How it Works
OKIDATA
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520
Service Manual
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OKIDATA 520, 521 Service Manual

Chapter 0 Manual Front Cover
Microline 520/521
Service Handbook
P/N 59257803
Part of the Microline 520/521Service Training Kit
P/N 58229403
Chapter 1
1.1.01 General Information
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. Okidatas one year limited warranty covers the parts, labor and printhead on both printers. The following items are available for the printer.
OKISMART Typer
typewriter on checks, labels and envelopes.
OKISMART Panel
computer. Scalable Fonts - 14 scalable fonts, available on diskette.
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.
paper handling. Patented Okidata technology does away with the manual head gap
- 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
%1.2 Physical Specifications
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)
%1.3 Power Requirements
1.3 POWER REQUIREMENTS
1.3.01 Input Power
120 VAC: +5.5 / -15% 230/240 VAC: +10 / -14%
1.3.02 Power Consumption
Operating: 110 VA Idle: 40 VA Local Test: 70 VA
1.3.03 Power Frequency
120 VAC: 60 Hz +/- 2% 230/240 VAC: 50/60 Hz +/- 2%
%1.4 Environmental Conditions
1.4 ENVIRONMENTAL CONDITIONS
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 Quiet Mode Microline 520 52.5 dBA Microline 521 52.3 dBA
1.4.01 Altitude
10,000 feet (3,050 meters)
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
%1.6 Operational Specifications
1.6 OPERATIONAL SPECIFICATIONS
1.6.01 Character Matrix Sizes Table of Print Speed and Character Matrix
Print Speed at Different CPI for the ML 520/521
Mode CPI CPS Horiz. DPI Vert DPI IPS
HSD 10 427 90 72 42.7
12 427 108 72 35.6 15 427 135 72 28.5
17.1 427 154 72 25.0 20 427 180 72 21.4
Utility 10 320 120 72 32
12 320 144 72 26.7 15 320 180 72 21.3
17.1 320 206 72 18.6 20 320 240 72 16.0
LQ 10 80 240 144 16.0
12 80 288 144 13.3 15 80 360 144 13.3
17.1 80 412 144 9.32 20 80 480 144 8.0
1.6.02 Characters Per Line Microline 520
Microline 521
1.6.03 Character Pitches
5, 6, 8.5, 10, 12, 15, 17.1, 20
1.6.04 Character 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 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)
1.6.12 Menu Mode
1.6.13 Paper Feed Methods Standard
Friction Feed (Top) Rear Push Tractor (Rear)
Optional
Pull Tractor (Bottom) Bottom Push Tractor Feed (Bottom) Single-Bin Cut Sheet Feeder (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 Paper Loading
Auto Loading (Top Feed) Press FORM FEED / Load switch to feed paper to default position
1.6.16 Paper Out Detection
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 Capabilities
Forms Tear-0ff (sharp edge on access cover) Metal Tear Bar (with optional bottom feed tractor unit)
1.6.18 Print Method Printhead Type General Information
Impact: Dot Matrix 9 pin printhead .0134 inch (0.34 millimeter) diameter pins
Overheat Protection
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.
1.6.19 Print Modes
Near Letter Quality Utility High Speed Draft
1.6.20 Print Speed Table of Print Speed and Character Matrix
%1.7 Paper 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) Paper Feed Path: Bottom Printhead Gap Information: Refer to the Printhead Gap Information, Section 1.6
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
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
1.7.05 Weight
NOTE: The recommended weight is specific to paper type.
Minimum: 9 lb. (35 g/m 2 ) Maximum: 120 lb. (90 g/m 2 )
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 inches Maximum Microline 521 13.6 inches Maximum
%1.8 Memory Specifications
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 Print Buffer DLL Buffer Scratch Pad
%1.9 Consumables
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
%1.10 Options - Cut Sheet Feeders
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. 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.)1-1-01.pcx
%1.10.02 Pull Tractor Kit
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
%1.10.04 Bottom Push Tractor Kit
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
%1.10.05 Serial Interface
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
%1.10.06 Roll Paper Stand
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
%1.11 Reliability
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)
Approximately 15 minutes to major sub-assembly level
1.11.03 Printer Life
Approximately 16,000 hours of power-on time: 25% duty cycle / 35% page density
1.11.04 Printhead Life
Average 200 million characters in 10 cpi utility mode @ normal 25% duty, 35% page density
1.11.05 Ribbon Life
Approximately 4 million characters
1.11.06 Warranty (Limited)
One year, parts and labor
1.11.07 Service
Authorized OKIdata Service Centers
Chapter 2
2.1 Electrical Operation
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
%2.1.01 Main Control Board
2.1.01 Main Control Board
The main control board is made up of the microprocessor, peripheral circuits, drive circuits, sensors and interface connectors. The power to the main control board is supplied by the transformer assembly through a wire harness. The power to other electrical parts (line feed motor, space motor and printhead) 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 address bus, a 16 bit data bus. The MPU can access 1 Mbyte of program memory and 1 Mbyte of data memory space. The microprocessor controls the entire printer by executing the control program through the LSIs
and the driver circuits.

%Block Diagram

Block Diagram
%Program ROM
Program ROM
Location 05CA: 27C1024 This 64k x 16 bit (1Mbit) EPROM contains the control program for the printer. The MPU executes the instructions contained in this 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
RAM
Location 05CB: 511664Z The RAM is CMOS dynamic RAM with 65,536 words x 16-bit configuration. It is used as a receive buffer, print buffer and work buffer.
%LSI
LSI
Location 04B: MSM79VO35 Detects the output of the two-phase sensor on the DC space motor to control the motor drive phase. Transmits and receives serial data to and from the printhead based on the dot timing (which is derived from the space motor speed). Controls the external interface. The LSI is connected to the MPU.
%Electrically Erasable Programmable Read Only Memory (EEPROM)
Electrically Erasable Programmable Read Only Memory (EEPROM)
(Location 03C: 93CS46) The EEPROM is a CMOS serial I/O type memory (EEPROM). It is capable of electrically erasing and writing 1,024 bits. The EEPROM contains the menu data and the head drive time correction data.
%2.1.02 Initialization
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 parallel interface. 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 reset operation initiated by I-PRIME does not reset the MPU.
The program sets the LSI (02D) mode, checks the memory (ROM/RAM), then executes carriage homing and determines the phase of the line feed motor. Finally, the program establishes the interface signals (P-I/F: ACK-P signal 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.
%2.1.03 Parallel Interface Control
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 processing is complete, the BUSY-N signal is disabled and the ACK-N signal is sent to request the next data. When the buffer is full and reception is not desired, the BUSY signal is sent to request data transmission be stopped.
%2.1.04 Print Control
2.1.04 Print Control
The print data is transmitted as serial data from the LSI to the control circuit and the driver contained in the printhead. 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 automatic head gap adjustment. This feedback system sets the optimum drive time for each pin in order to maintain high print quality. In the case of envelopes, where the medium thickness varies as the printhead moves along the platen, the strike force of the pins changes to compensate for the differences in thickness.
%LSI/Printhead Interface
LSI/Printhead Interface
The connection between the LSI and the printhead is made with the bi-directional serial data bus. The LSI transmits the print data as serial data to the logic circuit of the printhead. The printhead returns serial data from the printhead sensor analog circuit to the LSI. This information is used to determine the optimum drive time for the next print request. The logic circuit of the printhead signals the LSI if a parity error is detected in the print data.
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