Star Micronics SP500 Series User manual

DOT MATRIX PRINTER
SP500 Series
TECHNICAL MANUAL
[FOURTH EDITION]

NOTICE
•Allrightsreserved.Reproductionofanypartofthismanualinany
form whatsoever, without STAR’s express permission is forbid-
den.
•The contents of this manual are subject to change without notice.
•All efforts have been made to ensure the accuracy of the contents
of this manual at the time of going to press. However, should any
errors be detected, STAR would greatly appreciate being in-
formed of them.
•The above notwithstanding, STAR can assume no responsibility
for any errors in this manual.
© Copyright 2002 Star Micronics Co.,Ltd.

INTRODUCTION
This manual describes the thermal printer SP500 series.
It is designed for use as a reference for periodic inspections and maintenance procedures to be executed
by service personnel. It is not intended for the general user. Users of this manual should have a basic
knowledge and understanding of the English language.
•This manual is divided into the following sections:
Chapter 1 Adjustments
Chapter 2 Parts Replacement
Chapter 3 Maintenance and Lubrication
Chapter 4 Parts List
•First edition : Dec. 2002
Second edition
: Jan. 2003 Add the new black mark detector
Third edition
: May. 2004
Fourth edition
: Sep. 2005 Add the new models (USB / Ethernet / Wireless interface)
1
2
3
4

– 1 –
1
CHAPTER 1
ADJUSTMENTS
This printer has undergone various adjustments so that it will attain a given standard of performance.
In this chapter, a brief explanation is given of the methods for making adjustments.
Follow the instructions when performing maintenance inspections or when replacing parts to correct
malfunctions.
1. Adjustment of the Gap Between the Print Head and the Platen.......... 2
1-1. Measuring the Gap Between the Print Head and the Platen ............................. 2
1-2. Adjusting the Gap Between Print Head and the Platen ..................................... 3
2. Adjustment of the Dot Aligment ............................................................. 4
3. Adjustment of the Black Mark Sensor Alignment................................. 6

– 2 –
1. Adjustment of the Gap Between the Print Head and the Platen
1-1. Measuring the Gap Between the Print Head and the Platen
1. Remove the ribbon base as described in chapter 2.
2. Remove the ribbon separator [1] as described in
chapter 2.
Fig. 1-1 Removing the Ribbon Separator
Fig. 1-2 Gap Measurement
2. Insert a thickness gauge [2] between the print head
[3] and the platen [4] and measure the gap.
3. Measure the thickness at positions Left and Right.
0.45to 0.50 mm are the reference values for the gap.
If the gaps at these positions along the platen are not
withinthisrange,adjustthegapusingtheprocedures
described in section 1-2.
[2]
[4]
[3]

–3 –
3. Checkthegapatallmeasuringpositionsinsection
1-1.
4. If the gap is not between 0.45 and 0.50 mm at step3,
repeat steps 1 through 2.
5. Install the ribbon holder [1].
1-2. Adjusting the Gap Between Print Head and the Platen
1. Raise and lower the adjusting bushing [5] on the left
side to adjust the left head gap.
2. Raiseandlowertheadjustingbushing[6]ontheright
side to adjust the right head gap.
Fig. 1-3 Gap Adjustment
Fig. 1-4 Gap Adjustment
[5]
Gap
+
-
[6]
Gap
-
+

–4 –
2. Adjustment of the Dot Aligment
1. Set the roll paper.
2. Press the FEED switch on the printer's control panel while turning the power switch ON.
3. Enter the Adjusting the dot alignment mode by releasing the FEED switch after the buzzer sounds twice.
4. After entering the adjusting the dot alignment mode, a printout of the adjustment patterns similar to the printout
below will be printed. The asterisk indicates the current adjustment pattern.
5. To adjust, use the FEED switch to select the adjustment pattern from the printout with the smallest gap between
thefirstprintingpassandthereturnprintingpass.PresstheFEEDswitchoncetospecifythefirstadjustmentpattern,
twicetospecifythesecondadjustmentpattern,andsoonuptoseventimestospecifytheseventhadjustmentpattern.
Press and hold the FEED switch the last time you press the switch.
(For example, if you want to select the fourth adjustment pattern, press the FEED switch three times.
Then, press and hold the FEED switch until the long buzzer sounds.)
There are only seven adjustment patterns. The buzzer will sound each time the FEED switch is pressed.
However, if you press the FEED switch more than seven times, a warning alert will sound.
After setting the adjustment pattern, a printout with the selected adjustment pattern highlighted and the
message “Adjust Completed!”will be printed.
Fig. 1-5 Dot Alignment Adjustment Sample 1

–5 –
6. After the printout is printed, the printer settings will be entered into the nonvolatile memory of the printer.
When the settings are entered into memory, the long buzzer sounds once more, and the dot alignment
mode is complete.
Note: While the long buzzer is sounding, the printer settings are entered into the nonvolatile memory.
Do not turn the power off. If the power is turned off while the printer settings are being entered
into the nonvolatile memory, all of the memory switch settings will be reset.
Fig. 1-6 Dot Alignment Adjustment Sample 2

–6 –
3. Adjustment of the Black Mark Sensor Alignment
1. Turn the printer off and unplug the power cord.
2. Remove the screws. Then, remove the DIP switch cover on the bottom of the printer.
3. Since it is adjusted by rotating the volume VR22, check the position of the volume. Prepare a small slotted
screwdriver that will fit in the hole.
4. Set the roll paper not for black mark.
5. Press the FEED switch on the printer's control panel while turning the power switch ON.
6. Enter the black mark sensor adjustment mode by releasing the FEED switch after the buzzer sounds four times.
7. Rotate the volume VR22 using micro screwdriver, to adjust it to a position whereat both the ERROR (red LED)
and the POWER (green LED) lamps light.
8. Turn the power OFF.
This completes the black mark sensor adjustment.
Fig. 1-7 Adjustment Volume
41
101
VR22
Power off
VR22

–7 –
CHAPTER 2
PARTS REPLACEMENT
This chapter explains disassembly and reassembly of the printer. Note the following precautions during
disassembly and reassembly.
1. Disconnect the printer power cord plug from the wall outlet before servicing it.
2. Assembly is the reverse of disassembly unless otherwise specified.
3. After reassembly, coat the screw heads with locking sealant.
4. Lubrication information is not provided in this chapter. Refer to item 2 of chapter 3.
1. Case Unit .................................................................................................. 8
2. Printer Mechanism................................................................................... 9
3. Auto Cutter Unit ..................................................................................... 10
4. Ribbon Base ........................................................................................... 10
5. Motor Unit ............................................................................................... 11
6. Print Head ............................................................................................... 11
7. Ribbon Separator................................................................................... 12
8. Main Logic Board Unit........................................................................... 13
9. Power Supply Board Unit...................................................................... 13
10. Black Mark Detector Board Assembly ................................................. 14
11. Photo-interrupter for old type............................................................... 16
2

–8 –
1. Case Unit
(1) Turn off the power switch 1, disconnect the power
cord from the wall outlet.
(2) Lift up the front of printer cover 2and open printer
cover.
(3) SpreadtotheoutsideatpointsA(left/right) of printer
cover 2and remove printer cover.
(4) Remove
•Four screws 3
•Case unit 4
Lift the case unit 4.
At this time, avoid the power switch 1.
Caution 1:
When removing the case unit 4, rotate it while pulling
it toward so that it does not hit the FEED switch 5.
It is possible to damage the FEED switch if a strong
force is applied to it.
Whenremountingthecaseunit,becarefulnottohitthe
FEED switch 5.
Caution 2:
After removing or before remounting the case unit,
absolutely never set the mechanical unit 6with the
FEED switch facing downward.
The FEED switch can be pulled from the frame cause
a strong force to be applied to it which can result in its
becoming damaged.
ERROR
ERROR
POWER
POWER
FEED
FEED
1
5
3
2
4
A
A
6
5

–9 –
<Tear bar type>
2. Printer Mechanism
2-1.Tear bar type
(1) Turn off the power switch, disconnect the power cord
from the wall outlet.
(2) Remove the case unit according to the procedure
described in item 1.
Caution:
HandletheFEEDswitch5carefullyasdescribedinthe
cautions of item 1.
(3) Remove
•Two screws 1
•Flat cable 3
•Printer mechanism 4
2-2.Auto cutter type
(1) Turn off the power switch, disconnect the power cord
from the wall outlet.
(2) Remove the case unit according to the procedure
described in item 1.
Caution:
HandletheFEEDswitch5carefullyasdescribedinthe
cautions of item 1.
(3) Remove
•Two screws 1
•Connector 2
•Flat cable 3
•Printer mechanism 4
<Auto cutter type>
1
4
3
5
1
4
3
2
5

–10 –
3. Auto Cutter Unit (Auto cutter type only)
(1) Turn off the power switch, disconnect the power cord
from the wall outlet.
(2) Remove the printer mechanism according to the
procedure described in item 2.
(3) Remove
•Two screws 1
•Cutter holder plate R 2
•Cutter holder plate L 3
•Two fasteners 4
•Ferrite core 5
•Auto cutter unit 6
4. Ribbon base
(1) Turn off the power switch, disconnect the power cord
from the wall outlet.
(2) Remove the printer mechanism according to the
procedure described in item 2.
(3) Open the auto cutter unit. (Auto cutter type only)
(4) Remove
•Two screws 1(Tear bar type only)
•Tear bar 2(Tear bar type only)
•Screw 3
•Ribbon base 4
Caution in reassembly:
Insert two hooks 5of the ribbon base into the two
square holes 6of the frame unit.
3
1
5
6
4
4
1
2
1
6
6
2
3
45
5

–11 –
CR
PF
7
4
1
5. Motor Unit
(1) Turn off the power switch, disconnect the power cord
from the wall outlet.
(2) Remove the ribbon base according to the procedure
described in item 4.
(3) Remove
•Flat cable 1
Remove the four lead wires by using a soldering
iron. These leads are soldered on the terminal
board 7.
•Two screws 2
•Carriage motor unit 3
•Flat cable 4
Remove the four lead wires by using a soldering
iron. These leads are soldered on the terminal
board 7.
•Screw 5
•Paper feed motor unit 6
6. Print Head
(1) Turn off the power switch, disconnect the power cord
from the wall outlet.
(2) Remove the ribbon base according to the procedure
described in item 4.
(3) Remove
•Two screws 1
•Flat cable 2
•Print head 3
(4) After reassembly, adjust the gap between print head
and the platen. (Refer to the chapter 1)
WARNING
The print head becomes hot after printing so wait for
it to cool before removing it.
Blue line
Blue line
4
2
3
5
6
1
1
3
2

–12 –
1
5
7
5
2
6
4
3
1
2
4
7. Ribbon Separator
(1) Turn off the power switch, disconnect the power cord
from the wall outlet.
(2) Remove the ribbon base according to the procedure
described in item 4.
(3) Remove
•Ribbon separator 1
Use a tweezers for precision instruments.
a) The A portion 2on the left and right ribbon
separator (see Fig. 2-7-1 and Figure 2-7-2) is
inserted in the print head 3corner B portion 4
so use the tweezers to bend it approximately 5
degrees,thenremoveandlifttheribbonseparator
directly upward from the print head.
Fig. 2-7-1 Fig 2-7-2
b) In the joining portion of the carriage boss 5
and the ribbon separator hole a screw-lock 7
(blue color) is glued. When removing the
ribbon separator, it is fixed to the ribbon
separator and does not remain on the carriage,
andonly remainsin rarecases. Insuchcases,it
will be in the way when a new ribbon separator
isset,sousethetweezerstoremovescrew-lock
that remains near the carriage boss.
Reassembly
a) Insert the two holes on the ribbon separator
onto the two carriage bosses.
b) Use the tweezers to set the A portion 2on the
left and right of the ribbon separator to fit into
thecornerof theprinthead andpushnear the C
portion 6(Fig. 2-7-2) until you hear a click.
c) Apply a small amount of screw-lock to the
joining portion of the carriage boss and ribbon
separator hole.
See Fig. 2-7-3 for the amount to dispense.
Screw-lockmodelnumber: ThreeBond1400B
Fig. 2-7-3
1

–13 –
8. Main Logic Board Unit
(1) Turn off the power switch, disconnect the power cord
from the wall outlet.
(2) Remove the printer mechanism according to the
procedure described in item 2.
Caution:
HandletheFEEDswitch5carefullyasdescribedinthe
cautions of item 1.
(3) Remove
•Two screws 1
•Two screws 2
•Mechanism base 3
•Four screws 4
•Flat cable 6
•Connector 7
•Main logic board 8
Caution in reassembly:
Set the mechanism base 3on the main chassis Aso
that the two bosses 0of the main shassis enter the two
holes 9of the mechanism base.
9. Power Supply Board Unit
(1) Turn off the power switch, disconnect the power cord
from the wall outlet.
(2) Remove the main logic board unit according to the
procedure described in item 8.
(3) Remove
•Three screws 1
•Main chassis 2
•Screw 3
•Two screws 4
•Five screws 5
•Two TR chips 6
•Power supply board unit 7
Caution in reassembly:
Insert two hooks 8of the power schassis 9into the
two square holes 0of the main chassis.
1
9
12
3
4
9
7
0
0
4
8
4
4
A
6
5
1
5
5
7
5
6
5
9
0
05
4
3
4
1
2
1
8
8

–14 –
6
NF
NF
7
1
2
64
3
10. Black Mark Detector Board Assembly
(1) Turn off the power switch and disconnect the power
cord from the wall outlet.
(2) Remove the printer mechanism according to the
procedure described in item 2.
(3) Remove
•Screw 1
•Black mark detector board assembly 2
•Three lead wires 3
Remove the three lead wires by using a soldering
iron. These leads are soldered to the black mark
detector board assembly 2.
Notes for reassembly:
When shipped, the black mark detector is mounted in
a position to detect the left edge of 76 mm paper and
blackmarksontheprintingsideofthepaper,butitcan
also be mounted in five other locations.
To detect 57.5 mm wide recording paper and black
marks in different positions, move the detector to the
corresponding position.
At position 4, the detector can detect the right edge of
76mm widepaperandblackmarksonthereverse side
of the paper.
Place the board assembly 2on the paper guide A
4or the paper guide B 5so that the boss 6is
aligned with the board hole 7, and then tighten the
screw 1.
There are two positioning holes to align to the boss.
They are the N and F holes. F is for position 4 only.
All others use hole N. (See the page below.)
(4) After reassembly, adjust the Black Mark Sensor
Alignment. (Refer to the chapter 1)
<Position 1 (Default)>
<Position 4>
Orange
Purple Black
25
1

–15 –
Position 1 (Default) Position 2 Position 3
Position 4 Position 5 Position 6
Right edge of 76mm paper
Printing side
Hole N
Lead wires
Left edge of 58mm paper
Printing side
Hole N
Left edge of 76mm paper
Printing side
Hole N
Left edge of 76mm paper
Reverse side
Hole F
Left edge of 58mm paper
Reverse side
Hole N
Right edge of 76mm paper
Reverse side
Hole N
Lead wires
Back surface Back surface
Back surface

–16 –
11. Photo-interrupter for old type
(1) Turn off the power switch and disconnect the power
cord from the wall outlet.
(2) Remove the printer mechanism according to the
procedure described in item 2.
(3) Remove
•Screw 1
•Detector holder 2
•Black mark detector board assembly 3
Detach the two hooks on the detector holder.
•Photo-interrupter 4
Remove the photo-interrupter by using a
desoldering tool with vacuum pump.
Notes for reassembly:
Note the polarity of the Photo-interrupter.
Attach the photo-interrupter 4to the black mark
detector board assembly 3using soldering iron, so
that photo sections come left.
(4) After reassembly, adjust the Black Mark Sensor
Alignment. (Refer to the chapter 1)
1
2
3
4
Photo sections
3
4

–17 –
CHAPTER 3
MAINTENANCE AND LUBRICATION
1. Maintenance ........................................................................................... 18
1-1. Cleaning ............................................................................................................... 18
1-2. Checks.................................................................................................................. 18
1-3. Preverting Paper Jams and Removing Jammed Paper ................................... 18
2. Lubrication ............................................................................................. 20
2-1. Lubricant .............................................................................................................. 20
2-2. Lubricating Method ............................................................................................. 20
2-3. Lubricated Areas ................................................................................................. 20
3. Screw Locking........................................................................................ 20
3