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Table of ContentsPage
Service Guide ML520/521
0 About This Manual
Front Cover1
Copyright Information2
1 Product Specifications
1.1.01 General Information3
....1.2 Physical Specifications4
....1.3 Power Requirements5
....1.4 Environmental Conditions6
....1.5 Agency Approvals7
....1.6 Operational Specifications8
....1.7 Paper Specifications9
....1.8 Memory Specifications10
....1.9 Consumables11
....1.10 Options - Cut Sheet Feeders12
........1.10.02 Pull Tractor Kit13
........1.10.04 Bottom Push Tractor Kit14
........1.10.05 Serial Interface15
........1.10.06 Roll Paper Stand16
........1.10.08 OKISmart Typer Utility17
....1.11 Reliability18
2 Principles of Operation
2.1 Electrical Operation19
....2.1.01 Main Control Board20
........Block Diagram21
........Program ROM22
........RAM23
........LSI24
........Electrically Erasable Programmable Read Only Memory
(EEPROM)
....2.1.02 Initialization26
....2.1.03 Parallel Interface Control27
....2.1.04 Print Control28
........LSI/Printhead Interface29
........Gap Adjust Control30
........Print Compensation Control31
....2.1.05 Space and Line Feed (SP/LF) Motor Control32
........Line Feed Motor Control33
........Space Motor Control34
........Encoder Disk35
....2.1.06 Operation Panel36
....2.1.07 Alarm Circuit37
........Low Motor Drive Voltage Alarm38
25
Table of ContentsPage
........Head Drive Time39
........Print Speed40
........%Head Overheat Alarm Processing41
....2.1.08 Power Supply Circuit42
2.2 Mechanical Operation - Printhead Mechanism43
........Printhead Gap Information44
........Interconnect Diagram: Control Board to Printhead45
........Commonly Used Serial Cable Configurations149
....4.8.05 Hexadecimal Dump Mode150
4.9 Resistance Checks151
........Layout Diagram152
....4.9.02 Printhead153
....4.9.03 Line Feed Motor Resistance154
....4.9.04 Space Motor Resistance155
A Reference Charts
A.1 Overview - A.1.01 General Information156
A.2 Index To Charts157
........Board Layout158
....A.2.01 Main Controller Board (FJIM)159
....A.2.02 Operator Panel Board (LEOP)160
....A.2.03 Power Supply Assembly161
....A.2.04 Space Motor Board162
....A.2.05 RS232-C Serial Interface Board - Option (LXHI)163
B Illustrated Parts Listing
B.1 Overview - B.1.01 General Information164
Table of ContentsPage
........Format165
........Current Part Numbers166
....B.1.02 Definition of Terms167
....B.1.03 Parts Ordering Information168
B.2 Charts169
........Overview170
....B.2.01 Printer171
....B.2.02 Upper Cover Assembly172
....B.2.03 Printer General Assembly173
....B.2.04 Printer Unit174
....B.2.05 Printer Unit175
....B.2.06 Printer Unit176
....B.2.07 Carriage Assembly177
....B.2.08 Options178
....B.2.09 Option Parts179
....B.2.10 Consumables180
....B.2.11 Packing Materials181
....B.2.12 Documentation182
....B.2.13 Service Training Kit Revision List183
Service Guide ML520/521
Chapter 0 About This Manual
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.
Okidata
532 Fellowship Road
Mount Laurel, NJ 08054-3499
Fax Number: (609) 235-2600, ext. 7034
Okilink Login Name: Technical Training
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
Copyright 1997, Okidata, Division of OKI America, Inc. All rights reserved. See the OKIDATA Business
Partner Exchange (BPX) for any updates to this material. (http://bpx.okidata.com)
Page: 3
Service Guide ML520/521
Chapter 1 Product Specifications
1.1.01 General Information
The Microline 520 and Microline 521 are letter quality, nine-pin, dot-matrix printers which utilize
OKISMART
adjustment. The printer actually reads and learns the print medium being used, then automatically adjusts
the head gap to the optimum distance. This autogapping process leads to longer printhead life.
Options include the Bottom Feed Push Tractor, Cut-Sheet Feeder, Pull Tractor and Serial Interface Board.
The Microline 520 is an 80 column printer.
The Microline 521 is a 132 column printer.
Okidata's one year limited warranty covers the parts, labor and printhead on both printers.
The following items are available for the printer.
paper handling. Patented Okidata technology does away with the manual head gap
OKISMART Typer
typewriter on checks, labels and envelopes.
OKISMART Panel
computer.
Scalable Fonts - 14 scalable fonts, available on diskette.
- software which provides the flexibility for the Microline 590/521 to function like a
- a utility program that lets you control selected printer functions from your personal
NOTE:
The OkiSmart software includes three programs.
1. OkiSmart Control
2. OkiSmart Panel Emulator
3. OkiSmart Setup
Refer to the Printer Handbook for more information.
Copyright 1997, Okidata, Division of OKI America, Inc. All rights reserved. See the OKIDATA Business
Partner Exchange (BPX) for any updates to this material. (http://bpx.okidata.com)
Service Guide ML520/521
Chapter 1 Product Specifications
1.2 PHYSICAL SPECIFICATIONS
1.2.01 Dimensions
NOTE:
Dimensions INCLUDE the platen knob, acoustic cover, and paper separator.
Copyright 1997, Okidata, Division of OKI America, Inc. All rights reserved. See the OKIDATA Business
Partner Exchange (BPX) for any updates to this material. (http://bpx.okidata.com)
Copyright 1997, Okidata, Division of OKI America, Inc. All rights reserved. See the OKIDATA Business
Partner Exchange (BPX) for any updates to this material. (http://bpx.okidata.com)
1.4.03 Ambient Temperature and Relative Humidity (RH)
While operating: 41 to 104 degrees Fahrenheit (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
Copyright 1997, Okidata, Division of OKI America, Inc. All rights reserved. See the OKIDATA Business
Partner Exchange (BPX) for any updates to this material. (http://bpx.okidata.com)
1.5 AGENCY APPROVALS
1.5.01 Listings
UL No: UL Standard No. 1950 D3
CSA No: CSA Standard 22.2-950 D3
FCC: FCC Certified per Part 15, Subject J, Class B
IEC: IEC 950
VDE: VDE 0805 VDE 0875 Class B
BS: BS 7002
Page: 7
Service Guide ML520/521
Chapter 1 Product Specifications
Copyright 1997, Okidata, Division of OKI America, Inc. All rights reserved. See the OKIDATA Business
Partner Exchange (BPX) for any updates to this material. (http://bpx.okidata.com)
Service Guide ML520/521
Chapter 1 Product Specifications
1.6 OPERATIONAL SPECIFICATIONS
1.6.01 Character Matrix Sizes
Table of Print Speed and Character Matrix
Mode
Speed80 (12cpi)320 (12cpi)427 (12cpi)
Matrix (H x V)17 x 139 x 77 x 7
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 emulations are co-resident
Epson FX
IBM Proprinter
Microline Standard
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 (horizontal) x 144 (vertical) dots per inch (DPI) maximum
1.6.09 Interface
Standard
Centronics Parallel
Optional
RS232C Serial
1.6.10 Line Feed Increments
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/144 inch
n/216 inch
1.6.11 Line Feed Time
65 milliseconds 6 lines per inch (lpi)
6 milliseconds 8 lines per inch (lpi)
1 second 5.0 inches (Continuous paper feed rate)
When printhead temperature exceeds 110 degrees Celsius, the printer stops bi-directional printing.
Uni-directional printing begins.
If the temperature exceeds 118 degrees Celsius, printing stops.
Printing will resume when the printhead temperature drops below 118 degrees Celsius.
NOTE:
Refer to Section Two for more information on printhead operation.
Printhead Gap Information
Three items factor into printhead gap information:
1. Printhead Gap Adjustment
This is a SERVICE ADJUSTMENT made by a technician.
It is covered in Section 3.3 of this Service Handbook.
The Adjustment measures 0.014 +/- 0.001 inches 90.35, +/-0.03 mm).
2. Printhead Gap Adjustment
This is a MENU ITEM in the SET-UP Group.
It fine tunes the automatic setting of the printhead gap.
The settings are 0, 1 and -1.
Use 1 to darken print (if output is consistently light).
Use -1 to lighten print (if output is consistently dark).
3. Gap Control
This is a MENU ITEM in each (Paper Feed) Group.
The Groups are REAR FEED, BOTTOM FEED, and TOP FEED.
Gap Controls determines how the printhead gap is set.
The settings are listed below.
An explanation of each setting follows.
Auto Gap
printing.
Semi Auto Gap
job is printing.
Auto Gap, Semi Auto Gap, 1, 2, 3, 4, 5, 6, 7, 8, 9
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
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
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 head setting.
9 is the widest head setting.
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
Speed80 (12 cpi)320 (12 cpi)427 (12 cpi)
Matrix (H x V)17 x 139 x 77 x 7
Copyright 1997, Okidata, Division of OKI America, Inc. All rights reserved. See the OKIDATA Business
Partner Exchange (BPX) for any updates to this material. (http://bpx.okidata.com)
Near Letter QualityUtilityHigh Speed Draft
Service Guide ML520/521
Chapter 1 Product Specifications
1.7 PAPER SPECIFICATIONS
CAUTION:
Use Bottom Feed and/or optional Pull Tractor for card stock and labels.
1.7.01 Types
Card Stock
Weight: 120 lbs. (450 g/m 2 ) 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: .017 inches (0.44 millimeters)
Page: 9
Paper Feed Path: Bottom
Printhead Gap Information:
Continuous Form
Weight:
Single Part 12 - 24 lb. (45 to 90 g/m 2 )
Multi-Part, Carbonless 9 - 11 lb. (35 to 40 g/m 2 )
Multi-Part, Interleaf Paper 10 - 12 lb. (38 to 45 g/m 2 ) Carbon 9 lb. (35 g/m 2 )
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 millimeters) Bottom
Feed
Paper Feed Path: Rear or Bottom
Printhead Gap Information:
Refer to the Printhead Gap Information, Section 1.6
Refer to the Printhead Gap Information, Section 1.6
Cut Sheet
Weight: 12 to 24 lbs. (45 to 90 g/m 2 )
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)
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: 0.014 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/m 2 ) Maximum
Size:
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: .014 inches (.325 millimeters) Maximum
Paper Feed Path: Bottom
Printhead Gap Information: Refer to the Printhead Gap Information, Section 1.6.
Labels
Weight: N/A
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: .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 optional Pull Tractor for card stock and labels.
Transparency
NOTE:
Roller marks may mar the transparency under high temperature / high humidity conditions.
Weight: 12 to 24 lbs. (45 to 90 g/m 2 )
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: 0.14 inches (0.36 millimeters)
Paper Feed Path: Top
Printhead Gap Information: Refer to the Printhead Gap Information, Section 1.6.
1.7.02 Length
NOTE:
The recommended length is specific to paper type.
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
Microline 520 8 inches Maximum
Microline 521 13.6 inches Maximum
Copyright 1997, Okidata, Division of OKI America, Inc. All rights reserved. See the OKIDATA Business
Partner Exchange (BPX) for any updates to this material. (http://bpx.okidata.com)
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 Control Program - Fonts)
1.8.03 RAM
128 Kbyte Total Resident RAM
Used as
Receive Buffer
Receive Buffer Size is selected through the Menu.
Settings are: 64 K, 32 K, 1 line
Page: 10
Service Guide ML520/521
Chapter 1 Product Specifications
Print Buffer
DLL Buffer
Scratch Pad
Copyright 1997, Okidata, Division of OKI America, Inc. All rights reserved. See the OKIDATA Business
Partner Exchange (BPX) for any updates to this material. (http://bpx.okidata.com)
Service Guide ML520/521
Chapter 1 Product Specifications
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-inking
Type
Black Ribbon
Life (On average, at 10 characters per inch, Utility Mode)
4 million characters
Page: 11
Copyright 1997, Okidata, Division of OKI America, Inc. All rights reserved. See the OKIDATA Business
Partner Exchange (BPX) for any updates to this material. (http://bpx.okidata.com)
Service Guide ML520/521
Chapter 1 Product Specifications
1.10 OPTIONS - Cut Sheet Feeders
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.
Page: 12
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.)
Dual Bin
P/N 70022601 is a narrow feeder for the Microline 520.
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.)
P/N 70022801 is a wide feeder for the Microline 521.
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.)
Copyright 1997, Okidata, Division of OKI America, Inc. All rights reserved. See the OKIDATA Business
Partner Exchange (BPX) for any updates to this material. (http://bpx.okidata.com)
Service Guide ML520/521
Chapter 1 Product Specifications
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: Continuous Feed and Labels
Page: 13
Copyright 1997, Okidata, Division of OKI America, Inc. All rights reserved. See the OKIDATA Business
Partner Exchange (BPX) for any updates to this material. (http://bpx.okidata.com)
Service Guide ML520/521
Chapter 1 Product Specifications
1.10.04 Bottom Push Tractor Kit
NOTE:
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
Page: 14
Copyright 1997, Okidata, Division of OKI America, Inc. All rights reserved. See the OKIDATA Business
Partner Exchange (BPX) for any updates to this material. (http://bpx.okidata.com)
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