Epson R2400, R1800 User Manual

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SERVICE MANUAL
Color Inkjet Printer
EPSON Stylus Photo R1800/R2400
SEIJ04015
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.
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 © 2005 SEIKO EPSON CORPORATION.
I&I CS/Quality Management & PL Department
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.
WARNING
1. REPAIRS ON EPSON PRODUCT SHOULD BE PERFORMED ONLY BY AN EPSON CERTIFIED REPAIR TECHNICIAN.
2. MAKE CERTAIN THAT THE SOURCE VOLTAGES 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 MANUFAC TURE; INTRODUCTION OF SECOND-SOURCE
ICs OR OTHER NON-APPROVED COMPONENTS MAY DAMAGE THE PRODUCT AND VOID ANY APPLICABLE EPSON WARRANTY.
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 the 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 lists of Epson-approved lubricants and adhesives required for servicing the product.
APPENDIX Provides the following additional information for reference:
• Connector pin assignments
• Exploded diagram & Parts List
• Electric circuit boards components layout
• Electrical circuit boards schematics
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, or WARNING messages.
Indicates an operating or maintenance procedure, practice or condition that is necessary to keep the product’s quality.
Indicates an operating or maintenance procedure, practice, or condition that, if not strictly observed, could result in damage to, or destruction of, equipment.
May indicate an operating or maintenance procedure, practice or condition th at is necess ary t o acco mplis h a t ask eff icie ntly . It may also provide additional information that is related to a specific subject, or comment on the results achieved through a previous action.
Indicates an operating or maintenance procedure, practice or condition that, if not strictly observed, could result in injury or loss of life.
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 January 21, 2005 First Release B March 31, 2005 Revised Contents
8. Stylus Photo R2400 (p198)
• Stylus Photo specific information is added.
5.2.5.1 Printing Calibration Chart by Users (p165)
• Descriptions of the procedure are added.
5.2.5.2 Writing of Color ID by Users (p169)
• A caution is deleted.
Color Correction Value Entry Procedure (p170)
• Supported OS and ports are added.
Calibration Chart Print Procedure for Users (p166)
• Descriptions of the procedure are added.
EPSON Stylus Photo R1800/R2400 Revision B
CONTENTS
Chapter 1 Product Description
1.1 Overview.................................................................................................. 9
1.2 PG Setting ............................................................................................. 10
1.3 Functions .............................................................................................. 11
1.3.1 Control Panel ................................................................................ 11
1.3.2 Switches .................... ....... ...... ....... ...... ....... ...... ....... ...... ....... ......... 11
1.3.3 Indicators ................... ....... ...... ....... ...... ....... ...... ....... ...... ....... ...... ... 11
1.3.4 Switch Functions ........................................................... ....... ......... 11
1.3.5 Indicator Display in Normal Mode ................................................. 12
1.3.6 Error Status ................................................................................... 13
1.4 Casing Specifications .......................................................................... 14
1.5 Accessories .......................................................................................... 14
Chapter 2 Operating Principles
2.1 Overview................................................................................................ 16
2.2 Printer Mechanism ............................................................................... 16
2.2.1 Carriage Mechanism ..................................................... ....... ...... ... 17
2.2.2 Printhead Specificatio ns ... ...... ....... ...... ....... ...... ............................. 20
2.2.3 Paper Feeding Mechanism ................. ....... ...... ....... ...... ....... ...... ... 20
2.2.4 Paper Feeding Mechanism ................. ....... ...... ....... ...... ....... ...... ... 25
2.2.5 Ink System Mechanism ................................................................. 26
2.2.6 Ink Sequence ................................................................................ 28
2.2.7 Power-On Sequence ..................................................................... 30
2.3 Electrical Circuit Operating Principles............................................... 31
2.3.1 Power Supply Circuit Operating Principle ..................................... 32
2.3.2 C589 MAIN Circuit Operating Principle ......................................... 33
Chapter 4 Disassembly And Assembly
4.1 Overview ............................................................................................... 69
4.1.1 Precautions ................................................................................... 69
4.1.2 Tools ............................................................................................. 70
4.1.3 Screws .......................................................................................... 71
4.1.4 Work Completion Checklist ........................................................... 72
4.2 Disassembly ......................................................................................... 73
4.2.1 Removing the Housings ................................................................ 74
4.2.2 Waste Ink Pad ............................................................................... 80
4.2.3 Front Paper Guide Pad ................................................................. 82
4.2.4 ASF Assy ...................................................................................... 83
4.2.5 Removing the Boards ................................................................... 87
4.2.6 Disassembling the Printer Mechanism .......................................... 89
4.2.7 Removing the Motors .................................................................. 122
4.2.8 Removing the Sensors ................................................................ 124
Chapter 5 Adjustment
5.1 Adjustment Items and Overview....................................................... 129
5.1.1 Servicing Adjustment Item List .................................................... 129
5.1.2 Replacement Part-Based Adjustment Priorities .......................... 133
5.1.3 Required Adjustment Tools ......................................................... 136
5.2 Adjustment.......................................................................................... 137
5.2.1 PF Belt Tension Adjustment ....................................................... 137
5.2.2 PG Adjustment ............................................................................ 139
5.2.3 PF Roller Shaft Center Support Position Adjustment ................. 143
5.2.4 Colorimetric Calibration ............................................................... 147
5.2.5 Colorimetric Calibration by Users ............................................... 165
Chapter 3 Troubleshooting
3.1 Overview................................................................................................ 36
3.1.1 Troubleshooting according to Panel Messages ............................ 36
3.1.2 Troubleshooting based on Observed Faul ts ........................ ...... ... 59
Chapter 6 Maintenance
6.1 Overview ............................................................................................. 173
6.1.1 ROM Replacement ..................................................................... 173
6.1.2 Cleaning ...................................................................................... 173
6.1.3 Service Maintenance .................................................................. 174
6
EPSON Stylus Photo R1800/R2400 Revision B
6.1.4 Lubrication ................................................................................... 175
Chapter 7 Appendix
7.1 Connector Summary .......................................................................... 182
7.1.1 Connectors and Pin Layouts ....................................................... 182
7.2 Exploded Diagram.............................................................................. 183
7.3 Parts List for EPSON Stylus Photo R1800 ....................................... 190
7.4 Circuit Diagram................................................................................... 192
Chapter 8 Stylus Photo R2400
8.1 Overview.............................................................................................. 199
8.1.1 Overview ............. ....................................... ...... ....... ...... ....... ...... . 199
8.1.2 Indicator Display in Normal Mode ............................................... 200
8.1.3 Error Status ................................................................................. 201
8.2 Casing Specifications ........................................................................ 202
8.3 Accessories ........................................................................................ 202
8.3.1 Printhead Specificatio ns ... ...... ....... ...... ....... ...... ........................... 203
8.3.2 Ink Sequence .............................................................................. 203
8.4 Overview.............................................................................................. 204
8.4.1 Troubleshooting according to Panel Messages .......................... 204
8.5 Parts List for EPSON Stylus Photo R2400 ....................................... 227
7

PRODUCT DESCRIPTION

CHAPTER
1
EPSON Stylus Photo R1800/R2400 Revision B

1.1 Overview

The Stylus Photo R1800 is a photo printer designed for a wide range of users from individual users to commercial users. As a successor to the Stylus Photo 2100/2200, this consumer middle high model is capable of CD-R/DVD-R printing and roll paper cutter functions. This product has the following features.
FEATURES
High color print quality
5760 (H) x 1440 (V) dpi printing (Max resolution)8 color printing
(PPI Black, Photo Black, Cyan, Magenta, Yellow, Red, Violet, Clear)
Pigment Ink supportedSeparate Ink Cartridge for each colorBuilt-in 2 I/F
USB 2.0 (HS compatibility)
IEEE 1394
Figure 1-1. Product Appearance
Windows/Macintosh exclusiveRoll Paper SupportPrintable area expand (Bottom margin reduce) Card printing supportCD-R printing support
Product Description Overview 9
EPSON Stylus Photo R1800/R2400 Revision B

1.2 PG Setting

As this printer uses an Auto PG (APG), an appropriate PG position is set according to the used paper type. The following table indicates the PG positions, the main applications of each position, and the relationships between the two sensors used with the APG.
Table 1-1.
Application
Printing • PGPP
•A3
•A4
Non-printing
PG value 1.15mm 1.3mm 1.7mm 2.1mm 4.5mm
Sensor PG (– –) PG (–) PG (Typ) PG (+) PG (++) Release
APG Sensor 1 OFF OFF OFF OFF OFF OFF APG Sensor 2 ON ON ON ON OFF OFF
PG (– –) PG (–) PG (Typ) PG (+) PG (++) Release
• Exclusive paper • Plain paper
• Photo Album paper
• Photo Matte paper A3 fine
• PG (-) rub avoidance
• Standby position after power-on (For bottom stacker)
• At power-off
• The Ink Mark Sensor operates. (Auto Bi-D, Detection of dot missing)
PG Position
• Envelope
• PG (Typ) rub avoidance
• CD-R
• Photo stand paper –
• Initialization at power-
on
• Cleaning (wiping)
• Replace the Ink
Cartridge
• Waiting for CD-R/ Board paper to be fed
• Paper jam removal
Product Description PG Setting 10
EPSON Stylus Photo R1800/R2400 Revision B

1.3 Functions

1.3.1 Control Panel

The appearance of the control panel is shown below.
Paper LED
Ink LED
Power LED
Figure 1-2. Control Panel Appearance

1.3.2 Switches

Power switch
Paper switch
Ink switch
Roll paper switch
Power switch

1.3.4 Switch Functions

FUNCTIONS IN NORMAL STATUS
Table 1-2. Normal-status Functions
Switch Function
Power switch
Paper switch
Ink switch
Roll paper switch
• Power On / Off.
• Panel reset (off and on within 10 seconds).
• Loads or Ejects the P aper.
• When carriage is on the Ink Cartridge change position, return carriage from Ink Cartridge change position.
• In the condition of printing, cancel the print job.
• Starts the Cleaning of head with 3 second pushing.
• Moves the carriage to cartridge change position.
• When carriage is on the ink c hange p ositio n, return c arriage from Ink Cartridge change position.
• Loads the Roll paper.
• Back out the roll paper with 3 second pushing.
• Move to tear off position / Return from tear off position.
• When cartridge is on the Ink Cartridge change position, return carriage from Ink Cartridge change position.
• When the photo album is used, ejects the paper forwards only. (At this mode, the printer can’t move backwards without Top of Form.)
Paper switchInk switchRoll paper switch

1.3.3 Indicators

Power LED : Green
FUNCTION AT POWER-ON
Table 1-3. Power-on Function
Switch Function
Paper switch Starts stat us printings.
Note "*1": Status printings prints firmware version, ink counter and nozzle check
patterns.
*1
Paper LED : RedInk LED : Red
Product Description Functions 11
EPSON Stylus Photo R1800/R2400 Revision B

1.3.5 Indicator Display in Normal Mode

Table 1-4. Printer Condition and LED Status
Printer status Error status
Idle On 20 Data processing Blink 19
*1
Pause Ink sequence processing Blink 17 Ink cartridge change mode Blink 16 Ink low (warning) Blink 15 Tear off status 11h 14 Paper mismatch Error 0Ch Fast Blink 12 Paper Out 06h On 11 Ink end 05h On 10 No Ink cartridge or
Ink cartridge error Paper Jam Error 04h Blink 8 Card loading error 2Ah Blink 2 7 Cover Open Tray Error 2Bh Fast Blink Blink 2 13 Reset input On On On – Fatal error 00h Off Fast Blink Fast Blink 4
Maintenance request 10h Off Power off Fast Blink Off Off 1
Note: • "–" : Don't care
• Blink : 0.5sec on + 0.5sec off repetition
• Blink 2 : 0.2sec on + 0.2sec + 0.2sec on + 0.4sec off repetition
• Fast Blink : 0.1sec on + 0.1sec off repetit ion
• Blink alternately 1 : 0.5sec on + 0.5sec off repetition
• Blink alternately 2 : 0.5sec off + 0.5sec on repetition
Status 05h 18
05h
Power Paper Ink Priority
––On9
Indicators
Blink
alternately 1
Blink
alternately 2
2
Note"*1": When the Photo album paper is end, the printer goes to this status.
Product Description Functions 12
EPSON Stylus Photo R1800/R2400 Revision B

1.3.6 Error Status

If any of the following states is detected, this printer is put in an error status and turns the interface signal -ERROR "Low" and BUSY "High" to inhibit data input. At this time, the printer is automatically disabled from printing. However, when communication is being made using the IEEE1284.4 protocol, communication with the printer is enabled.
General error
After the cause of this type of error is removed, the printer can resume its operation from where it stopped due to the error
Table 1-5. General error
Error Status Occurring Condition Resuming Condition
Cover open (tray) error
Paper mismatch error
Paper out When printer fails to load a sheet, it
Ink out When the printer runs out the most
No ink-cartridge When printer detects that ink-
When the front cover is opened at ASF, roll paper or photo album printing mode, the printer goes this error.
If the paper path specified by the print data is different from the printer’s real paper path, the printer goes to this error.
goes paper out error.
part of the ink of any one color, it warns ink-low and keeps printing. When the printer runs out the whole ink of any one color, it stops printing and indicates ink-out error.
cartridge comes off, it goes this error mode.
Close the front cover.
Change the printer’s paper path to the one specified by the data.
Set the paper to the ASF and push the Paper switch.
Install the new Ink Cartridge.
Install the new Ink Cartridge.
Table 1-5. General error
Error Status Occurring Condition Resuming Condition
Paper jam • Failure of ejecting a sheet
• Failure of loading a sheet to the loading position
Card loading error When the card was loaded to the
wrong position, the printer goes this error.
Remove the jammed paper.
Set an A4 paper to the ASF, and press the paper switch. If the card couldn’t eject at your first try, repeat again the same method.
Fatal error
After the cause of this type of error is removed, the printer cannot return to normal unless it is powered off and then on again
Table 1-6. Fatal error
Error Status Occurring Condition Resuming Condition
Maintenance request
Fatal errors • CR motor control error
When the total quantity of ink wast ed through the cleanings and flushing is reaches to the limit, printer indicates this error and stops.
• PF motor control error
• ASF motor control error
• Auto Platen Gap control error
• Head temperature error
• PW sensor error
Replace the absorber in the printer enclosure by a service person.
Turn off and turn on.
Product Description Functions 13
EPSON Stylus Photo R1800/R2400 Revision B

1.4 Casing Specifications

EXTERNAL DIMENSIONS
When tucked : 615 (width) x 314 (depth) x 219 mm (height) When used : 615 (width) x 453 (depth) x 737 mm (height)
WEIGHT
11.7 kg (without the Ink Cartridges, Roll paper holder and CD-Tray)
EXTERNAL DIMENSION DIAGRAM
737
219
314
453
615

1.5 Accessories

STANDARD ACCESSORIES
User’s guideInk Cartridge (one for each of 8 colors)Setup SheetPower CordSoftware CD-ROMCD-R Print Position Check sheetRoll Paper Holder8-cm CD/DVD adapterCD/DVD tray
CONSUMABLES AND OPTIONS
Ink Cartridges
Gloss Optimizer : T0540Black : T0541Cyan : T0542Magenta : T0543Yellow : T0544Red : T0547Matte Black : T0548Blue : T0549
802.11g Radio printing adapter : PA-W11G
Figure 1-3. External Dimension Diagram
Product Description Casing Specifications 14

OPERATING PRINCIPLES

CHAPTER
2
EPSON Stylus Photo R1800/R2400 Revision B

2.1 Overview

This chapter explains the operating principles of the mechanical sections and electrical circuits in this product. The main components of this product are as follows.
Control circuit board : C589 MAINPower supply circuit board : C589 PSBControl panel board : C589 PNLControl panel B board : C589 PNL-B

2.2 Printer Mechanism

Like the conventional model, this product uses DC motors and stepping motors as power sources. The following table describes the motor types and their applications.
Table 2-1. Motors
Motor Name Type Applications/Functions
Used for carriage driving. Makes little noise during driving. The CR linear scale and CR encoder sensor are used to control the motor.
Drives the Paper loading rollers at the time of fixed-value paper loading or paper feed/eject operation. To grasp the paper feed pitch, the precision gear surface is fitt ed with th e PF sc ale and the PF encoder sensor is used to control the motor.
Drives the Carriage Unit at the time of PG setting. The two APG Sensors and Carriage Shaft are driven vertically to control the motor.
Drives the paper feed operation of the ASF. Since this is a stepping motor, any scales or photo sensors to know the driv ing conditions are not required.
Drives the pump, wiper, etc. of the Ink System. Since this is a stepping motor, any scales or photo sensors to know the driv ing conditions are not required.
CR Motor
PF Motor
APG Motor
ASF Motor
Pump Motor
DC motor with
brushes
DC motor with
brushes
DC motor with
brushes
4-phase, 48-pole
PM type
stepping motor
4-phase, 48-pole
PM type
stepping motor
The basic mechanism is almost same as the Stylus Photo R800. The most major difference is that this Stylus Photo R1800 is equipped with a dedicated sensor to detect a open or close status of the Front Cover. This prevents the Print Head from damaging by mistake. The schematic diagram below sho ws the pri nte r mecha nis m.
PF Encoder
Sensor
Front Paper Eject Roller
Rear Paper
Eject Roller
PF Roller
CR Scale
PW Sensor
Ink Mark
Sensor
Carriage
Unit
Ink System
Unit
Pump Motor
CD-R Sensor
Carriage
Shaft
PF Scale
PF Motor
APG Sensors
APG Motor
APF Sensor
Timing Belt
CR Encoder
Sensor
LD Roller
Retard
Roller
PE Sensor
ASF Motor
CR Motor
Figure 2-1. Printer Mechanism Outline
Operating Principles Overview 16
EPSON Stylus Photo R1800/R2400 Revision B

2.2.1 Carriage Mechanism

The Carriage mechanism consists of the Carriage Motor (CR Motor), Carriage Shafts, Platen Gap Adjustment Mechanism, Carriage Lock Mechanism, and others.
2.2.1.1 Carriage Mechanism
The following indicates the specifications of the CR motor (DC motor) that drives the Carriage.
Table 2-2. CR Motor Specifications
Item Specifications
Type DC motor with brushes Drive voltage +42V ± 5% (voltage applied to driver) Armature resistance 29.2 ± 10% Inductance 30.0mH ± 25% Drive method PWM, constant-current chopping Drive IC A6628
Closed loop control based on the CR Motor (DC Motor) and CR Encoder Sensor has advantages in stabilized print quality and silent operation.
Heat Generation Control
The printer has a machanism to reduce the variations in the torque constant and coil resistance of the DC motors, and variations in output voltage of the Power Supply Board to obtain a designated heating value.
CR Variation Measurement Sequence
The variations mentioned above are measured in a CR variation measurement sequence when the CR mechanical load is in the initial status and saved into the EEPROM (A6<H>). According to the saved information, the printer controls the drive voltage to obtain a designated driving current. This minimizes the unit-to-unit variation.
CR Measurement Sequence
To set the appropriate drive current value according to the CR mechanical load, the mechanical load is measured in a CR measurement sequence and saved into the EEPROM A4<H>, A5<H> at power-on or after replacement of the Ink Cartridge (s). However, if 6E is saved at the EEPROM A4<H> and 05 at A5<H>, Fatal error will occur since too large load is applied to the CR drive system.
The above control and sequences correct the drive current value of the CR Motor according to not only the mechanical load but also the variations of the motor and like. In addition, the resultant CR drive current value is used to calculate a heating value, and when the specified heating value is reached, wait time is provided per CR path for printing.
Operating Principles Printer Mechanism 17
EPSON Stylus Photo R1800/R2400 Revision B
2.2.1.2 Carriage Home Position Detection
As in the conventional model, the Carriage Home Position is detected using the drive current of the CR Motor and the speed/position signal of the CR Linear Encoder. The basic home position detection sequence is as described below.
1. The CR linear encoder pulse counter in the CPU is reset by the initialization operation performed at power-on.
2. When the CR Motor rotates counterclockwise, the Carriage Unit moves from left to right. When the following conditions are satisfied, the CPU assumes that the Carriage Unit made contact with the right frame.
The ASIC detects 1158/1500 counts or more in the PWM output under
CR Motor load positioning control.
P1 (number of output pulses from when power is switched on until the
Carriage Unit makes contact with the right frame) is 19 steps or less.
3. When the CR Motor rotates clockwise, the Carriage Unit moves from right to left. When the following conditions are satisfied, the CPU assumes that the Carriage Unit reached the CR lock confirmation position.
The ASIC detects 575/1500 counts or more in the PWM output under
CR Motor load positioning control.
A difference between P1 and P2 (number of output pulses from when
the Carriage Unit made contact with the right frame until it reaches the Carriage lo ck confirmation position) is 19 steps or less.
4. When the CR Motor rotates counterclockwise to move the Carriage from left to right and the CPU detects 1158/1500 counts or more in the PWM output under CR Motor load positioning control, the printer judges that the Carriage moved to the far right position (is in contact with the right frame ).
5. When a difference between P1 and P3 (number of output pulses from when the Carriage Unit reached the Carriage lock confirmation position until it makes contact with the right frame) is 4 steps or less, the printer judges that the Carriage Unit is in the home position.
The IC14 (ASIC) sets the drive current value adequate for the Carriage Unit motion and outputs it to the motor driver.
Based on the signal output from the IC14 (ASIC), the IC5 (Motor Driver) outputs the CR Motor drive current to the CR Motor.
2.2.1.3 Sequen ce Used for PW Detection
The PW (paper width detection) Sensor installed on the Carriage Unit bottom is used to control the printer according to various sequences.
The following briefly describes the PW Sensor operating principle. A dark voltage is measured by the PW Sensor in three places at the right flat
area (area without the absorber) on the Front Paper Guide every time the printer is turned on, and the measurement values are saved into the EEPROM as threshold values.
Threshold value detection voltage: Paper presentThreshold value detection voltage: Paper absent
The following sequences are performed.
Detection of Left and Right Edges of Paper and Control
Before Printing
The printer detects that paper has been loaded. And it sets the print range according to the paper-size information from the Driver and the actual paper-size detected by the PW sensor.
During Printing
When executing a borderless printing, the printer sets the off-range margins by detecting the paper edges with the PW Sensor. And when the resolution is 1440 x 1440 (VSD3) or 2880 x 1440 (VSD3) dpi, the printer performs the Off-Range Thinning Out Control to make a further correction to the off-range margins.
Detection of Top Edge of Paper and Control
Before starting a print job, the printer detects the top edge of a loaded single sheet of paper, roll paper, or board paper to set the off-range top margin. (Only when not detecting the top edge of paper with the PW Sensor.)
Detection of Bottom Edge of Paper and Control
After starting a borderless printing, the printer sets the off-range bottom margin.
Detection of Edges of CD-R and Control
Before starting to print, the PW Sensor detects top, bottom, left and right edges of the CD-R. See Section 2.2.3.4 CD-R Printing Mechanism on
page 24.
Operating Principles Printer Mechanism 18
EPSON Stylus Photo R1800/R2400 Revision B
PW sensor dark voltage (VH) measurement
PW sensor dark voltage (VH) measurement is performed at the following timings and locations and used to calculate the threshold value of whether paper is present or not.
Cut sheets, Roll paper
The dark voltage is measured and updated at every power-on, and the threshold value (VS) is calculated and saved in the EPROM area as a PW detection level.
Threshold value detection voltage: Paper present
Threshold value detection voltage: Paper absent
CD-R Tray
When printing on a CD-R, the dark voltage is measured on the CD-R tray, and the threshold value (VS) is then calculated and saved in the EPROM area as a PW detection level.
Threshold value detection voltage: CD-R present
(tray home position detected)
The measurement voltage in the presence of the CD-R is saved into the EEPROM as a white level. The white level value is used to check the sensor deterioration condition during servicing or like.
• If the measurement value of the white level is close to that of the PW detection level, it means that the sensor is dirty or deteriorated.
2.2.1.4 APG (Auto PG) Mechanism
The following indicates the specification of the DC motor that drives the APG.
Table 2-3. APG Motor Specifications
Item Specifications
Type DC motor with brushes Drive voltage +42V ± 5% (voltage applied to driver) Armature resistance 64.7 ± 15% Inductance 37.6mH ± 25% Drive method PWM, constant-current chopping Drive IC A6628
The APG Motor (DC Motor) and two APG Sensors drive the PG Cam to automatically adjust the PG amount according to the paper.
APG
Sensor
Carriage Shaft Carriage Unit
PG CamAPG Sensor
APG Motor
Figure 2-2. APG Mechanism
Operating Principles Printer Mechanism 19
EPSON Stylus Photo R1800/R2400 Revision B

2.2.2 Printhead Specifications

The Printhead of this product is a F-Mach head. The following shows the arrangement of the nozzles and the color arrangement of each nozzle line when viewed the Print Head from behind.
0.071mm
(1/360inch)
7.620mm
(216/720inch)
2.258mm
(64/720inch)
Line A
(64/720inch)
Line C
Line B
Carriage moving direction
Figure 2-3. Nozzle Arrangement
7.620mm
(216/720inch)
2.258mm
Line D
31.89mm
41.66mm
2.258mm
(64/720inch)
Line E
7.620mm
(216/720inch)
Line F
2.258mm
(64/720inch)
LineG
Paper feeding
direction
Line H
0.141mm
(1/180inch)

2.2.3 Paper Feeding Mechanism

The paper feeding mechanism is a mechanism that feeds paper or CD-R Tray to the PF Roller Shaft.
CD-R Tray
Star Wheel Rollers
Board paper
Front Paper Eject Roller
Figure 2-4. Paper Feeding Mechanism
PE Sensor
Rear Paper Eject Roller
Cut sheet
PF Roller
Roll paper
Table 2-4. Nozzle Lines and the Corresponding Ink Color
Line Ink
AYellow B Magenta CCyan D Matte-black E Photo-black
F Red GBlue H Gloss Optimize r
Operating Principles Printer Mechanism 20
EPSON Stylus Photo R1800/R2400 Revision B
2.2.3.1 ASF Paper Feeding Mechanism
The following shows the specifications of the stepping motor that drives the ASF Assy.
Table 2-5. ASF Motor Specifications
Item Specifications
Type 4-phase, 48-pole PM type stepping motor Drive voltage +42V ± 5% (voltage applied to driver) Winding resistance 7.0 ± 10% (per phase at 25°C) Inductance 10.2mH ± 20% (1kH, 1Vrms, 25Åé) Drive method Bipolar drive/constant-current drive Drive IC A6628
Driven by the ASF Motor, the ASF Assy performs the following feeding operation.
1. When a paper feeding command is issued from the PC or the Paper Switch of the panel is pressed after power-on, the driving force of the ASF Motor begins to be transmitted to the LD Roller following the route shown below.
ASF Motor
Combination Gear 29, 11
4. When the next sheet of paper is fed by the LD Roller and the Retard Roller, the Hopper is pressed against the Frame again by the Hopper Cams. And the Paper Holder of the Paper Back Lever rises by the Cams at the left and right ends of the LD Roller to prevent the next sheet from being fed with the previous sheet.
5. The LD Roller stops to rotate when it makes one revolution and the Flag of the ASF Sensor Wheel returns to the ASF Sensor.
LD Shaft Spur Gear
LD Roller
2. When the LD Roller starts rotating, the Flag of the ASF Sensor Wheel comes free from the notch on the ASF Sensor. And at the same time, the Paper Back Lever becomes free from the Cams located at the left and right ends of the LD Roller, then the Paper Holder on the Paper Back Lever inclines downward by tensile force of the Paper Back Lever Torsion Spring.
3. By the LD Roller's rotation, the Hopper is released from the Hopper Cams located at the left and right ends of the LD Roller, and the Hopper pops up by tensile force of the Hopper Compression Spring.
Operating Principles Printer Mechanism 21
EPSON Stylus Photo R1800/R2400 Revision B
2.2.3.2 Roll Paper Feeding
Relay Board
Sensor
LD
Roller
Cam
ASF
ASF Sensor
Wheel
Hopper
LD Roller
Paper
Hopper
Compression
Spring
ASF Motor
LD Shaft
Spur Gear
Combination
Gear 29.11
When selecting the Roll Paper Mode, the contol Panel switches function in different ways from when printing other than roll paper. This section describes the deifference.
1. The roll peper is fed into the printer after a lapse of three seconds from when the PE sensor detects the paper.
2. The roll paper is fed backward to be set at the print position.
While the printer is performing the above operation, the switches are disabled. After the roll peper is set to the print position, the switches operation becomes defferent from when printing other than roll paper.
The details of the difference are described below. When Loading Roll Paper.
Pressing the Roll Paper Switch for more than 3 seconds feeds the leading edge of the roll paper backward to the PE Sensor (the Paper LED flashes). In this state, draw the roll paper and press the Paper Switch to return the panel operation to the normal mode that enables paper feeding from the ASF.
When Received a Print Job for Roll Paper
1. After finished the print job, press the Roll Paper Switch.
2. A cutoff line is printed, and the roll paper is fed to the roll paper cut position.
3. After cutting the roll paper with a pair of scissors or like, press the Roll Paper Switch again. This returns the leading edge of the paper to the print starting position.
Retard
Roller
Standby State Feeding Paper
Paper Back Lever
Torsion Spring
Paper Back Lever
Figure 2-5. ASF Paper Feeding Mechanism
Operating Principles Printer Mechanism 22
EPSON Stylus Photo R1800/R2400 Revision B
2.2.3.3 CD-R Tray Base Lock Mechanism
To prevent the Print Head from being damaged by mistake, the printer is designed to lock the CD-R Tray Base when the Carriage Unit is out of its home position.
The following explains the lock mechanism of the CD-R Tray Base. Lock Release Sequence
1. When the Carriage Unit returns to its home position, the Pump Motor drive is transmitted to the Paper EJ Lock Release Cam.
2. The salient of the Cam presses down the Paper EJ Transmission Lock Lever to release the tab of the Paper EJ Lock Lever from the Paper EJ Transmission Lock Lever.
3. The CD-R Release Lever comes free from the Paper EJ Lock Lever and comes down to enable the CD-R Tray Base to open.
When the Carriage Unit is out of its home position, the salient of the Paper EJ Lock Release Cam does not press down the Paper EJ Transmission Lock Lever, and the tab of the Paper EJ Lock Lever is not released. Therefore, the CD-R Tray Base cannot be opened.
CD-R Tray Base
Paper EJ Lock Lever
Paper EJ Transmission Lock Lever
Paper EJ Lock Release Cam
CD-R Release Lever
Jointed positionTab
Salient
Figure 2-6. CD-R Tray Base Lock Mechanism
Operating Principles Printer Mechanism 23
EPSON Stylus Photo R1800/R2400 Revision B
2.2.3.4 CD-R Printing Mechanism
CD-R Tray Home Position Detection Sequence
The following sequence is performed after opening the Front Cover (CD-R Sensor closing), inserting the CD-R Tray to the specified position, and pressing the Paper SW.
When the close signal of the CD-R Sensor is detected, no paper is fed from the ASF if the Paper Switch is pressed. In this case, the Paper Switch executes a CD-R Tray home position detection sequence.
1. When the APG Assy is driven, the PG position is set to "++" and the Driven Roller of the Upper Paper Guide presses the CD-R Tray.
2. When the Carriage Unit moves leftward and the PW Sensor detects the CD-R, the Carriage Unit returns to its home position (HP).
3. After waiting for about 5 seconds at the HP, the Carriage Unit moves to the CD-R Tray HP detectable position (right end of the CD-R Tray).
4. The CD-R Tray is pulled in the ASF direction, the PW Sensor detects the CD-R Tray HP, and then the Carriage Unit moves to the center of the CD-R Tray.
5. When the PW Sensor detects the white marking in the center of the CD-R Tray, the CD-R Tray is fed in the paper ejection direction.
6. The Carriage Unit moves leftward, the PW Sensor detects the left side white marking, then the Carriage Unit moves rightward, and the PW Sensor detects the right side white marking.
7. The Carriage Unit moves to the center of the CD-R Tray, and the PW Sensor starts detection in the back-and-forth direction of the CD-R. After the leading edge of the CD-R is detected, the CD-R Tray is fed in the paper ejection direction, and the trailing edge of the CD-R is detected. After that, the CD-R Tray is fed to the center of the CD-R in the paper ejection direction.
8. The Carriage Unit moves leftward, and the PW Sensor starts detection in the horizontal direction of the CD-R. After the left end of the CD-R is detected, the Carriage Unit moves rightward, and the right end of the CD-R is detected.
9. The Carriage Unit moves to the CD-R Tray HP detectable position and stops there, and then the CD-R Tray is fed in the ASF direction.
10. When the CD-R Tray stops operating, the Carriage Unit moves to the carriage HP and stands by.
If the CD-R Tray HP, white marking or CD-R cannot be detected within the steps predetermined for the CD-R Tray HP detection sequence, the CD-R Tray is ejected and Paper Out Error is displayed.
PW Sensor
CD-R Tray
Carriage Unit
CD-R home position
Figure 2-7. CD-R Printing Mechanism
Operating Principles Printer Mechanism 24
EPSON Stylus Photo R1800/R2400 Revision B

2.2.4 Paper Feeding Mechanism

The Paper Feeding Mechanism is designed to transfer the paper fed from the ASF, Roll Paper Guide or Board Paper Guide or the CD-R fed from the CD-R Tray according to the print data.
2.2.4.1 Paper Feeding Mechanism
The following shows the specifications of the DC motor that drives the Paper Feeding Mechanism.
Table 2-6. PF Motor Specifications
Item Specifications
Type DC motor with brushes Drive voltage +42V ± 5% (voltage applied to driver) Armature resistance 21.2 ± 10% Inductance 17.2mH (1kHz) Drive method PWM Drive IC A6628
Like the CR Motor, a DC motor is used as the PF Motor in this product. Closed loop control based on the DC Motor and Rotary Encoder has the
following advantages.
Improved paper feed accuracyPaper feed amount control
PF Motor
PF Timing Belt
Combination Gear
36.294, 45.5
PF Roller
Spur Gear 31.5
Spur Gear 68
Front Paper Ejec t Roller
Spur Gear 16; B (front)
Spur Gear 15.5
Spur Gear 16; B (rear)
Rear Paper Eject Roller
The following shows the part names and outline of the drive transmission path.
Combination Gear
36.294, 45.5
PF Timing Belt
PF Motor
Spur Gear 16; B (rear)
Spur Gear 68 Front Paper
Eject Roller
Spur Gear 15.5
Spur Gear 31.5
The PF Motor drive is transmitted to the PF Roller and the Paper EJ Roller following the route shown below. The route is also followed by the paper.
PF Roller
Front Paper Eject Roller
Front Paper Guide
Rear Paper Eject Roller
Figure 2-8. Paper Feeding Mechanism
Operating Principles Printer Mechanism 25
EPSON Stylus Photo R1800/R2400 Revision B
The fed paper is detected by the PE Sensor, and its leading edge is then transferred to the front of the Front Paper Guide. To eliminate the deflection of the paper, the paper is then returned toward the ASF Assy by the specified number of steps according to the paper feed mode. The paper is transferred again to the specified paper locating position of the Front Paper Guide.
2.2.4.2 PF Measurement Sequence
The mechanical load in the paper feeding path is measured in the following
cases to perform control so that an adequate current value is set according to the mechanical load.
When power is switched onWhen the Ink Cartridge is replaced
When the mechanical load in the paper feeding path reaches the specified
value, a Fatal Error is displayed.

2.2.5 Ink System Mechanism

The Ink System Mechanism consists of the following units.
Pump Unit (including the CR Lock Lever)Cap Unit
2.2.5.1 Pump Unit
The Pump Unit is designed to suck ink from the Print Head or Cap Unit. The Cap Unit has a built-in Head Cleaning Wiper. The following shows the specifications of the stepping motor that drives Pump Unit.
Table 2-7. Pump Motor Specifications
Item Specifications
Type 4-phase, 48-pole PM type stepping motor Drive voltage +42V ± 5% (voltage applied to driver) Winding resistance 10.3 ± 10% (per phase at 25°C) Inductance 13.4mH ± 20% (1kH,1Vrms) Drive method Bipolar drive/constant-current drive Drive IC A6628
The following operations are performed when the drive of the Pump Motor is transmitted to the Pump Unit.
Table 2-8. Pump Motor Rotation Directions and Functions
Pump Motor Rotation Direction* Functions
•Cap closing
CW direction
CCW direction
Note "*": The direction (CW or CCW) was determined viewing the motor from the
output shaft of the motor mounting plate.
• Ink suction
• Wiper resetting
• CR Lock setting
• Cap opening
• Pump release
• Wiper setting
• CR Lock resetting
Operating Principles Printer Mechanism 26
EPSON Stylus Photo R1800/R2400 Revision B
2.2.5.2 Drive Transmission Path to Pump Unit
The drive of the Pump Motor is transmitted to the Pump Unit in the following path.
Pump Motor
Combination Gear 10.2, 21.2 IS
Spur Gear 20.4 IS
Pump Unit
The following shows the internal part names and operation outline of the Pump Unit.
<Pump Unit in s ide>
Combination Gear 10.2, 21.2 IS
Spur Gear
20.4 IS
The following shows the Pump Unit operating principle.
Cap Unit Side
To Waste ink pad
Figure 2-10. Pump Unit Operating Principle
Ink Suction
1. The Pinion Gear of the Pump Motor rotates in the CW direction.
2. The Roller turn s and si mult an eou sl y pres se s the tube.
3. Ink is fed from the Cap Unit toward the Waste Ink Pad.
Pu mp Rel ease
1. The Pinion Gear of the Pump Motor rotates in the CCW direction.
2. The Roller moves away from the tube and releases the tube.
Pump Motor and Motor Pini on Ge ar
3. Ink is not sucked.
Figure 2-9. Outline of Pump Unit Inside
Operating Principles Printer Mechanism 27
EPSON Stylus Photo R1800/R2400 Revision B
2.2.5.3 Cap Unit
The Cap Unit is designed to make airtight in the Cap sticking fast to the Print Head surface so that ink suction can be performed by the driving force of the Pump Unit.
When the printer is in a standby status or its power is OFF, the Cap Unit prevents the ink from thickening.
The following figures shows the Cap Unit operation.
Carriage Unit
Cap
Print Head
Figure 2-11. Capping M echanism
Slider cap rises to perform capping.

2.2.6 Ink Sequence

The following ink sequence is executed according to various timer, counter, flag and other information saved on the EEPROM.
CSIC-related sequence
The ink type code stored in the CSIC Memory Chip is saved in the Main Board EEPROM. At power-on, data is read from each color CSIC and the CSIC data status becomes valid. If the data read from each CSIC has any problem, No Ink Cartridge, CSIC Error or Ink Out will be displayed. After CSIC operation is checked, the ink consumption of the I/C currently installed per color is compared with the ink consumption saved in the printer EEPROM, and control is performed under the following conditions.
When the current ink consumption data differs between the Ink
Cartridge and the EEPROM
1. The printer judges that the Ink Cartridge was replaced while the printer was turned off. Then it resets the 1st I/C flag in the EEPROM.
2. The printer updates the number of times the CSIC is installed.
3. After incrementing the counter of I/C replacement, the printer reads the ink consumption data from the CSIC to write it over the existing data in the EEPROM following the CSIC data replacement sequence.
4. The printer model name data on the CSIC is rewritten.
Note:The reason why the model name data is rewritten from the printer
to the CSIC is to know for which model was the I/C used at the time of collecting used I/Cs.
5. The replacement flag 2 (flag that indicates CL after Replacement) is set and the CL is executed.
Operating Principles Printer Mechanism 28
EPSON Stylus Photo R1800/R2400 Revision B
When the current ink consumption data in the Ink Cartridge and that in
the EEPROM is same
1. When the initial filling flag is set and the CSIC ink consumption is 0, the printer judges that initial filling is not yet performed. (The printer before initial filling judges that the I/C is fitted in a power-off status.)
2. Installation count updating, CSIC information rewriting, and initial filling are executed in that order.
3. If the initial filling flag is not set, the printer judges that I/C(s) has not been replaced during power-off and regards the current CSIC data as valid.
Data is written to the CSIC at the following timings.
At powe r-of fWhen starting the power saving modeWhen replaced an Ink Cartridge(s)At the tim e of clean in g
1. Reads the data from the CSIC.
2. Compare the date with the ink consumption data in the EEPROM.
3. If the EEPROM data is same as the CSIC data, ends the sequence. If they differ, the difference is added to write the sum in the CSIC.
Initial Ink Filling
When the printer is powered on for the first time after purchase, the printer executes the initial ink filling operation to fill the ink cavities of the Head with ink. When the initial ink filling operation is performed properly, the printer clears the flag in the EEPROM so that initial ink filling operation will not be performed when it is powered on the next time. The Stylus Photo R1800 requires about 160 seconds to perform the initial ink filling operation. If the sequence does not end normally during initial filling, the initial filling flag is not cleared and the CL operating flag is set. Because of these flags, when powered on the next time, the printer assumes that it was powered off for some reason during initial filling and executes CL3 instead of the initial filling sequence. (On the conventional mode, initial filling was executed again. However, when this operation was performed, ink was wasted and therefore CL3 is executed to cover the ink filling performance.) When the initial filling flag is set and the CL operating flag is not set, the printer judges that the initial filling was not executed at all (power was switched on but the cartridges were not installed), and when the printer is powered on the next time, it executes initial filling.
Replacement Cleaning
Replacement CL1 is executed when replaced an Ink Cartridge(s). Amount of Ink Suction
Replacement CL1: 3.09g (0.386g per color)
Operating Principles Printer Mechanism 29
EPSON Stylus Photo R1800/R2400 Revision B
Manual Cleaning
This printer provides three different manual cleanings to remove ink coagulated by air bubbles, viscous material or foreign matter. Perform the following manual CL operations by operating the panel or using the utility included in the printer driver. Independently of the printing path after the previous CL, perform manual CL from CL1 to CL3 in order if the cumulative printing timer counter is less than 7min. Only when the cumulative printing timer counter is more than 7min, execute only CL1.
Amount of Ink Suction
CL1: 1.55g (0.194g per color)
CL2: 4.08g (0.510g per color)
CL3: 6.47g (0.809g per color)
Wiping Operation
Clean the nozzle surface with the right-half rubber part of the wiper.
Flushing Operation
Prevent color mixture. Stabilize the ink surface inside the nozzles.
In addition, the printer determines which CL to perform according to the remaining amount of ink in the Cartridge. When the printer detects the amount is low, it automatically choose the CL that uses ink less than the other CLs. If the remaining amount of ink is extremely low (Ink Low or Ink Out status), the printer disables the all manual Cleanings and indicates the status on the EPW3.
Timer Cleaning
Ink is consumed depending on the combination of the cumulative printing timer, cumulative cleaning count and cleaning timer.
Flushing
There are two types of flushing. Flushing before printing
This is performed to reduce the viscosity of ink in the Print Head nozzles before starting to print.
Scheduled Flushing
This is performed to prevent ink in the Print Head nozzles from increasing its viscosity during printing.

2.2.7 Power-On Sequence

The following describes the printer operation after it is powered on.
When the Carriage Unit is in the Home Position wit h the CR Locked
1. After power-on, the drive of the APG Motor is transmitted to the Carriage Shaft, and the PG position changes from PG Typ. to PG++.
2. The drive of the CR Motor is transmitted to the Carriage Unit, and the Carriage Unit performs HP detection operation in the following path.
Home position Right frame CR Lock confirmation position
Right frame Home position
3. The drive of the Pump Motor is transmitted to the Cap Unit, the Cap opens (lowers), and the CR Lock is released.
4. After the Carriage Unit has moved leftward by the specified number of steps, the Wiper, driven by the Pump Motor, performs the following.
W ipe r set tin g ⇒ Wiper resetting
5. The Carriage Unit returns to the home position, and the PG position returns from PG++ to PG Typ.
6. The drive of the PF Motor is transmitted to the PF Roller and Paper Eject Rollers (front and rear), which then rotate for about 2 seconds.
7. After moving between the left and right frames twice, the Carriage Unit moves to the right end of the Front Paper Guide.
8. The PF Roller and Paper Eject Rollers (front and rear) rotate. Rotation for about 4 seconds (slow speed) ⇒ Rotation for about 2
seconds
9. The Carriage Unit returns to the home position and is secured by the CR Lock.
Operating Principles Printer Mechanism 30
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