Epson 4004677 User Manual

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EPSON COLOR INKJET PRINTER

Stylus Pro XL

SERVICE MANUAL

EPSON

4004677

Chapter 1 Product Description

Table of Contents

1.1 FEATURES 1-1

1.2 SPECIFICATIONS 1-3

1.2.1 PrintingSpecifications........................................1-3

1.2.2 PaperHandlingSpecifications..................................1-5

1.2.3 PaperSpecifications..........................................1-5

1.2.4 InkCartridgeSpecifications....................................1-7

1.2.5 ElectricalSpecifications.......................................1-8

1.2.6 EnvironmentalConditions .....................................1-8

1.2.7 Reliability ..................................................1-9

1.2.8 SafetyApprovals ............................................1-9

1.2.9 PhysicalSpecifications........................................1-9

1.3 INTERFACE SPECIFICATIONS 1-10

1.3.1 SerialInterfaceSpecifications.................................1-10

1.3.2 ParallelInterfaceSpecifications................................1-12

1.4 OPERATIONS 1-13

1.4.1 ControlPanel..............................................1-13

1.4.2 PanelOperationatPowerOn .................................1-14

1.4.3 Defaultsettings.............................................1-15

1.4.3.1 DefaultSettingItems..................................1-15

1.4.3.2 ChangingtheDefaultSettings...........................1-16

1.4.4 ErrorConditions............................................1-18

1.4.5 PrinterInitialization..........................................1-18

1.4.5.1 HardwareInitialization.................................1-18

1.4.5.2 SoftwareInitialization..................................1-18

1.4.5.3 PanelInitialization....................................1-18

1.5 MAIN COMPONENTS 1-19

1.5.1 MainControlBoard(C162MAINBoard).........................1-19

1.5.2 PowerSupplyBoard(C137PSB/PSEBoard).....................1-20

1.5.3 ControlPanel(C137PNLBoard)...............................1-20

1.5.4 PrinterMechanism(M-4A60)..................................1-21

1.5.5 Housing ..................................................1-21

Rev.-A 1-i

List of Figures

Figure 1-1. Exterior View of the Stylus Pro XL Figure 1-2. Nozzle Configuration Figure 1-3. Printable Area for Cut Sheet Figure 1-4. Printable Area for Envelope Figure 1-5. Adjustment Lever Setting Figure 1-6. Temperature/Humidity Range Figure 1-7. Data Transmission Timing Figure 1-8. Control Panel Appearance Figure 1-9. C162 MAIN Board Component Layout Figure 1-10. C137 PSB/PSE Board Component Layout Figure 1-11. Printer Mechanism (M-4A60)

List of Tables

Table 1-1. Interface Cards Table 1-2. Print Speed and Printable Columns Table 1-3. Character Table Table 1-4. Cut Sheet Paper Specifications Table 1-5. Envelope Specifications Table 1-6. Adjust Lever Setting Table 1-7. Rated Electrical Ranges Table 1-8. Acceptable Environmental Conditions Table 1-9. Signal and Connector Pin Assignments for Parallel Interface Table 1-10. DTR and X-ON/X-OFF Protocol Table 1-11. Signal and Connector Pin Assignments for Serial Interface Table 1-12. Printer Condition Panel Status Table 1-13. Default Setting Items Table 1-14. Characteristics of Print Direction Mode Table 1-15. Printing Direction and ESC U Command Table 1-16. Language Selection Table 1-17. Feature Selection Table 1-18. Character Table Selection Table 1-19. Error Indications

1-ii Rev.-A

Printer Cover

Front Cover

Knob

Control Panel

Paper Supply

Tray

Paper C atch

Tray

Interface Card

Cover

Serial In ter fa c e

Connector

Parallel Interface

Connector

AC Inlet

Stylus Pro XL Product Description

1.1 FEATURES

The Stylus Pro XL is a 64 + 48-nozzle (monochrome and CMY) color ink jet dot matrix printer. The major features of this printer are:

❏ High-quality color print

-Micro Dot 720 dpi printing

-Plain paper 720 dpi printing

-Special coated paper 720 dpi printing

❏ High print speed

-LQ 200 cps

❏ Built-in auto sheet feeder

-Holds 100 cut sheets (64 g/m2)

-Holds 10 envelopes

-Holds 50 transparency films

-Hold 70 special paper

❏ Built-in 3 I/

-Mac serial I/F

-Parallel I/F

-Type B I/F (option)

❏ Easy setup.

-No dip-switches

-Multi-lingual setting messages (5 languages)

❏ 4 scalable fonts and 5 LQ fonts standard.

-Roman T, Sans Serif H, Roman, Sans Serif (scalable)

-Roman, Sans Serif, Courier, Prestige, Script (LQ)

❏ 21 character tables

Italic, PC437, PC850, PC860, PC863, PC865, PC437, Greek, PC852, PC853, PC858, PC857, PC866, PC869, PC861, BRASCII, Abicomp, MAZOWIA, Code MJK, ISO 8859-7, ISO Latin 1T, Bulgaria

❏ Low running cost The figure below shows the Stylus Pro XL.

Figure 1-1. Exterior View of the Stylus Pro XL

Rev.A 1-1

Product Description Stylus Pro XL

Table 1-1. Interface Cards

Interface Card Model Number

Serial interface card C823051/C823061 32KB serial interface card C823071/C823081 32KB parallel interface card C82310✽ 32KB IEEE-488 interface card C82313✽ LocalTalk Twinax interface card C82315✽ Coax interface card C82314✽

The asterisk represents the last digit, which varies by country.

✽

interface card C82312✽

1-2 Rev.A

Row CRow D

#62

#63

1/360"

20/360"

72/360"

MagentaCyan

Yellow

#16#16

1/90"

#16

64/360"

Row ARow B

#61

#64

1/90"

Stylus Pro XL Product Description

1.2 SPECIFICATIONS

This section provides statistics and other detailed information for the printer.

1.2.1 Printing Specifications

Print system: On demand ink jet system Nozzle configuration:

64 nozzles (16 × 4 staggered): monochrome 48 nozzles (16 × 3 staggered): color

Figure 1-2. Nozzle Configuration

Printing direction: Bidirectional with logic-seeking Print speed: See Table 1-2. Printable columns: See Table 1-2.

Table 1-2. Print Speed and P rintable Columns

Character Pitch Printable Columns Print Speed (LQ)

10 cpi (Pica) 127 200 cps 12 cpi (Elite) 152 240 cps

15 cpi 190 300 cps 17 cpi (Pica condensed) 218 340 cps 20 cpi (Elite condensed) 254 400 cps

Rev.A 1-3

Product Description Stylus Pro XL

Character sets: Legal and 14 international character sets. Character tables: See Table 1-3.

Table 1-3. Character Tables

Bit map font Scalable font

EPSON Roman EPSON Sans Serif

Character Tables

Italic ❍❍m PC437 (U.S./Standard Europe) PC850 (Multilingual) ❍❍m PC860 (Portuguese) PC861 (Iceland) ❍❍m PC863 (Canadian-French) PC865 (Nordic) ❍❍m Abicomp BRASCII ❍ mm PC437 (Greek) PC852 (East Europe) PC853 (Turkish) ❍ m PC855 (Cyrillic) ❍ m PC857 (Turkish) PC866 (Russian) ❍ m PC869 (Greek) MAZOWIA (Poland) ❍ m Code MJK (Czecho/Slovakia) ISO 8859-7 (Greek) ❍ m ISO Latin 1T (Turkish) Bulgaria (Bulgaria) ❍ m

EPSON Courier EPSON Prestige EPSON Script

❍❍m

❍ mm

❍ m ❍

❍ m

EPSON Roman EPSON Sans Serif

❍

EPSON Roman EPSON Sans Serif H

× × × × × × × × × × × ×

❍ Supported ×

Fonts: [Bitmap LQ fonts]

Control codes: ESC/P 2 and expanded raster graphics code Input data buffer: 64KB

Not supported

- EPSON Roman (10 cpi/12 cpi/15 cpi/Proportional)

- EPSON Sans Serif (10/12/15/Proportional)

- EPSON Courier (10/12/15)

- EPSON Prestige (10/12/15)

- EPSON Script (10/12/15)

[Scalable fonts]

- EPSON Roman 10.5 points, 8 ∼32 points (in units of 2 points)

- EPSON Sans Serif 10.5 points, 8 ∼32 points (in units of 2 points)

- EPSON Roman T 10.5 points, 8 ∼32 points (in units of 2 points)

- EPSON Sans Serif H 10.5 points, 8 ∼ 32 points (in units of 2 points)

1-4 Rev.A

Stylus Pro XL Product Description

1.2.2 Paper Handling Specifications

Feeding method: Friction feed paper is fed from the built-in auto sheet feeder (ASF).

Notes: The following operations are not allowed.

1. Reverse feeding within 3 mm (0.12 in.) from the top edge of the paper or 16 mm (0.63 in.) from the bottom edge of the paper.

2. Reverse feeding beyond 7.9 mm (0.3 in.).

Line spacing: 1/6 inch feed, 1/8 inch feed, or programmable with a 1/360 inch minimum

increment. Paper path: Cut sheet: Built-in auto sheet feeder (ASF) (front entry) Feeding speed: 89 msec. (at 1/6-inch feed pitch)

1.2.3 Paper Specifications

Table 1-4. Cut Sheet Paper Specifications

A3+/US B+: 329 mm (13.0 in.) × 483 mm (19.0 in.)

A3: 297 mm (11.7 in.) × 420 mm (16.5 in.)

US B: 279 mm (11.0 in.) × 432 mm (17.0 in.)

Size (W × L)

Thickness Weight Quality Plain paper, Special coated paper for 720dpi, Special coated paper for 360dpi,

Note:

• Special coated paper for 720dpi, Special coated paper for 360dpi, Transparency film

• High Quality Glossy paper printing are only available at normal temparature.

Legal: 216 mm (8.5 in.) × 356 mm (14.0 in.)

Letter: 216 mm (8.5 in.) ×279 mm (11.0 in.)

A4: 210 mm (8.3 in.) × 297 mm (11.7 in.)

Executive: 184 mm (7.25 in.) × 267 mm (10.5 in.)

Statemrnt: 140 mm (5.5 in.) ×216 mm (8.5 in.)

0.08 mm (0.003 in.) ∼ 0.11 mm (0.004 in.)

64g/m

Transparency film, High Quality Glossy paper, Glossy paper

(17 lb.) ∼ 90 g/m

(24 lb.)

Table 1-5. Envelope Specifications

Size (W × L) No. 10:240 mm (91⁄2in.) × 104 mm (41⁄

DL:220 mm (8.7 in.) × 110 mm (4.3 in.)

C5: 229 mm (9.0 in.) × 162 mm (6.4 in.)

Thickness Less than 0.52 mm (0.020 in.) Weight Quality Plain paper

Note:

•

Envelope Printing is only available at normal temperature.

•

Keep the longer side of the envelopes horizontal at setting.

75 g/m

(20 lb) ∼ 90 g/m

(24 lb)

in.)

Rev.A 1-5

Product Description Stylus Pro XL

Printable area: Cut sheets

B (Left Margin)

C (Right Margin)

(Top Margin)

Printable Area

D (Bottom Margin)

Figure 1-3. Printable Area for Cut Sheets

Envelopes

C (Right Margin)

Printable Area

Figure 1-4. Printable Area for Envelopes

Notes: A:Theminimumtopmargin=3mm(0.12in.)

B: The minimum left margin = 3 mm (0.12 in.) C:The minimum right margin is:

A3+/US B+ size: 3mm (0.12 i n.) A3 size: 3 mm (0.12 in.) A4 size: 3 mm (0.12 in.) A4 (Landscape)size:3 mm (0.12 in.) USB size: 9 mm (0.35 in.) Legal size: 9 mm (0.35 in.) Letter size: 9 mm (0.35 in.)

Letter size (Landscape)size:9 mm (0.35 in.) Executive size: 9 mm (0.35 in.) Statement size: 9 mm (0.35 in.) Envelopes: 3 mm (0.12 in.)

D: The minimum bottom margin = 14 mm (0.55 in.)

A (Top Margin)

D (Bottom Margin)

1-6 Rev.A

Cut Sheets Envelopes

Carriage Un it

Stylus Pro XL Product Description

Setting the adjust lever: The adjust lever on the carriage unit must be set to the proper position for

the paper thickness, as shown in Table 1-6.

Table 1-6. Adjust Lever Settings

Lever Position Paper Paper Thickness

LEFT

(Vertical)

RIGHT

(Horizontal)

Cut Sheets

Envelopes Less than 0.5 mm (0.020 in.)

Figure 1-5. Setting the Adjust Lever

1.2.4 Ink Cartridge Specifications

Black

Type: Exclusive cartridge

0.08 ∼ 0.11 mm

(0.003 ∼ 0.004 in.)

Color: Black Print capacity: 1.2 million characters (315 dots/character, Roman 10 cpi) Life: The effective life from the indicated production date is 2 years. Storage temperature:

Dimension (W × D × H): 26.9 ×67.4 × 41.8 mm (1.06 × 2.65 × 1.65 in.)

Color

Type: Exclusive cartridge Colors: Cyan, magenta, yellow Print capacity: Life: The effective life from the indicated production date is 2 years. Storage temperature:

Dimension (W × D × H): 54.0 ×67.4 × 41.8 mm (2.13 × 2.65 × 1.65 in.)

Notes: The ink cartridge cannot be refilled; it is the only consumable article.

Do not attempt to use an ink cartridge that has exceeded its ink life. Ink freezes at

−3°

−30 ∼ 40° C(−22 ∼ 104° F)(Storage:amonthorlessat40°C (104° F))

−30 ∼ 60° C(−22 ∼ 140° F) (Transit: a month or less at 40°C (104° F))

−30 ∼ 60° C(−22 ∼ 140° F) (Transit: 120 hours or less at 60° C (140° F))

28 sheets/color (A4 or letter, full-image printing at 360 dpi)

−30 ∼ 40° C(−22 ∼ 104° F)(Storage:amonthorlessat40°C (104° F))

−30 ∼ 60° C(−22 ∼ 140° F) (Transit: a month or less at 40°C (104° F))

−30 ∼ 60° C(−22 ∼ 140° F) (Transit: 120 hours or less at 60° C (140° F))

C(37°F); however, it can be used after it returns to room temperature.

Rev.A 1-7

Product Description Stylus Pro XL

1.2.5 Electrical Specifications Table 1-7. Rated Electrical Ranges

Specification 120 V Version 220 - 240 V Version

Rated voltage 120 VAC 220 - 240 VAC Input voltage range Rated frequency range Input frequency range

103.5 ∼ 132 V 198 ∼ 264 V 50 ∼ 60 Hz 50 ∼ 60 Hz

49.5 ∼ 60.5 Hz 49.5 ∼ 60.5 Hz

Rated current 0.6 A 0.4 A Power consumption

Insulation resistance

Dielectric strength

Approx. 20 W

(self-test with 10-cpi LQ characters)

10 MΩ, minimum

(applying 500 VDC between AC line

and chassis)

1000 VAC rms - 1 minute or

1200 VAC rms - 1 second

(between AC line and chassis)

(self-test with 10-cpi LQ characters)

(applying 500 VDC between AC line

(between AC line and chassis)

Approx. 20 W

10 MΩ,minimum

and chassis)

1500 VAC rms - 1 minute

1.2.6 Environmental Conditions Table 1-8. Acceptable Environmental Conditions

Condition Operating Non Operating

*1,3

−20 ∼ 60° C(−4∼122° F) 5 ∼ 85% RH

Temperature Humidity

10 ∼ 35° C(50∼ 95° F)

20 ∼ 80% RH Shock resistance 1G (within 1 msec.) 2G (within 2 msec.) Vibration resistance 0.15 G 0.50 G

: For printer operation, conditions must be in the range shown in the figure below.

: These conditions are applicable when the printer is in its shipping container.

: Without condensation.

*2,3

Humid ity (% RH)

80%

55%

20%

(50˚F)

27˚C 35˚C (80˚F)

(95˚F)

Guaranteed

˚C (˚ F)

Figure 1-6. Temperature / Humidity Range

1-8 Rev.A

Stylus Pro XL Product Description

1.2.7 Reliability

Total print volume: 75,000 pages (A4, letter) Printhead life: 1,000 million dots/nozzle

1.2.8 Safety Approvals

Safety standards: 120 V version: UL1950 with D3,

CSA22.2 #950 with D3

220-240 V version: EN 60950 (TÜV, SEMKO, DEMKO,

NEMKO, SETI)

Radio frequency interference (RFI): 120 V version: FCC Part 15 Subpart B Class B

220-240 V version: Vfg.243 (VDE0878 part 3, part 30)

EN55022 (CISPR PUB. 22) class B

1.2.9 Physical Specifications

Dimensions (W × D × H): 580 ×597 × 182 (mm) (22.8 × 23.5 × 7.17 in.) Weight: About 10 Kg (22 lb)

Rev.A 1-9

Product Description Stylus Pro XL

1.3 INTERFACE SPECIFICATIONS

The Stylus Pro XL is standard-equipped with an 8-bit parallel and serial interface.

1.3.1 Parallel Interface Specifications

Data format: 8-bit parallel Synchronization: By Handshaking: By BUSY and

STROBE pulse synchronization

ACKNLG signals Signal level: TTL compatible level Adaptable connector: 36-pin 57-30360 (Amphenol) or equivalent Data transmission timing: See Figure 1-7.

BUSY

ACKNLG

DATA

STROBE

0 µsec (minimum)

0.5 µsec (minimum)

0 µsec (minimum)

5 µsec (typical)

Figure 1-7. Data Transmission Timing

Note:

The Busy signal is active (HIGH) under the following conditions:

The

The PE signal is active (HIGH) under the following conditions:

Transition time (rise time and fall time) of every input signal must be less than 0.2

❏ During data reception (See Figure 1-7.) ❏ When the input buffer is full ❏ When the

INIT input signal is active

❏ During initialization ❏ When the

ERROR or PE signal is active

❏ During the self-test mode ❏ During the demonstration mode ❏ During the default setting mode ❏ When a fatal error occurs

ERROR signal is active (LOW) under the following conditions:

❏ When a paper-out error occurs ❏ When a no ink cartridge error occurs ❏ When a fatal error occurs

❏ When a paper-out error occurs ❏ When a fatal error occurs

1-10 Rev.A

Stylus Pro XL Product Description

Table 1-9 shows the connector pin assignments and signal functions of the 8-bit parallel interface.

Table 1-9. Signal and Connector Pin Assignments for Parallel Interface

Pin No. Signal Name I/O* Description

The

STROBEpulseisusedtoreaddatafromthehost

2-9 DATA 1-8 I

11 BUSY O

STROBE I

ACKNLG

computer. The pulse width must be 0.5 µs or more. Normally, it is HIGH, and data is latched with the rising edge of this signal.

DATA 1-8 are parallel data bits. When one of these signals is HIGH, the data bit is 1; when LOW, the data bit is 0. The most significant bit (MSB) is DATA 8. The signal state must be maintained for 0.5 µs on either side of the signal’s active edge.

ACKNLG is an acknowledge pulse with a width of approximately 10 µs. This signal goes LOW upon the

completion of data reception to indicate that the printer is ready to receive further data.

The BUSY signal informs the host computer of the printer’s status. When this signal is HIGH, the printer cannot accept any more data.

STROBE

12 13 SLCT O

32 35 +5 V —

17 CHASSIS — Chassis ground.

16 GND — Signalground. 19-30 — — — 33,36

15,18,34 — — —

AFXT I

INIT

ERROR

—

This signal indicates whether paper is available in the printer

or not. A HIGH level indicates no paper. Pulledupto+5Vthrougha1.0KΩresistor in the printer. If this signal is set to LOW, the printer automatically performs

one line feed upon receipt of a CR (carriage return) code. The status of this signal is checked only at power on and initialization.

If this signal goes LOW, the printer is initialized. The pulse

width of this signal must be 50 µsormore. This signal goes LOW if the printer has a fatal error or runs

out of paper. Pulledupto+5Vthrough1.0KΩresistor in the printer.

—

Not used.

* The I/O column indicates the direction of the signal as viewed from the printer.

Rev.A 1-11

Product Description Stylus Pro XL

1.3.2 Serial Interface Specifications

Data format: RS-422 serial Synchronization: Asynchronous Handshaking: By DTR signal and X-ON/X-OFF protocol

Table 1-10. DTR and X-ON/X-OFF Protocol

State

Busy Ready

Word length

Start bit: Data bit: Parity bit:

Stop bit: Bit rate: 57.6K bps /230.4 Kbps Adaptable connector: 8-pin mini-circular connector Recommended I/F cable: Apple

Buffer Space DTR X-ON/X-OFF

Less than 512 bytes Off X-OFF More than 1,024 bytes On

1bit 8bit none 1bit

System Peripheral-8 cable

X-ON

Table 1-11. Signal and Connector Pin Assignments for Serial Interface

Pin No.

1 2 3 4 5 6 7 8

Signal Name I/O* Description

DTR Out Data terminal ready

NC — No connection

TXD

SG In Signal ground

RXD

TXD Out Balanced transmit

NC — No connection

RXD In Balanced receive

Out Transmit data

In Receive data

* The I/O column indicates the data flow as viewed from the printer.

1-12 Rev.A

Operate

Alt

Font

Economy/ Condensed

Load/Eject

Pause

Stylus Pro XL Product Description

1.4 OPERATIONS

This section describes the basic operations of the printer.

1.4.1 Control Panel

The control panel for this printer has 1 lock-type, 5 non-lock-type push buttons, and 14 LED indicators for easy operation of the various printer functions.

Figure 1-8. Control Panel Appearance

Buttons

Operate Alt

Font Cycles through the font choices. Pressing the Font button, while holding

Economy/Condensed

Load/Eject

Pause

Turns the printer on or off. Modifies the function of other buttons. Holding down this button for

3 seconds causes the printer to move the carriage to the ink cartridge installation position. Pressing Alt again causes the carriage to return to the home position.

down the Alt button causes the carriage to move to the gap adjustment position. Pressing the Alt button again causes the carriage to return to the home position.

Selects either economy or condensed printing mode. Pressing the Economy/Condensed button while holding down the Alt button starts the color printhead cleaning cycle.

Either loads a new sheet into the printer or ejects paper currently in the paper path. Pressing the Load/Eject button while holding down the Alt button starts the black printhead cleaning cycle.

Stops printing temporarily or resumes printing if it has been stopped temporarily. Pressing Pause while holding down the Alt button resets the printer.

Rev.A 1-13

Product Description Stylus Pro XL

Indicators

Operate Data On when print data is in the input buffer. Data and Pause lights blink if

Paper Out No Ink Cartridge Economy Condensed Font Pause

On when the printer is on. Blinks during power on and off sequence.

an error occurs. On when the printer is out of paper. Blinks when a paper jam occurs. On when ink cartridge is out. On when economy printing mode is selected. On when condensed printing mode is selected. These LEDs indicate the selected font. On when printing is paused.

1.4.2 Panel Operation at Power On

You can activate the following modes by doing the following: Self-test mode

Hex dump mode

Demonstration mode Default setting mode

Initialize EEPROM

Turn on the printer while holding down the Load/Ejectbutton. Turn on the printer while holding down the Font and Load/Eject

buttons. Once this mode is selected, the printer prints all received data in hexadecimal format.

Turn on the printer while holding down the Altbutton. Turn on the printer while holding down the Economy/ Condensed

button. For more information about the mode, see Section 1.4.3. Turn on the printer while holding the Alt, Font, Load/Eject,andPause

buttons.

Table 1-12. Printer Condition Panel Status

Printer status

Power on condition

Data exit

Economy mode

Condensed mode

Pause condition

Power on/off sequence

Ink sequence

Ink cartridge change mode

Head gap adjust mode

Paper out

No ink cartrdige

Paper jam condition

Maintenance request

Cartidge error

Operate

—

Blinks

—

Indicators

Data

—— — — — —

On — — — — —

—— — On — — —— — — On — —— — — — On —— — — — — —— — — —Blinks —— — — —Blinks

Blinks — — — — —

—On — — — — —— On — — —

— Blinks — — — — Blinks Blinks Blinks — — Blinks Blinks — — — — Blinks

Paper

Out

No Ink

Cartridge

Economy Condensed Pause

—don’tcare

1-14 Rev.A

Stylus Pro XL Product Description

1.4.3 Default Settings

The printer can save some printer setting parameters that define its functions at initialization. You can change these parameters by using the printer’s default setting mode.

1.4.3.1 Default Setting Items

You can use the default setting mode to change settings listed in the table below. Activate default-setting mode by holding down Economy/Condensed while turning on the printer.

Table 1-13. Default Setting Items

Menu Contents

Character table

Print direction

Network I/F mode

Auto line feed

Loading position

Interface mode

Auto I/F wait mode

Mode

Black and White Printing Color (CMYK) Printing

Description

Selects the character table — Controls the print direction. (See Tables 1-12 and 1-13)

Auto Bi-D Uni-D

Off: For normal environments. On: For network environments.

On: Valid Off: Invalid

3.0/8.5 mm (0.12/0.33 in.) 3.0 mm Auto I/F mode

Parallel I/F mode Serial I/F mode Optional I/F mode

10/30 seconds 10 sec.

Table 1-14. Characteristics of Print Direction Mode

Factory

Setting

—

Off

—

Throughput is better. Color quality with special paper is worse. (Color correction depends on the printing direction.)

Throughput is worse. Color quality is best.

Auto

Bi-D

Uni-D

Throughput and quality is

better.

Throughput is best.

Print quality may be down.

Throughput is worse. Print quality is better.

Table 1-15. Printing Direction and ESC U Command

Default Setting Mode

Character mode (for MS-DOS

Raster graphics mode (for Windows

)

™

)

ESC U0 ESC U1 None ESC U0 ESC U1 None ESC U0 ESC U1 None

Auto Auto Auto Bi-D Uni-D Bi-D Uni-D Uni-D Uni-D

Bi-D Uni-D Auto Bi-D Uni-D Bi-D Bi-D Uni-D Uni-D

Note: Printing direction is controlled by driver in Windows environment.

Auto Bi-D Uni-D +

Rev.A 1-15

Product Description Stylus Pro XL

1.4.3.2 Changing the Default Settings

To change the printer’s default settings:

Hold down the Economy/Condensed button and turn on the printer. The printer prints a sheet that shows the firmware version and describes how to select the language used to print messages.

Press the Font button until the appropriate font LED is selected. The following table shows which language corresponds to which font LED.

Table 1-16. Language Selection

Language

English

Français

Deutsch

Italiana

Español

Press the Alt button. The printer prints the current settings using the selected language. It also prints a table showing how to change the printer settings.

Press the Font button to advance through the setting menu. The current printer settings are indicated by the Courier, Roman T (PS), and San Serif H (PS) LEDs. Each time you press the Font button, you adance to the next setting, and the three font LEDs change according to the selection.

Font LED

Courier

Roman T (PS)

Sans Serif H (PS)

Roman

Sans Serif

Table 1-17. Feature Selection

Feature/Menu

Courier

LED

Roman T (PS) LED

Sans

Serif H

(PS) LED

Setting

Setting Value

Operate

LED

Data

LED

Paper Out

LED

Character table Print direction ^ ^ Network I/F mode ^ Auto line feed ^ Loading position ^ Interface mode ^ ^ ^ Auto I/F wait time ^

Change the setting value by pressing Alt button. Pressing the Alt button changes the setting for the current menu. The status of the LEDs will be changed as the button is pressed.

On On On See Table 1-18 +

Auto On Off Off

On Off Off

Off On Off

On On Off

Off Off On

On Off On

Off On On

Bi-D Off On Off

Uni-D On On Off

Off Off Off Off On On Off Off Off Off Off Off On On Off Off

3 mm Off Off Off

8.5 mm On Off Off Auto On Off Off

Parallel Off On Off

Serial On On Off

Option Off Off On 10 sec. Off Off Off 30 sec. On Off Off

1-16 Rev.A

Stylus Pro XL Product Description

Table 1-18. Character Table Selection

Version

Common ^ ^ ^ ^ ^ ^ ^ ^ ^ Standard ^ ^ ^ ^ ^ NLSP ^ ^ ^ ^ ^ ^ ^ ^ ^ ^ ^

6. Repeat steps 4 and 5 to change other printer settings. The setting menu selection will return to the first menu after the last menu selection is over.

7. Turn off the printer. The setting is stored in non-volatile memory.

Settings

Italic U.S.A.

Italic France

Italic Germany

Italic U.K.

Italic Denmark 1

Italic Sweden

Italic Italy

Italic Spain 1

PC437 PC850 PC860 PC863 PC865

PC861 BRASCII Abicomp

PC437 Greek

PC853

PC855

PC852

PC857

PC866

PC869

MAZOWIA Code MJK

ISO 8859-7

ISO Latin 1T

Bulgaria

Operate LED Data LED

Off On Blinks Off On Blinks Off On Blinks Off On Blinks Off On Blinks Off Off Blinks Off On Blinks Off On Blinks Off On Blinks Off

Off Off Off Off Off Off On Off On Off

On Off Blinks Off Blinks Off Blinks Off

Off On

On On

On On Blinks On

Off On

On On

On On Blinks On Blinks On Blinks On

Off Blinks

On Blinks

Paper Out

LED

Rev.A 1-17

Product Description Stylus Pro XL

1.4.4 Error Conditions

The printer can detect various errors and indicate them with LEDs.

Table 1-19. Error Indications

No Ink

Cartridge

LED

Economy

LED

Condensed

LED

Pause

LED

Error

Paper out No ink cartridge Paper jam Maintenance request Carriage error

Data LED

Off Off Off On Off Off Off Off Blinks Off Off Off Off Blinks Blinks Blinks Blinks Blinks Blinks Blinks

Paper Out

LED

On Off Off Off Off

Off Off Off Off Blinks

1.4.5 Printer Initialization

There are three initialization methods: hardware initialization, software initialization, and panel initialization.

1.4.5.1 Hardware Initialization

Hardware initialization is performed by:

- Turning on the printer.

- Sending the parallel interface INIT signal is active when the printer is turned on, hardware initialization is started when the INIT

(If the

signal becomes inactive.)

INIT signal.

When the hardware initialization is performed:

- The printer mechanism is initialized.

- Input data buffer is cleared.

- Downloaded character definitions are cleared.

- Print buffer is cleared.

- Default values are set.

1.4.5.2 Software Initialization

Software initialization is performed upon receipt of the control code ESC @. When the software initialization is performed:

- Print buffer is cleared.

- Default values are set.

1.4.5.3 Panel Initialization

This printer is initialized by pressing the Load/Eject button while pressing the Alt button. When the panel initialization is performed:

- Input data buffer is cleared.

- Print buffer is cleared.

- Default values are set.

1-18 Rev.A

GA E05B09 (IC2)

CPU (IC1)

4M DRAMs (IC5, 6)

Program ROM (IC3)

Mask ROM M160A69 (IC16)

Mask ROM M80B00 (IC17)

Stylus Pro XL Product Description

1.5 MAIN COMPONENTS

The main components of the Stylus Pro XL are:

❏ Printer mechanism (M-4A60) ❏ Main control board (C162 MAIN Board) ❏ Power supply unit (C137 PSB/PSE Board) ❏ Control panel board (C137 PNL Board) ❏ Housing

1.5.1 Main Control Board (C162 MAIN Board)

The Main Control Board (C162 MAIN Board) consists of an H8/3003 16-bit CPU, E05A96 gate array, a program ROM (4M), a dynamic RAM (4M), a mask ROM (4M or 8M), an EEPROM (1K), and a lithium battery for powering the protect counters. The reset IC (M51955 and PST 592) is equipped with both a logic system and a power system. The 8M program ROM is used only for the NLSP (National Language Support Printer) specification.

Figure 1-9. C162 MAIN Board Component Layout

Rev.A 1-19

Product Description Stylus Pro XL

1.5.2 Power Supply Board (C137 PSB/PSE Board)

The power supply board (C137 PSB/PSE Board) consists of an RCC switching regulator circuit. This board is equipped with a power switch connected to the secondary circuit. Thus, if the printer is turned off, it can continue to operate in order to eject the paper and perform the head capping operation. The power on/off signal is always monitored by the E05A96 gate array on the C162 MAIN Board, and the logic system recognizes the power switch status.

IC51 (TL494)

CN2

Q51

C51

C82

PC1

D51

C11

DB1

CN1

Figure 1-10. C137 PSB / PSE Board Component Layout

1.5.3 Control Panel (C137 PNL Board)

The 14 LEDs on this board indicate the error status (there is no buzzer system); by using the 6 switches in combination with one another, the printer can operate in each protect operation (color or black cleaning, cartridge exchanging, self-test, default setting value exchanging, reset, and EEPROM clear operation).

1-20 Rev.A

Stylus Pro XL Product Description

1.5.4 Printer Mechanism (M-4A60)

The M-4A60 printer mechanism is equipped with a 64-nozzle black printhead and 48-nozzle color (CMY) printhead on the carriage unit. Resolution of 720 dpi is possible with special (non-absorbent) paper.

The ink system has both a black pump unit and a color pump unit. Waste ink from each printhead is made to flow into the individual caps. Power for the pump system and paper feed system is supplied from the paper feed motor.

Figure 1-11. Printer Mechanism (M-4A60)

1.5.5 Housing

The Stylus Pro XL housing consists of the printer cover, upper case, and the lower case. Attached to the housing are the front paper support and the ejected paper support with paper separator.

Rev.A 1-21

Chapter 2 Operating Principles

Table of Contents

2.1 OVERVIEW 2-1

2.2 OPERATING PRINCIPLES OF THE PRINTER MECHANISM 2-1

2.2.1 PrinterMechanism...........................................2-2

2.2.2 CarriageDriveMechanism.....................................2-5

2.2.2.1 PlatenGapAdjustLever................................2-6

2.2.3 PaperFeedMechanism.......................................2-6

2.2.4 ImkSystem.................................................2-8

2.2.5 PumpMechanism............................................2-9

2.2.6 CapMechanism............................................2-12

2.2.7 WipingMechanism..........................................2-12

2.3 OPERATING PRINCIPLES OF THE ELECTRICAL CIRCUITS 2-13

2.3.1 Operating Principles of the Power Supply Circuit . . . . . . . . . . . . . . . . . . 2-13

2.3.2 OperatingPrinciplesoftheMainControlCircuit ...................2-15

2.3.2.1 ResetCircuit ........................................2-16

2.3.2.2 SensorCircuit .......................................2-16

2.3.2.3 Carriage Motor Drive Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

2.3.2.4 PaperFeedMotorDriveCircuit..........................2-19

2.3.2.5 PrintheadDriveCircuit.................................2-20

2.3.2.6 DMAController ......................................2-22

2.3.2.7 D-RAMRefreshmentController..........................2-23

2.4 INK SYSTEM MANAGEMENT 2-24

2.4.1 InkOperations.............................................2-25

2.4.2 TimerandCounter..........................................2-27

2.4.2.1 Refresh Timer (Monochrome and YMC Head) . . . . . . . . . . . . . . 2-27

Rev.-A 2-i

List of Figures

Figure2-1. PrinterMechanismBlock................................. 2-1

Figure2-2. StructureofPrinthead................................... 2-2

Figure2-3. PrinciplesofthePrintingOperation......................... 2-3

Figure 2-4. Carriage Drive Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Figure2-5. PlatenGapLeverOperation.............................. 2-6

Figure2-6. PaperFeedMechanism.................................. 2-7

Figure2-7. InkSystemBlock....................................... 2-8

Figure2-8. PumpMechanismBlock ................................. 2-9

Figure2-9. SwitchLeverSet....................................... 2-9

Figure2-10. PaperFeedMechanismBlock........................... 2-10

Figure2-11. SwitchLeverReset................................... 2-10

Figure2-12. PumpOperation...................................... 2-11

Figure2-13. CapMechanism...................................... 2-12

Figure2-14. WipingMechanism.................................... 2-12

Figure2-15. BlockDiagramoftheElectricalCircuit..................... 2-13

Figure2-16. PowerSupplyCircuitBlockDiagram...................... 2-14

Figure2-17. MainControlCircuitBlockDiagram....................... 2-15

Figure2-18. ResetCircuitBlockDiagram............................ 2-16

Figure2-19. SensorCircuitBlockDiagram........................... 2-16

Figure 2-20. Carriage Motor Circuit Block Diagram. . . . . . . . . . . . . . . . . . . . . 2-17

Figure2-21. SerialDataTransferProcedure.......................... 2-18

Figure 2-22. Paper feed Motor Drive Circuit Diagram . . . . . . . . . . . . . . . . . . . 2-19

Figure 2-23. Normal/Micro Dot Mode Switch Block . . . . . . . . . . . . . . . . . . . . . 2-20

Figure2-24. TrapezoidalDriveWaveForm........................... 2-21

Figure 2-25. Printhead Drive Circuit Block Diagram . . . . . . . . . . . . . . . . . . . . 2-21

Figure2-26. DMAControllerOperation.............................. 2-22

Figure2-27. D-RAMCycleTimings................................. 2-23

Figure2-28. JunctionMethod(CPU-DRAM).......................... 2-23

List of Tables

Table 2-1. Carriage Drive Motor Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Table 2-2. Drive Terms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Table2-3. PlatenGapAdjustLeverPosition........................... 2-6

Table2-4. PaperFeedDriveMotorSpecifications ...................... 2-6

Table 2-5. Drive Terms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Table2-6. PumpMechanismOperation ............................. 2-11

Table2-7. DCVoltageDistribution.................................. 2-13

Table2-8. SerialDataContents.................................... 2-17

Table2-9. PaperFeedMotorDriveModes........................... 2-19

Table2-10. JunctionMethod(CPU-2CASDRAM) ..................... 2-23

2-ii Rev.-A

Stylus Pro XL Operating Principles

2.1 OVERVIEW

This section describes the operating principles of the printer mechanism and the electrical circuits of the Stylus Pro XL.

2.2 OPERATING PRINCIPLES OF THE PRINTER MECHANISM

The Stylus Pro XL printer mechanism is composed of the printhead unit, paper feed mechanism, carriage drive mechanism, pump mechanism, and various sensors. The figure below shows a functional block diagram of the printer mechanism.

ASF Plunger Disengage Lever

ASF Pickup Mechanism Paper Feed Mechanism

Paper Feed Motor

Carriage Motor

Figure 2-1. Printer Mechanism Block Diagram

Pump Unit Drive Mechanism

Carriage Unit

Color Bla c k

REV.-A 2-1

Operating Principles Stylus Pro XL

2.2.1 Printer Mechanism

The printer mechanism of this printer uses a drop-on-demand ink jet system similar to the system used on all other EPSON ink jet printers. However, the printhead in this system is completely redesigned to make it more compact and ensure a high level of reliability. The figure below shows the structure of the printhead and ink supply system.

❏Piezo When a drive pulse (voltage) is applied, this element pushes the vibration plate,

compressing the cavity for ink injection from the nozzle.

❏ Cavity Ink supplied from the ink cartridge is stored in this space and is ejected fr

om the nozzles when the vibration plate compresses this area.

❏ Nozzles These eject ink against the paper’s surface in response to the application of the

print signal. There are 64 (black head) or 48 (color head) individual nozzles making up the printhead.

Cartridge Needle

Ink Supply Tube

Nozzle Plate

Printhead Driver Board

Piezo

Nozzle

Ink Supply Tank

Cavit y

Piezo

Figure 2-2. Structure of Printhead

2-2 REV.-A

Cavity

Nozzle

Vibration Plate

Normal State

Piezo

Cavity

Nozzle

Ejecting State

Ink Dot

Piezo

Stylus Pro XL Operating Principles

Principles of the Printing Operation

The printhead operates in one of two modes to eject ink from each nozzle: ❏ Normal state

No electrical charge is applied to the MLP (Multi-Layer Piezoelectric) element attached to the back of the cavity, and pressure inside the cavity is kept at a constant level.

❏ Ejecting state

The head data signal is applied to the specific nozzle control line to select the active nozzle for printing, and the MLP element is gradually charged by the drive voltage. By charging the MLP element, the vibration plate is bent to compress the cavity. Then, ink is ejected from the nozzle.

Figure 2-3. Principles of the Printing Operation

When the ink charge or printhead cleaning operation is performed, the ink in the cavity is vacuumed out with the pump mechanism. During printing, on the other hand, the ink is simultaneously supplied from the ink cartridge and ejected from the nozzle, according to the change of volume in the cavity.

A thermistor is attached to the side of the color printhead drive board to monitor the temperature, because the viscosity of the ink varies, depending on the temperature. The detected temperature level is fed back to the printhead drive voltage control circuit to change the timing of the Tc pulse. (The Tc pulse is shown in Section 2.3.2.5.)

REV.-A 2-3

Operating Principles Stylus Pro XL

Micro Dot Printing mode

The Stylus Pro XL printer has a special printing mode, called “Micro Dot Printing mode”. This printing mode can be selected by a command from the host computer. Using the Micro Dot printing mode can improve the quality of output. In Micro Dot Printing mode, the ink dot size became to be smaller than the normal dot size.

2-4 REV.-A

CR Motor

CR HP Sensor

Carriage Guide Shaft

Belt Pulley

Stylus Pro XL Operating Principles

2.2.2 Carriage Drive Mechanism

The timing belt attached to the base of the carriage unit is driven by the carriage motor, causing the carriage unit to move along the carriage guide shaft left to right, or vice versa. The carriage drive motor on this printer is a 4-phase, 200-pole, hybrid-type stepping motor mechanism, allowing the printer to stop the carriage or change the carriage movement at any position. The position of the carriage is recognized by the home position sensor, and position information is fed back to the carriage drive control circuit. This carriage motor is driven by the motor driver IC SLA7041 (see Section 2.3.2.3 for more information).

Table 2-1. Carriage Drive Motor Specifications

Item Description

Motor Type 4-phase / 200-pole hybrid-type stepping motor Drive Voltage Coil Resistance Drive Frequency 960 ~ 4800 PPS Excitation Mode Constant current unipolar drive, micro step drive

In the following table, 2 W1-2 phase means the 1/8 2-2 phase drive control. Values in parentheses ( ) are for the 2-2 phase.

+35 VDC ± 5%

10.0 Ω±7%

Table 2-2. Drive Terms

Acceleration/

CR Speed Frequency Phase Drive Method

Mode 1 (200 CPS)

Mode 2 (100 CPS)

Mode 3 (40 CPS)

4800 (2400)

2400 (1200)

960 (480)

❏ Acceleration/Deceleration Area:

2 W1-2 phase + 1-2 phase

❏ Constant Area: 1-2 phase

❏ Acceleration/Deceleration Area:

2W1-2 phase + 1-2 phase

❏ ConstantArea: 1-2 phase ❏ Acceleration/Deceleration Area:

2W1-2 phase

❏ Constant Area: 2 W1-2 phase

Deceleration

Step

Acceleration

40 (5)+110 (55)

Deceleration

32 (4)+112 (56)

40 (5)+40 (20)

16 (2)

REV.-A 2-5

Figure 2-4. Carriage Drive Mechanism

(A)

(B)

0.6 mm

Platen Gap Adjust Lever

(Plain Paper or Bond Paper)

(Envelope or Transparency)

Gap

Operating Principles Stylus Pro XL

2.2.2.1 Platen Gap Adjust Lever

The platen gap adjust lever, which is attached to the carriage unit, needs to be set to an appropriate position for the paper thickness. To change the platen gap, put the printer in the PAUSE state; then press the Font button, while holding down the Alt button. The carriage unit moves the platen gap position automatically.

Table 2-3. Platen Gap Adjust Lever Position

Paper Type Lever Position

Cut sheets Envelopes Vertical (B) (+0.6 mm)

Figure 2-5. Platen Gap Adjust Lever Operation

2.2.3 Paper Feed Mechanism

Horizontal (A) (± 0 mm)

This printer’s paper feed mechanism can feed paper only from the built-in ASF (auto sheet feeder). The paper feed drive motor is a 4-phase, 96-pole, hybrid-type stepping motor that directly drives the paper feed mechanism (paper advancing operation, paper pickup operation). This motor also drives the pump mechanism, but only when the printer is in the cleaning state. The paper feed drive method is driven by the 2-2 phase drive method, except the paper feed drive sequence (2 W1-2 phase).

Table 2-4. Paper Feed Drive Motor Specification

Item Description

Motor Type 4-phase, 96-pole, hybrid-type Drive Voltage Coil Resistance Drive Frequency 300 ~ 1800 PPS Excitation Mode Paper feed / pump drive: 2-2 phase, 2 W1-2 phase

+35 VDC ± 5%

11.5 Ω±1.1Ω

2-6 REV.-A

PF Transmission Gear

Quenchin g Ro ller

PF Pinch Roller Unit

Pickup Roller

Paper

PF Motor Pinion Gear

Platen Dr ive Ge ar

Paper Pickup Lever

Tension Spring

Plunger Hopper Frame

Left Side Frame

Stylus Pro XL Operating Principles

Table 2-5. Drive Terms

Current Value (mA)

Mode

Paper loading 1600 970/750 750 750 240 ASF feed 1600 970/750 750 750 240 Paper feed 391 — / — 970 — 240 Pump drive 1 1800 1380/1380 1380 750 240 Pump drive 2 300 — / — 1380 — 240

Frequency

(pps)

Acceleration/

Deceleration

Constant Rush Hold

Figure 2-6. Paper Feed Mechanism

REV.-A 2-7

Air Valve

Black Head

Color Head

Pump 1

Pump 2

Ink Ab sor ber

Waste Ink Drain Tank

Cleaning Blade (for Color / Black Head)

Pump Unit

Friction Clutch

Disengage Unit

Platen Rolle r

PF Motor

Operating Principles Stylus Pro XL

2.2.4 Ink System

This printer’s ink system is composed of the following mechanisms:

❏ Ink cartridge ❏ Pump mechanism ❏ Cap mechanism ❏ Waste ink drain tank ❏ Wiping mechanism

The figure below shows a diagram of the ink system.

Figure 2-7. Ink System Block Diagram

2-8 REV.-A

Carriage

D/E Set Lever

D/E Reset Lever

D/E Lever

Stylus Pro XL Operating Principles

2.2.5 Pump Mechanism

The paper feed motor drives the pump mechanism when the transmission gear is moved to the position where the paper feed motor engages the pump mechanism gear trains, when the carriage unit is at the ink system home position. The figure below shows a block diagram of the pump mechanism. Pump system operation depends on the rotational direction of the paper feed drive motor, as shown in Table 2-6.

Drive: Pump Mechanism

Left Frame

Platen Drive Gear

PF Motor

Drive: Switch Lever Set

Carria ge

Spring

Hook

Platen

Disenga ge Lever

Rele as e Clutc h

Sub Fram e

Figure 2-8. Pump Mechanism Block

Pump Drive Gear

Right Frame

Pump Unit

Figure 2-9. Switch Lever Set

REV.-A 2-9

Operating Principles Stylus Pro XL

Drive: Paper Feed Mechanism

Carriage

Figure 2-10. Paper Feed Mechanism Block Diagram

Switch Lever: Reset

Carria ge

D/E Reset Le ver

D/E Lever

Figure 2-11. Switch Lever Reset

2-10 REV.-A

Stylus Pro XL Operating Principles

Table 2-6. Pump Mechanism Operation

PF Motor Rotational Direction Oper ation

Clockwise (CW) forward rotation

❏Color absorption ❏Color micro absorption ❏Color false absorption ❏Wiper reset ❏Carriage lock reset

Counterclockwise (CCW) backward rotation

❏Monochrome absorption ❏Monochrome micro absorption ❏Monochrome false absorption ❏Wiper set ❏Carriage lock set

The pump draws ink from the printhead nozzles and drains it to the waste ink drain tank. The printer performs this operation to eliminate dust or bubbles in the nozzles. Figure 2-12 illustrates pump operation. When the paper feed drive motor rotates CW (forward), the color pulley pumps in the wheel pump unit rotate in the direction of the arrow while squeezing the ink tube to push the ink inside the tube out to the waste ink drain tank. When the motor rotates CCW (backward), the black pulley pumps in the wheel pump unit rotate in the direction of the arrow while squeezing the ink tube to push the ink inside the tube out to the waste ink drain tank.

There are two pump rollers in the pump unit, and the drive power is supplied from the paper feed motor via the pump drive gear (D/E gear), which is moved by carriage operation. In the pump unit, the transmission gear drives both the black and color pulley, which are rotated by the movement of the other.

Ink Draini ng

Vacuuming

Pump Moto r (CW): Colo r Pump ing

No Ink Draining

No Vacuuming

Pump Motor (CW): Black Not Pumping

Figure 2-12. Pump Operation

Ink Draini ng

Vacuuming

Pump Motor (CCW): Black Pumping

No Ink Draini ng

No Vacuumi ng

Pump Motor (CCW): Color Not Pumping

REV.-A 2-11

Cap 1 Cap 2

Col or Ca rtrid ge

Bl ack Cart ridg e

Cap Ho lder

Air Valve

Air Tube

Valve Sp ri n g

Ca rriage

Operating Principles Stylus Pro XL

2.2.6 Cap Mechanism

The cap mechanism prevents the printhead nozzles from drying and keeps bubbles from forming inside the nozzle while the printer is not in use. The printer performs this operation automatically when print data is not received or when the printer power is turned off during printing or ink system operations. (The secondary circuit for the power switch allows this operation to be performed.) Also this printer has two caps, one for the black head and one for the color head.

Figure 2-13. Cap Mechanism

2.2.7 Wiping Mechanism

The wiping mechanism cleans the surface of the printhead nose when the printer is in the ink system sequence. The wiper drive gear transmits power from the paper feed motor via the clutch gear. When the wiper is raised (against the printhead surface), the hook for securing the carriage to the home position is raised, too. When the wiper goes down toward the bottom frame, the hook goes down, too. Both black and color heads are cleaned by this wiper.

Hook

Hook Lev er

Wiper (Cleaning Blade)

Wiper Drive Gear

Platen

Clutch

Wiper Drive Gear Frame

Figure 2-14. Wiping Mechanism

2-12 REV.-A

C137 PSB

+5 VDC

+35 VDC

C162 MAIN

C137 PNL

R-T0 2 Head

M-4A60 Printer Mechanism

YMC Head Driver

Black He ad Driver

R-T0 1 Head

CR/PF Motor

Stylus Pro XL Operating Principles

2.3 OPERATING PRINCIPLES OF THE ELECTRICAL CIRCUITS

The Stylus Pro XL contains the following circuit board units:

❏ C162 MAIN Board (main control circuit board) ❏ C137 PSB/PSE Board (power supply circuit board) ❏ C137 PNL (control panel board)

In addition to the circuit boards above, part of the printhead drive circuit is built on a separate circuit board installed in the carriage unit; the printhead is attached directly to this board. The figure below shows a block diagram of the electrical circuitry.

Figure 2-15. Block Diagram of the Electrical Circuitry

2.3.1 Operating Principles of the Power Supply Circuit

The power supply circuitry for this printer is provided either by the C137 PSB Board (120 VAC) or the C137 PSE Board (220-240 VAC). Both boards are identical in design and functionality, except for the components in the primary circuit that accommodate the specified input voltage. The input voltage and the application of output voltages are summarized in the table below.

Table 2-7. DC Voltage Distribution

Voltage Application

+35 VDC

+5 VDC

Motor drive (carriage and paper feed) Printhead (through the drive voltage generation circuit)

C137 MAIN Board Sensors (home position, paper end, no ink cartridge, head thermistor) Control panel, head nozzle selector

REV.-A 2-13

Operating Principles Stylus Pro XL

The figure below shows a block diagram of the power supply circuit (C137 PSB/PSE). The power switch is equipped with a secondary circuit that allows the CPU to remain active for a while after the printer is turned off. This allows the printhead to return to the capping position after power is off. The CPU mounted on the C137 MAIN Board always monitors the PSC (power on/off) signal. If this signal becomes LOW, the CPU resets each device after performing the head capping sequence.

Also, this board employs the RCC (ringing choke converter) switching system. This AC voltage is first input to the filter circuit for higher harmonics absorption, and then input to the rectification and smoothing circuit, converting it into DC voltage. This DC voltage is then input to the switching circuit for the switching operation. Along with the switching operation on the primary side, +35 VDC is generated after passing through the +35 V line voltage detection circuit. This +35 VDC output level is stabilized. This +35 VDC is also input to the +5 VDC generation circuit to generate a stable +5 VDC.

DB1 C11

Full-wave Rectifier C ircuit

L1, R1 C1-C4

Filter C irc uit

Fuse

Main Sw itc hin g Circuit

Feedback Circuit

Figure 2-16. Power Supply Circuit Block Diagram

Smoothing Circuit

C51

Transformer

Smoothing Circuit

ZD51, 81-84

P-OFF Detection and Delay Circuit

ZD86, C82

Drop Protection Circuit

Over Voltage Protection Circuit

Photo Coupler

PC1

+35 VDC

+5 VDC

TL 494

ZD52

ZD53

Over Voltage Protection Circuit

P-OF F Sig na l

1) +5 VDC line over voltage protection circuit

The output voltage level of +5 V line is monitored by a Zener diode (ZD53). If the voltage level exceeds +7 V, the status is fed back to the primary switching circuit through a photocoupler (PC1) to stop the +35 V generation.

2) +5 VDC line over current / over voltage control circuit.

The output current is monitored by a detection resistor (R53) and fed back to the +5 VDC generation switching control IC (IC51), which monitors the output voltage. This information is input to the internal comparater and outputs the high signal to turn off the transistor (Q51) when the voltage or the current becomes abnormal.

3) +35 VDC line over voltage protection circuit

The output level is monitored by a Zener diode (ZD36). If the voltage level exceeds +36 V, a photocoupler (PC1) is activated; stopping the primary switching circuit operation.

4) +35 VDC line drop protection circuit

The output level of +35 VDC line is monitored by a detection circuit that consists of a Zener diode (ZD51 and ZD81 to 84). This circuit feeds back the output voltage level status through a photocoupler to the primary switching circuit to control the ON/OFF time of the switching transistor for contast output voltage.

2-14 REV.-A

Stylus Pro XL Operating Principles

2.3.2 Operating Principles of the Main Control Circuit

The main control circuit of this printer is the C162 MAIN Board. This circuit is controlled by the 16-bit CPU H8/3003 (IC1), running at 14.7456 MHz. This CPU has a unique architecture capable of handling data on the data bus at either an 8-bit or 16-bit bus width. Because of this, a 16-bit or 8-bit data bus width-type ROM is used on this board, increasing the internal processing speed. Also, the CPU has a unique architecture capable of the refresh control function. A 4M DRAM (2 CAS method) on this board is controlled by the CPU itself. The CPU controls the serial interface control (RS-422 for Mac).

Gate array E05A96 (IC2) manages printhead drive control, external Centronics extension CG board and the control panel, and the controls that create the 4-bit signal for the carriage or the paper feed motor. (The carriage and paper feed motor are controlled by the current duty data.)

This board also is equipped with EEPROM 93C46 (IC12) to store certain parameters, such as the printer mechanism control parameter, default setting parameters, as well as a special counter value used for printhead (ink management) protection.

The timer, IC NJU6355E (IC7), counts each time the printer is cleaned and keeps track of how long the printer is not used, thereby allowing the printer to be cleared only when necessary.

parallel I/F,

PROM (4M)

(IC3)

Type B I/F

EEPROM

Reset (Power)

RS-422 Serial I/F

Note 1

PROM (8M)

(IC4)

(IC12) 93C46

(IC8)

M51955B

C162 MAIN Board

DRAM (4M) (IC5)

Refre sh

CPU H8/3003 (IC1)

SD I/O

CLK

(IC7)

NJU6355E (Timer Coun ter)

DRAM (4M) (IC6)

DMAREQ

Battery

Carriage

CG-ROM (4M) (IC16)

Parallel I/F

(Centronics)

E05A96 (IC2)

To B

Carriage / Paper Feed

Drive Signal

Note 2

CG-ROM (8M) (IC17)

Data Bus

Address Bus

(IC13)

PST592D

Panel

To A

Black / Color Head

Common and Nozzle

Selector Drive Signal

Reset (Logic)

From A

From B

Black / Colo r He ad Common Driver Circuit

SLA7041MS (IC14, 15)

Carriage / Paper Feed Motor Driver

Note 1:

IC4 is a 32 -pin IC so cke t only .

Note 2:

IC17 is an IC socke t only .

(IC17 is only installed in JAPAN version.)

SED5620 (U1,U2 )

Black 64 Nozzles

Color 48 Nozzles

Figure 2-17. Main Control Circuit Block Diagram

REV.-A 2-15

1 2

+5 V

AN3

(CN12)

CCO

AN5

CPU (IC1)

AN1

AN0

+5 V

(CN8)

(CN9)

AN4

BCO

(CN11)

Operating Principles Stylus Pro XL

2.3.2.1 Reset Circuits

The C162 MAIN Board contains 2 reset circuits: the +5 V monitor reset circuit and the +35 V monitor reset circuit. The +5 V monitor reset circuit monitors the voltage level of the +5 V line, using reset IC PST592D (IC12), and outputs a reset signal to the E05A96 gate array (IC2) when the voltage level drops below +4.2 V. The +35 V monitor reset circuit monitors the voltage level of the +35 V line, using reset IC M51955B (IC8), and outputs a reset signal to the CPU. The reset signal is generated when the voltage level drops below +28 V, and this causes a non-maskable interrupt (NMI).

+35 V

M51955B

(IC8)

+5 V

PST592D

(IC13)

+5 V

72 68

135

CPU (IC1)

NMI

P62

RES

E05A96 (IC2)

RESET

PA8

RST Type B

Figure 2-18. Reset Circuit Block Diagram

2.3.2.2 Sensor Circuits

The following sensor circuits enable the C162 MAIN Board to monitor printer mechanism status: HP sensor The photocoupler-type home position (HP) sensor is attached to the surface of the

printer mechanism to detect the carriage home position. A LOW level from the signal indicates that the carriage is in home position.

PE sensor The mechanical switch paper end (PE) sensor is built into the printer mechanism to

determine whether there is paper in the printer or not. A LOW level from the signal indicates that no paper is loaded.

BCO sensor, CCO sensor

Thermistor A thermistor is attached to the color printhead driver board to monitor its

The cartridge out (CO) sensor is micro switch attached to the bottom of each ink cartridge holder in the carriage unit. When the ink cartridge is installed, these switches are pressed and a LOW level from the signal indicates that the ink cartridge is installed into the ink cartridge holder.

temperature by thermister’s resistance value (at 25°C approx. 10kΩ). The CPU changes the printhead drive signal’s pulse width (charge pulse width) based on the temperature level.

Figure 2-19. Sensor Circuit Block Diagram

2-16 REV.-A

NPN Tr

(Q27, 28)

E05A96

(IC2)

CRB

CRSTB

CLKA

CRA

SLA7041MS

(IC 15 )

CLK B STBA

STBB

DATA A DATA B

CRVRF

REF A

REF B

CRHLD

RSA

RSB

CRCLK

(PB0-PB7)

A A B

8 11 18

+35 V

(CN6)

31-38

Stylus Pro XL Operating Principles

2.3.2.3 Carriage Motor Drive Circuit

The carriage motor drive IC SLA7041MS (IC15) outputs a constant current to drive the carriage motor for the printer mechanism. Gate array E05A96EA (IC2) decides the motor phase and speed and then sends a signal to the carriage motor driver IC (SLA7041MS) using the 4-bit serial transmission line.

The first bit indicates the direction of the motor rotation. The other three bits are current duty data for the motor speed of each printing sequence. SLA7041MS can select the reference voltage itself based on these three current duty data. Also, it receives these signals by 2 serial transmission lines for 2 motor’s phases (phase A and phase B). Due to this, the carriage motor can drive the micro step sequence (min. 1/720 inches).

Figure 2-20. Carriage Motor Circuit Block Diagram

Four-bit serial data is read by the SLA7041MS motor driver with four clock counts from the E05A96 (IC2) clock. Each bit is read at the falling edges of these clock pulses. Due to this, received serial data is placed in the shift register and then shifts the latch register. When the STROBE pulse becomes active from the E05A96 (IC2), the serial data is moved into the reference voltage selection circuit, and the voltage is changed. Therefore, when the printer is in the constant speed mode, this current duty of each carriage motor speed mode.

STROBE pulse becomes inactive. The following table indicates the

Table 2-8. Serial Data Contents

Mode

REV.-A 2-17

c b a Vref (typical) +

000 001

010 011 100 101 110 111

(Vref = +5 V)

Vref × 1/3

× 0%

×20% ×40 % ×55.5% ×71.4% ×83% ×91% ×100%

Operating Principles Stylus Pro XL

The following figure shows the contents of the four-bit serial data and how this data transacts with the SLA7041MS driver. The step time of the reference voltage is determined by the interval time of the

STROBE pulse.

Vref

+5 V

SLA704 1MS

Vref

To M ot or (Phase Signal)

STRB

4-bit Serial Data

CLK

STRB

Vref Voltage Selection

Circuit

1-bit 2-bit 3-bit 4-bit

Phase

1-bit 2-bit 3-bit 4-bit

abc

Latch

4-bit Shi ft Re gisterPhase

Reading of serial data from the Phase signal in order

At this time, the reference voltage selection circuit checks phase signal outputs

Figure 2-21. Serial Data Transfer Procedure

2-18 REV.-A

Stylus Pro XL Operating Principles

2.3.2.4 Paper Feed Motor Drive Circuit

The paper feed motor for this printer drives the following mechanisms:

❏ Paper feed mechanism ❏ Paper pickup mechanism ❏ Pump mechanism

Driver IC SLA7041MS (IC14) drives the paper feed motor by a constant current. Its principle of operation is same as for the carriage motor drive circuit. But the driving method is different for paper feed and the pump.

Table 2-9. Paper Feed Motor Drive Modes

Mode Phase Excitation Drive Frequency

Paper feed 2-2 phase or 2 W1-2 phase 391 or 1600 pps

Pump drive 2-2 phase 300 or 1800 pps

E05A96 (IC2 )

SLA7041MS (IC14)

PFCLK

PFSTB

PFA PFB

PFVRF

(PB8-PB13)

PFHLD

41 40

44-48, 39

NPN Tr (Q25, 26)

CLKA

CLKB

STBA

STBB

DATA A

DATA B

REF A

REF B

RSA

RSB

+35 V

Figure 2-22. Paper Feed Motor Drive Circuit Diagram

1 2 3

(CN7)

4 5

REV.-A 2-19

Operating Principles Stylus Pro XL

2.3.2.5 Printhead Drive Circuit

The printhead drive circuit for this printer is composed of the following two parts:

❏ Common drive circuit (trapezoidal drive pulse generation) ❏ Head drive circuit (nozzle control built on the printhead)

SED5620D, the 64-bit thermal head driver in the head drive circuit on the carriage, is used as a nozzle selector to drive the printhead nozzles selectively. Print data is converted into serial data by gate array E05A96 (IC2) and is output from port BSO (pin 20) to the black head drive circuit or output from port CSO (pin 24) to the color head drive circuit. Then, head driver SED5620D latches the head data when gate array E05A96BA outputs the BLAT or CLAT signal, and the latched data becomes 64-bit parallel data for the black head, or 48-bit parallel data for the color head. One bit corresponds to each nozzle.

When data transfer and nozzle selection is complete, gate array E05A96 outputs the common drive pulse BPWC or CPWC (charge pulse) and BPWD or CPWD (discharge pulse) to the common drive circuit. The common drive circuit then generates the trapezoidal pulse and applies it to the printhead as a common drive pulse. After this, the nozzle selected by the head data is activated to inject ink.

In the Micro Dot Printing mode, the gate array E05B09 arranges the puise width of CPWC and CPWD to became small size of injection ink dot.

SELM Pu lse

Common Driver Drive Pu lse

Figure 2-23. Normal / Micro Dot Mode Switch Block

SELN Pulse

Block Resistor

Normal

Micro

Normal Dot Mode Drive Waveform

Head

Micro Dot Mode Drive Waveform

2-20 REV.-A

Stylus Pro XL Operating Principles

Micro Dot Printing Mode

The Stylus Pro XL printer has a special printing mode, called “Micro Dot Printing Mode.” This printing mode can be selected by command from computer. Using Micro Dot Printing Mode can improve the quality of output. In Micro Dot Printing Mode, the ink dot size becomes smaller than the normal dot size.

E05A96 (IC2)

COM GND

BPWC CPWC

BPWD CPWD

Tc: Charge Time Th: Idle Time Td: Discharge Time

Figure 2-24. Trapezoidal Drive Waveform

BPWC BPWD

BLAT BCLK BCLKIN BSO

CPWC CPWD

CLAT CCLK CCLKIN CSO

13 14

19 18 17

20 15

22 21 24

Pc: Charge Pulse Ph: Idle Pulse Pd: Discharge Pulse

Commo n Drive r

Common D riv er

17-22

18-22

COM1-8

SED5620D (U1)

CN11

4 2

CN1

CN12

CN2

LAT

CLK

COM1-6

SED5620D (U2)

LAT

CLK

DO64-49 DO48-33

DO32-17

DO16-1

DO64-49 DO48-33

DO32-17 DO16-1

Row A Row B Row C

Row D

Not Connected Row R (Magenta)

Row S (Cyan) Row T (Yellow)

C162 MA IN

On Carriage (Head Driver Board)

Figure 2-25. Printhead Drive Circuit Block Diagram

REV.-A 2-21

Operating Principles Stylus Pro XL

2.3.2.6 DMA Controller

Data from the host computer is received automatically by the STB signal via the external Centronics interface. The data is input to the input buffer on the DRAM (IC5). At this time, E05A96 detects the rising edge of the external CPU. When the CPU detects this signal, the DMA controller in the CPU sends a bus request to the bus controller in the CPU, and then the CPU releases the bus line. Due to this, external data is transported into the memory, bypassing the CPU.

STB signal and outputs the STBDMA (strobe DMA request) signal to the

STB ACK

BUSY

E05A96 (I C2)

166 161

162

CPU H8 (I C1)

STBDMA

DMARQ

128 14

9129

DREQ 1

DREQ 2

BAREQ

Figure 2-26. DMA Controller Operation

BACDMAC

Memory

2-22 REV.-A

CPU H8 (IC1) DRAM (IC5)

CAS RAS

WE OE

101

DRAM (IC6)

CS3

CAS RAS

WE OE

Stylus Pro XL Operating Principles

2.3.2.7 DRAM Refresh Controller

The H8 CPU is equipped with a refresh controller in the internal controller. This CPU can contact the 16-bit-long IC5 DRAM, which is a 2 CAS type. The following table lists the junction method between the H8 CPU and the 2 CAS DRAM.

Table 2-10. Junction Method (CPU — 2 CAS DRAM)

CPU 2 CAS DRAM

HWR UCAS

LWR LCAS

CS3 RAS

RD WR

The method of the DRAM refresh is used only for the CAS before RAS cycle method. The following figure shows the timing for each cycle.

CAS

RAS

CAS

RAS

Read Cycle

Write Cycle

(Read / Write Cycle) (Refresh Cycle)

Figure 2-27. DRAM Cycle Timing

Figure 2-28. Junction Method (CPU — DRAM)

REV.-A 2-23

Operating Principles Stylus Pro XL

2.4 INK SYSTEM MANAGEMENT

This section explains how the ink system is controlled to protect the printhead and ink supply system and to ensure high-quality output. Ink system control is composed of the following operations:

❏ Power On ❏ Wiping Operation 1 ❏ Cleaning Selection ❏ Wiping Operation 2 ❏ Micro Absorbing Cleaning ❏ Rubbing Operation ❏ Power Off ❏ Disengage On ❏ Print Start ❏ Disengage Off ❏ Refresh ❏ Micro Absorbing ❏ Standby ❏ Carriage Lock Set ❏ False Absorbing ❏ Carriage Lock Reset ❏ Ink Cartridge Replacement ❏ Refresh (when loading or ejecting paper)

❏ Forwarding (not described)

These ink system operations are controlled by the following counters and timers:

❏ Refresh Timer ❏ Monochrome / Color Head Timer ❏ Flushing Counter ❏ Ink Level Counter R ❏ CL Counter K ❏ Protect Counter

2-24 REV.-A

Stylus Pro XL Operating Principles

2.4.1 Ink Operations

Various ink operations can be performed selectively by the printer.

1 Power On Operation

This operation is performed when power is turned on.

2 Cleaning Selection Mode

This operation cleans each nozzle to ensure that the nozzle fires and that no dots are skipped during printing. Cleaning selection is performed by pressing the cleaning switch (Alt + Load/Eject or Economy/Condensed) while the printer is in PAUSE status.

3 Micro Absorbing Cleaning Operation

This operation prevents an increase in the viscosity of the ink inside the printhead by ink absorbing discharge.

4 Power Off Operation

This operation ensures the carriage is in the home position when the printer turns off, and prevents the disengage gear from turning continuously when the printer turns off. Power off operation is performed when the secondary side switch is turned off.

5 Print Start Operation

This operation eliminates ink from the nozzle surface, and is performed when the printer receives print data while in the standby state.

6 Refresh Operation

This operation prevents an increase in the viscosity of the head ink.

7 Standby Operation

This operation prevents an increase in the viscosity of the head ink.

8 False Absorbing Operation

This operation absorbs ink inside the cap, and eliminates ink from the nozzle plate.

9 Ink Cartridge Replacement Operation

This operation is performed when the Alt button is pressed for more than 3 seconds; the carriage then moves to the ink cartridge replacement position.

10 Wiping Operation 1

This operation eliminates dust from the nozzle plate before performing the ink absorption.

11 Wiping Operation 2

This operation eliminates dust or ink from the nozzle plate after performing the ink absorption.

12 Rubbing Operation

This operation removes dust or ink that adheres to the head surface.

13 Disengage ON Operation

This operation sets the switch lever to the position where it transmits the PF motor drive to the pump mechanism. It also moves the carriage to the home position where the lever is set to the specified position.

REV.-A 2-25

Operating Principles Stylus Pro XL

14 Disengage Off Operation

This operation resets the switch lever to the position where it transmits the PF motor drive to the pump mechanism. It also moves the carriage to the flushing position, where the lever is reset to the specified position.

15 Micro Absorbing Operation

When the cartridge is removed, it is possible for a small amount of air to form small air bubbles that can block the ink from the nozzle. This operation eliminates small air bubbles from the cavity of the printhead.

16 Carriage Lock Set

This operation prevents the carriage from moving out of the home position if the printer is turned off or is pauesd. This operation is performed when the carriage is in the ink system home position and no paper is loaded.

17 Carriage Lock Reset

This operation resets the carriage lock lever.

18 Refresh Operation (Performed when Loading or Ejecting Paper)

This operation prevents an increase in the viscosity of ink inside the black head while paper is being loaded or ejected. When paper is loaded or ejected, just the black head is ready, and the color head is capped. The refresh flushes the black head only.

19 Adjust Lever Position Moving Sequence

This operation is performed when the Alt and Font buttons are pressed simultaneously while the printer is paused.

20. Transportation Sequence

This sequence is performed to clean the printhead when the printer is transported to the market.

2-26 REV.-A

Stylus Pro XL Operating Principles

2.4.2 Timer and Counter

EEPROM LE93C46 (IC12) on the main board stores certain counter and timer values used for controlling ink system operation.

2.4.2.1 Protect Counter

Protect counter A and Ink Amount Counter R values are stored in the EEPROM on the main board, and while the printer is on, this data is saved in the RAM on the main board.

❏ Protect Counter A This counter is used to manage the total amount of drained ink. If

the counter value is equal to or exceeds 51000, the printer indicates an error on the control panel and maintenance is required. This counter is incremented by the following every sequence. (Values in parentheses ( ) mean only the color head. 1 point = 0.025 cc.)

1. Power On

(Micro): 40 steps × 6 (5) 2 points

40 steps × 10 (9) 3 points 40 steps × 15 (12) 5 (4) points

2. CL 1: 3600 (4800) steps 16 (20) points

40 steps × 12 absorption 4 points

3. CL 2: 720 steps 4 points 7800 (8200) steps 40 points 40 steps × 12 4 points

4. CL 3: 40 steps × 12 4 points

5. I/C Replacement: 8900 (14000) steps 48 (72) points 8900 (8800) steps 48 (44) points 40 steps × 12 4 points

6. Fixed time

False Absorption: Monochrome and CMY = 2

7. Power On

(Normal): 3600 (4800) steps 16 (20) points

40 steps × 12 4 points

Note for Service

Also, protect counter A resets when:

1. The printer is shipped from the factory.

2. After the maintenance is performed. (When the ink drain tank (ink-eject porous pad, part number 130) is replaced.)

REV.-A 2-27

Chapter 3 Disassembly and Assembly

Table of Contents

3.1 OVERVIEW 3-1

3.1.1 PrecautionsforDisassemblingthePrinter.........................3-1

3.2 DISASSEMBLY AND ASSEMBLY 3-2

3.2.1 UpperCaseRemoval.........................................3-3

3.2.2 Power Supply Unit (C137 PSB/PSE Board) Removal . . . . . . . . . . . . . . . . 3-4

3.2.3 MainController(C162MAINBoard)Removal......................3-5

3.2.4 PrinterMechanism(M-4A60)Removal...........................3-7

3.2.5 PrinterMechanismDisassembly................................3-8

3.2.5.1 PrintheadUnitRemoval.................................3-8

3.2.5.2 Carriage Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

3.2.5.3 PumpUnitRemoval...................................3-13

3.2.5.4 CleanerHeadReplacement ............................3-14

3.2.5.5 CRMotorRemoval...................................3-15

3.2.5.6 PFMotorRemoval....................................3-15

3.2.5.7 Carriage Home Position (HP) Sensor Removal . . . . . . . . . . . . . 3-16

3.2.5.8 PaperEnd(PE)SensorRemoval........................3-16

3.2.5.9 PaperFeedRollerAssemblyRemoval....................3-17

3.2.5.10 UpperFrameRemoval ...............................3-18

Rev.-A 3-i

List of Figures

Figure3-1. DisassemblyFlowchart.................................. 3-2

Figure3-2. C137PNLControlPanelRemoval ......................... 3-3

Figure3-3. UpperCaseRemoval.................................... 3-3

Figure3-4. PowerSupplyUnitRemoval.............................. 3-4

Figure3-5. MainControllerRemoval................................. 3-5

Figure 3-6. Printer Mechanism (M-4A60) Removal . . . . . . . . . . . . . . . . . . . . . . 3-7

Figure3-7. InkCartridgeClampRemoval............................. 3-8

Figure3-8. InkCartridgeHolderremoval.............................. 3-9

Figure3-9. PrintheadRemoval ..................................... 3-9

Figure3-10. HeadSpacerPosition ................................. 3-11

Figure3-11. FrontFrameRemoval................................. 3-12

Figure3-12. CarriageUnitRemoval................................. 3-12

Figure3-13. PumpUnitRemoval................................... 3-13

Figure3-14. CleanerHeadReplacement ............................ 3-14

Figure3-15. CRMotorRemoval ................................... 3-15

Figure3-16. PFMotorRemoval.................................... 3-15

Figure3-17. HPSensorRemoval .................................. 3-16

Figure3-18. PESensorRemoval................................... 3-16

Figure3-19. TensionRollerAssemblyRemoval....................... 3-17

Figure 3-20. Paper Feed Roller Assembly Removal . . . . . . . . . . . . . . . . . . . . 3-17

Figure3-21. UpperFrameRemoval................................. 3-18

Figure3-22. AttachingtheTorsionSpring............................ 3-18

List of Tables

Table3-1. InsertLocationoftheBlockResistor ........................ 3-7

Table3-2. InsertLocationoftheBlockResistor ....................... 3-10

3-ii Rev.-A

Stylus Pro XL Disassembly and Assmbly

3.1 OVERVIEW

This section describes procedures for disassembling the main components of this printer. Unless otherwise specified, disassembled units or components can be reassembled by reversing the disassembly procedure. Therefore, no assembly procedures are included. Precautions for any disassembly or assembly procedure are described under the heading “Disassembly/Assembly Points.” Adjustments required after assembling the unit are described under the heading “Required Adjustments.”

3.1.1 Precautions for Disassembling the Printer

See the precautions below when disassembling the printer.

WARNING

❏ Disconnect the power cable before disassembling or assembling the printer. ❏ Wear protective goggles to protect your eyes from ink. If ink gets in your eye, flush the

eye with fresh water and see a doctor immediately.

❏ If ink comes into contact with your skin, wash it off with soap and water. If irritation

occurs, contact a physician.

❏ A lithium battery is installed on the C162 MAIN Board of this printer. Be sure to observe

the following instructions when servicing the battery:

1. Keep the battery away from any metal or other batteries so that electrodes of the

opposite polarity do not come in contact with each other.

2. Do not heat the battery or put it near fire.

3. Do not solder on any part of the battery. (Doing so may result in leakage of electrolyte

from the battery, burning, or explosion. The leakage may affect other devices close to

the battery.)

4. Do not charge the battery. (An explosive gas may be generated inside the battery, and

cause burning or explosion.)

5. Do not dismantle the battery. (The gas inside the battery may hurt your throat.

Leakage, burning, or explosion may also result.)

6. Do not install the battery in the wrong direction. (This may cause burning or explosion.)

CAUTION

Danger of explosion if battery is incorrectly replaced. Replace only with the same or equivalent type recommended by the manufacturer. Dispose of used batteries according to government’s laws and regulations.

ATTENTION

Risque d’explosion si la pile est remplacée incorrectement. Ne remplacer que par une pile du même type ou d’un type équivalent recommandé par le fabricant. Elminer les piles déchargées selon les lois et les règles de sécurité en vigueur.

CAUTION

❏ Never remove the ink cartridge from the carriage unless manual instructions specify to

do so.

❏ When transporting the printer after installing the ink cartridge, be sure to pack the

printer for transportation without removing the ink cartridge.

❏ Use only recommended tools for disassembling, assembling, or adjusting the printer. ❏ Apply lubricants and adhesives as specified. (See Chapter 6.) ❏ Make specified adjustments when you disassemble the printer. (See Chapter 4.)

REV.-A 3-1

START

3.2.1

3.2.2

3.2.4

3.2.3

3.2.5.1

3.2.5.2

3.2.5.3

3.2.5.4

3.2.5.5

3.2.5.6

3.2.5.7-8

3.2.5.9

3.2.5.10

Uppe r Cas e Removal

Page 3-3

Power Supply Unit Removal

Page 3-4

Main Controller Removal

Page 3-5

Printer Mechanism Remova l

Page 3-7

Printhead Unit Remova l

Page 3-8

Carriage Unit Remova l

Page 3-12

Pump Unit Removal

Page 3-13

Clerner Head Remova l

Page 3-14

CR Motor Removal

Page 3-15

PF Motor Removal

Page 3-15

HP,PE Sensor Removal

Page 3-16

Removal

Page 3-17

Upper Frame Removal

Page 3-18

PF Roller Assembly

Disassembly and Assembly Stylus Pro XL

3.2 DISASSEMBLY AND ASSEMBLY

Follow the precautions in Section 3.1.1 when disassembling the printer.

This section consists of the subheads shown in the diagram below. See the exploded view of the printer in the Appendix, if necessary.

WARNING

Figure 3-1. Disassembly Flowchart

3-2 REV.-A

C137 PNL Board

Cable

Carriage Lock Lever

CBB (M3x11)

Stylus Pro XL Disassembly and Assmbly

3.2.1 Upper Case Removal

1.1. Remove the printer cover (center of top) by releasing the 2 tabs holding it to the upper case.

2. Remove the front cover (front of top) by releasing the 2 tabs holding it to the lower case.

3. Remove the paper guide by releasing the 2 tabs holding it to the printer mechanism.

4. Move the carriage to the middle of the printer while pressing the hook that fixes the carriage unit to the home position.

5. Remove the control panel. (Release the tab by inserting a screwdriver into the hole in the upper case, as shown in the figure below.) At this time, disconnect the connector on the C137 PNL Board.

Figure 3-2. C137 PNL Control Panel Removal

Remove the 2 CBB (M3 × 11) screws securing the upper case to the lower case.

6. Release 1 tab by inserting a flathead screwdriver into the holes at the bottom of the lower case, as shown in the figure below.

7. Remove the upper case by lifting the front side. At the same time release 1 tab, located in the center front of the lower case.

DISASSEMBLY/ASSEMBLY POINT

Hold the upper case firmly and pull it to remove it, while you release the tabs.

Figure 3-3. Upper Case Removal

REV.-A 3-3

Disassembly and Assembly Stylus Pro XL

3.2.2 Power Supply Unit (C137 PSB/PSE Board) Removal

1. Remove the upper case (see Section 3.2.1).

2. Disconnect the cables from connectors CN1 on the C137 PSB /PSE Board and CN5 on the C162 MAIN Board.

Remove the 2 screws, 1 CBN (M3×8)and1CBB(M3×12), securing the shield plate to the lower case via the C137 PSB/PSE Board.

Remove the 3 screws, 2 CBB (M3×12) and 1 CBN (M3×8), securing the C137 PSB/PSE Board to the lower case, and remove a CBN (O) (M3×6) screw fixing the earth line from the AC cable to the earth plate.

5. Remove the wire harness for the motors in the locking tab on the shield plate, and take the shield plate out by pulling upward toward the back of the printer.

6. Remove the power supply unit by pulling it upward toward the back of the printer.

CAUTION

The shield plates of C137 PSB/PSE and C162 MAIN boards have sharp edges, so take care in handling them.

CBS (M3x8)

C162 MAIN Boar d

C137 PSB Board

CBB (M3x12)

CBS(O) (M3x6)

Figure 3-4. Power Supply Unit Removal

3-4 REV.-A

CBB (M3x12)

CBS (M3x8)

Grounding Plate

Shield Plate

Stylus Pro XL Disassembly and Assmbly

3.2.3 Main Controller (C162 MAIN Board) Removal

1. Remove the upper case (see Section 3.2.1).

2. Remove the grounding plate from the shield plate.

Remove the 4 CBB (M3×12) screws securing the shield plate to the lower case.

Remove the 2 CBB (M3×12) screws securing the Type-B interface cover to the lower case.

5. Disconnect the cables from connectors CN5, CN6, CN7, CN8, CN9, CN10, CN11, CN12, and CN13 of the C162 MAIN Board.

Remove the 4 CBB screws, 2 (M3×12)and2(M3×8), securing the main controller to the lower case and then remove the C162 MAIN Board.

Figure 3-5. Main Controller Removal

REV.-A 3-5

Disassembly and Assembly Stylus Pro XL

ASSEMBLY POINT

❏ When you replace the main board, initialize EEPROM contents as follows:

1. Reassemble the printer.

2. Turn the printer on while holding down the Alt, Font, Load/Eject ,andPause buttons

on the control panel.

❏ It is possible to misconnect the cables. When reconnecting the cables from connectors

CN6, CN7 and connectors CN11, CN12 of the C162 MAIN board, see the following instructions.

1. CN11: Printhead FFC cable (white mark: rear direction) CN12: Printhead FFC cable (blue mark: rear direction)

2. CN6: Carriage motor cable (red mark: the red mark indicates pin 1 of CN6.) CN7: Paper feed motor cable (black mark: the black mark indicates pin 1 of CN7.)

REQUIRED ADJUSTMENT

❏ When replacing the main controller board, adjust both the head gap and the

bidirectional adjustment alignment, and save the adjusted parameters into the

EEPROM on the C162 MAIN Board. (See Chapter 4.)

❏ When you replace the main board, the parameters in the internal timer are all reset.

Therefore, it is possible for printing to become abnormal. At this time, perform the cleaning operation using the control panel or command (Refer to Chapter 4) until the printing becomes normal.

CAUTION

The shield plates for the C162 MAIN Board and C137 PSB/PSE Board have sharp edges, so take care in handling them.

3-6 REV.-A

CBB (M4x13)

Stylus Pro XL Disassembly and Assmbly

3.2.4 Printer Mechanism (M-4A10) Removal

1. Remove the upper case (see Section 3.2.1).

2. Remove the power supply unit (see Section 3.2.2).

3. Remove the main controller (see Section 3.2.3).

Remove the 4 CBN (M4×13) screws and take out the printer mechanism.

DISASSEMBLY/ASSEMBLY POINT

Wipe off any ink around the end of the ink drain tube when you remove the printer mechanism.

❏ When reinstalling the printer mechanism, check that the waste ink drain tube is properly

inserted between the lower case and the waste ink absorbing material.

Figure 3-6. Printer Mechanism (M-4A60) Removal

CAUTION

When you replace the printhead or printer mechanism, you must replace the block

resistor at location RM4 (for Micro Mode - Color (R-No.)), RM5 (for Normal Mode -

Color (M-No.)), RM11 (for Micro Mode - Monochrome (R-No.)), and RM12 (for Normal Mode - Monochrome (M-No.)) on the C162 MAIN Board. (Every spare printhead or spare printer mechanism comes with a block resistor that is specifically selected for

each printhead.) Refer to Table 3-1.

❏ Adjust both the head gap and bidirectional alignment when replacing the printer

mechanism.

Table 3-1. Insertion Location for Block Resistors

Mode

Normal

Micro

Head Indication No. Location

Monochrome

Color

Monochrome

M-×× M-×× R-×× ×

RM12 RM5 RM11

REV.-A 3-7

Color

R-×× ×

RM4

Disassembly and Assembly Stylus Pro XL

3.2.5 Printer Mechanism Disassembly

The procedures described in this section explain how to remove the components within the printer mechanism.

3.2.5.1 Printhead Unit Removal

1. Remove the printer mechanism (see Section 3.2.4).

2. Move the carriage to the middle of the printer while pressing the hook that fixes the carriage unit to the home position.

3. Pull the ink cartridge clamp toward you and remove the ink cartridge.

CAUTION

When removing the ink cartridge, always install a new cartridge immediately after removing the old one.

❏ When the ink cartridge is replaced, the printer performs the ink cartridge replacement

operation automatically. The exclusive cartridge is: Monochrome: 1020626

YMC: 1020627

❏ Ink cartridges should never be kept longer than 6 months.

4. Push the 2 hooks from the inside of ink cartridge holder with tweezers, and push down the ink cartridge clamp (monochrome/color) to remove the clamps from ink cartridge holder.

Remove the 3 CBB (M3×11) screws and 3 plain washers securing the ink cartridge holder to

the carriage base, and then lift the ink cartridge holder out of the carriage base sliding a little toward left.

Ink Cart ridge Fixing Lever

Cartridge Holder

Figure 3-7. Ink Cartridge Clamp Removal

Note: The head flexible flat cables (FFCs) are secured to the ink cartridge holder with adhesive

tape. Tear the cables off the ink cartridge holder before removing the ink cartridge holder from the cartridge base.

3-8 REV.-A

Color Head

Black Head

Stylus Pro XL Disassembly and Assmbly

Remove the CBB (M3×11) screw (under the CR cap cover) and plain washer securing the monochrome and color printheads to the carriage base.

Rubber Cap

CBB (M3x11)

Head Fixing Sczew

CBB (M 3x 11)

Figure 3-8. Ink Cartridge Holder Removal

7 Pull the black or color head toward you, and disconnect the head FFC cable on the head driver

board (nozzle selector). Then remove the black or color head.

Figure 3-9. Printhead Removal

REV.-A 3-9

Disassembly and Assembly Stylus Pro XL

CAUTION

❏ Take proper measures to protect the printhead unit from static electricity, because the

driver IC is directly attached to the printhead unit.

❏ Never touch the printhead’s metallic nozzle cover surface. Handle it only by holding the

edges of the printhead.

❏ When you replace the printhead or the printer mechanism, you must replace the block

resistor at location RM4 (for Micro Mode - Color (R-No.)), RM5 (for Normal Mode -

Color (M-No.)), RM11 (for Micro Mode - Monochrome (R-No.)), and RM12 (for Normal

Mode - Monochrome (M-No.)) on the C162 MAIN Board. (Every spare printhead or

spare printer mechanism comes

with a block resistor that is specifically selected for each printhead. (Refer to Table 3-2.)

Table 3-2. Insertion Location of the Block Resistors

Mode Head Indication No. Location

Normal

Micro

Monochrome Color Monochrome Color

M-×× M-×× R-×× × R-×× ×

RM12 RM5 RM11 RM4

3-10 REV.-A

Spacer Setting Locations

Spacer

Head Nose

(For Black Head)

Stylus Pro XL Disassembly and Assmbly

REQUIRED ADJUSTMENT

❏ When removing or changing the black head, the following adjustments are needed.

1. Black head angle adjustment (see Section 4.1.4).

2. Black - Color head vertical adjustment (see Section 4.1.5).

3. Head gap adjustment (see Section 4.1.3).

4. Bidirectional alignment adjustment (see Section 4.1.2).

❏ When removing or changing the color head, the following adjustments are needed.

1. Color head angle adjustment (see Section 4.1.6).

2. Black - Color head vertical adjustment (see Section 4.1.5).

3. Head gap adjustment (see Section 4.1.3).

4. Bi-D alignment adjustment (see Section 4.1.2).

❏ When removing or changing both heads, the following adjustments are needed.

1. Color head angle adjustment (see Section 4.1.6).

2. Black head angle adjustment (see Section 4.1.4).

3. Black - Color head vertical adjustment (see Section 4.1.5).

4. Head gap adjustment (see Section 4.1.3).

5. Bidirection alignment adjustment (see Section 4.1.2).

WARNING

❏ When removing the color or black head, do not lose the spacer attached to each head.

This spacer modifies the angle error that occurs during manufacturing. Also, this spacer is different from the linear spacer or angular spacer. (See Chapter 4.)

Figure 3-10. Head Spacer Position

REV.-A 3-11

Disassembly and Assembly Stylus Pro XL

3.2.5.2 Carriage Unit Removal

1. Remove the printer mechanism (see Section 3.2.4).

2. Move the carriage to the left side of the printer while pressing the hook that fixes the carriage to the home position.

Remove the 2 CBN (O) (M3× 6) screws securing the eject frame to both side frames.

CBS(O) (M3x6)

CBS(O) (M30x11)

Eject Frame

Figure 3-11. Front Frame Removal

4. Remove the cartridge holder with ink cartridge from the carriage unit (see Section 3.2.5.1).

5. Release the carriage timing belt from the belt pulley while pressing the pulley lever.

6. Remove the grounding wire from the left side frame.

7. Remove the 2 parallelism adjustment bushings from both side frames.

8. Lift the carriage unit with the carriage guide shaft out of the printer mechanism.

Pulley Lever

Grounding Wire

Para llelism Adjust Bushing

Parallelism Adjust Bushi ng

Figure 3-12. Carriage Unit Removal

CAUTION

❏ Take proper measures to protect the printhead unit from static electricity, because the

driver IC is directly attached to the printhead unit.

❏ Never touch the printhead’s metallic nozzle cover surface. Handle it only by holding the

edges of the printhead.

❏ When you replace the printhead or the printer mechanism, you must replace the block

resistor. (see Table 3-2).

ADJUSTMENT REQUIRED

Platen gap adjustment (see Chapter 4).

3-12 REV.-A

CBS (M3x6)

Bottom F rame

Pump Unit

(1)

(2)

Disassembly and Assembly Stylus Pro Service Manual

3.2.5.3 Pump Unit Removal

1. Remove the printer mechanism. (See Section 3.2.4.)

2. Remove the carriage unit. (See Section 3.2.5.2.)

3. Remove the CBS (M3×6) screw securing the pump unit to the bottom frame.

4. Push the pump unit outward while releasing the tab at the bottom side of the pump unit, and then lift

up the pump unit.

Figure 3-14. Pump Unit Removal

3-12 Rev.A

Disassembly and Assembly Stylus Pro XL

3.2.5.4 Cleaner Head Replacement

1. Remove the printer mechanism (see Section 3.2.4).

2. Use tweezers to unhook the cleaner head from the hook on the cleaning lever.

CAUTION

Keeping the cleaner head clean is extremely important to keep the ink injection system working properly in the printhead, and it directly affects printing quality. Therefore, handle the cleaner head very carefully, and observe the following precautions.

■ Never touch the cleaner head with your bare hands.

■ When attaching the cleaner head to the pump unit, wear gloves and use clean tweezers

to handle it.

Cleaner Head

Hook

Cleaner Le ver

Figure 3-14. Cleaner Head Replacement

3-14 REV.-A

CBS (M3x6)

PF Motor

Stylus Pro XL Disassembly and Assmbly

3.2.5.5 CR Motor Removal

1. Remove the printer mechanism (see Section 3.2.4).

2. Release the timing belt (see section 3.2.5.2).

3. Remove the 3 screws securing the CR motor to the upper frame, and then remove the CR motor.

Screws

CR Motor

Figure 3-15. CR Motor Removal

3.2.5.6 PF Motor Removal

1. Remove the printer mechanism (see Section 3.2.4).

Remove the 2 CBN (M3×6) screws and then remove the PF motor.

Figure 3-16. PF Motor Removal

REV.-A 3-15

Sensor Cable

Carriage Home Position Sensor

Sensor Cable

PE Sensor

Botto m Frame

Stylus Pro Service Manual Disassembly and Assembly

3.2.5.7 Carriage Home Position Sensor Removal

1. Remove the printer mechanism. (See Section 3.2.4.)

2. Disconnect the sensor cable from the carriage home position sensor.

3. Unhook the 3 notches securing the carriage home position sensor to the upper frame. Then remove the carriage home position sensor.

Figure 3-18. Carriage Home Position Sensor Removal

3.2.5.8 PE Sensor Removal

1. Remove the printer mechanism. (See Section 3.2.4.)

2. Disconnect the connector for the PE sensor.

3. Rotate the printer mechanism upside down; use tweezers to release the 2 hooks securing the PE sensor to the paper feed roller assembly. Then remove the PE sensor.

Figure 3-19. PE Sensor Removal

Rev.A 3-15

CBB (M3 x8)

Tension Wire

Tensi o n R oll er Assem bl y

Eject Paper Roller

Tension Wire

Paper Feed Roller

Stylus Pro XL Disassembly and Assmbly

3.2.5.9 Paper Feed Roller Assembly Removal

1. Remove the printer mechanism (see Section 3.2.4).

2. Remove the carriage unit (see Section 3.2.5.2).

3. Remove the pump unit (see Section 3.2.5.3).

4. Remove the tension spring holding the tension roller assembly to the sub frame.

5. Remove the tension wire on the left side frame holding the tension roller assembly to the left side frame.

Remove a CBB (M3×8) screw securing the tension roller assembly to the sub frame and remove the tension roller assembly.

Figure 3-19. Tension Roller Assembly Removal

7. Release the 2 bushings securing the paper feed roller assembly to both the left side frame and the sub frame. Then remove the paper feed roller assembly.

REV.-A 3-17

Figure 3-20. Paper Feed Roller Assembly Removal

Disassembly and Assembly Stylus Pro XL

3.2.5.10 Upper Frame Removal

1. Remove the printer mechanism (see Section 3.2.4).

2. Remove the carriage unit (see Section 3.2.5.2).

3. Remove the E-ring securing the knob shaft to the sub frame; then remove the knob with the knob shaft from the right side frame.

Remove the 5 CBN (M3×5) screws securing the upper frame to both side frames or the sub frame. Then remove the upper frame with 4 PF support rollers.

5. Remove the upper frame with 4 PF support rollers.

Upper Frame

CBS (M3x5)

E-ring

CBS (M3x5)

Tension Spring

Knob

Figure 3-21. Upper Frame Removal

ASSEMBLY POINT

Assemble each straight end of torsion spring 6700s to attach to the center of the driven roller support.

Base Fram e

PF Support Roller

Tension Spring

Figure 3-22. Attaching the Torsion Spring

3-18 REV.-A

Chapter 4 Adjustments

Table of Contents

4.1 OVERVIEW 4-1

4.1.1 DestinationDataWritingOperation..............................4-2

4.1.2 Bi-D(BidirectionalPrinting)AlignmentAdjustment..................4-3

4.1.3 HeadGapAdjustment(BlackandColorHead).....................4-4

4.1.4 BlackHeadAngleAdjustment..................................4-5

4.1.5 Black-ColorHeadVerticalAdjustment............................4-9

4.1.6 ColorHeadAngleAdjustment.................................4-12

4.1.7 PlatenGapAdjustment ......................................4-16

4.1.8 InternalTimerResetOperation................................4-17

List of figures

Figure4-1. HeadGapAdjustmentSample.............................4-4

Figure4-2. B-HeadAngleandLinear,AngularSpacer....................4-5

Figure 4-3. Spacer Kinds & Relation of the Shape and Thickness. . . . . . . . . . . 4-5

Figure4-4. BlackHeadAngleAdjustmentSample.......................4-6

Figure4-5. SpacerSlection.........................................4-6

Figure4-6. RemovingtheRubberCap................................4-7

Figure4-7. SpacerAngularReplacementMethod.......................4-8

Figure4-8. Black-ColorHeadVerticalAdjustConception .................4-9

Figure4-9. SpacerLinearSelectionSample............................4-9

Figure4-10. RemovingtheRubberCap..............................4-10

Figure4-11. SpacerLinearreplacementMethod.......................4-11

Figure 4-12. C-Head Angle and Spacer Angular Position. . . . . . . . . . . . . . . . . 4-12

Figure4-13. ColorHeadAngleConfirmationSample....................4-12

Figure 4-14. Relationship of the Shape and Thickness . . . . . . . . . . . . . . . . . . 4-13

Figure4-15. SpacerSelectjudgement...............................4-13

Figure4-16. RemovingtheRubberCap..............................4-14

Figure 4-17. Spacer Angular Replacement Method (YMC) . . . . . . . . . . . . . . . 4-15

Figure4-18. AdjustingthePaperGap................................4-16

Figure4-19. ConfirmingtheGap....................................4-17

List of Table

Table4-1. RequiredAdjustments....................................4-1

Table4-2. GapandAdjustmentDirection.............................4-16

Rev.-A 4-i

Stylus Pro XL Adjustments

4.1 OVERVIEW

This section describes adjustments required when the printer is disassembled and assembled after repair. Since this printer has both a black and color head, it needs new adjustments not required for previous printers. Refer to the following table to perform the appropriate adjustments.

WARNING

❏ Always perform the adjustments in the order indicated. ❏ After performing steps 1-5, perform a cleaning operation for the black and color

printheads. the cleaning operation is needed because printing sample patterns for the

head angle, Bi-D alignment, and the head gap increases the viscosity of the ink, and the

printer will not print the correct value. For instance if you replace the black head, you

must do the following adjustments in the order shown:

(1) Black head angle, (2) black-color head vertical, (3) head gap, (4) Bi-D alignment.

❏ After removing an ink cartridge, always install a new cartridge immediately. During

adjustments and testing, use cartridges designed exclusively for service (Monochrome: 1020626, CMY: 1020627).

Table 4-1. Required Adjustments

Service Performed Adjustment Needed

When replacing the M-4A60 printer mechanism

When replacing or disassembling the C162 MAIN board or printer mechanism

When replacing or disassembling the black head (board)

When replacing or disassembling the color head (board)

When replacing or disassembling both the color and black head

1. Bi-D alignment adjustment (see Section 4.1.2).

2. Head gap adjustment (see Section 4.1.3).

3. Internal timer reset operation (see Section 4.1.8).

1. Destination data writing operation (see Section 4.1.1).

2. Bi-D alignment adjustment (see Section 4.1.2).

3. Head gap adjustment (see Section 4.1.3).

1. Black h ead angle adjustment (see Section 4.1.4).

2. Black - Color head vertical adjustment (see Section 4.1.5).

3. Head gap adjustment (see Section 4.1.3).

4. Bi-D alignment adjustment (see Section 4.1.2).

1. Color head angle adjustment (see Section 4.1.6).

2. Black - Color head vertical adjustment (see Section 4.1.5).

3. Head gap adjustment (see Section 4.1.3).

4. Bi-D alignment adjustment (see Section 4.1.2).

1. Color head angle adjustment (see Section 4.1.6).

2. Black h ead angle adjustment (see Section 4.1.4).

3. Black - Color head vertical adjustment (see Section 4.1.5).

4. Head gap adjustment (see Section 4.1.3).

5. Bi-D alignment adjustment (see Section 4.1.2).

When replacing or disassembling the carriage unit

Rev. A 4-1

1. Platen gap adjustment (see Section 4.1.7).

Adjustments Stylus Pro XL

4.1.1 Destination Data Writing Operation

The setup value that specifies the printer destination is stored in the EEPROM on the C162 MAIN board. Therefore, this setup value must be written into the EEPROM when the MAIN board or EEPROM chip is replaced.

CAUTION

Before writing the destination data writing, set the interface to parallel.

1. Connect the PC to the target printer using a parallel interface cable and turn the printer on.

2. Execute BASIC on the PC, and run the program “VERxxx.BAS.” You see the following menu.

1. Destination Setting

2. Head Angle Confirmation Pattern Printing (Black Head Spacer Selection)

3. Head Vertical Position Confirmation

4. Head Gap Adjustment

5. Bi-D Adjustment

6. Internal Timer Reset

7. END

3. When the main menu appears, choose “Destination Setting” by typing 1 and Enter.

4. The main menu immediately disappears briefly and then reappears. (At this time, specific destination parameters, including the destination, interface mode, TOF value, and economy/condensed, are automatically written to the EEPROM.)

5. Choose “END” by typing 7 and ENTER. The next message appears on the display.

All parameters that you have specified so far are written to EEPROM upon power off.

Turn the printer OFF, Now!

6. Turn off the printer.

4-2 Rev. A

Stylus Pro XL Adjustments

4.1.2 Bi-D (Bidirectional Printing) Alignment Adjustment

The bidirectional alignment is required when the printer mechanism, main board, or printhead (board) is replaced. Performing this adjustment determines a compensation value to rectify any deviation in the print position. This deviation could be caused by the different print speeds, which are due to tolerances in the mechanical components, or to differences in print timing between odd-numbered lines and even-numbered lines in bidirectional printing. The printer stores the compensation data in the EEPROM on the C162 MAIN board and refers to this data when performing bidirectional printing.

1. Connect the PC to the target printer, and turn the printer on.

2. Execute BASIC on the PC and run the program “VERxxx.BAS.”

1. Destination Setting

2. Head Angle Confirmation Pattern Printing (Black Head Spacer Selection)

3. Head Vertical Position Confirmation

4. Head Gap Adjustment

5. Bi-D Adjustment

6. Internal Timer Reset

7. END

3. When the main menu appears, choose “Bi-D Adjustment” by typing 5 and ENTER.(Theprinter

prints a check pattern with a sample compensation value.)

4. The next menu appears on the display.

Input Bi-D value No. (-30=≤ No. ≤=30,If O.K, input [Y] key.)? _

5. If the sample print is not vertically aligned for both the odd-numbered and even-numbered

lines, enter a compensation value in the range from −30 to +30.

❏ Positive compensation value: Shifts the 2nd line to the left ❏ Negative compensation value: Shifts the 2nd line to the right

When the sample print becomes vertically aligned for both lines, press Y and ENTER;this returns you to the main menu.

6. Choose “END” by typing 7 and ENTER. The next message appears on the display.

All parameters that you have specified so far arewrittentoEEPROMuponpoweroff.

Turn the printer OFF, Now!

7. Turn off the printer.

Rev. A 4-3

Adjustments Stylus Pro XL

4.1.3 Head Gap Adjustment (Black and Color Head)

The head gap adjustment is required when the printer mechanism, main board, or printhead (board) is replaced or diassembled. This adjustment calibrates the head drive timing between the black and color head. If this adjustment is not made, the vertical alignment will not be completed.

1. Connect the PC to the target printer, and turn the printer on.

2. Execute BASIC on the PC and run the program “VERxxx.BAS.”

1. Destination S etting

2. Head Angle Confirmation Pattern P rinting (Black Head Spacer Selection)

3. Head Vertical Position Confirmation

4. Head Gap Adjustment

5. Bi-D Adjustment

6. Internal Timer Reset

7. END

3. When the main menu appears, choose “Head Gap Adjustment” by typing 4 and ENTER.(The

printer prints a check pattern with a sample compensation value.)

4. The printer prints a sample like the one shown in Figure 4-1.

5. If the sample print is not vertically aligned for both odd-numbered lines (black lines) and

even-numbered lines (magenta lines), enter a compensation value in the range from −16 to +16.

❏ Positive compensation value: Shifts the 2nd line to the left ❏ Negative compensation value: Shifts the 2nd line to the right

When both the black and magenta lines are vertically aligned, press Y and ENTER; this returns you to the main menu.

6.6. Choose “END” by typing 7 and ENTER. The next message appears on the display.

All parameters that you have specified so far arewrittentoEEPROMuponpoweroff.

7. Turn off the printer.

Head Gap Adjustment No. 0

Color (Magenta ) Line

Turn the printer OFF, Now!

Black Line

Figure 4-1. Head Gap Adjustment Sample

4-4 Rev. A

Black Head

(Angle Adjustment Concept)

Black Head (Reverse Side)

Head Base

Carriage

Angular Spacer

Linear Spacer

(Spacer Setting Position)

Stylus Pro XL Adjustments

4.1.4 Black Head Angle Adjustment

The black head angle adjustment is required when the black head is replaced or disassembled. If this adjustment is not correct, a white banding problem may occur, or the color head timing may not match the black head timing. The following figure illustrates the black head angle adjustment.

The black head angle is adjusted with linear and angular spacers. A linear spacer is attached to both sides of the head base, and an angular spacer is attached only to the right side of the head base. Spacers for the black head come in different shapes for the thickness needed. The following figure shows the relationship between the shape and thickness.

Figure 4-2. Black Head Angular and Linear Spacers

Angular Spacers (For Black Head)

Spacer Name Spacer NameThickness Thickness

angular spacer BK

angular spacer BK:B

angular spacer BK:C

angular spacer BK:D

angular spacer BK:E

0.05

0.10

0.15

0.20

0.25

Shape

Linear Spacers (Only Use for Black Head)

linear spacer K

linear spacer J

linear spacer I

linear spacer

linear spacer B

linear spacer C

linear spacer D

linear spacer E

linear spacer F

Shape

0.05

0.12

0.19

0.26

0.33

0.40

0.47

0.54

0.61

Rev. A 4-5

linear spacer G

linear spacer H

0.68

0.75

Figure 4-3. Types of Spacers and Relationship between

Shape and Thickness

Black Head Angle Adjustment

Adjustments Stylus Pro XL

1. Connect the PC to the target printer, and turn the printer on.

2. Execute BASIC on the PC and run the program “VERxxx.BAS.”

1. Destination S etting

2. Head Angle Confirmation Pattern P rinting (Black Head Spacer Selection)

3. Head Vertical Position Confirmation

4. Head Gap Adjustment

5. Bi-D Adjustment

6. Internal Timer Reset

7. END

3. When the main menu appears, choose “Head Angle Confirmation Pattern Printing” by typing

2 and ENTER. (The printer prints the check pattern, along with the sample name. )

WARNING

❏ When replacing both the black and color heads, always adjust the color head angle first.

The black head angle is based on the color head angle.

❏ After you replace the black head and print the black head angle pattern, you only have

to insert an angular spacer if the pattern is incorrect.

4. The printer prints a pattern like one in the following sample. Only the nozzles in rows A and D are fired (making it is easy to see the angle of the black head).

Figure 4-4. Black Head Angle Adjustment Sample

5. In the figure above, pay attention to position A. (Do not look at position B.)

6. Using the following flowchart, replace the angular spacer for the black head, which is under the right linear spacer. The procedure for this replacement is explained beginning with step 7.

Check p osit ion A.

Position A Position A

4-6 Rev. A

Replace the right angular spacer with a thinner one.

Figure 4-5. Spacer Selection

Replace the right angular spacer with a thicker one.

1: Push

Carriage Unit

Platen Gap Adjust Lev er

Linear Spac er

Black Head

Head Ba se

Angular Spacer

2: Replace

(Angular Spacer Replacement Position)

Stylus Pro XL Adjustments

7. Turn the printer power off now.

8. Manually move the carriage to the center while pressing the carriage lock lever, and remove the two ink cartridges.

9. Remove the rubber cap covering the head screw at the side of color ink cartridge. Then loosen (but do not remove) 3 screws. (Refer to Figure 4-6.)

Figure 4-6. Removing the Rubber Cap

WARNING

After replacing the spacer, always install new ink cartridges before returning the printer to the user. During this adjustment, use ink cartridges exclusively for service (Monochrome: 1020626, CMY: 1020627). You can reuse old ink cartridges for other purposes.

10. Replace the angular spacer for the black head with a new one, referring Figure 4-7. (Replace the angular spacer by using tweezers to push the head base toward the rear.)

Rev. A 4-7

1: Push

Carriage Unit

Platen Gap Adjust Lev er

Linear Spac er

Black Head

Head Ba se

Angular Spacer

2: Replace

(Angular Spacer Replacement Position)

Adjustments Stylus Pro XL

11. After replacing the angular spacer, reassemble the ink cartridge holder and reinstall the ink cartridges. Use the BASIC program to verify the angle of the black head. Confirm the angle by performing the steps 1 to 6 again, and if the angle is wrong, perform the adjustment again until the head angle is correct.

WARNING

❏ The angular spacer comes in five thicknesses. Continue performing this adjustment, by

changing the black head angle is correct.

❏ When inserting an angular spacer, always place the angular spacer on the linear spacer.

Figure 4-7. Angular Spacer Replacement Method

4-8 Rev. A

#16

#1#2

#61

#62

#63

#64

Carriage Unit

Adjust

Color Head

Black Head

Vertical Position

Magenta

Cyan

Yellow

Stylus Pro XL Adjustments

4.1.5 Black - Color Head Vertical Adjustment

This adjustment calibrates the vertical position between the black head and the color head. Align the top nozzles (both nozzle #1 on the black head and nozzle #1 on the color head). You can make this adjustment by using only the linear spacers for the black head. This adjustment is required when the black head or the color head is replaced or disassembled. The following figure illustrates this adjustment.

Figure 4-8. Black-Color Head Vertical Adjustment Concept

1. Connect the PC to the target printer, and turn the printer on.

2. Execute BASIC on the PC and run the program “VERxxx.BAS”.

1. Destination Setting

2. Head Angle Confirmation Pattern P rinting (Black Head Spacer Selection)

3. Head Vertical Position Confirmation

4. Head Gap Adjustment

5. Bi-D Adjustment

6. Internal Timer Reset

7. END

3. When the main menu appears, choose “Head Vertical Position Confirmation” by typing 3 and ENTER. (The printer prints the check pattern, along with the sample name.)

WARNING

When replacing the black head, always adjust the black head angle first, because the blackcolor head vertical adjustment is based upon the black head angle.

2-3 BLACK HEAD SPACER SELECTION

Magenta

-5 -4

-3 -2

-1

OK (0)

Black

+1 +2 +3 +4

Figure 4-9. Linear Spacer Selection Sample

Rev. A 4-9

Adjustments Stylus Pro XL

4. In Figure 4-10, the vertical position is correct when both the magenta line and the black line

are aligned (as shown in position OK (0)). If the vertical position is correct, turn off the printer. If the black and magenta lines are not aligned, perform the vertical adjustment as described in steps 5-10.

WARNING

❏ The number shown in the sample indicates the thickness level compared to the current

linear spacer. (See * .) There are 11 linear spacers with 11 different thicknesses.

❏ The linear spacer is attached by two pieces, one on each side of the head base. Therefore,

when you need to replace one linear spacer, always replace both linear spacers at the

same time.

❏ When replacing the linear spacer, place it under the angular spacer.

* If necessary, replace the linear spacer. For instance, if your pattern is similar to the pattern

shown under –2, replace the linear spacer with a thinner linear spacer. If your pattern is similar to the pattern shown under 2, replace the linear spacer with a thicker spacer.

5. Turn the printer off.

6. Move the carriage to the center while pressing the carriage lock lever, and remove the two ink cartridges.

Rubber Cap

Screw 1

Screw 2

Screw 3

Figure 4-10. Removing the Rubber Cap

7. Remove the rubber cap that covering a head screw at the side of color ink cartridge and then loosen (but do not remove) 3 screws. (Refer to the figure below.)

WARNING

After replacing the spacer, always install new ink cartridges before returning the printer to the user. During adjustment, use the ink cartridges exclusively for service (Monochrome: 1020626, CMY: 1020627). You can reuse the old ink cartridges for other purposes.

4-10 Rev. A

1: Push

Carriage Un it

Platen G ap Adjust Lever

2: Replace

Black Head

Head Base

Linear Spacer x 2

(Linear Spacer Replacement Position)

Angular Spacer

Stylus Pro XL Adjustments

8. Change the linear spacers (2 spacers for the monochrome head only) with new ones, referring the figure below. (Replace linear spacers using tweezers to push the head base toward the rear.)

Figure 4-11. Linear Spacer Replacement Method

9. Rerun the BASIC program, and choose the “Head Vertical Position Confirmation” by typing 3 and ENTER; then confirm that the sample print is correct. If the sample is incorrect, change the thickness of the linear spacer and perform this adjustment again until the two black and magenta lines are aligned at the position “OK (0).”

10. When you complete this adjustment, exit the BASIC program and turn off the printer.

Rev. A 4-11

4.1.6 Color Head Angle Adjustment

The color head angle adjustment is required when the color head is replaced or disassembled. If this adjustment is not correct, a white banding problem may occur, or the black head timing may not match the color head timing. The following figure illustrates the color head angle adjustment.

The color head angle is adjusted by the angular spacer. The angular spacer is attached only to the left side of the head base.

1. Connect the PC to the target printer, and turn the printer on.

2. Execute BASIC on the PC and run the program “VERxxx.BAS”.

1. Destination S etting

2. Head Angle Confirmation Pattern P rinting (Black Head Spacer Selection)

3. Head Vertical Position Confirmation

4. Head Gap Adjustment

5. Bi-D Adjustment

6. Internal Timer Reset

7. END

3. When the main menu appears, choose “Head Angle Confirmation Pattern Printing” by typing

2 and ENTER. (The printer prints the check pattern with the sample name.)

WARNING

When replacing both the black head and color head, always adjust the color head angle first. The black head angle and the black-color head vertical position adjustments are based on the color head angle adjustment.

0.30

0.35

0.40

0.45

0.50

Angular Spacer (for Color Head)

Spacer Name

Thickness

Shape

angular spacer YMC

angular spacer YMC-B

angular spac er YM C-C

angular spacer YMC-D

angular spacer YMC-E

(A) (B ) (A) (B)

Check

positions A, B

Positio n A, B

Position A, B

Replace the right angular spacer with a thicker one.

Replace the right angular spacer with a thinner one

Magenta

Cyan

Magenta

Cyan

Stylus Pro XL Adjustments

Angular spacers for the color head come in five thicknesses, each having its own shape. The following figure shows the relationship between the shape and thickness. Since the color head is not equipped with a linear spacer, the angle adjustment is decided only by the angular spacer (specifically designed for the color head), which is placed under the left side of the head base.

Figure 4-14. Relationship between the Shape and Thickness

4. In Figure 4-13, pay attention to the position of A and B while you reset the left angular spacer. The replacement procedure is explained beginning in step 5.

5. Turn off the printer now.

6. Move the carriage to the center manually, and loosen (but do not remove) the screw securing the color head to the carriage.

Rev. A 4-13

Figure 4-15. Spacer Selection

Adjustments Stylus Pro XL

Rubber Cap

Screw 1

Screw 2

Screw 3

Figure 4-16. Removing the Rubber Cap

Remove the rubber cap covering the head screw at one side of color ink cartridge. Then loosen (but do not remove) 3 screws. (Refer to the figure below.)

8. Replace the angular spacer on the left side with a new one, referring the figure below. (Replace the angular spacer using tweezers to push the head base toward the rear.)

4-14 Rev. A

Stylus Pro XL Adjustments

9. Rerun the BASIC program and choose “Head Angle Confirmation Pattern” again by typing 2 and ENTER. Then verify that the confirmation sample is correct.

Carriage Unit

1: Push

Head Base

Color H ead

Angular Spacer (one side on ly)

Platen Gap Adjust Lever

2: Replace

Figure 4-17. YMC Angular Spacer Replacement

10. If the sample is incorrect, repeat steps 5-9 until the upper lines in the sample are aligned with one another and the lower lines in the sample are exactly equidistant to one another (as shown at B in Figure 4-15).

11. When you complete this adjustment, turn off the printer.

Rev. A 4-15

Attach the thickness gauge under the PF pinch roller unit.

Left Adjustment Position

Right Adjustment Position

Paper Guide P late

Bushing

Pump Un it

Eject Frame

Thickness Gau ge

Thickness Gauge

Front

Fron t Frame

PF Pinch Roller Unit

Attach ment Point

Tension Roller

Thickness Gau ge

Paper G uide

Platen

Adjustments Stylus Pro XL

4.1.7 Platen Gap Adjustment

This adjustment is required when the carriage unit is replaced or removed from the printer mechanism. Adjust the distance between the printhead nose and the paper surface to 1.1 mm.

1. Attach a thickness gauge (commercially available) to the left side adjustment position on the paper guide plate, as shown in the figure below, so that one side hooks the paper feed pinch roller unit.

2. Move the carriage unit manually onto the thickness gauge.

Table 4-2. Gap and Adjustment Direction

Gap between Head Nose and Gauge Surface Left Bushing Right Bushing

Narrow CW CCW Spread CCW CW

3. Rotate the parallelism adjustment bushing, attached to the left and right ends of the carriage guide shaft, when the black and color printheads contact the thickness gauge.

4. After attaching the printheads to the gauge surface, verify that the gap between the carriage roller and the front frame is less than 0.04 mm. (See Figure 4-16.)

5. Attach the 1.1 mm thickness gauge to the right side adjustment position on the paper guide plate, as shown below, so that one side hooks the paper feed pinch roller unit.

Note: When checking the gap between the carriage roller and the front frame, use the thickness

gauge or the paper guide plate. If the gap is correct the gauge cannot be installed into the gap. If the gap is incorrect, the gauge can be inserted in the gap.

4-16 Rev. A

Figure 4-18. Adjusting the Platen Gap

0.04 mm

Carriage Roller

Thickness Gauge

Gap

Eject Frame

Stylus Pro XL Adjustments

6. Move the carriage manually to the right adjustment position and repeat steps 3 and 4, referring to Figures 4-18 and 4-19.

Figure 4-19. Confirming the Gap

4.1.8 Internal Timer Reset Operation

This operation is required when the M-4A60 printer mechanism is replaced. There are 6 timers in this printer:

1. Refresh timer

2. Timer (monochrome and CMY)

3. Flushing level decision timer

4. False absorbing timer

5. Total print timer

6. PAUSE timer

When the printer mechanism is replaced, reset the timers as described here:

1. Connect the PC to the target printer, and turn on the printer.

2. Execute BASIC on the PC and run the VERxxx.BAS program.

1. Destination Setting

2. Head Angle Confirmation Pattern Printing (Black Head Spacer Selection)

3. Head Vertical Position Confirmation

4. Head Gap Adjustment

5. Bi-D Adjustment

6. Internal Timer Reset

7. END

3. When the main menu appears, choose “Internal timer reset” by typing 6 and ENTER.This

resets the internal timer. The following message then appears.

All parameters of the internal timer are now reset. Press Y and ENTER to return to the main menu.

4. Press Y and ENTER.

5. Press 7 and ENTER.

6. Turn off the printer.

Rev. A 4-17

Chapter 5 Troubleshooting

Table of Contents

5.1 OVERVIEW 5-1

5.2 UNIT LEVEL TROUBLESHOOTING 5-3

5.2.1 Printer Does Not Operate at Power on. . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

5.2.2 Error is Detected. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

5.2.3 Failure Occurs During Printing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

5.2.4 Printer Does Not Feed the Paper Correctly . . . . . . . . . . . . . . . . . . . . . . 5-7

5.2.5 Control Panel Operation is Abnormal . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

5.3 UNIT REPAIR - C137 PSB/PSE BOARD 5-9

5.4 UNIT REPAIR - C164 MAIN BOARD 5-10

5.5 UNIT REPAIR - PRINTER MECHANISM (M-4A11) 5-12

LIST OF FIGURES

Figure 5-1. Troubleshooting Process Flowchart. . . . . . . . . . . . . . . . . . . . . . . 5-1

LIST OF TABLES

Table 5-1. Motor Coil Resistance Test Points. . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Table 5-2. Sensor Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Table 5-3. Sensor Test Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Table 5-4. Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Table 5-5. Symptoms and Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Table 5-6. Repair of the C137 PSB/PSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

Table 5-7. Repair of the C164 MAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

Table 5-8. Repair of the Printer Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

Rev.-A 5-i

START

UNIT LEVEL T R OUBL ESHOOT ING

UNIT REPAI R [C13 7 PSB/PS E BOAR D]

UNIT REPAIR [C162 MAI N BOARD]

UNIT REPAIR [M-4A60 MECHANISM]

ASSEMBLY AND ADJUS TM EN T

END

Stylus Pro XL Troubleshooting

5.1 OVERVIEW

The printer may exhibit different symptoms for the same problem, which makes troubleshooting more difficult. However, this section provides simple and effective ways to facilitate troubleshooting. The following flowchart illustrates the main steps of the troubleshooting process.

Figure 5-1. Troubleshooting Process Flowchart

Sensor Point Signal Level Status

PE Sensor

BCO Sensor

CCO Sensor

HP Sensor

TH Sensor

Table 5-1. Motor Resistances

Motor Resistance Range Temperature

CR Motor PF Motor

10.0Ω±10% At 25 °C(77°F)

11.5Ω±10% At 25 °C(77°F)

Table 5-2. Sensor Status

CN8

Pin1(PE)toPin2

(GND)

CN11

Pin 8 (BCO) to

Pin7(GND)

CN12

Pin8(CCO)to

Pin7(GND)

CN9

Pin3(HPV)to

Pin2(GND)

CN10

Pin10(SW0-5)to

Pin1(GND)

H(5V)

L (GND)

Paper exists No paper (paper end)

L (GND) Black cartridge exists

H (5 V) No black cartridge

L (GND)

H(5V)

Color cartridge exists No color cartidge

L At home position (HP)

Out of HP Change the pulse width of

Analog data

the charge pulse for the common driver circuit

Rev. -A 5-1

Troubleshooting Stylus Pro XL

Table 5-3. Error Codes

LED

Error

Status

Paper out On On

Data

Paper

Out

No Ink

Cartridge

Economy Condensed Pause

Recovery

Load paper in the tray, press Load/

Eject, and then the Pause button.

No ink

cartridge

Paper jam Blinks

Maintenance

request

Carriage

error

Blinks Blinks Blinks Blinks Blinks Blinks

Blinks Blinks

On On

Install the new ink cartridge and press the Pause button.

Load paper and press Pause and Load/Eject buttons.

Service maintenance request. (Change the waste ink drain tank and reset the counter.)

Turn off the printer andturnitonagain.

5-2 Rev. -A

Stylus Pro XL Troubleshooting

5.2 UNIT LEVEL TROUBLESHOOTING

When a problem occurs, you can identify the defective unit based on the symptoms exhibited. The table below lists the symptoms of certain problems. Once the problem is identified, refer to the flowchart that corresponds to the problem.

Table 5-4. Symptom and Problem

Symptom Problem Flowchart No.

Printer does not operate at power on Error is detected ❏ Error is indicated by LED indication.

Failure occurs during printing

Printer does not feed the paper correctly

Control panel operation is abnormal ❏ No response to button access.

❏ LEDs do not light up. ❏ Printer mechanism does not operate.

❏ Printing is not performed. ❏ Abnormal printing (missing dots, etc.) ❏ Print quality is poor

❏ No paper is fed. ❏ Paper feed is irregular. ❏ Paper jam occurs.

5.2.1

5.2.2

5.2.3

5.2.4

5.2.5

Rev. -A 5-3

Troubleshooting Stylus Pro XL

5.2.1 Printer does not operate at power on.

START

Is the AC

input voltage

correct?

YES

Has fuse

(F1) on the C137

PSB/PSE

blown?

Check the ou tput voltage of the C137 PSB/PSE at CN 2.

YES

Use the correc t input voltage.

Replace the fuse and disc onnect CN5 on t he C162 MAIN board.

Does the

fuse blow again

at power on?

YES

Is the output

voltage correct?

YES

Replace the C1 62 MAIN board.

Is the problem corrected

YES

END

Replace the C137 PSB/P SE board

Check motors and drivers. Refer to the section describing repair of the printer mechanism.

5-4 Rev. -A

Stylus Pro XL Troubleshooting

5.2.2 Error is detected.

START

Identify the type of error indicated. (See Table 5-3.)

Turn the printer

Carriage error

YES

off and try to move the carriage manually.

No ink cartriage

Waste ink drain tank overflow

Replace the waste ink absorbing material, and reset the protect counter. (See Chapter 6.)

YES

Check ink cartridge sensor and, if bad, replace.

Replace the ink cartridge with a new one.

Does error

occur again?

carriage mo ve

Check CR motor and dr iver s. If t hey are OK, replace the C162 MAIN b oar d.

YES

Refer to the section describing repair of the printer mechanism.

Does th e

smoothly?

YES

Is the

problem

corrected?

END

Rev. -A 5-5

Replace the C162 MAIN board.

START

END

YES

Run the self-test .

Connect the cables correctly.

Perform the color or black head cleanin g .

Adjust the bidirectional print alignment or readjust the head arrangement adjustment . (See Chapter 4.)

See the section describing repair of the printer mechanism.

Check all motors, drivers, and printhead for shorts. If they are OK, replace the C162 MAIN board.

Is the problem

corr ected?

Is print

quality bad?

Does the self-

test print?

Is the problem

corr ected?

Is the pro blem

corr ect ed?

Are all cables

connected to the C162

MAIN board firmly?

Troubleshooting Stylus Pro XL

5.2.3 Failure occurs during printing.

5-6 Rev. -A

Stylus Pro XL Troubleshooting

5.2.4 Printer does not feed the paper correctly.

START

Is paper loaded

in the sheet feeder

correctly?

YES

Does a

paper jam

occur?

Check the PF motor and driver. If OK, replace the C162 MAIN board.

Is the problem

corr ected?

YES

Load the paper correctly.

Verify that the paper path is clear. Also conf ir m that there ar e n o foreig n object s t h a t m ay interf e r e with p aper moveme n t.

Perform the PF roller cleaning with the cleaning sheet.

Is the problem

corrected?

YES

END

YES

See the section describing repair of the printer mechanism.

Is the problem

corr ected?

END

Rev. -A 5-7

Epson 4004677 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Chapter 1 Product Description

Chapter 2 Operating Principles

Chapter 3 Disassembly and Assembly

Chapter 4 Adjustments