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DFX-5000+
SERVICE MANUAL
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EPSON TERM NAL PR NTER
DFX-5000+
SERVICE MANUAL
EPSON
NOTICE
All rights reserved. Reproduction of any part of this manual in any form whatsoever without SEIKO EPSON's express written permission is forbidden. The contents of this manual are subjects to change without notice. All efforts have been made to ensure the accuracy of the contents of this manual. However, should any errors be detected, SEIKO EPSON would greatly appreciate being informed of them. The above notwithstanding SEIKO EPSON can assume no responsibility for any errors in this manual or the consequence thereof. Centronics is a registered trademark of Centronics Data Computer Corporation. Epson and Epson ESC/P are registered trademark of Seiko Epson Corporation.
@Copyright 1994 by SEIKO EPSON CORPORATION Nagano, Japan
-iv-
PRECAUTIONS
Precautionary notations throughout the text are categorized relative to 1) personal injury and 2) damage to equipment.
DANGER
Signals a precaution which, if ignored, could result in serious or fatal personal injury. Great caution should be exercised in performing procedures preceded by DANGER Headings.
WARNING Signals a precaution which, if ignored, could result in damage to equipment.
The precautionary measures itemized below should always be observed when performing repair/ maintenance procedures.
1.
ALWAYS DISCONNECT THE PRODUCT FROM BOTH THE POWER SOURCE AND PERIPHERAL DEVICES PERFORMING ANY MAINTENANCE OR REPAIR PROCEDURE. NO WORK SHOULD BE PERFORMED ON THE UNIT BY PERSONS UNFAMILIAR WITH BASIC SAFETY MEASURES AS DICTATED FOR ALL ELECTRONICS TECHNICIANS IN THEIR LINE OF WORK. WHEN PERFORMING TESTING AS DICTATED WITHIN THIS MANUAL, DO NOT CONNECT THE UNIT TO A POWER SOURCE UNTIL INSTRUCTED TO DO SO. WHEN THE POWER SUPPLY CABLE MUST BE CONNECTED, USE EXTREME CAUTION IN WORKING ON POWER SUPPLY AND OTHER ELECTRONIC COMPONENTS.
2.
3.
1. 2.
REPAIRS ON EPSON PRODUCT SHOULD BE PERFORMED ONLY BY AN EPSON CERTIFIED REPAIR TECHNICIAN. MAKE CERTAIN THAT THE SOURCE VOLTAGE IS THE SAME AS THE RATED VOLTAGE, LISTED ON THE SERIAL NUMBER/RATING PLATE. IF THE EPSON PRODUCT HAS A PRIMARY AC RATING DIFFERENT FROM AVAILABLE POWER SOURCE, DO NOT CONNECT IT TO THE POWER SOURCE. ALWAYS VERIFY THAT THE EPSON PRODUCT HAS BEEN DISCONNECTED FROM THE POWER SOURCE BEFORE REMOVING OR REPLACING PRINTED CIRCUIT BOARDS AND/OR INDIVIDUAL CHIPS. IN ORDER TO PROTECT SENSITIVE MICROPROCESSORS AND CIRCUITRY, USE STATIC DISCHARGE EQUIPMENT, SUCH AS ANTI-STATIC WRIST STRAPS, WHEN ACCESSING INTERNAL COMPONENTS. REPLACE MALFUNCTIONING COMPONENTS ONLY WITH THOSE COMPONENTS BY THE MANUFACTURE; INTRODUCTION OF SECOND-SOURCE ICS OR OTHER NON APPROVED COMPONENTS MAY DAMAGE THE PRODUCT AND VOID ANY APPLICABLE EPSON WARRANTY.
3.
4.
5.
- ii -.
PREFACE
This manual describes functions, theory of electrical and mechanical operations, maintenance, and repair of DFX-5000+. The instructions and procedures included herein are intended for the experience repair technician, and attention should be given to the precautions on the preceding page. The chapters are organized as follows:
CHAPTER 1. GENERAL DESCRIPTION
Provides a general product overview, lists specifications, and illustrates the main components of the printer.
CHAPTER 2. OPERATING PRINCIPLES
Describes the theory of printer operation.
CHAPTER 3. DISASSEMBLY AND ASSEMBLY
Includes a step-by-step guide for product disassembly and assembly.
CHAPTER 4. ADJUSTMENTS Includes a step-by-step guide for adjustment. CHAPTER 5. TROUBLESHOOTING
Provides Epson-approved techniques for adjustment.
CHAPTER 6. MAINTENANCE AND LUBRICATION
Describes preventive maintenance techniques and lists Lubricants and adhesives required to service the equipment.
APPENDIX
Describes connector pin assignments, circuit diagrams, circuit board component layout and exploded diagram.
The contents of this, manual are subject to change without notice.
- iv -
REVISION SHEET
Revision
/ Rev.-A
Issue Data
Revision Page
/ 1 st issue
1
,
February 9, 1994 April 20, 1994 November 22, 1994
Rev.-B Rev.-C
Page 4-10: Addition the notes Page 4-1 1: Addition the notes Page 4-4 to 4-7: Change the explanation
1
I
Rev.-D Rev.-E
i December 15, 1994
I
Whole Revise of the Chap.4 Page 4-12: Change the explanation Page 4-12: Addition the notes
March 7, 1995
TABLE OF CONTENTS
CHAPTER 1. CHAPTER 2. CHAPTER 3. CHAPTER 4. CHAPTER 5. CHAPTER 6. APPENDIX
GENERAL DESCRIPTION OPERATING PRINCIPLES DISASSEMBLY AND ASSEMBLY ADJUSTMENTS TROUBLESHOOTING MAINTENANCE AND LUBRICATION
- vi -
CHAPTER 1 Product Description
Table of Contents 1.1 GENERAL FEATURES
1-1
1-3 1.2 SPECIFICATIONS 1.2.1 Printer Capabilities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l-3 1.2.2 Paper Handling Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l-3 1.2.3 Paper Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 1.2.4 Ribbon Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12 1.2.5 Environmental Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12 1.2.6 Electrical Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13 1.2.7 Reliability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13 1.2.8 Safety Approvals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13 1.2.9 Physical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13 1-14 1.3 INTERFACE SPECIFICATIONS 1.3.1 Parallel Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14 1.3.2 RS-232C Serial interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16 1-17 1.4 PRINTER OPERATION .1.4.1 Control Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17 1.4.2 Self-test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18 1.4.3 Hexadecimal Dump Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18 1.4.4 Paper Out Detection Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18 1.4.5 Cover Open Detection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18 1.4.6 Paper Width Detection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19 1.4.7 Automatic PaperThickness Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 1-19 1.4.8 Paper Memory Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19 1.4.8.1 Using the Paper Memory Function . . . . . . . . . . . . . . . . . . . . . . 1-20 1.4.8.2 Saving Paper Format and Thickness Information.. . . . . . . . . . 1-20 1.4.9 Automatic Tear Off Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21 1.4.10 PaperJam Detection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... 1-21 1.4.11 Automatic Interface Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21 1.4.12 Thermal Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21 1.4.13 Skip Binding Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22 1.4.14 Printer Initialization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22 1.4.15 Buzzer Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .......... 1-22 1.5 DIP SWITCH SETTINGS 1-23
1-26 1.6 MAIN COMPONENTS 1.6.1 M-3C11 Printer Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27 1.6.2 Main Control Board (Cl 17 MAIN Board Assembly). . . . . . . . . . . . . . . . 1-28 1.6.3 Power Supply Circuit (C117 PSB/PSE Board Assembly) . . . . . . . . . . . 1-28 1.6.4 Control Panel Board (C117 PNL Board Assembly). . . . . . . . . . . . . . . . 1-29 1.6.5 Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-29
List of Figures
Figure 1-1. Exterior View of the DFX-5000+. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Figure 1-2. Pin Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Figure 1-3. Printable Area for Fanfold Paper. . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Figure 1-4. Unsuitable Paper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Figure 1-5. Form Override Area. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Figure 1-6. Perforation Pitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Figure l-7. Paper Edge at a Horizontal Perforation . . . . . . . . . . . . . . . . . . . . . . 1-7 Figure l-8. Perforation Intersections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 Figure l-9. Raised Portion at aPerforation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 Figure 1-10. Sprocket Holes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 Figure 1-11. Aligned Sprocket Holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 Figure 1-12. Incorrectly Folded Paper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 Figure 1-13. Printable Area, Overlapping Multi-part Forms. . . . . . . . . . . . . . . . 1-8 Figure 1-14. Dotted Paste Positions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 Figure 1-15. Stapled Area 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 Figure 1-16. Stapled Area 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 Figure 1-17. Stapled Area 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10 Figure 1-18. Correct Multi-part Form Binding. . . . . . . . . . . . . . . . . . . . . . . . . . 1-10 Figure 1-19. Printable Area for Fanfold Paper with a Label. . . . . . . . . . . . . . . 1-10 Figure 1-20. Printable Area for Labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11 Figure 1-21. Label and Carrier. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12 Figure 1-22. Data Transmission Timing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14 Figure 1-23. Control Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17 Figure 1-24. Multi-part Forms with a Label. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19 Figure 1-25. overlapping Multi-part Forms. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19 Figure 1-26. Main Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26 Figure 1-27. M-3C11 Printer Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27 Figure 1-28. C117 MAIN Board Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28 Figure 1-29. C117 PSB/PSE Board Assembly. . . . . . . . . . . . . . . . . . . . . . . . . 1-28 Figure 1-30. C117 PNL Board Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29 Figure 1-31. Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29
..
List of Tables
Table 1-1. Options and Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Table 1-2. Character Size and Pitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Table 1-3. Printing Speeds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Table 1-4. Character Tables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Table 1-5. Acceptable Environmental Conditions. . . . . . . . . . . . . . . . . . . . . . . 1-12 Table 1-6. Rated Electrical Ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13 Table 1-7. Parallel lnterface Signals and Connector Pin Assignments. . . . . . . 1-15 Table 1-8. Serial Interface Signals and Connector Pin Assignments . . . . . . . 1-16 Table 1-9. Selecting the Paper Memory Area . . . . . . . . . . . . . . . . . . . . . . . . . 1-20 Table 1-10. Setting the Page Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20 Table 1-11. Setting the Paper Type.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21 Table 1-12. DIP Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23 Table 1-13. IBM Mode Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23 Table 1-14. ESC/P Mode Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24 Table 1-15. Interface Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25 Table 1-16. Baud Rate Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25 Table 1-17. Page Length Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25
DFX-5000+ Service Manual
Product Description
1.1 GENERAL FEATURES
The DFX-5000+ is a 9-pin, serial, dot matrix printer with a maximum speed of 560 characters per second (cps). It is designed for business use and provides high-speed, high-volume printing and continuous-sheet handling. The main features of the printer are: Cl Maximum printing speeds: 560 cps (high-speed draft mode) 504 cps (draft elite mode) 420 cps (draft pica mode) Cl Advanced paper handling: -10 inches per second (ips) paper feeding - Paper jam detection - Paper width detection - Front and rear two-way push tractors - Automatic paper back-out and loading from another paper path and paper park - Automatic platen gap adjustment for paper thickness - Automatic tear off - Paper memory function - Automatic paper path changing Cl Eight-bit parallel interface and RS-232C serial interface standard Cl Epson ESC/P-83 (ESC/P version 83) printer driver (compatible with the FX-870/1170 and DFX-5000) D 9 character tables in the standard version 21 character tables in the NLSP (National Language Support) version Cl Upgraded data handling: - 20KB input buffer - Automatic interface selection - Type B optional I/F cards The figure below shows the DFX-5000+.
too cover
"'"'"'"" `NV'
control panel
poper separator
----,
.-n".fltnr ~"p=, >Gpu,.. a"$ f-flue, ----
rial interface
e cover for I interface
-,
~orallel interface
Figure 1-1. Exterior View of the DFX-5000+ 1-1
Rev. A
Product Description
DFX-5000+ Service Manual
Table 1-1. Options and Consumables
I
Model #8309 #8766 #8767 t I C82305*
I
Description
Pull tractor unit Ribbon cartridge Ribbon pack , I Serial I/Fcard, simple serial interface** (SSi), inch screw Serial I/F card, SSI, mm screw 1 I 32KB intelligent serial l/F card (inch screw) 32KB intelligent serial I/F card (mm screw) 32KB intelligent parallel l/F card LocalTalk l/F card 32KB IEEE-488 I/F card Coax l/F card
I
C82306* C82307' C82308* C8231O* C82312* C82313*
I
C82314* i I C82315*
I Twinax
I/F card
I
C82324*
I Ethernet I/Fcard
`The digit indicated by an asterisk (*) vanes by country. q *A simple serial interface card has no CPU; the printer processes the data from the card.
1-2
Rev. A
DFX-5000+ Service Manual
Product Description
1.2 SPECIFICATIONS
This section provides detailed information about the DFX-5000+.
1.2.1 Printer Capabilities
Printing method: Pin configuration: Pin diameter: Serial impact dot matrix 9 wires 0.29 mm (0.01 inches)
mm (1/72")
o 8/72" o 0 0 0 L3I
Figure 1-2. Pin Configuration
Dot matrix: 9 x 7 (high-speed draft mode) 9 x 9 (draft mode) 18x 23 (NLQ mode) Printing direction: Text mode Bit image mode Built-in fonts: Bidirectional with logic seeking (Unidirectional mode can be selected using the ESC U command.) Unidirectional Draft NLQ Roman NLQ Saris Serif
Table 1-2. Character Size and Pitch
Type of Letters Pica (1 O cpi) Elite (12 cpi) 15 cpi Condensed (17.1 cpi) Condensed elite (20 cpi) Width in mm
(inches)
2.12 (0.08) 1.69 (0.07) 1.41 (0.06) 1.06 (0.04) 0.85 (0.03)
Height in mm (inches)
3.1 (0.12) 3.1 (0.12) 3.1 (0.12) 3.1 (0.12) 3.1 (0.12)
Pitch in mm printable Columns (inches)
2.54 (0.10) 2.12 (0.08) 1.69 (0.07) 1.48 (0.06) 1.27 (0.05) 136 163 204 233 272
I
Rev. A
1-3
Product Description
DFX5000+ Service Manuai
Table 1-3. Printing Speeds
Type of Letters High-speed draft Draft pica 10@ Draft elite 12 cpi Draft 15 cpi Draft condensed pica NLQ pica NLQ elite 17 Cpi 210 84 200 80 Draft emphasized pica 20cpi 420 400 420 Print Speed (cps) High Duty (cps) 533 400
101
20KB or O bytes (selectable by DIP switch 2-2) ESC/P-83 mode
96
Input data buffer: control codes:
Table 1-4. Character Tables
Character Tables Italic PC437 (U. S., Standard Europe) PC850 (Multilingual) PC860 (Portuguese) PC863 (Canadian-French) PC865 (Norwegian) PC861 (Iceland) BRASCII
Abicornp
standard Version
NLSP* Version
IBM Mode x
o
o o o o
0
0
0
0
x
x
0
0
x
o o
o
o
x
x
PC853(Turkish) PC857(Turkish) ISO Latin IT (Turkish) PC437 (Greak) PC869 (Greek) ISO 8859-7 (Greek) PC855 (Cyrillic) PC866 (Russian) PC852 (East Europe) MAZOWIA (Polish) Code MJK (Czecho, Slovak) Bulgaria (Bulgaria)
x x x x x x x x x x
0 0 0 0 o o o o o o o o o o o o
0
x
x x
x x x x
x x
x
x
x x x x
0: supported
x: Not supported *: Nationa/Language Support
1-4
Rev. A
DFX-5000+ Service Manual
Product Description
1.2.2 Paper Handling Specifications
Feeding methods: Paper size: Fanfold paper Single sheet paper Roll paper Line spacing: Feeding speed (1/6-inch per line): Continuous Intermittent Note: Push tractor feed (front and rear) Push-pull feed with the optional pull tractor (front or rear) 101 -406 mm (4 - 16 inches) wide Not available Not available 1/6- or l/8-inch feed or programmable with a l/216-inch minimum increment
17 ins/line (10 inches per second) 26 ins/line
The feeding speed (10 ips) is reduced to 6 ips when the optional pull tractor is installed.
1.2.3 Paper Specifications
Fanfold Paper
Quality: Width: Copy capability: Front Rear Total thickness: Front Rear Weight: Single Multi-part Plain paper 101 -406 mm (4 - 16inches) 6 sheets (1 original + 5 carbonless copies) 4 sheets (1 original + 3 carbonless copies) Up to 0.46 mm (0.018 inches) Up to 0.30 mm (0.012 inches) 45-70 kg(14- 22 lb) 35-48 kg (11 - 15 lb) x n (n < 8), up to the total thickness 13-31 mm More than 13mm
~
o .-------- wxY~ ~ o rABCD
I
o
> g s
H
m
E
I I
o 0 I I o 0
0 0 I 0 0
0-- - -- --- -- ----- --------0 - -- - --w--- : ~~BcD I
A A
`o O~BCD WXYZJ ---------
01
/0
Figure 1-3. Printable Area for Fanfold Paper
Rev. A
1-5
Product Description
DFX-5000+ Service Manual
Notes: 1. Horizontal alignment maybe irregular in the top 75 mm (3 inches) of the first page. 2. When using the optional pull tractor, the top 120 mm (4.8 inches) of the first page are unprintable. 3. Use clean paper with no folds, creases, or tears (especially for multi-part paper). Figure 1-4 shows paper you should not use.
creases
Figure 1-4. Unsuitable Paper
4. Form override printing is available for 20 lines after the paper end. The paper feeding pitch is not guaranteed. The end of the printable area is 15 mm (0.60 inches) above the bottom edge of the paper. A A o :p6D-- --- ~lo 0' 0 o` o E In END OF PAPER o 0 I 10 10 `o
s ,~
E 1$ il
,
w)(wJ L%D--. ---
V If?
Figure 1-5. Form override Area
5. 6. Weak horizontal and vertical perforations cause paper jams. The pitch of perforations (the ratio of the cut part to the uncut part) must be less than 5:1.
cut
_f&__t?tVE!?L
Figure 1-6. Perforation pitch
1-6
Rev. A
DFX-5000+ Service Manual
Product Description
7.
Horizontal perforations must have uncut parts on both edges of the paper.
Figure 1-7. Paper Edge at a Horizontal Perforation
8. At the intersection of a horizontal and vertical perforation, the perforation cuts must not cross each other. Figure 1-8 shows examples of correct perforation intersections.
I I -----.
-'/
Paper edge
Uncut
[ ------
cut l_-
II
9.
I I ------ I
I I ---- I
Figure 1-8. Perforation Intersections
The raised portion at a perforation (fold) must be less than 1 mm (0.04 inches) from the flat part, and the bottom layer must be kept flat by force. Perforations
Figure 1-9. Raised Portion at a Perforation
10. Sprocket holes must be circular and may have teeth.
OC3
Figure 1-10. Sprocket Holes
11. The sprocket holes of each paper layer must be properly aligned.
Figure 1-11. Aligned Sprocket Holes
Rev. A 1-7
3
NG
o
-b
U 0
II
Product Description
DFX-50oo+ Service Manual
12. Any pieces of paper remaining in the sprocket holes must be removed. 13. The paper should be fanfolded at the horizontal perforations. Never use incorrectly folded paper, such as the paper shown below. NG
Figure 1-12. Incorrectly Folded Paper
14. Make sure there are no holes in the printable area. 15. The paper must be tom off cleanly along a perforation.
Overlapping Mutti-part Forms
Paper path: Quality: Width: Copy capability: Overlap length: Total thickness: Print area Overlap area Weight: Multi-part Carrier Front only Plain paper 101-406 mm (4 -16 inches) 5 sheets (1 original + 4 carbonless copies), excluding the bottom carrier 10 mm (0.394 inches) maximum 0.46 mm (0.018 inches) maximum 0.70 mm (0.028 inches) maximum, including the bottom carrier 35-48 kg (11 - 15 lb), up to the total thickness 45- 70kg (14- 221b) More than 13mm 13-31mm
T
4 -
--D
--
7
Carrier o
r
0 0
Perforations / ./ o ------------------- --..-- ----. 0 Ma)
z
o 0
.1
0 -. 0
-.
0 0 0 0
5 --
-.
0
o o
A
0 --
Figure 1-13. Printable Area, Overlapping Multi-part Forms
DFX-5000+ Service Manual
Product Description
r,
When using overlapping multi-part forms, do not use the paper select (change tractors) or tear offfunction; to avoid a paper jam, it is important not to feed overlapping multi-part forms backward. Notes:
Ii
1.
Rough multi-part form binding causes paper jams. stapling (mechanical staking), or tape stitching. Forms joined with spot gluing are recommended for the best printing quality.
2. The multi-part form sheets should be bound together with spot gluing (dotted paste), paper
3. For multi-part forms joined with dotted paste, the form sheets can be joined on either a single
side or both sides. Figure 1-14 shows the recommended paste positions.
Surface
a
o
"
m
o
0 0
o 0
Ea
-------------------
m
0 0 0 0
mB-
0
m
m
0
0 0
W
0
0
0
m
0
0
-------------------
0
Figure 1-14. Dotted Paste Positions
4. The pasted areas must be pressed flat. There must be no creases in the paper. 5. Paper stapling must be applied from the front, and the paper must be flat. Figure 1-15 shows a
cross section of the stapled area.
a: Less than paper thickness
Figure 1-15. Stapled Area 1
6. Paper stapling must be applied for both feeding directions. Figure 1-16 shows a cross section of the stapled area.
Paper feeding direction
Figure 1-16. Stapled Area 2
Rev. A
1-9
Pfvduct Descfiptkm
DEMO(M+ Servke hisnual
7.
The binding area must be fiat. Figure 1-17 shows a cross section of the stapled area.
NG
Figure 1-17. Stapled Area 3
8. Never use forms joined with metal staples. 9. The binding (dots of paste or paper staples) must be outside the printable area. 10. Overlapping multi-part forms must be bound at the top side by spot gluing. The binding must be secure and there should be no spilled giue. Figure 1-18 shows the correct multi-part form binding method. 11. Multi-part firm sheets should be securely bound to each other, and the binding area must not be too large.
Paate
Figure 1-18. Correct Muiti-part Form Binding
Fanfold Paper with a Labal Paper path: Quality: Width: Total thickness: Weight: Single Multi-part Front only Plain paper 101-406 mm (4 - 16 inches) 0.46 mm (0.018 inches) rruximum 4 5 - 70kg(14- 221b) 35- 48kg (11 -15 lb) x n (n < 8), up tothe total thickness No pmling area
`w
13nml
. -,. c'\
~` t -,
01
1-1o
A
A
10
Rev. A
Figure 1-19. Printabie Area for Fanfoid Paper with a Labei
DFX-5000+ Service Manual
Product Description
Labels
Paper path: Label size (W x H): Front only 2%x 15/16 inches 4 x 15/16 inches 4 x 17/16 inches 4- 16 inches 3.5 inches minimum 0.19 mm (0.0075 inches) maximum Differences in thickness must be less than 0.12 mm (0.0047 inches). Avery continuous form labels Avery mini-line labels
Bottom carrier: Width Length Total thickness: Label examples:
" 0 IIr-lr-lI 10 II o
I 01
0 I
II
II
I
o
I 10
0
0
0
0 0
L.-----H---J o r-l~-l!o 10
II
II
10
H
A
11
0
Inside of each. label
Figure 1-20. Printable Area for Labels
When using labels, do not use the paper select (change tractors) or tear oflfinction; to avoid a paper jam, it is important not to feed label forms backward. Notes: 1. 2. Load label forms only onto the front tractor. The paper select function must not be used. Feed label forms only in the forward direction, using the forward-feeding MICRO FEED button (A). Do not feed label forms in the reverse direction. (Feeding label forms backward may cause a paper jam, or the labels may come off the backing and stick to the printer.) When using label forms, do not use the TOF (top of form) function. Do not use easy-peel labels. Label comers must be rounded. The labels and the bottom carrier should have no folds or creases. Labels must be on carrier paper, and there should be carrier paper between the labels. (The labels should not touch each other.) The label surface must be flat.
3. 4. 5. 6. 7. 8.
Rev. A
1-11
Product Description
DEX-50(W+ Service hWw81
r
A
4-16"
A
I
o [ o H ---------------------------J .0' O,
r-- r
`T 0
~
`k' j i `*e' j
r`7
10; r-l
v
0 ~ ~ o ----------------------------o 0( H A
\
bb' i i `ab' j,
0 o
H
~w
r
Figure 1-21. Label and Carrier 1.2.4 Ribbon Specifications
Ribbon cartridge: Ribbon pack: Ribbon pack exchanges: Ribbon color: Dimensions: Cartridge Ribbon Life: #8766 #8767 4 times per cartridge maximum Black 506 (W) X 23 (H) X 140(D) mm (20.24X 0.92 x5.60 inches) 13 mm x 70 m (0.52 inches x 231.0 tit), endless 15 million characters (14 dots/character)
1.2.5 Environmental Conditions Table 1-5. Acceptable Environmental Conditions
Condition Temperature Humidity Shock resistance Vibration resistance
q ': 7hese conditions are q2: wjj~mnsationm
Operating 5- 35°C (41" - 95"F) 10WY.
storage -30- 80"C (-22 - 140"F) "' 5- 85% RH ""v 2 G (within 2 maec.)" 0.50 G, 55 Hz maximum
RH q
1 G (within 1 msec.) 0.25 G, 55 Hz maximum
acceptable when theprinterisin itssh@ping mntainer.
..c.,.?
.4
`{ . ...~
1-12
Rev. A
DFX-5000+ Service Manual
Product DescriMion
1.2.6 Electrical Specifications Table 1-6. Rated Electrical Ranges
120 V Version Rated voltage Input voltage range Rated frequency range Input frequency range Rated current Power consumption 120 VAC 103.5- 132 V
5 0 - 6 0 HZ 220-240 V Version
I
I
220-240 VAC
198-264 V 5 0 - 6 0 tiz 49.5 -60.5 tiz 3.0 A Approx.110 W (self-test in 10 cpi draft mode)
I
49.5 -60.5 Hz 5.0 A Approx. 115 W (self-test in 10 cpi draft mode)
Insulation resistance
10 MQ minimum 10 MQ, minimum (applying 500 VDC between AC line (applying 500 VDC between AC IHw and chassis) and chassis) 1000 VAC rms -1 minute or 1200 VAC rrns -1 second (between AC line and chassis) 1500 VAC rrns -1 minute (between AC line and chassis)
Dielectric strength
1.2.7 Reliability
MTBF: MCBF: Printhead life: 8000 power-on hours (POH) at a duty cycle of zs~o 24 million lines (excluding the printhead and ribbon) 300 million characters (14 dots/character)
1.2.8 Safety Approvals
Safety standards: U.S. version: European version: Radio frequency interference (RFI): U.S. version: European version: UL1950 with D3 CSA22.2 #950 with D3 EN 60950 ~, SEMKO, DEMKO, NEMKO, SETI) FCC part 15 sub-part B class B Vfg 243 (VDE 0878 part 3) CISPR Pub 22 class B
1.2.9 Physical Specifications
Size (W x D x H): Weight: 700 x 382x 369 mm (27.6 x 15.0 x 14.5 inches) 29 kg (63.8 lb)
Rev. A
1-13
Product Description
LKMO#+ Serukw Mwd
1.3 INTERFACE SPECIFICATIONS
1.3.1 Parallel Interface
Data forrmt: Synchronization: Handshaking: Signal level: Connector: 8-bit parallel
" By STROBE Pllk Sy'dWXWa tion
By BUSY and ACKNLG TT'compatible level
SigdS
%-pm 57-30360 (Amphenol) or equivalent
ACKNLG
DATA
., 6!'!?
`,$ `. .>.. ,:,
&
Note:
L 0.5uS(Min.)
O.SuS(Min.) 0.5uS(Min.)
Figure 1-22. Data Transmission Timing
The transition time (the rise and fall time) of each input signal must be less than 0.2 ILS.
The BUSY signal is active (HIGH) under the following conditions: - During data reception (See Figure 1-22.) - When the ~t buffer is full - When the INIT' input signal is active - During initialization - When the ERROR or PE signal is active - During the self-test - II-I paper memory setting mode - IrI pause mode - When a fatal error occurs The ERROR signal is active (LOW) under the following conditions: - When a paper out error occurs - When a paper jam error occurs - When a fatal error occurs The PE signal is active (HIGH) when a paper out error occurs.
1-14
Rev. A
DFX-5000+ Service Manual
Product Description
Table 1-7 shows the signal functions and connector pin assignments for the 8-bit parallel interface.
Table 1-7. Parallel Interface Signals and Connector Pin Assignments
Pin No. Signal Name Return Pin No.
I/o'
I
Description
1
STROBE
19
STROBE pulse to read the input data. The pulse width must exceed 0.5 @. Input data is latched after the falling edge of this signal. Parallel input data to the printer. HIGH level means data 1. LOW level means data O. This pulse indicates data has been received and the printer is ready to accept the next data. The pulse width is approximately 12 p.s. HIGH indicates the printer cannot accept the next data. HIGH indicates paper out. This signal is effective only when the ERROR signal is LOW. Always HIGH output. (Pulled up to +5 V through a 3.3 KQ resistor.) If the signal is LOW when the printer is initialized, a line feed is automatically performed when a CR code is input (auto LF). No connection (not used). Signal ground level. Chassis ground. In the printer, chassis ground and signal ground are short circuited. Pulled up to +5 V through a 3.3 KQ resistor. Ground for twisted-pair return signal. Pulse input (width: 50 p.s minimum, active LOW) for printer initialization. LOW indicates that some error has occurred in the printer. Signal ground. If the signal is LOW when the printer is initialized, DC1/DC3 control is disabled.
2-9
DATA 1- DATA 8
20-27
I
10 11 12 13 14 15,34 16 17 18,35 19-30 31 32 33 36
ACKNLG BUSY PE SLCT AFXT NC
28 29 30
0 0 0 o
I
Ov
FG +5 v GND INIT ERROR GND SLCTIN I I -
o
*The 1/0 column indicates the direction of the signal as viewed from the printer.
Rev. A
1-15
Product Lkscription
DEX401W+ Servka Mm&#
1.3.2 RS-232C Serial Interface
Data format: Synchronization: Handshaking: Word length: Start bit Data bit Parity bit Stop bit Bit rate: Logic level: MARK (logical 1) SPACE (logical O) Connector: RS-232C serial Asynchronous By DTR signal or X-ON/X-OFF protocol 1 bit 8 bits Odd, even, or no parity 1 bit or more 300,1200,9600, or 19200 bps (selectable by DIP switches 2-7 and 2-8) -3 to 27 V +3 to +27 V EIA standard 25-pin cmnector
Table 1-8 shows the signal functions and connector pin assignments for the serial interface.
Table 1-8. Serial Interface Signals and Connector Pin Assignments
Pin No.
1
I
r
Signal Name FG TXD RXD SG DTR
I I/o* I
. I I O I . I Receive data. Signal ground.
Description
I I I
2 3 7 11,20 4-6,8-10, 12-19.21-25
q
I
I Chassis ground. [ TmllSmt*tafOrx-Ow-OFF
hndShake.
o
I
NC
I .
Indicates whether the printer is ready to receive data. If the printer is not ready, the DTR signal becomes MARK. No connection (not used).
The PO column indicates the data flow as tiewed fmm the printer.
j P
.>,;, , 0
,,,'; .;.,,,
1-16
Rev. A
DFX-5000+ Service Manual
Product Description
1.4 PRINTER OPERATION
This section describes the basic operation of the printer.
1.4.1 Control Panel
The printer's control panel contains eight non-lock type push buttons and twelve LED indicators for easy use of the various printer functions.
Cl POWER n PAPER OUT
PAUSE
LFIFF LOAO
TEAR OFF
MICRO FEEO m A
TOP OF `
O R M
PITCH 0 o `
0
PAPER SELECT g m ~o B FRONT/REAR
12
cl
in
a
m
a
(e)
(A)
(B)
(c)
Figure 1-23. Control Panel Buttons
PAUSE: LF/FF LOAD: Stops or starts printing, if any print data exists in the input buffer. (Turns pause mode on or off.) Advances the paper line by line according to the set line spacing while the printer is ready to print or paused by the PAUSE button. Holding down the button for about one second advances the paper to the next top of form (TOF) position. This button is also used to load the paper from the push tractor of the selected paper path when the printer is in the paper-out state. Enables tear off mode and advances the paper to the tear off position. This button functions only when the printer is in pause mode. The tear off position can be adjusted using the MICRO FEED buttons. The adjusted value is stored in the EEPROM on the main board when the printer is turned off. Adjusts the paper position, including the top of form (TOF) and tear off positions. The forward MICRO FEED button (A) advances the paper in 1/216 inch increments and the backward MICRO FEED button (v) feeds the paper backward in 1 /216 inch increments. Enables top of form (TOF) setting mode, so that the TOF position can be adjusted using the MICRO FEED buttons. This button functions only when paper is loaded into the printer using the LF/FF LOAD button and the printer is in pause mode. In TOF setting mode, the PAUSE LED is lit and the TOF LED blinks. Selects a character pitch of 10,12, or 17 cpi. Selects the front or rear paper path. If there is paper in the current path and the printer is in pause mode, the paper is fed backward to the tractor. Then, the selected paper from the other tractor is fed to the TOF position. If all the paper in the current path is not fed backward to the tractor by the single 22-inch (55.9-cm) backward feeding sequence, make sure your previous print job is tom off and press the PAPER SELECT button again until the current path is empty.
TEAR OFF:
MICRO FEED:
TOP OF FORM:
PITCH: PAPER SELECT:
Rev. A
1-17
Product Descrhtion
DFX-5009+ Servkm MwnuJ
LED Indicators
POWER (green): PAPER OUT (red): PAUSE (orange): TEAR OFF (orange): TOP OF FORM (green): PITCH (3) (green): FRONT (2) (green): (red): REAR (2) (green): (red): Lit when the printer is turned on. Lit when the printer is out of paper. Flashes when there is a paper jam. Lit when the printer is in pause mode. Lit when the printer is in tear off mode. Lit when the printer is in TOF mode. The lit PITCH LED indicates the selected pitch. Lit when the front paper path is selected with paper loaded onto the front tractor. Lit when the front paper path is selected with no paper loaded onto the front tractor. Lit when the rear paper path is selected with paper loaded onto the rear tractor. Lit when the rear paper path is selected with no paper loaded onto the rear tractor.
1.4.2 Self-test
The printer's self-test (self printing) function checks the following - Control arcuit Printer mechanism Print quality To run the self-test in draft* mode, hold down the LF/FF LOAD button and turn on the printer. To run the self-test in NLQ mode, hold down the TEAR OFF button and tmm on the printer. The self-test can be interrupted by pressing the PAUSE button. To end the self-test, press the PAUSE button and then turn off the printer. The self-test prints the following: - Program ROM version number Built-in characters To print the current DIP switch settings, hold down the PAUSE button and turn on the printer. * The printer does not print the self-test in draft mode if NLQ mode is selected using DIP switch 1-3.
1.4.3 Hexadecimal Dump Function
The hexadecimal dump function prints the data the printer receives in hexadecimal format. To print a hexadecimal dump, hold down the LF/FF LOAD and TEAR OFF buttons and turn on the printer. "HEX DUMP MODE" is printed on the first line. Then 16 bytes an? printed in hexadedmal on each line, and the ASCII character correspondkg to each byte is printed on the right side. "." is printed if there is no corresponding ASCII character (such as, for a control code). If less than 16 bytes remain, they can be printed by pressing the PAUSE button. To cancel hexadecimal dump mode, turn off the printer.
1.4.4 Paper Out Detection Function
When the paper out sensor detects the printer is out of paper, the printer automatically enters pause mode. Load new paper properly, and then press the PAUSE button to turn off pause mode so the printer is ready to print.
1.4.5 Cover Open Detection
When the printer cover is opened, the printer stops printin& beeps 4 times with 0.1 second intervals, and enters pause mode. Close the printer cover and press the PAUSE button to turn off pause mode so the printer is ready to print. 1-18 Rev. A
DFX-5000+ Service Manual
Product Description
1.4.6 Paper Width Detection
The printer detects the right paper edge and determines the right end of the printable area. This disables printing in areas where there is no paper.
1.4.7 Automatic Paper Thickness Adjustment
The printer measures the paper thickness each time paper is loaded. The distance between the printhead and the platen is automatically adjusted to match the paper's thickness and obtain the best print quality.
1.4.8 Paper Memory Function
The paper memory function allows the printer to print properly when different areas of the same form vary in thickness. For the best print quality when using forms with a label or overlapping forms, use the paper memory function. It allows you to save paper format and thickness information using the DIP switches and the control panel buttons. The paper memory function is available only for forms loaded on the front tractor. Cl Forms with a label Multi-part forms that vary in thickness include forms with a label; the label area is thicker than the rest of the form.
0 0
Figure 1-24. Multi-part Forms with a Label
Q Multi-part forms that partly overlap the next page Multi-part forms that vary in thickness include forms that overlap slightly where they are glued together; the overlap area is twice as thick as the rest of the form.
Figure 1-25. Overlapping Multi-part Forms
Set the information about the label and overlap areas before printing. The printer works according to this information. Note: The tear off and paper select functions are not available when the paper memory function is used.
Rev. A
1-19
Product Description 1.4.8.1 Using the Paper Memory Function
DFX-5000+ Servke Manual
To use the paper memory function, you must first save paper format and thickness information for up to two different types of paper as described in fktion 1.4.8.2, below. To turn on the paper memo~ function after saving your paper format and thickness information, hold down one of the buttons below and turn on the printer.
MICRO FEED
(A)
MICRO FEED (v)
Recalls the paper format and thickness information stored in memory area 1. RecaIls the paper format and thickness information stored in memory area 2.
To turn off the paper memory function and use normal paper, hold down the PAPER SELECT button and turn on the printer. Notes: Cl A l-inch skip over perforation area is automatically included for overlapping forms. Ct ESC C (set page length) is valid when using the paper memory function. O ESC N (set skip over perforation) is valid when using the paper memory function; however, if the skip length is less than 1 inch, the setting is ignored when using overlapping forms. Q ESC O (reset skip over perforation) is valid when using the paper memory function with overlapping forms. Q When using overlapping forms, the loading position must be adjusted each time you load paper.
1.4.8.2 Saving Paper Format and Thickness Information
To save paper format and thickness information for overlapping forms, forms with a label, or overlapping forms with a label, follow these steps: 1. Turn off the printer. 2. Use DIP switch 3-4 to select the memory area where you want the printer to store the paper format and thickness information. Memory area 1 is sekcted when DIP switch 3-4 is off. This is the printer's default setting. To select memory area 2, turn on the switch.
Table 1-9. Selecting the Paper Memory Area
Paper Memory Area
1
DIP SW 3-4 OFF ON
2
3. Use DIP switches 3-1 and 3-2 or softwareco rnmands to set the page length.
Table 1-10. Setting the Page Length
Page Length (inches) 11 12 8.5 70/6 DIP SW 3-1 OFF OFF ON ON DIP SW 3-2 OFF ON OFF ON
.o,, :. .
1-20 Rev. A
DFX-5000+ Service Manual
4.
Product Description
Use DIP switches 3-5 and 3-6 to set the paper type.
Table 1-11. Setting the Paper Type
Paper Type Normal paper Forms with a label Overlapping forms Overlapping forms with a label I
Sw 3-5
OFF OFF ON ON [
Sw 34
OFF ON OFF ON
5. Hold down both MICRO FEED buttons and turn on the printer. 6. If you are using forms with a label, indicate the label's position by following these steps:
(1) Open the printer cover. (2) Align the pointer on the ribbon mask with one of the label's comers. To feed the paper up or down, press the appropriate MICRO FEED button. To move the pointer right or left, move the printhead by hand. (3) Press the TOP OF FORM button. (4) Move the pointer to the comer of the label diagonally opposite the first comer. (5) Press the TOP OF FORM button. (6) Close the printer cover. 7. Use the printer beeps to confirm that the paper format and thickness information has been saved properly. If the printer beeps once or twice, the information has been saved correctly in memory area 1 or 2. If the printer beeps 10 times, the information has not been saved; carefully follow steps 1 through 7 in this section again.
1.4.9 Automatic Tear Off Function
Use DIP switch 3-8 to enable or disable the automatic tear off function. When the tear off function is enabled, the printer automatically feeds fanfold paper until its perforation reaches the tear off position of the printer cover under these conditions: Cl The paper is advanced to the TOFposition after a print job. Q The printer receives an FFcode and then no other codes or characters for at least3 seconds. (The printer has finished a print job.) Ll The pull tractor is not being used. D The paper memory function is not being used. Then, if the printer receives more data, it automatically feeds the paper backward to the original position and printing starts.
1.4.10 Paper Jam Detection
When a paper jam is detected, the printer beeps, stops feeding the paper, and enters pause mode. The PAPER OUT indicator flashes. Remove the paper and load new paper properly. Then press the PAUSE button to turn off pause mode so the printer is ready to print.
1.4.11 Automatic Interface Selection
When the printer does not receive any data tbr the set time over the currently selected interface, it checks the parallel interfam, serial interfam, and optional interfam, and selects the intert%ce that receives data fit. The standby time can beset to 10 seconds or30 seconds using DIP switches 24,2-5, and 245.
Note:
The built-in serial interface and Type B simple serial interface card cannot be used at the same time. The simple serial interface card takes precedence over the built-in serial interface.
1.4.12 Thermal Protection
The printhead has a thermistor inside it, and the printhead cooling fan also has a thermistor. When the pnnthead or cooling fan is too hot, the printer stops printing while it cools. Rev. A
1-21
Product Dascrfption
DEW(W)+ Service Mmual
1.4.13 Skip Binding Function
The skip binding function is used for printing on multi-part forms with binding that could scratch the printhead during paper feeding. When this function is used, the head parks away from the binding during paper feeding to avoid paper jams. Use DIP switch 3-7 to enable or disable the skip binding function; when it is enabled, throughput is reducwl.
1.4.14 Printer Initialization
The printer is initialized in the following cases: Lt When thep@er is turned on. il men the NIT signal is input through the parallel rnterface. Initialization performs the following functions: Returns the printhead to th~ far left position (carriage home). Puts the printer in ready mode, so it is ready to print. Clears the print buffer and input data buffer. Clears download characters (CG ROM copy in IBM mode). Sets the line spacing to 1/6 inch. Sets the page length according to the DIP switch settings. Clears all vertical tab positions. Sets the horizontal tab position to every 8 columns. Sets the print mode according to the DIP switch settings and non-volatile memory. The top of form (T'OF) position is reset by the following: ~ Printer initializ.ation Li ESC/P software reset command (ESC @) ~ Page length command (ESCC) 2 IBM top-of-form setting command (ESC4)
1.4.15 Buzzer Operation
The buzzer sounds for approximately 0.1 second when a BEL code (07H) is input. Buzzer beeps indicate printer status, as shown below. Each asterisk (*) represents one 0.1 second beep. The ESC BEL command (07H) is input. A carnage error is detected due to: CRlockup. Low insulation resistance (less than 1 IQ. A paper out or paper jam is detected. (The printer runs out of paper or a paper jam occurs during paper feeding or printing.) Another paper error is detected: Incomplete back+ut. (The previous print job is not tom off.) Empty during operation. (The paper is out at power on.) An abnormal voltage is detected. RAM error is detected. A cover open is detected: The cover open sensor detects that the cover is open. The interlock switch detects that the cover is open. A short circuited printhead is detected. (The head driver FETs are bad.) A short circuited printhead fan is detected. An illegal paper memory setting is detected. A micro adjust limit is detected. A platen gap adjust error is detected. * *0.3 sWmd interval ** 0.1 second interval Note: 1-22 *(1 beep) "** "w (2 sets of 3 beepa)
q
*** `* *-*`~ ****(5
sek
of 4 beeps)
*"* (3 beeps)
c'"
* **·" (sbeepswi~ a w= ~ tween each beep) ** w ** ** q * (5 SPJS of z beeps) *** (4 beeps)
* * * * q q * * q * (II) &P ~~ a Pam between ~? ~ - ** q * - ** ** (B *S of 2 ~) **** W-* @ *S, ***-**-**... (continuom beeps) *** *** *** (3* of 3 *)
each beep)
Rev. A
DFX-5000+ Service Manual
Product Description
1.5 DIP SWITCH SEITINGS
This section describes the functions of the DIP switches. After settimz one or more DIP switches, turn on the printer to put your settings into effect.
Table 1-12. DIP Switch Settings
SW No. 1-1 Function ON I OFF Factory Setting
Emulation mode Drafl speed Character quality IBM mode ESC/P mode Shape of zero Input buffer Automatic LF bv CR Interface Serial bit rate Page length Skip over perforation Paper memory area** Overlapping forms** Forms with a label** Skip binding Automatic tear off See Table 1-13. See Table 1-14.
OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF
1-2 1-3 1-4 1-5 1-6 1-7 1-8 2-1 2-2 2-3 2-4 2-5 2-6 2-7 2-8 3-1 3-2 3-3 3-4 3-5 3-6 3-7 3-8
E
See Table 1-15. See Table 1-16. See Table 1-17. Valid (1") 2 Valid Valid Valid Valid Invalid 1 Invalid Invalid Invalid
I Invalid
* IBM mode indicates IBM ProPrinter emulation mode. ** These DIP switches are used forpaper memory function settings.
t
SW No. 1-4
I
Table 1-13. IBM Mode Selection I I
Function ON OFF
I
Factory Setting
Automatic CR by LF, ESC J Reserved Codes 80-9FH Reserved Character table
Invalid Characters
PC865
Valid Commands
PC437
OFF OFF OFF OFF
OFF
1-5 1-6 1-7 1-8
Rev. A
1-23
Product Description
DEW50tM+ Swvke Manual
Table 1-14. ESC/P Mode Selection
Character Table
Sw 1-4 Sw l-a Sw l-e Sw 1-7 Sw 14
Standard Italic Us. Italh France Italk Germany Itzk U.K. Italic Denmark Italic Sweden Italic Italy Italii Spain PC437 PC850 PC860 PC863 PC865 PC861 BRASCII Abicomp PC437 PC850 PC860 PC863 PC865 PC861 BRASCII Abicomp PC437 Greek PC869 1s0 8859-7 PC853 PC857 ISO Latin IT PC865 PC866 PC852 MAZOWIA Code MJK Bulgaria NLSP OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF ON ON ON ON ON ON ON ON ON ON ON ON OFF OFF OFF OFF OFF OFF OFF OFF ON ON ON ON ON ON ON ON OFF OFF OFF OFF OFF OFF OFF OFF ON ON ON ON OFF OFF OFF OFF ON ON ON ON OFF OFF OFF OFF ON ON ON ON OFF OFF OFF OFF ON ON ON ON OFF OFF OFF OFF OFF OFF ON ON OFF OFF ON ON OFF OFF ON ON OFF OFF ON ON OFF OFF ON ON OFF OFF ON ON OFF OFF ON ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON
1-24
Rev. A
DFX-5000+ Service Manual
Product Description
Table 1-15. Interface Selection
Interface Automatic selection, serial interface, odd parity (30 seconds*) Automatic selection, serial interface, odd parity (10 seconds*) Automatic selection, serial interface, no parity (30 seconds*) Automatic selection, serial interface, no parity (10 seconds*) Parallel interface Serial interface, odd parity Serial interface, even parity Serial interface, no parity Sw 2-4 OFF OFF OFF OFF ON ON ON ON SW 2-5 OFF OFF ON ON OFF OFF ON ON Sw 2-6 OFF ON OFF ON OFF ON OFF ON
*This is the standby time. See Section 1.4.11, `Automatic Interface Selection."
Table 1-16. Baud Rate Selection
Bit Rate (bps) 19,200 9,600 1,200 300 SW 2-7 OFF OFF ON ON Sw 2-8 OFF ON OFF ON
Table 1-17. Page Length Selection
Page Length 11 inches 12 inches Sw 3-1 OFF OFF I ON ON I SW 3-2 OFF ON OFF ON
I
8.5 inches 70/6 inches
I
Rev. A
~ 1-25
Pfvduct Dwcription
DEX4i'W+ Swvice Msnusl
1.6 MAIN COMPONENTS The main components of the DFX-5000+
main components are: Printer mechanism (M-3C11)
are designed fix easy removal and replacement. These
e
Main control board (C117 MAIN board assembly) Power supply board ( C117 PSB/PSE board assembly) Control panel (C117 PNL board assembly) Housing
Connector Junction Board
@
,.' .+. ,,.. ..,;,
Y
c
Figure 1-26. Main Components
1-26
Rev. A
DFX-5000+ Service Manual
Product Description
1.6.1 M-3CI 1 Printer Mechanism
The M-3C11 printer mechanism is a 9-pin, serial, dot matrix printer mechanism developed for the DFX-5000+. It is designed to provide high-speed, high-volume printing, and is especially heavy and durable when compared with existing terminal printer mechanisms. Its paper feeding mechanism uses fanfold paper, and an automatic mechanism is included to provide enhanced paper handling. The structural differences between the DFX-5000+ and the DFX-5000 are: U The DFX-5000+ includes a CR motor isolation resistance sensor. Ll The DFX-5000+ includes a paper jam sensor. Cl To prevent paper jams, the DFX-5000+ includes a tractor wire at the front and rear tractors. U The DFX-5000+ does not include a carriage home position sensor. LI The detection method of the carriage encoder sensor has been changed. In the DFX-5000, the encoder plate was attached to the rotor of the CR motor, while the DFX-5000+ uses a belt-type encoder. Cl In the DFX-5000+, the angle between the printhead and the surface of the platen has been changed to reduce noise. El In the DFX-5000+, the ribbon guide is not attached to the ribbon mask; the ribbon mask is attached to the pnnthead carriage.
Figure 1-27. M-3C11 Printer Mechanism
Rev. A
1-27
Product LA9ecriotkn
DEX-45000+ Service Manual
1.6.2 Main Control Board (C117 MAIN Board Assembly)
The C117 MAIN board assembly cxmsists ofi a TA4P96C14 8-bit CPU, an E05A87 gate array, a PROM (2 megabit including the CG ROM), a PS-RAM (256K), an EEPROM, an SLA7026M for the paper feed motor, an SLA5007 for the CR motor, each driver's IC, and the parallel and serial interface control circuits.
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Db-witches
~ W? S,22,10,13,16,i4,16,20,21(dnv.r for PRINTHEAD)
L
Q28 031(dnvor for MOTOR, RF)
figure 1-28. C117 MAIN Board Assembly 1.6.3 Power Supply Circuit (C117 PSB/PSE Board Assembly)
The C117 PSB/PSE tmrd assembly power supply circuit supplies the control circuit and printer mechanism drive circuit with power. The fan motor on this board keeps the temperature in the lower case constant and cools the CR motor. The printer contains one of two power supply boards; see Table 2-1 for irhrrnation on the input voltage and fuse ratings of your printer's board.
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Figure 1-29. C117 PSWPSE Board Assembly
1-28
Rev. A
DFX-5000+ Service Manual
Product Description
1.6.4 Control Panel Board (C117 PNL Board Assembly)
The C117 PNL board assembly is the operator control panel. It contains the buttons, indicator LEDs, and buzzer.
9 10 5
RA1
Figure 1-30. C117 PNL Board Assembly 1.6.5 Housing
The housing consists of many parts. The lower case is the main frame which holds the printer mechanism and circuits. These components are covered by the upper case, bottom plate, and two side covers, each of which has various covers. The housing has large openings in the front and rear for the paper entrances and exits. It also has a cover on the bottom plate to provide easy access to the PROM on the main board.
-- -- c-) `\"
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Figure 1-31. Housing
Rev. A
1-29
CHAPTER 2 Operating Principles
Table of Contents
2.1 OVERVIEW OF PRINTER MECHANISM OPERATION 2-1
2.1.1 Printhead Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 2.1.2 Carriage Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 2.1.3 Platen Gap Adjustment Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 2.1.4 Paper Feed Mechanism. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 2.1.4.1 Tractor Wire Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 2.1.5 Ribbon Feed and Tractor Select Mechanism. . . . . . . . . . . . . . . . . . . . . . 2-9 2.1.6 Plunger Mechanism. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
2-12 2.2 POWER SUPPLY OPERATION 2.2.1 PowerSupplyOverview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
2.2.2 +5 VDCLine RegulatorCircuk. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 2.2.3 +35 VDCLine RegulatorCircuti. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 2.2.4 +/-12 VDC Half-wave Rectifier Smoothing Circuit. . . . . . . . . . . . . . . . . 2-16
2-17 2.3 CONTROL CIRCUIT 2.3.1 Control Circuit Operation Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17 2.3.2 Reset Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21 2.3.3 Sensor Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-Z 2.3.4 CR Motor Driver Cimufi. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25 2.3.5 PF Motor Driver Cimuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30 2.3.6 RF Motor Driver Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31 2.3.7 PG Motor Driver Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32 2.3.8 Plunger Driver Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33 2.3.9 Printhead Driver Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
c)
62
-." .,, .-. *..
List of Figures
Figure 2-1. Mode13Cll Printer Mechanism. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Figure 2-2. Printer Mechanism Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Figure 2-3. Printer Mechanism Operation 2. . . . . . . . . . . . . . . . . . . . ........2-3 Figure 2-4. Printhead Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. ....2-3 Figure 2-5. Carriage Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. ....2-4 Figure 2-6. Platen GapAdjustment Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Figure 2-7. Tension Roller and PF Roller Operation . . . . . . . . . . . . . . . . . . . . . 2-6 Figure 2-8. Front Tractor Assembly Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Figure 2-9. RearTractorAssembly Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Figure 2-10. Tractor Wire Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Figure2-ll. Ribbon Feed Mechanism. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Figure 2-12. TractorSelect Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Figure 2-13. Plunger Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Figure 2-14. PowerSupplyBoard Block Diagram . . . . . . . . . . . . . . . . . . . . . . 2-12 Figure2-15. +5VDC Line RegulatorCircuit. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 Figure2-16. +35VDC Line Regulator Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 Figure 2-17. Half-wave Rectifier Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 Figure 2-18. Control Circuit Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18 Figure2-19. Data Flow from the Parallel Interface . . . . . . . . . . . . . . . . . . . . . . 2-19 Figure2-20. Reset Circuit Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21 Figure 2-21. SensorCircuit Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22 Figure 2-22. CRMotor Internal Circuit.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25 Figure 2-23. CR Motor Driver Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25 Figure 2-24. Acceleration Control Cutve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27 Figure 2-25. Deceleration Control Curve.... . . . . . . . . . . . . . . . . . . . . . . . . . 2-28 Figure 2-26. Measurement Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30 Figure 2-27. PFMotor Driver Circuit, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30 Figure 2-28. RF Motor Driver Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2'31 Figure 2-29. PG Motor Driver Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32 Figure 2-30. Plunger Driver Circuit., . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33 Figure 2-31. Printhead DriverCircuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34
List of Tables
Table 2-1 PowerSupplyBoards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Table 2-2 DC Voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 Table 2-3 Main IC Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20 Table 2-4. CR Motor Drive Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26 Table 2-5. CR Motor Drive Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27 Table 2-6. PF Motor Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31 Table 2-7. RF MotorSpecifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31 Table 2-8. PG MotorSpecifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32 Table 2-9. PlungerSwitching Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
DFx-5tW(h Sewka Manual
Oparathg Prfncipka
2.1 OVERVIEW OF PRINTER MECHANISM OPERATION
This section describes the Model 3C11 printer mechanism and explains how the printer works. The Model 3C11 printer mechanism features a 9-pin, impact dot printhead for serial printing. The printer mechanism is the main component of the printer and is supported by the other mmponents (the power supply and control arcuits). Figure 2-1 shows the Model 3C11 printer mechanism.
PAPER BA~L ASSEMBLY
Plunger TIMING BEL Connector Junction Board
TRACTOR ASSEMBLY (FRONT) D MOTOR
\
PLATEN GAP ADJUSTMENT MOTOR
Figure 2-1. Model 3C11 Printer Mechanism
The printer mechanism consists of the following main components: 22 Printhead The printhead is the component that actually pMts characters (dot matrix patterns). Printing is performed by striking the pins (arranged in a vertical line) against the surface of the paper and the ribbon. A character is printed by repeating this printing operation in the horizontal direction (as the printhead moves). The printhead includes a head fan and temperature sensor. The head fan also has a thermistor. When the printhead or fan is too hot, the printer stops printing until it cools. (Refer to Section 1.4.12, Themud Probation.) L1 Carnage mechanism The carriage mechanism moves the printhead in the horizontal direction. The CR motor drives the carriage, with the printhead on it. The CR sensor detects the CR motor speed and carriage position. The CR motor is closed-loop controlled. Because the CR motor is driven at a very high speed, it includes an isolation resistance sensor to detect abnormal resistance. The sensor detects an error if the resistance is less than 1 I@. Cl Interlock switch Because the carnage moves at a very high speed, it would be dangerous if a hand or finger were inserted inside the printer mechanism during printing. Therefore, as a safety measure, when the top cover is opened, the interlock switch cuts the drive voltage to the CR motor to slow down the carriage speed and prevent acadents. A control circuit controIs CR motor driver deceleration. (Refer to Section 2.3.4., CR Motor Dine Circuit.) Printing resumes when the top cover is closed. LI Auto platen gap adjustment mechanism The printer mechanism has an automatic platen gap adjustment function that measures the thickness of the paper and provides the appropriate gap between the platen and printhead. The platen gap is adjusted by moving the carriage (and printhead) either forward or backward. Because the front and rear carriage guide shafts which hold the @rriage are purposely mounted off-center, the carriage moves as the PC motor rotates the shafts. The PG sensor transmits the amount of movement (= gap) to the control circuit.
Rev. A
2-1
Operating Principles Cl Ribbon feed mechanism
DFX-5000+ Service Manual
The printer's ribbon cartridge contains an endless ribbon. The ribbon feed mechanism takes up the ribbon so that the portion hit by the pins is constantly changing. The RF motor drives the ribbon feed mechanism. Figures 2-2 and 2-3 show the operation of the ribbon feed mechanism. SHAFT, CR, GUIDE, REAR PLATEN GAP Inter Lock Switch CARRIAGE
ADJUSTMENT MOTOR 6 ,
II I 1,
I
PRINTHEAD I & 4
I
\
L
MOTOR ,
1
I I
I [ I I
2JJJJU
I
I I I I 11
/
I
9
Carriage Encoder Belt
Platen Gap Home Position Sensor
DETECTOR, CR
Figure 2-2. Printer Mechanism Operation 1
Cl Paper feed mechanism The CR motor controls printing in the horizontal direction, and the paper feed mechanism controls movement in the vertical direction (line feeding and form feeding). The paper feed mechanism feeds paper vertically. The PF motor drives the paper feed mechanism. The front, rear, and top PE sensors detect whether paper is present in the paper path, and stop the printer from printing when there is no paper. The printer is equipped with three PE sensors: the front PE sensor at the front tractor, the rear PE sensor at the rear tractor, and the top PE sensor at the paper bail. The pull tractor sensor detects whether the optional pull tractor is installed. The printer is also equipped with a paper jam sensor. The control circuit reads the signals from the sensors and indicates when an error occurs. D Tractor select mechanism The printer mechanism has two paper entrances: one at the front tractor and one at the rear tractor. By controlling the RF motor, the txactor select mechanism chooses which tractor to use, and power from the PF motor is conveyed via a series of gears. The tractor select sensor detects the selected tractor and signals that information to the control circuit. D Plunger mechanism During printing, the paper bail assembly holds the paper under tension so that it is fed smoothly. When paper is loaded or ejected or when the tear off function is executed, the paper bail assembly needs to move up to prevent a paper jam. The plunger moves the paper bail assembly up. Figure 2-3 shows this operation.
2-2
Rev. A
DEX-4XXW Service Manual
Opating Princ@ha
Paper
TRACTOR ASSY., PULL
\.fi( PRINTHEAD SENSOR ASSY., PE, UPPER - S E N S O R ASSY., P A P E R TRASCOTR SELECT SENSOR JAM
SENSOR ASSY., PE, FRONT
SENSOR ASSY., PE, REAR
Rear Tractor Sprocket Front Tractor Sprocket