Refer to the Printer Handbook for more information.

Specificati ons 1 - 24 Microline 520/52 1 Serv ice Handb ook

P/N 59257803

1.11 RELIABILITY

1.11.01 Mean Time Before Failure (MTBF)

Approximately 6,000 hours: 25% duty cycle / 35% page density

1.11.02 Mean Time To Repair (MTTR)

Approxim at ely 15 min u tes to maj or sub-a ssemb l y level

1.11.03 Printer Life

Approxim at el y 16,0 0 0 hou rs of powe r-on ti me: 25% du t y cycl e / 35% pa ge densit y

1.11.04 Printhead Life

Average 200 milli on charac te rs in 10 cpi utili ty mode @ normal 25% duty , 35% page density

1.11.05 Ribbon Life

Approxim at el y 4 milli on charact ers

1.11.06 Warranty (Limited)

One year, pa rts and labor

1.11.07 Service

Authorized OKIdata Service Centers

Microline 520/ 521 Service Handbook 1 - 25 Specification s P/N 59257803

This page was intentionally l eft blan k.

Specificati ons 1 - 26 Microline 520/52 1 Serv ice Handb ook

P/N 59257803

SECTION TWO

PRINCIPLES O F OPERAT ION

2.1 ELECTRICAL OPERATION

The printer is comprised of the electrical components listed below.

Main Control Board Power Supply Assembly

Transformer Filter Board

Operator Panel Space Motor / Line Feed Motor Printhead

Microline 520/ 521 Servi ce Han dbo ok 2 - 1 Principles of Operation P/N 59257803

2.1.01 Main Control Board

The main con tro l board is mad e up of the mic roprocessor, pe rip h eral circ ui ts, dr i ve circu i ts, sensors and interface connectors.

The power to the main control board is suppli ed by the transfo rme r assemb ly th rou gh a wire harness. The power to other elec tri ca l parts (li n e feed mot or, space motor an d pri nth ea d) is provided by the power supply circuitry through connectors on the main control board.

Microprocessor (MPU) (Location 04C: 67X640)

16 bit MPU, using CMOS technology. The MPU contains a 20 bit addre ss bus, a 16 bit data bus. The MPU can access 1 Mbyte of program memory and 1 Mbyte of data memory

space. The micropro ce ssor cont ro ls th e enti re pri n ter by ex ecut ing the control program

through the LSIs and the driver circuits.

Principles of Opera tio n 2 - 2 Microline 520/52 1 Servic e Handb ook

P/N 59257803

Block Diagram

2-1-01a.tif

Microline 520/ 521 Servi ce Han dbo ok 2 - 3 Principles of Operation P/N 59257803

Program ROM

Location 05C A: 27 C 10 2 4 This 64k x 16 bit (1Mbit) EPROM

cont ains the control program for the printer. The MPU exe cu tes the instructi ons contained in th is program.

The Program ROM is assigned to the program memory area of the MPU and instructions are fetched by the PSEN signal of the MPU.

RAM

2-1-01b.tif

Location 05CB: 511664Z

The RAM is CMOS dynamic RAM with 65,536 words x 16-b it configurat io n. It is used as a receive buffer, print buffer and work buffer.

2-1-01c.tif

Principles of Opera tio n 2 - 4 Microline 520/521 Serv ic e Handboo k

P/N 59257803

LSI

Location 04B : MSM7 9VO3 5 Detects the outpu t of the two-p hase

sensor on the DC spa ce motor to control the motor drive phase.

Transmits and receives serial data to and from the printhead based on the dot timing (wh ic h is deriv ed from th e spa ce motor speed ).

Controls the external interface. The LSI is connected to the MPU.

2-1-01e.tif

Electrically Erasable Programmable Read Only Memory (EEPROM)

(Loc atio n 03C: 93 CS46) The EEPROM is a CMOS serial

I/O type memory (EEPROM). It is capable of elect ri cally erasing and writing 1,024 bits.

The EEPROM contains th e menu data and the head drive time correction data.

2-1-01d.tif

Microline 520/ 521 Servi ce Han dbo ok 2 - 5 Principles of Operation P/N 59257803

2.1.02 Initialization

This printer is initialized when the printer is powered on or when the I-PRIME-N signal is input from the host via the paralle l interfac e.

The steps in Printer Initialization are listed below.

The RST-N signal is output from the reset circuit to reset the MPU and LSIs. The program is executed and the LSIs are reset by the MPU via IORST-N.

NOTE:

A r ese t op era t io n ini t iat ed by I-PRIM E do es no t reset the MPU.

The program sets the LSI (02 D) mode, checks the mem ory (ROM /R AM ), th en execut es carriage homing and determines the phase of the line feed motor.

Finally, the program establishe s the interface signals (P-I/F: ACK-P sig nal sending, and S-I/F: BUSY-N signal off) and lights the SELECT lamp to indicate that the printer is in the ON-LINE state.

2-1-02.tif

Principles of Opera tio n 2 - 6 Microline 520/521 Serv ic e Handboo k

P/N 59257803

2.1.03 Parallel Interface Control

The parallel data input from the host to the interface LSI is latched to the internal register at the falling edge of the STROBE-N signal.

The LSI sets the BUSY-N signal to inform the host that the data is being processed . The LSI also outputs the RXD-N signal to inform the MPU of data reception . The data is read upon receiving the RD-N signal from the MPU.

When the data processin g is comp lete , the BUSY-N signa l is disab led and the ACK-N signal is sent to request the next data. When the buffer is full and rece pti on is not desire d, the BUSY signal is sent to request data transmission be stopped.

2-1-03a.tif

2-1-03b.pcx

Microline 520/ 521 Servi ce Han dbo ok 2 - 7 Principles of Operation P/N 59257803

2.1.04 Print Control

The print data is transmi tt ed as serial data from the LSI to the control circuit and the driver cont ained in the pri nt head.

After the data is printed, the sensor analog circuit controlling each pin returns the pin stroke data to the MPU. The MPU will make an automati c head gap adj ust me nt . This fee dbac k syst em sets the optimum drive time for each pin in order to maintain high print quality.

In the case of envelope s, where the medi um th ic kness va rie s as the prin th ead mo ve s along the platen, the strik e forc e of the pi ns chan ge s to comp ensat e for t he differences in thickness.

2-1-04a.tif

LSI/Printhead Interface

The connectio n betwe en the LSI and the prin th ead is mad e wit h the bi-d irectional serial da ta bus. The LSI transmits the print data as serial data to the logic circuit of the printhead. The printhead retu rns seri al data from the pri n thea d sen sor anal og circ uit to the LSI. This information is used to determine the optimum drive time for the next print request.

The logic circuit of the pri nth ead sign al s the LSI if a parity erro r is detected in the prin t data.

2-1-04b.tif

Principles of Opera tio n 2 - 8 Microline 520/521 Serv ic e Handboo k

P/N 59257803

Gap Adjust Control

The Gap Adjust LSI receives stro k e length informa tio n for all of the printhead pins from the sensor analog circuit. The Gap Adjust LSI then sets the optimum printhead gap for the printing medium.

NOTE:

Refer to Section 2.2.03 for a decriptio n of th e mech ani ca l pr ocess.

All values in the below chart are in millimeters

Print Compensation Control

The printhead compensates for the shape of the platen as shown below.

NOTE:

Also ref er to Sec tio n 2.1.07 - Head Driv e Time

2-1-04c.tif

2-1-04d.tif

Microline 520/ 521 Servi ce Han dbo ok 2 - 9 Principles of Operation P/N 59257803

2.1.05 Space and Line Feed (SP/LF) Motor Control

The LSI (Location 04B: MSM7 9 V03 5) gen erat es th e spa ce mo tor a nd the line feed mo tor control signals according to commands received from the MPU. These signals are sent to the SP/LF motor driver.

2-1-05a.tif

Line Feed Motor Control

The SP/LF motor driv er (Locat ion 5A: MHM 2025 ) driv es th e line feed motor in two-p ha se bipolar, based on the phase chan geov er data output from the LSI.

The serial data from the LSI (04B: MSM 79V0 35 ) is processe d by a register contained in the SP/LF motor driv er to measu re th e overd ri ve tim e and to chang e the phase.

2-1-05d.tif

Principles of Opera tio n 2 - 10 Microline 520/52 1 Serv ice Handb ook

P/N 59257803

Space Motor Control

The SP/LF motor driver (Location 5A: MHM2025) drives the three -ph ase brush l ess motor. Motor movement is based on the phase signal (SPU,SPV and SPW) and the speed instruction data from the LSI. The MPU can identify the current speed of the space motor by measuring the pulse wid th of the output (Phase A, Phase B) of the encoder disk sensor.

After comparing the target speed for each print mode with the actual speed, the motor is accelerat ed or decelerated to maintain the desired speed for each print mode.

2-1-05b.tif

Encoder Disk

As the space motor operates, the encoder disk spins. When the encoder disk interrupts the photo sensors, the sig nals Pha se A and Phase B are generated . The LSI (Locatio n 04B : MSM79V035) divides these edge pulse signals (the frequency division is based on the selected print pitch) to generate the signal IPT. The IPT signal provides do t-on timing and carriage position detection timing.

2-1-05c.tif

Microline 520/ 521 Servi ce Han dbo ok 2 - 11 Principles of Ope rat io n P/N 59257803

2.1.06 Operation Panel

The Serial I/O Port (Ports 20 - 23) of the MPU reads the operatio n panel switch data from the operation panel contro l LSI (Lo cati on IC1 : BUS14 8S).

A two byte (15 bits +1 parity bit (even parity)) command (OPTXD) is transmitted from the MPU to the operation panel LSI in sync hro niz at ion with the OPCLK sig nal . Once the LSI decodes th e command, the command must pass a comma nd code check and have no parity errors. Then, the specified I/O control will return the two byte command response to the MPU.

2-1-06a.tif

Principles of Opera tio n 2 - 12 Microline 520/52 1 Serv ice Handb ook

P/N 59257803

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2.1.07 Alar m Circuit

Driver Circuit Alarm Process ing

The printhead driver output and the head gap magnet output drive signals are monitored at R29 and C8. The POWER OFF-P signal is output by the comparator (Location 02C: IC2901) when driven for more than the spe ci fie d time . Thi s sig nal beco mes th e ALM signal . The ALM sign al is sent to the power supply board and causes the DC volt ages to be turned off.

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Low Motor Drive Voltage Alarm

+40V is converted into the POWLEV signal (0 vdc to +5 vdc) by the voltage divider network of R542 and R544, then inpu t to the A/D po rt of th e MPU. The value of this volt ag e is use d to control the driv e time and the print speed (pass numb er) of the he ad.

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Head Drive Time

The head drive time is modifi ed to comp en sat e for the amo u nt of the volt ag e dro p of the POWLEV signal. By monitoring the voltage drop every 500 microseconds, the MPU is able to control and maintain the impact necessary for each printhead pin.

Print Speed

Actual Voltage (+40 vdc) Passes Required Relative Print Speed

+34 vdc or greater 1 100% +32 vdc to +34 vdc 1 Approximately 85% +30 vdc to +32 vdc 1 Approximately 50%

+30 vdc or less 2 Less than 50%

Head Overheat Alarm Processing

If the printhead temperature exceeds 110 degrees Celsius, the printer will switch to uni-direct io nal prin t . If the tempera ture ex cee ds 11 8 deg rees Celsius, printing wil l stop . Once the printhead cools, printing will resume.

Two thermistors are used to monitor the printhead temperature. One is contained in the printhead. The other is in the printhead driver.

A thermistor in th e pri nth ead prev en ts ove r-he at ing of the coi l duri ng peri ods of co nt inu o us bi-direct i onal pri nt i ng. If the tem pe rat ure of the coil exceeds th e pre -determined limits, the control circuit detects the thermistor signal (TSD).

Another thermi st or mo ni t ors the te mp erat u re of th e pri nth ead dri ve r. If the temperature of the driver exceeds the pre-determined limi ts, th e control circuit detects the thermi st or sig nal (TSD).

The voltage of the TSD signal is monito red at the MPU A/D port to cont rol the pass numb er and print method (uni-directional / bi-directional) at each of seven levels.

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2.1.08 Power Supply Circ uit

The switching type powe r supp l y circu it sup pli es th e +5 vdc, +/-8 vdc, 10 VAC and +40 vdc .

Table of Output Voltages

Voltage / Signal Purpose

+5 vdc IC logic levels, LED drive voltages +8 vdc Serial interface line voltage, comparator IC

+10 VAC Serial interface line voltage and the printhead analog circuit

+40 vdc Printhead, space mo tor and line fee d mot or drive volta ge

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2.2 MECHANICAL OPERATION

2.2.01 Printhead Mechanism

The printhea d is a spring-charged, 9-pi n prin th ead. It is attache d to the carri age, whi ch moves parallel to the pl at en . El ectricall y, the prin t he ad is con tro l le d by th e mai n cont rol board via the carriage cable and the space motor.

The printhea d is co mp ose d of the fol l owi n g parts.

Wire Guide Spring Assembly

Wire, Armature, Spri ng, Yoke, Spac er

Magnet Assembly

Magnet, Core, Coil, Yoke

Printed Circuit Board

Logic Control , Prin t Drive r, Anal o g Sensor Co n tro l and Therm ist o r

Cooling F in

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Printhead Gap Information

Three items factor int o prin thea d gap info rmat i on.

Auto Gap, Semi Auto Gap, 1, 2, 3, 4, 5, 6, 7, 8, 9

An explanati o n of eac h setti n g fol l ows.

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Auto Gap

This is the factory default. Automatically determines paper thickness of the first page. During single-sheet feed, each page’s thickness is checked while a job is

printing.

Semi Auto Gap

Similar to Auto Gap. Automatically determines paper thickness of the first page. During single-sheet feed, each page’s thickness IS NOT checked "while"

a job is printing.

1, 2, 3, 4, 5, 6, 7, 8, 9

Used when the same paper is used ALL of the time. Bypasses the automatic head gap adjustment. 1 is the narrowest gap setting. 9 is the widest gap setting.

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Interconnect Diagram: Control Board to Printhead

NOTE:

The printhead coil r e sist anc e values AR E NOT LISTED. The individ ual prin t wi re control lines CAN N O T be accesse d on th is pri n thea d .

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Line Feed Motor Resistance

The resistance of each coil shoul d be approx i mat el y 13 ohms.

Space Motor Resistance

The resistance of each coil shoul d be approx i mat el y 5 ohms.

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Printhead Operation

When the printhead is idle, the armature is attracted to the permanent magnet. The print wires, which are attached to each arma ture, are then concealed inside the wire guide.

When a signal to pri n t a charact er is rece iv ed , cu rren t flo ws th rou g h a coil . The magne ti c fie ld generated by the coil opposes the magnetic field between the armature and the permanent magnet. The armature is then dri ve n in the direct i on of the plat en by the force of the armat u re spring. The print wire (which is attac hed to the armat u re) pro tru d es from the ti p of the wire guide and strikes the paper through the ribbon. This prints a dot on the paper.

As the armature gets clo ser to the ele ct rod e of the an alog senso r, the cap ac itan ce between them increases and a small amoun t of curren t flo ws. Thi s current is ampl ified and sent to the logic control LSI to indicate armat ure activ ity . In order to attai n opti mu m dri ve time, thi s info rma ti on is transferred to the MPU. The MPU continually modifies the head gap to maintain the optimum drive time condition.

The analog sensor element monitors all of the pins. The difference in pin stroke due to the curvature of the platen is co mp en sat ed for at th e lo gic co nt ro l section of the pri nt h ead and is not transferred to the MPU.

After the character has been print ed, the perman en t magnet attrac ts the arma ture an d the prin t wires are retracted into the wire guide.

Printhead Temperature

Two thermistors are used to monitor the printhead temperature. One is contained in the printhead. The other is in the printhead driver.

The voltage of the TSD signal is monito red at the MPU A/D port to cont rol the pass numb er and print method (uni-directional / bi-directional) at each of seven levels.

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2.2.02 Spacing Mechanism

The spacing mechani sm consi sts of a carri age shaft (m ounte d paral le l to the plat en), and a carriage frame which moves alon g the shaft. The carriage frame is driven by a DC servo motor mounted on the carriage fram e. Items inclu ded in the spac ing mechan ism are list ed belo w.

Space Motor Assembly

DC Servo Motor Motor Gear Sensor Encoder Disk

Carriage Frame Carriage Shaft Space Rack

Spacing Operation

The carriage frame, which contains th e printh ead and space motor, m oves along the carriage shaft parallel to the platen. When the space motor rotates, the driving force is transmitted to the motor gear. As the motor gear rot at es, the carria ge mov es alon g the plat en . For every revolution of the DC servo mot or, the carriage frame moves 0. 8 inch (20.3 2 mm).

As the DC servo motor rota te s, a slott ed disk (c alle d the en code r disk ), rot at es wit h the servo motor and passes through the photosenso r. The posit i on of th e carri age fra me can be dete rmi ne d by counting the pulses ge ne rat ed by the pho tosen sors.

In the same way, the rotati on of the spa ce motor can be recognized and controlled by measurin g the phase relationshi p and the pulsewidth of the signals generate d by the photo sen sors.

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2.2.03 Head Gap Mechanism

The head gap is automat ic ally set for the thi ck ness of the medi um lo ad ed in the pri nte r. In the case of envelopes, where the medium thickness va rie s as the pri nth ea d move s alo ng the pl at en, the strike force of th e pins chan ge s to comp en sat e for th e differen ce s in thi ckne ss.

Head Gap Setting Operation

Once printi n g starts, the space motor rot at es th e rib bon gear, c ausing idle gear C to turn the change gear.

When the MPU requests a change in the head gap setting, the GAP-P signal causes the armature (whic h is holdin g the change gear) to be attra cted to the pranger mag n et. The gap reset spring can now push the change gear so it conta ct s the gap change gear .

The rotati on of th e gap cha nge ge ar cau ses id le gear D to turn the adj ust gea r. The adju st gear turns the adjust i ng screw, resulting in a new head gap setti ng.

NOTE:

As the adjusti ng screw turns coun ter-clockw i se, the ga p narrows. As the adjusting screw turns clockwise, the gap widens.

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There is a cam at each setting of th e gap chang e gear. Whe n the ch ange gear is at the top of the cam, the change gear disen g ag es from the ga p chan ge gear. At this time , the armature resets, changing the head gap by one setting.

The head gap is modified in .06 mm units for each range setting.

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2.2.04 Ribbon Drive Mechanism

Ribbon Drive Operation

The ribbon drive mechanism feeds the ribbon in synchronization with the spacing operation. The force required to drive the ribbon is obtained from the space motor.

The ribbon drive mechanism is composed of the items listed below.

Ribbon Drive Gear Assembly Ribbon Gear

This gear is located on the space motor assembly

Ribbon Cartridge

A continuous loop ribbon with uni-directional feed is used. Ink is suppli ed from an ink tank, which is built into the ribbon cartridge.

When the space motor turns, the ribbon gear on the spacing mot or sha ft rot at es. The rotation is transmitted via a combination of gears, from the ribbon drive gear assembl y to the dri ve gear in the ribbon cartridge.

Although the space motor moves in both the forward and reverse directions during bi-directional printing, the gears in the ribbon drive assemb ly mai ntai n uni-directional ribbon feed by switching the rotation direc tio n of the gears.

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Oki MICROLINE 520, MICROLINE 521 Service Handbook

Specifications and Main Features

Frequently Asked Questions

User Manual