Epson C58, C59, ME2, C79, D78 Service manual

SERVICE MANUAL

Color Inkjet Printer

EPSON Stylus C58/C59/ME 2

EPSON Stylus C79/D78

EPSON Stylus C90/C91/C92/D92

SEIJ06-003

Notice:

All rights reserved. No part of this manual may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of SEIKO EPSON CORPORATION.

The contents of this manual are subject to change without notice.

All effort have been made to ensure the accuracy of the contents of this manual. However, should any errors be detected, SEIKO EPSON would greatly appreciate being informed of them.

The above not withstanding, SEIKO EPSON CORPORATION can assume no responsibility for any errors in this manual or the consequences thereof.

EPSON is a registered trademark of SEIKO EPSON CORPORATION.

General Notice:	Other product names used herein are for identification purpose only and may be trademarks or registered trademarks of their
	respective owners. EPSON disclaims any and all rights in those marks.

Copyright © 2006 SEIKO EPSON CORPORATION.

Imaging Products CS, PL & Environmental Management

	PRECAUTIONS
Precautionary notations throughout the text are categorized relative to 1) personal injury and 2) damage to equipment.
DANGER	Signals a precaution which, if ignored, could result in serious or fatal personal injury. Great caution should be exercised in performing procedures preceded by
	DANGER Headings.
WARNING	Signals a precaution which, if ignored, could result in damage to equipment.

The precautionary measures itemized below should always be observed when performing repair/maintenance procedures.

DANGER

1.ALWAYS DISCONNECT THE PRODUCT FROM THE POWER SOURCE AND PERIPHERAL DEVICES PERFORMING ANY MAINTENANCE OR REPAIR PROCEDURES.

2.NO WORK SHOULD BE PERFORMED ON THE UNIT BY PERSONS UNFAMILIAR WITH BASIC SAFETY MEASURES AS DICTATED FOR ALL ELECTRONICS TECHNICIANS IN THEIR LINE OF WORK.

3.WHEN PERFORMING TESTING AS DICTATED WITHIN THIS MANUAL, DO NOT CONNECT THE UNIT TO A POWER SOURCE UNTIL INSTRUCTED TO DO SO. WHEN THE POWER SUPPLY CABLE MUST BE CONNECTED, USE EXTREME CAUTION IN WORKING ON POWER SUPPLY AND OTHER ELECTRONIC COMPONENTS.

4.WHEN DISASSEMBLING OR ASSEMBLING A PRODUCT, MAKE SURE TO WEAR GLOVES TO AVOID INJURY FROM METAL PARTS WITH SHARP EDGES.

WARNING

1.REPAIRS ON EPSON PRODUCT SHOULD BE PERFORMED ONLY BY AN EPSON CERTIFIED REPAIR TECHNICIAN.

2.MAKE CERTAIN THAT THE SOURCE VOLTAGE IS THE SAME AS THE RATED VOLTAGE, LISTED ON THE SERIAL NUMBER/RATING PLATE. IF THE EPSON PRODUCT HAS A PRIMARY AC RATING DIFFERENT FROM AVAILABLE POWER SOURCE, DO NOT CONNECT IT TO THE POWER SOURCE.

3.ALWAYS VERIFY THAT THE EPSON PRODUCT HAS BEEN DISCONNECTED FROM THE POWER SOURCE BEFORE REMOVING OR REPLACING PRINTED CIRCUIT BOARDS AND/OR INDIVIDUAL CHIPS.

4.IN ORDER TO PROTECT SENSITIVE MICROPROCESSORS AND CIRCUITRY, USE STATIC DISCHARGE EQUIPMENT, SUCH AS ANTI-STATIC WRIST STRAPS, WHEN ACCESSING INTERNAL COMPONENTS.

5.REPLACE MALFUNCTIONING COMPONENTS ONLY WITH THOSE COMPONENTS BY THE MANUFACTURE; INTRODUCTION OF SECOND-SOURCE ICs OR OTHER NON-APPROVED COMPONENTS MAY DAMAGE THE PRODUCT AND VOID ANY APPLICABLE EPSON WARRANTY.

6.WHEN USING COMPRESSED AIR PRODUCTS; SUCH AS AIR DUSTER, FOR CLEANING DURING REPAIR AND MAINTENANCE, THE USE OF SUCH PRODUCTS CONTAINING FLAMMABLE GAS IS PROHIBITED.

About This Manual

This manual describes basic functions, theory of electrical and mechanical operations, maintenance, and repair procedures of the printer.

The instructions and procedures included herein are intended for experienced repair technicians, and attention should be given to the precautions on the preceding page.

Manual Configuration

This manual consists of six chapters and Appendix.

CHAPTER 1.PRODUCT DESCRIPTIONS

Provides a general overview and specifications of the product.

CHAPTER 2.OPERATING PRINCIPLES

Describes the theory of electrical and mechanical operations of the product.

CHAPTER 3.TROUBLESHOOTING

Describes the step-by-step procedures for the troubleshooting.

CHAPTER 4.DISASSEMBLY / ASSEMBLY

Describes the step-by-step procedures for disassembling and assembling the product.

CHAPTER 5.ADJUSTMENT

Provides Epson-approved methods for adjustment.

CHAPTER 6.MAINTENANCE

Provides preventive maintenance procedures and the list of Epsonapproved lubricants and adhesives required for servicing the product.

APPENDIX Provides the following additional information for reference:

•Exploded Diagram

•Circuit Diagrams

Symbols Used in this Manual

Various symbols are used throughout this manual either to provide additional information on a specific topic or to warn of possible danger present during a procedure or an action. Be aware of all symbols when they are used, and always read NOTE, CAUTION, and WARNING messages.

Indicates an operating or maintenance procedure, practice or condition WARNING that, if not strictly observed, could result in injury.

Indicates an operating or maintenance procedure, practice, or condition CAUTION that, if not strictly observed, could result in damage to, or destruction of,

equipment.

CHECK

May indicate an operating or maintenance procedure, practice or

POINT condition that is necessary to accomplish a task efficiently. It may also provide additional information that is related to a specific subject, or

comment on the results achieved through a previous action.

ADJUSTMENT REQUIRED

Indicates an operating or maintenance procedure, practice or condition that is necessary to maintain the product’s quality.

Indicates that a particular task must be carried out according to a certain standard after disassembly and before re-assembly, otherwise the quality of the components in question may be adversely affected.

		Revision Status
Revision	Date of Issue	Description
A	August 7, 2006	First Release
B	December 1, 2006	[Chapter 4]
		• “4.3.1 Upper Housing (p36) ”
		Note when replacing the Base Frame is added to the reassembly procedure.
		[Chapter 7]
		• “7.1 Exploded Diagrams (p82) ” are updated.
C	May 1, 2007	[All chapters]
		• The model name; EPSON Stylus C90/C91/C92/D92 are added.
		[Chapter 1]
		• “1.2.3 Ink Cartridge (p13) ” is updated.
		[Chapter 2]
		• “2.3 Electrical Circuit Operating Principles (p22) ” is updated.
		[Chapter 4]
		• “4.5.6 Ink System removal (p48) ”
		Caution during inserting the Ink Tube into the connector is added.
		• “4.5.8 EJ Frame Assy/EJ Roller (p51) ”
		Reassembly procedure of the Grounding Spring, Frame is added.
		[Chapter 5]
		• “5.2.1 Head angular adjustment (p72) ”
		Print samples made by the adjustment program for Stylus C90/C91/C92/D92 is added.
		[Chapter 6]
		• “6.1.3 Lubrication (p78) ”
		Lubrication point for Stylus C90/C91/C92/D92 is added.
		[Chapter 7]
		• “7.1 Exploded Diagrams (p82) ”
		Exploded Diagrams for Stylus C90/C91/C92/D92 are added.
		• “7.3 Circuit Diagrams (p96) ”
		Circuit diagram of Stylus C90/C91/C92/D92; C683 Main is added.

EPSON Stylus C58/C59/ME 2 Stylus C79/D78/C90/C91/C92/D92

Revision C

Contents

Chapter 1 PRODUCT DESCRIPTION

1.1	Features.................................................................................................................		9
1.2	Printer Specifications..........................................................................................		10
	1.2.1	Paper Support ..........................................................................................	11
	1.2.2	Printable Area Size and Margins.............................................................	12
	1.2.3	Ink Cartridge............................................................................................	13
	1.2.4 Black Ink Save Mode ..............................................................................		14
1.3	Interface..............................................................................................................		14
	1.3.1	USB Interface ..........................................................................................	14
1.4	General Specifications........................................................................................		15
	1.4.1	Electrical Specifications ..........................................................................	15
	1.4.2	Acoustic Noise.........................................................................................	15
	1.4.3	Safety Approvals .....................................................................................	15
	1.4.4 CE Marking .............................................................................................		15
	1.4.5 Environmental Performance ....................................................................		15
	1.4.6	Durability.................................................................................................	15
1.5	Control Panel ......................................................................................................		16
	1.5.1	Buttons.....................................................................................................	16
	1.5.2	Indicators .................................................................................................	16
	1.5.3	Errors and Panel Status............................................................................	17
	1.5.4	Printer Initialization.................................................................................	17

Chapter 2 OPERATING PRINCIPLES

2.1	Overview ............................................................................................................	19
2.2	Printer Mechanism..............................................................................................	19
	2.2.1 Printhead Specifications ..........................................................................	20
	2.2.2 Carriage Mechanism................................................................................	20
	2.2.3 Paper Feeding Mechanism ......................................................................	21
	2.2.4 Ink System Mechanism ...........................................................................	22
2.3	Electrical Circuit Operating Principles...............................................................	22
	2.3.1 C664 PSB/PSE Board..............................................................................	23
	2.3.2 C664/C683 Main Board ..........................................................................	23

Chapter 3 TROUBLESHOOTING

3.1	Overview ............................................................................................................		27
	3.1.1	Specified Tools........................................................................................	27
	3.1.2	Preliminary Checks .................................................................................	27
3.2	Troubleshooting With LED Error Indications....................................................		28
3.3	Troubleshooting for Motors and Sensors ...........................................................		29

Chapter 4 DISASSEMBLY/ASSEMBLY

4.1	Overview ............................................................................................................		31
	4.1.1	Precautions ..............................................................................................	31
	4.1.2	Tools........................................................................................................	32
	4.1.3 Screws .....................................................................................................		32
	4.1.4 Work Completion Check.........................................................................		33
	4.1.5	Caution After Repair ...............................................................................	33
	4.1.6	Procedural Differences between the Models...........................................	34
4.2	Disassembly Procedures.....................................................................................		35
4.3	Removing Housing.............................................................................................		36
	4.3.1 Upper Housing ........................................................................................		36
4.4	Removing Board.................................................................................................		38
	4.4.1 Main Board..............................................................................................		38
4.5	Disassembling Printer Mechanism.....................................................................		40
	4.5.1 Hopper .....................................................................................................		40
	4.5.2	Printhead..................................................................................................	41
	4.5.3 CR Scale ..................................................................................................		44
	4.5.4 CR Motor.................................................................................................		45
	4.5.5 CR Unit/Timing Belt ...............................................................................		46
	4.5.6 Ink System removal.................................................................................		48
	4.5.7 Power Supply Board................................................................................		50
	4.5.8 EJ Frame Assy/EJ Roller.........................................................................		51
	4.5.9 Main Frame .............................................................................................		53
	4.5.10 LD Roller/ASF Unit ..............................................................................		56
	4.5.11 Waste Ink Pads ......................................................................................		58

6

EPSON Stylus C58/C59/ME 2 Stylus C79/D78/C90/C91/C92/D92					Revision C
	4.5.12	PF Roller................................................................................................		59
	4.5.13 PF Motor................................................................................................			60
4.6	Procedure Specific to Stylus C58/C59/ME 2 .....................................................			61
	4.6.1	Printhead..................................................................................................		61
	4.6.2 Waste Ink Pads ........................................................................................			64
4.7	The Shortest Way to Remove the Main Frame. .................................................			65
Chapter 5			ADJUSTMENT
5.1	Adjustment Items and Overview ........................................................................			67
	5.1.1	Servicing Adjustment Item List...............................................................		67
	5.1.2	Replacement Part Adjustment Items .......................................................		70
5.2	Adjustment by Using Adjustment Program .......................................................			72
	5.2.1	Head angular adjustment .........................................................................		72
	5.2.2 Top Margin Adjustment ..........................................................................			73
	5.2.3 Bi-D Adjustment .....................................................................................			73
	5.2.4	First Dot Adjustment ...............................................................................		74
	5.2.5 PF Band Adjustment................................................................................			74
Chapter 6			MAINTENANCE
6.1	Overview		............................................................................................................	76
	6.1.1	Cleaning...................................................................................................		76
	6.1.2	Service Maintenance ...............................................................................		76
	6.1.3	Lubrication ..............................................................................................		78
Chapter 7			APPENDIX
7.1	Exploded Diagrams ............................................................................................			82
7.2	Parts List.............................................................................................................			95
7.3	Circuit Diagrams ................................................................................................			96

7

C H A P T E R

1

PRODUCT DESCRIPTION

EPSON Stylus C58/C59/ME 2 Stylus C79/D78/C90/C91/C92/D92

Revision C

1.1 Features

Main features of Stylus C58/C59/ME 2 and Stylus C79/D78/C90/C91/C92/D92

High quality color printing

Maximum print resolution: 5760 (H) x 1440 (V) dpi

4-color printing (Yellow, Magenta, Cyan, and Black)

Separate ink cartridges for each color

Build-in ASF (Auto Sheet Feeder)

Holds 80 cut sheets (24 lb, 90 g/m2)

Holds 20 special media (EPSON Premium Glossy Photo Paper, L (3R) size)

USB 1.1 compatible

Windows/Macintosh supported

Borderless printing

The difference between the Stylus C58/C59/ME 2 and Stylus C79/D78/C90/C91/ C92/D92

The main difference is the ink type as shown in the table below.

Table 1-1. Difference between the Models

Model	Ink Type
Stylus C58/C59/ME 2	Dye-based ink which has a good distinction of color
Stylus C79/D78/C90/	Pigment-based ink that provides the water, light and
C91/C92/D92	ozone resistant

Dimension

With the output tray and paper support closed Width: 435 mm (17.1 inches)

Depth: 219 mm (8.6 inches) Height: 165 mm (6.5 inches)

Maximum dimension

Width: 435 mm (17.1 inches) Depth: 418 mm (16.5 inches) Height: 289 mm (11.4 inches)

Weight

2.8 kg (6.2 lb) without ink cartridges

Stylus C79/D78/C90/C91/C92/D92

Stylus C58/C59/ME 2

Figure 1-1. External View

PRODUCT DESCRIPTION

Features

9

EPSON Stylus C58/C59/ME 2 Stylus C79/D78/C90/C91/C92/D92

Revision C

1.2 Printer Specifications

	Table 1-2. Printer Specifications
Item			Specification
Print method		On-demand ink jet
Nozzle configuration		Black: 90 nozzles
		Color: 87 nozzles (29 each cartridge: cyan, magenta, yellow)
Print direction		Bidirectional with logic seeking
		Horizontal x Vertical (dpi)
Print resolution		• 360 x 120	• 720 x 720
		• 360 x 360	• 1440 x 720
		• 360 x 720	• 5760 x 1440
Control code		• ESC/P2 expanded raster graphics code
		• EPSON Remote command
Internal font		Character code:	ASCII 20H to 7FH
		Font:	Bit map LQ font
			EPSON Courier
Input buffer size		32 Kbytes
Paper feed method		Friction feed with ASF (Auto Sheet Feeder)
Paper path		Sheet feeder, top entry
		• High quality mode, 10.16-mm (0.4") feed
Paper feed rates (TBD)			TBD mm/sec (TBD inch/sec)
		• High speed mode, continuous feed
			TBD mm/sec (TBD inch/sec)

PRINT SPEED & PRINTABLE WIDTH

Table 1-3. Character Mode

Character Pitch	Printable Columns	CR Speed
10 CPI (Pica)	80	419 mm/s (165 CPS*)

Note * : CPS: Characters per second

Table 1-4. Graphics Mode

				Dot Size
	Horizontal	Printable	Max. Dot			CR
				Stylus C58/	Stylus C79/
	Resolution	Area	Count		D78/C90/C91/	Speed
				C59/ME 2
					C92/D92
				Eco	Eco	723.9 mm/s
						(360 CP)S
		209.8 mm
	360 dpi		2976	VSD1	VSD1	419.1 mm/x
		(8.26")
						(165 CPS)
				---	VSD2’ (Color)
				VSD2	VSD2
	720 dpi	209.8 mm	5952	---	VSD2’ (Black)
		(8.26")		VSD3	---	609.6 mm/s
				---	VSD3’ (Color)
						(240 CPS)
	1440 dpi	209.8 mm	11904	VSD3	VSD3
		(8.26")		---	VSD3’ (Black)
	5760 dpi	209.8 mm	23808	VSD3	VSD3
		(8.26")

PRODUCT DESCRIPTION

Printer Specifications

10

EPSON Stylus C58/C59/ME 2 Stylus C79/D78/C90/C91/C92/D92

Revision C

1.2.1 Paper Support

Following table shows the paper type and sizes supported by the printer. Supported paper type and sizes vary depending on the markets.

Table 1-5. Paper Support

		Item	Paper Size	Thickness	Weight
				(mm)
			Letter
			Legal
			Half Letter
	Plain paper		A4	0.08-0.11	64-90 g/m2
	Recycled paper		A5		(17-24 lb.)
			A6
			B5
			User defined
	Envelope		No.10		45-75g/m2
			DL	N/A
	(Bond paper, Air mail, PPC)				(12-20 lb.)
			C6
		Premium Ink Jet Plain Paper	A4	0.11	80 g/m2 (21 lb.)
		Bright White Ink Jet Paper	A4	0.13	92.5 g/m2 (25 lb.)
			Letter
			A4*1
	paper	Premium Photo Paper Glossy (EAI)	8" x 10"	0.27	255 g/m2 (68 lb.)
			5" x 7"*1
	special	Premium Glossy Photo Paper (Other)
			4" x 6"*1
			4" x 7.11"*1
	EPSON
			Letter
			L (3R)*1
		Premium Photo Paper Semi-Gloss (EAI)
			A4*1	0.27	250 g/m2 (66 lb.)
		Premium Semigloss Photo Paper (Other)
			4" x 6"*1
		Premium Presentation Paper Matte (EAI)	Letter	0.23	167 g/m2 (44 lb.)
		Matte Paper-Heavyweight (Other)	A4*1

Table 1-5. Paper Support

		Item	Paper Size	Thickness	Weight
				(mm)
			Letter
		Photo Paper Glossy (EAI)	A4*1	0.25	258 g/m2 (68 lb.)
		Glossy Photo Paper (EUR, Asia)
	paper		5" x 7"*1
			4" x 6"*1
	special
			A4*1
			Letter
	EPSON
		Ultra Premium Photo Paper Glossy (EAI)	8" x 10"	0.30	290 g/m2 (77 lb.)
		Ultra Glossy Photo Paper (Other)	5" x 7"*1
			4" x 6"*1
			L (3R)*1

Note 1: For paper width and length, see Table 1-6, “Paper Width and Length,” on page 12.

Note *1: Borderless printing supported.

CAUTION Make sure that the paper is not wrinkled, fluffed, torn, or folded.

The curve of paper must be 5 mm or below.

When printing onto an envelope, be sure that the flap is on the

long edge and is folded.

Do not use the adhesive envelopes.

Do not use double envelopes and cellophane window envelopes.

PRODUCT DESCRIPTION

Printer Specifications

11

EPSON Stylus C58/C59/ME 2 Stylus C79/D78/C90/C91/C92/D92

Revision C

PAPER WIDTH AND LENGTH

Table 1-6. Paper Width and Length

		Paper Size	Width	Length
		A4	210 mm (8.3")	297 mm (11.7")
		A5	148 mm (5.8")	210 mm (8.3")
		A6	148 mm (5.8")	210 mm (8.3")
		B5	182 mm (7.2")	257 mm (10.1")
		Letter	215.9 mm (8.5")	279.4 mm (11")
	sheet	Legal	215.9 mm (8.5")	355.6 mm (14")
		Half Letter	139.7 mm (5.5")	215.9 mm (8.5")
	Cut
		8" x 10"	203.2 mm	254 mm
		5" x 7"	127 mm	178 mm
		4" x 7.11"	101.6 mm	180.6 mm
		4" x 6"	101.6 mm	152.4 mm
		L (3R)	89 mm (3.5")	127 mm (5")
		User defined	50.8-329 mm	127-1117.6 mm
			(2-12.6")	(5-44")
	Envelope	No.10	104.8 mm (4.125")	241.3 mm (9.5")
		DL	110 mm	220 mm
		C6	114 mm	162 mm

1.2.2 Printable Area Size and Margins

Refer to the table and figure below for the printable area size and margins.

Table 1-7. Guaranteed Print Area

	A	B-L	B-R	C	D
Minimum	3 mm	3 mm	3 mm	12.5 mm	20 mm
margin	(0.12")	(0.12")	(0.12")	(0.12")	(0.12")

A

B-L	B-R
Cut sheet	C	Borderless printing*
A	B-R	D

Envelope

B-L

Note * : Borderless printing is carried out by enlarging the image size wider than the paper size as shown in the figure. The image width protruding from the paper size is shown below.

Table 1-8. Borderless Printing

	Paper Size	Top	Bottom	Left/Right
	A4, Letter, 8" x 10",	2.96 mm (0.12")	4.02 mm (0.16")	2.54 mm (0.1")
	5" x 7", 4" x 7.11"
	4" x 6", L (3R)	2.82 mm (0.11")	3.60 mm (0.14")	2.54 mm (0.1")

PRODUCT DESCRIPTION

Printer Specifications

12

EPSON Stylus C58/C59/ME 2 Stylus C79/D78/C90/C91/C92/D92

Revision C

1.2.3	Ink Cartridge
Type/color: EPSON-brand special ink cartridges
			Table 1-9. Stylus C58/C59/ME 2
	Color				ECC		Pacific, Asia (Other)
	Black				T0761			T0751
	Cyan				T0762			T0752
	Magenta				T0763			T0753
	Yellow				T0764			T0754
			Table 1-10. Stylus C79/D78
	Color				Latin, Asia, Pacific			Europe
	Black				T0731			T0711
	Cyan				T0732			T0712
	Magenta				T0733			T0713
	Yellow				T0734			T0714
			Table 1-11. Stylus C90/C91/C92/D92
Color			Latin		Asia		Europe	CISMEA
Black			T0731		T0731		T0711	T0921
			T0901		T0911*
Cyan			T0732		T0732		T0712	T0922
					T0912*
Magenta			T0733		T0733		T0713	T0923
					T0913*
Yellow			T0734		T0734		T0714	T0924
					T0914*
Note * :	Except EHK.

Print Capacity (TBD)

Stylus C58/C59/ME 2

Black Ink Cartridge: TBD pages/A4

(ISO/IEC10561 Letter Pattern at 360 x 720 dpi) TBD pages/A4

(360x720 dpi, 5% duty)

Color Ink Cartridge: TBD pages/A4 (360 x 720 dpi, 5% duty for each color)

Stylus C79/D78/C90/C91/C92/D92 Black Ink Cartridge: TBD pages/A4

(ISO/IEC10561 Letter Pattern at 360 x 720 dpi) TBD pages/A4

(360x720 dpi, 5% duty)

Color Ink Cartridge: TBD pages/A4 (360 x 720 dpi, 5% duty for each color)

Shelf life: Two years from production date (if unopened), six months after opening package.

Storage Temperature

Table 1-12. Storage Temperature

	Situation	Storage Temperature	Limit
	When stored in individual boxes	-30 oC to 40 oC
		(-22oF to 104oF)
			1 month max. at 40 oC (104oF)
	When installed in main unit	-20 oC to 40 oC
		(-4oF to 104oF)

Dimension

Stylus C58/C59/ME 2

12.7mm (W) x 43 mm (D) x 47 mm (H)

Stylus C79/D78/C90/C91/C92/D92

12.7mm (W) x 68 mm (D) x 47 mm (H)

CAUTION The ink cartridge cannot be refilled.

The ink cartridge that passes the expiration date should not be used.

The ink in the ink cartridge freezes at -16 °C (3.2 oF). Ink thaws

and is usable after approximately three hours at 25 °C (77oF).

PRODUCT DESCRIPTION

Printer Specifications

13

EPSON Stylus C58/C59/ME 2 Stylus C79/D78/C90/C91/C92/D92

Revision C

1.2.4 Black Ink Save Mode

Black ink save mode allows you to print images with color ink only when the remaining amount of black ink is low. This mode can be selected when the remaining amount of color ink is sufficient since black areas of the images are printed with a mixture of other colors.

Supported OS: Windows 98, ME, 2000, XP, XP x64

Printing mode: Plain Paper & Text Mode (360 dpi)

Operating procedure

1.User carries out printing from an application.

2.The printer driver checks both the printing mode and the amount of remaining ink, and displays the specific window if the conditions described below are all met.

•Selected printing mode supports black ink save mode.

•Remaining amount of black ink is less than 5%, or the status of the black ink is “ink low”.

•Remaining amount of all the color ink is more than 10%, or the status of all the color ink is NOT “ink low”.

Starts printing in black ink save mode.

Starts printing in a normal manner.

Starts printing in a normal manner. This window will not be displayed again until the black ink cartridge is replaced.

Flowchart 1-1. Black Ink Save Mode

1.3 Interface

Stylus C58/C59/ME 2 and Stylus C79/D78/C90/C91/C92/D92 provide an USB interface.

1.3.1 USB Interface

	Standard:		Based on Universal Serial Bus Specifications Revision 1.1,
			Universal Serial Bus Device Class Definition for Printing
			Devices Version 1.1
	Descriptors:		Based on Design Specification for USB Device Requests and
			USB Descriptors for EPSON USB Printer
	Product ID:		0005h
	Transfer rate:		12 Mbps (Full Speed Device)
	Cable length:		Under 2 meters (6.6 feet)
	Device ID
			Table 1-13. Device ID
	Product		Device ID	Product	Device ID
	Name			Name
		<00H><4BH>			<00H><4BH>
		MFG:EPSON;			MFG:EPSON;
	Stylus C58	CMD:ESCPL2,BDC;		Stylus C79	CMD:ESCPL2,BDC;
		MDL:Stylus C58			MDL:Stylus C79
		CLS:PRINTER;			CLS:PRINTER;
		DES:EPSON<SP>Stylus C58;			DES:EPSON<SP>Stylus C79;
		<00H><4BH>			<00H><4BH>
		MFG:EPSON;			MFG:EPSON;
	Stylus C59	CMD:ESCPL2,BDC;		Stylus D78	CMD:ESCPL2,BDC;
		MDL:Stylus C59			MDL:Stylus D78
		CLS:PRINTER;			CLS:PRINTER;
		DES:EPSON<SP>Stylus C59;			DES:EPSON<SP>Stylus D78;
		<00H><3FH>
		MFG:EPSON;
	ME 2	CMD:ESCPL2,BDC;
		MDL:ME 2
		CLS:PRINTER;
		DES:EPSON<SP>ME 2;

Note : Device IDs shown in the table above are for when IEEE1284.4 is invalid. When IEEE1284.4 is valid, the line that starts with “CMD” changes to “CMD:ESCPL2,BDC,D4,D4PX”.

PRODUCT DESCRIPTION

Interface

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EPSON Stylus C58/C59/ME 2 Stylus C79/D78/C90/C91/C92/D92

Revision C

1.4	General Specifications
1.4.1	Electrical Specifications
Primary power input
	Table 1-14. Primary power input
		100-120 V model			220-240 V model
Rated power supply voltage (ACV)		100 to 120			220 to 240
Input voltage range (ACV)		90 to 132			198 to 264
Rated current (A)		0.4 (max. 0.7)			0.2 (max. 0.4)
Rated frequency (Hz)				50 to 60
Input frequency range (Hz)			49.5 to 60.5
		11 (ISO10561 Letter Pattern)
Power consumption (W)		2.5 (Sleep mode)			3.0 (Sleep mode)
		0.2 (Power off mode)			0.4 (Power off mode)

Note 1: This product complies with the “Energy Star” standards.

2:If the printer is not operated for more than five minutes, the standby function reduces the current to the motor to conserve power.

Dielectric strength

AC1000 Vrms for 1 min. or AC1200 Vrms for 1 sec. (100-120V version)

AC1500 Vrms for one min. (220-240V version)

1.4.2 Acoustic Noise

Noise level: Approx. 44 dB (according to ISO7779)

1.4.3 Safety Approvals

Table 1-15. Safety Approvals

		100-120 V version	220-240 V version
	Safety standards	UL60950	EN 60950
		CSA C22.2 No.60950
	EMI	FCC part15 subpart B class B	EN 55022(CISPR Pub.22) class B
		CSA C108.8 Class B	AS/NZS CISPR22 class B

1.4.4 CE Marking

220-240V version

Low voltage directive 73/23/EEC: EN60950

EMC directive 89/336/EEC:	EN5502 Class B, EN61000-3-2,
	EN61000-3-3, EN55024

1.4.5 Environmental Performance

Table 1-16. Environmental Performance

	Condition		Temperature	Humidity*2	Impact		Vibration
	Operating		10 to 35°C	20 to 80%*4	1G,		0.15G
			(50 to 95°F)*3*4		1 x 10-3	seconds
	Not operating*1		-20 to 60°C	5 to 85%	2G,		0.50G
			(-4°F to 140°F)		2 x 10-3	seconds
	Note *1:	After opening package
	*2:	No condensation
	*3:	One month at 40°C (104°F), 120 hours at 60°C (140°F)

*4: Under the following conditions:

90

	80
	70
	60
Humidity (%)	50
	40
	30
	20
			27/80
	10/50	20/68	30/86	35/95	40/104

Temperature (°C/°F)

1.4.6 Durability

Total print life:10,000 pages (A4, Letter) or five years (whichever comes first)

Printhead life: Seven billion shots (per nozzle) or five years (whichever comes first)

PRODUCT DESCRIPTION

General Specifications

15

EPSON Stylus C58/C59/ME 2 Stylus C79/D78/C90/C91/C92/D92

Revision C

1.5 Control Panel

1.5.1 Buttons

The control panel contains following two buttons (non-lock type), which are used to set and execute some operations. The functions of each button are described in the table below.

		Table 1-17. Operations
	Button	Function
	Power	Turns on or off this unit.
		When Paper out occurred
		Loads paper.
		When Paper jam occurred
		Ejects paper.
		When Double feed occurred
		Clears the error and resumes the printing.
		When Ink end or No ink cartridge occurred
	Maintenance	Moves the carriage to ink-check position.
		When the carriage is in the ink-check position
		Moves the carriage slightly to check the adjacent ink cartridge.
		When the carriage is in “Ink low” or “Ink out” position
		Moves the carriage to the replacement position.
		During printing
		Cancels the current print job.
		When pressed for three seconds
		Cleans the printhead.
		When the printer is turning on
	Power + Maintenance*	Print a nozzle check pattern.
		When the printer is on
		Shuts down the printer.

Note * : Hold down [Maintenance] first and press [Power]. Keep the buttons pressed for over seven seconds.

1.5.2 Indicators

The control panel contains following two LED to indicate some status.

				Table 1-18.	Indicators
LED					Function
Power [Green]	Lights while the printer is turned on.
	Lights: Paper out, Paper jam, Double feed, No ink cartridge,
Maintenance [Red]				Ink end, Incorrect ink cartridge
	Flashes: Ink low
Power Button					Maintenance Button

Power LED

Maintenance LED

Figure 1-2. Control Panel

PRODUCT DESCRIPTION

Control Panel

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Revision C

1.5.3 Errors and Panel Status

Followings are the errors that occur on the printer:

Fatal error:	Carriage control error.
Maintenance request:	Waste ink pads need to be replaced.
Ink end:	Ink has run out.
No ink cartridge:	Ink cartridge(s) is not installed.
Incorrect ink cartridge:	Non-genuine ink cartridge(s) is installed.
Paper jam:	Paper remains in the paper path.
Paper out:	Failed to load papers.
Double feed:	Two or more papers have been fed during duplex printing.
Ink low (warning):	Ink is running low.

Table 1-19. Errors and Panel Status

	Printer Status	Indicators		Priority
		Power LED	Maintenance LED
	Turning the power off	Flashes fast	Off	1
	Fatal error	Off	Flashes fast	2
	Maintenance request	Flashes alternately		3
	Paper jam	---	On	4
	Paper out	---	On	4
	Double feed	---	On	4
	Ink cartridge replacement	Flashes	---	5
	Ink sequence	Flashes	---	6
	Incorrect ink cartridge	---	On	7
	No ink cartridge/Ink end	---	On	7
	Data processing	Flashes	---	8
	Ink low	---	Flashes	9
	Turning the power on	On	---	10
	Note 1: “---”: no change

2: When multiple errors occur at the same time, the one with higher priority will be indicated.

1.5.4 Printer Initialization

There are four kinds of initialization method, and the following explains each initialization.

1.Power-on initialization

This printer is initialized when turning the printer power on, or printer recognized the cold-reset command (remote RS command).

When printer is initialized, the following actions are performed.

(a)Initializes printer mechanism

(b)Clears input data buffer

(c)Clears print buffer

(d)Sets default values

2.Operator initialization

This printer is initialized when turning the printer power on again within 10 seconds from last power off, or printer recognized the -INIT signal (negative pulse) of parallel interface.

When printer is initialized, the following actions are performed.

(a)Cap the printer head

(b)Eject a paper

(c)Clears input data buffer

(d)Clears print buffer

(e)Sets default values

3.Software initialization

The ESC@ command also initialize the printer.

When printer is initialized, the following actions are performed.

(a)Clears print buffer

(b)Sets default values

4.Power-on initialization except I/F

The printer recognized the IEEE 1284.4 “rs” command.

When printer is initialized, the following action is performed.

(a)Initializes printer mechanism

(b)Clears input data buffer

(c)Clears print buffer

(d)Sets default values except I/F

PRODUCT DESCRIPTION

Control Panel

17

C H A P T E R

2

OPERATING PRINCIPLES

EPSON Stylus C58/C59/ME 2 Stylus C79/D78/C90/C91/C92/D92

Revision C

2.1 Overview

This section describes the operating principles of the printer mechanism and electrical circuit boards. The printer mechanism does not differ between the Stylus C58/C59/ ME2 and Stylus C79/D78/C90/C91/C92/D92.

2.2 Printer Mechanism

Printer mechanism of Stylus C58/C59/ME 2 and Stylus C79/D78/C90/C91/C92/D92 consists of printhead, carriage mechanism, paper loading/feeding mechanism, and ink system.

As in the case of conventional models, Stylus C58/C59/ME 2 and Stylus C79/D78/ C90/C91/C92/D92 has two motors; one is a stepping motor for paper loading/feeding mechanism, and the other is a DC motor for carriage mechanism.

Papers are fed from the backside and ejected from the front side of the printer. Paper feeding mechanism feeds papers using the LD roller and the retard roller.

PF motor	PF roller

	Star wheel
	rollers
		CR timing belt
	Carriage unit	CR encoder
		sensor
		Retard roller
		Compression
		spring
		LD roller
	Paper eject	PE sensor
		Cam, large
	roller
	CR lock lever	Cam, small
		Clutch
	Cap unit	Pump unit
		CR motor

Figure 2-1. Printer Mechanism Outline

OPERATING PRINCIPLES

Overview

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EPSON Stylus C58/C59/ME 2 Stylus C79/D78/C90/C91/C92/D92

Revision C

2.2.1 Printhead Specifications

The Printhead of this product is a D2-CHIPS type.

Nozzle configuration

Monochrome 90 nozzles

Color 29 nozzles x 3 (Cyan, Magenta, Yellow)

The following shows the arrangement of the nozzles and the color arrangement of each nozzle line when viewed the printhead from behind.

2.822mm (40/360 inch)

		C#29	K#90
			K#89
	Cyan: 29nozzles
		C#1
		M#29
		Color	Black	Paper Loading
	Magenta: 29nozzles			Direction

M#1

Y#29

Yellow: 29nozzles

Y#3

	Y#2	K#3	0.2117mm
	Y#1	K#2
			(1/120 inch)
		K#1

Carriage Moving Direction

Figure 2-2. Nozzle Rear View

2.2.2 Carriage Mechanism

Main components of the carriage mechanism are carriage unit (including printhead, CR encoder sensor), CR motor, timing belt, and CR scale.

2.2.2.1 CR Motor Specifications

	Table 2-1. CR Motor Specifications
Item	Specification
Type	Motor with DC brush
Drive voltage	+42 V ± 5% (applied voltage to the driver)
Electric resistance	28.8 Ω ± 10%
Inductance	20.1 mH ± 25%
Drive method	PWM, constant-current chopping
Drive IC	A6628

OPERATING PRINCIPLES

Printer Mechanism

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EPSON Stylus C58/C59/ME 2 Stylus C79/D78/C90/C91/C92/D92

Revision C

2.2.3 Paper Feeding Mechanism

Paper loading/feeding mechanism consist of CR lock lever inside the ink system, LD roller shaft (including clutch mechanism), and ASF unit.

CR lock lever and clutch mechanism play an important role in paper loading mechanism. Refer to 2.2.3.2 Drive Process (p21) for details.

2.2.3.1 PF Motor Specifications (For both ASF and Pump motor)

		Table 2-2. PF Motor Specification
	Item	Specification
	Type	4-phase, 48-pole PM stepping motor
	Drive voltage	+42 V ± 5% (applied voltage to the driver)
	Wire wound	4.3 Ω +8 / -12% (per one phase at 20 °C)
	resistance
	Inductance	5.5 mH ± 20% (1KH, 1Vrms)
		Bipolar drive
	Drive method	2-2 phase, 1-2 phase, W1-2phase, 2W1-2phase, 4W1-2 phase
		constant-current drive
	Drive IC	A6628

2.2.3.2 Drive Process

1.Drive of the PF motor is always transmitted to the paper eject roller and the PF roller, however, it is not transmitted to the LD roller and the retard roller owing to the clutch of the LD roller shaft.

2.The carriage unit moves to the ASF trigger position once the paper loading command is received.

3.PF motor is rotated counter clockwise, and the clutch is released by the CR lock lever.

4.After the clutch is released, the PF motor rotates clockwise. Drive is transmitted to the LD roller and the paper loading operation begins.

5.During paper loading operation, papers are fed from the ASF unit to inside the printer by the rotating movement of the two cams of the LD roller.

Cam, large:releases hopper

Cam, small:releases paper back lever

6.Once a sheet of paper is fed, the hopper and the paper back lever bring back rest of the papers to the position in readiness by the rotating movement of the two cams mentioned above.

7.When the LD roller is turned a full circle, the CR lock lever release the clutch and the drive to the LD roller is interfered.

OPERATING PRINCIPLES

Printer Mechanism

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EPSON Stylus C58/C59/ME 2 Stylus C79/D78/C90/C91/C92/D92

Revision C

2.2.4 Ink System Mechanism

The Ink system mechanism consists of pump mechanism and capping mechanism that includes wiper mechanism.

2.2.4.1 Pump Unit Mechanism

When the PF motor turns, power is always transmitted to the ink system.

Table 2-3. PF Motor Rotational Direction & Ink System Mechanism

Direction*	Function
Counterclockwise	Absorbs the ink by the Pump Unit
Clockwise	Release pump.

Note * : The PF Motor rotational direction = seen from the left side of the printer.

2.2.4.2 Capping Mechanism

The Capping mechanism covers the printhead with the cap to prevent the nozzle from increasing viscosity when the printer is in stand-by state or when the printer is off.

2.3 Electrical Circuit Operating Principles

The electric circuit of Stylus C58/C59/ME 2 and Stylus C79/D78/C90/C91/C92/D92 consists of the following boards:

Main board:		C664	Main Board (Stylus C58/C59/ME 2/C79/D78)
		C683Main Board (Stylus C90/C91/C92/D92)
	CSIC Board:	C654	Head Board (Stylus C58/C59/ME 2/C79/D78)
		CR contact Module (Stylus C90/C91/C92/D92)
	Power supply board:	C664	PSB/PSE Boards

Below is a block diagram of C664 Main Board, C664 PSB/PSE Boards, and C654 Head Board.

C664/C683 Main Board

+42V PowerOFF

C664PSB/PSE Board

Printer Mechanism

CR Motor

PF Motor

Printhead

Sensors

CSIC Board/

C654 Head Board/

CR contact Module*

Note * : Varies depending on the model.
Stylus C58/C59/ME 2:	CSIC Board
Stylus C79/D78	C654 Head Board
Stylus C90/C91/C92/D92:	CR contact Module

Figure 2-3. Electrical Circuit Block Diagram

OPERATING PRINCIPLES

Electrical Circuit Operating Principles

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EPSON Stylus C58/C59/ME 2 Stylus C79/D78/C90/C91/C92/D92

Revision C

2.3.1 C664 PSB/PSE Board

In the PSB/PSE Boards of Stylus C58/C59/ME 2 and Stylus C79/D78/C90/C91/C92/ D92, the simulated oscillating stimulation flyback converter circuit method is used, and it supplies +42 VDC to the drive line. The application of the output voltage is described below.

C664PSB Board:100-120V

C664PSE Board:220-240V

AC voltage input from AC inlet first goes through filter circuit that removes high frequency components and is then converted to DC voltage via the rectifier circuit and the smoothing circuit. DC voltage is then led to the switching circuit and FET QF1 preforms the switching operation. By the switching operation of the primary circuit, +42VDC is generated and stabilized at the secondary circuit.

2.3.2 C664/C683 Main Board

The following lists the components of the logic circuit on C664/C683 Main Board.

Logic line (CPU-ASIC 4 in 1, Flash-ROM and so on)

Motor control/drive circuit (CR Motor, PF Motor)

Head control/drive circuit

USB I/F circuit

Sensor circuit

Reset circuit, EEPROM circuit

Table 2-4. C664/C683 Main Board Major Components and Primary Functions

	IC	Location	Function
	FLASH ROM	IC3	3.3 V drive 4 M bit flash ROM that stores the program.
	Reset Regulator	IC1	3.3V/1.5V generate regulator, 2 ch reset circuit
	EEPROM	IC4	Makes back up of default setting values and parameters
	Motor Driver	IC6	Drives CR/PF motors, controls PWM by the program timer,
			adjusts 5 V, drives 42 V
	Head Driver	IC7	Generates trapezoidal waveform, drives 5 V
	ASIC	IC10	Drives CPU (H8S/2674 base), internal 8 K byte x 4 RAM,
			24 Mhz, 3.3 V/1.5V

OPERATING PRINCIPLES

Electrical Circuit Operating Principles

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EPSON Stylus C58/C59/ME 2 Stylus C79/D78/C90/C91/C92/D92

Revision C

Figure 2-4. C664 Main Board Block Diagram (Stylus C58/C59/ME 2)

OPERATING PRINCIPLES

Electrical Circuit Operating Principles

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EPSON Stylus C58/C59/ME 2 Stylus C79/D78/C90/C91/C92/D92

Revision C

Figure 2-5. C664/C683 Main Board Block Diagram (Stylus C79/D78/C90/C91/C92/D92)

OPERATING PRINCIPLES

Electrical Circuit Operating Principles

25

C H A P T E R

3

TROUBLESHOOTING

EPSON Stylus C58/C59/ME 2 Stylus C79/D78/C90/C91/C92/D92

Revision C

3.1 Overview

This chapter describes how to solve problems.

WARNING	Be careful to avoid electric shocks when checking the electrical
	circuit boards (C664 MAIN, PSE and B circuit boards) while
	the power is turned on.

Touching an FET, transistor or heat sink with one hand while touching a metal part of the mechanism with the other hand could result in an electric shock, so carefully avoid this.

After initial filling of ink has been repeated several times, immediate moving or tilting of the printer could result in leaking of ink that has not been completely absorbed by the Waste Ink Pad. When initial filling of ink has been repeated several times, check the ink remaining in the tip of the Waste Ink Tube and the waste ink not absorbed by the Waste Ink Pad before moving the printer.

CHECK	Disassembly and reassembly of parts is often required when
POINT	identifying the causes of problems. The parts should be
	disassembled and re-assembled correctly while referring to
	DISASSEMBLY/ASSEMBLY (p30) so that the operation and
	status of each check item can be correctly verified.

Some individual part and units may require adjustment once they are removed or replaced. If removing or replacing parts which have specific instructions for adjustment included in DISASSEMBLY/ASSEMBLY (p30), be sure to make these adjustments after repairing the problem location.

3.1.1Specified Tools

This printer does not require any specified tools for troubleshooting.

3.1.2 Preliminary Checks

Before starting troubleshooting, be sure to verify that the following conditions are all met:

The power supply voltage must be within the specification limits. (Measure the voltage at the electrical outlet.)

The power cable must be free from damage, short circuit, or breakage, and must not be miswired.

The printer must be grounded properly.

The printer should not be located in a place where it can be exposed to too high or low temperature, too high or low humidity, or abrupt temperature change.

The printer should not be located near waterworks, near humidifiers, near heaters or near flames, in a dusty atmosphere or in a place where the printer can be exposed to blast from an air conditioner.

The printer should not be located in a place where volatile or inflammable gases are present.

The printer should not be located in a place where it can be exposed to direct sunlight.

The printer must be located in a well-ventilated place.

The printer must be placed on a strong and steady level table (without an inclination larger than five degrees).

Be sure to use papers that conform to the specifications.

There should be no errors in handling of the printer.

Check the inside of the printer, and remove foreign matters if any, such as paper clips, staples, bits of paper, paper dust or toner.

Clean the inside of the printer and the rubber rollers.

TROUBLESHOOTING

Overview

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Revision C

3.2 Troubleshooting With LED Error Indications

LED error display, cause, and remedy are explained here.

Table 3-1. Troubleshooting With LED Error Indications

	Error	LED status		Cause		Remedy
		Power	Maintenance
	Ink end/ No ink cartridge/			• Ink inside Bk, Y, M, C cartridges has run out.	• Check the ink cartridge(s) and reinstall it correctly.
		---	On	• Ink cartridge(s) is not installed.	• Replace the ink cartridge(s) with a genuine one.
	Incorrect ink cartridge
				• Non-genuine ink cartridge(s) is installed.
				• Paper loading operation is executed when there is no paper.	1.	If there is no paper on the paper tray, load papers.
	Paper Out	---	On	• Papers stopped before the PE Sensor or could not be fed.	2.	If the paper has stopped halfway, remove the paper, check if the
				• Papers are fed without being placed against the right edge guide.		paper is not bent, fan the paper, and load it against the edge guide.
				• Connector of the PE sensor is disconnected.	3.	Press the [Maintenance] button to release the error.
				• When performing duplex printing, blank paper is ejected.	1.	Remove the blank paper, or check the paper size.
	Double feed error	---	On	• The printer detected that the paper is too long upon ejection.	2.	Press the [Maintenance] button to eject the paper and release the
						error.
					1.	Press the [Maintenance] button on the panel.
				Even though paper feeding operation is carried out for	2.	If paper jam occurred again after pressing the button, open the
						printer cover and remove all the papers inside the printer and
	Paper jam	---	On	predetermined times, leading edge or back-end of the paper could
						papers set on the hopper.
				not be detected.
					3.	Making sure there is no paper inside the printer, load paper on the
						hopper and press [Maintenance].
	Maintenance request			As a result of cleaning and flushing, total emission of ink has	Replace the waste ink pad, and reset the waste ink counter using the
		Flashes alternately			adjustment program. Refer to Chapter 5 “ADJUSTMENT” (p.66) for
	(Waste ink overflow)			exceeded the specific level.
					details.
				• Home position of the carriage could not be detected.	1.	Turn the power off, wait for a few seconds, and turn the power
				• Abnormal external pressure is applied to the printer when the		back on again.
				power is on.	2.	If the fatal error still appears, turn the power off, remove the
				• Carriage movement is interfered during printing.		papers on the hopper, and check the following:
	Fatal error	Off	Flashes fast		•	Open the printer cover, check the ink cartridges, and reinstall
						them correctly.
					•	Check is there is no foreign material or papers inside the printer.
						If there is any, remove them.
					3.	Turn the printer power on.

Note : “---”: no change.

TROUBLESHOOTING

Troubleshooting With LED Error Indications

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Revision C

3.3 Troubleshooting for Motors and Sensors

Motor

Table 3-2. Motor Resistance and Check Points

	Motor name	Type	Location	Check point	Resistance
	CR motor	Motor with DC brush	CN5	Pin 1 & 2	28.8 Ω ± 10%
	PF motor	4-phase, 200-pole HB stepping motor	CN6	Pin 1 & 3	4.3 Ω ± 8%/-
				Pin 2 & 4	12%(20ºC)
	Sensor	Table 3-3. Sensor Check
	Sensor name	Detecting system	Location	Signal level	Sensor status
	PE sensor	Transmission photo interrupter	CN7 pin 1 & 2	2.6 V or more	Paper loaded
				0.4 V or less	No paper

TROUBLESHOOTING

Troubleshooting for Motors and Sensors

29

C H A P T E R 1

4

DISASSEMBLY/ASSEMBLY