Epson Stylus 800 Service Manual

“)

EPSON TERM

Myk.

NAL PRINTER

800

SERVICE MANUAL

EPSON

4001968

)

Rev. A

NOTICE

Allrightsreserved.ReproductionofanypartofthismanualinanyformwhatsoeverwithoutSEIKO
EPSON’sexpresswrittenpermission isforbidden.

The contentsof this manualare subjectsto change without notice.

Alleffortshavebeenmadetoensuretheaccuracyofthecontentsofthismanual.However,shouldany
errorsbe detected,SEIKOEPSONwould greatlyappreciatebeinginformedof them.

TheabovenotwithstandingSEIKOEPSONcanassumenoresponsibilityforanyerrorsinthismanualor
the consequencethereof.

Epsonisa registeredtrademarkofSeiko EpsonCorporation.

GeneralNotice:Otherproductnamesusedhereinareforidenticationpurposesonlyandmaybetrademarks
of theirrespective campanies.

Copyright © 1992 by SEIKO EPSON CORPORATION Nagano, Japan

-i-

PRECAUTIONS

Precautionary notations throughout the text are categorized relative to
damage to equipment.

DANGER

WARN/NG

The precautionary measures itemized below should always be observed when performin
maintenance procedures.

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.

Signals a precaution which, if ignored, could result in damage to equipment.

1)

personal injury and 2)

grepair/

DANGER

1.

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

NO WORK SHOULD BE PERFORMED ON THE UNIT BY PERSONS UNFAMILIAR

2.
WITH BASIC SAFETY MEASURES AS DICTATED FOR ALL ELECTRONICS TECH­NICIANS IN THEIR LINE OF WORK.

WHEN PERFORMING TESTING AS DICTATED WITHIN THIS MANUAL, DO NOT

3.
CONNECT THE UNIT TO A POWER SOURCE UNTIL INSTRUCTED TO DO SO.

WHEN THE POWER SUPPLY CABLE MUST BE CONNECTED, USE EXTREME CAU­TION
NENTS.

IN

WORKING ON POWER SUPPLY AND OTHER ELECTRONIC COMPO-

WARNING

1.

REPAIRS ON EPSON PRODUCT SHOULD BE PERFORMED ONLY BY AN EPSON
CERTIFIED

MAKE CERTAIN THAT THE SOURCE VOLTAGE IS THE SAME AS THE RATED

2.
VOLTAGE, LISTED ON THE SERIAL NUMBER/RATING PLATE. IF THE EPSON
PRODUCT HAS A PRIMARY AC RATING DIFFERENT FROM AVAILABLE POWER

SOURCE, DO NOT CONNECT IT TO THE POWER SOURCE.

ALWAYS VERIFY THAT THE EPSON PRODUCT HAS BEEN DISCONNECTED

3.

FROM THE POWER SOURCE BEFORE REMOVING OR REPLACING PRINTED CIR­CUIT BOARDS AND/OR INDIVIDUAL CHIPS.

IN ORDER TO PROTECT SENSITIVE MICROPROCESSORS AND CIRCUITRY, USE

4.

STATIC DISCHARGE EQUIPMENT, SUCH AS ANTI-STATIC WRIST STRAPS,
WHEN ACCESSING INTERNAL COMPONENTS.

REPLACE MALFUNCTIONING COMPONENTS ONLY WITH THOSE COMPO-

5.

NENTS BY THE MANUFACTURE; INTRODUCTION OF SECOND-SOURCE ICS OR

REPALR

TECHNICIAN.

-

ii

-

PREFACE

This manual describes

of stylus 800.
The instructions and procedures included

attention should be given to the precautions on the preceding page. The chapters are organized as
follows:

functions, theory of electrical and mechanical operations, maintenance, and repair

herein are intended for the experience repair technician, and

CHAPTER 1. GENERAL DESCRIPTION

Provides

a general product overview, lists specifications, and illustrates the main components of the printer.

CHAPTER 2. OPERATING PRINCIPLES

Describes the theory of printer operation.

CHAPTER 3. DISASSEMBLY AND ASSEMBLY

Includes a

step-by-step guide for product disassembly and assembly.

CHAPTER 4. ADJUSTMENTS

Includes a step-by-step guide for adjustment.

CHAPTER 5. TROUBLESHOOTING

Provides Epson-approved techniques for adjustment.

CHAPTER 6. MAINTENANCE

Describes preventive maintenance techniques and lists lubricants and adhesives

required to service the equipment.

APPENDIX

Describes connector pin assignments,

circuit diagrams, circuit board component layout

amd

exploded diagram.

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

-

iv -

Revision

Issue Date

Revision Page

Rev. A

Rev. B

Rev. C

Rev. D

December

June 11, 1993

March 10, 1994

18, 1992

May 7, 1993

First issue

Added information:
Chapter 2 (Page 2-23)
Chapter 3 (Page 3-5/6)
Chapter 6 (Page 6-1/2)

Corrected the figure:
Chapter 2 (Page 2-8)

Added information:
Appendix (Page A-i, A-5’, A-7’,
A-8’, A-9’, A-1 O’)

-v-

TABLE OF CONTENTS

CHAPTER 1.
CHAPTER 2.
CHAPTER 3.
CHAPTER 4.
CHAPTER 5. TROUBLESHOOTING
CHAPTER 6.

APPENDIX

GENERAL DESCRIPTION
OPERATING PRINCIPLES
DISASSEMBLY AND ASSEMBLY

ADJUSTMENTS

MAINTENANCE

-

vi -

Chapter 1

General Description

Table of Contents

FEATURES

1.1

1.2 SPECIFICATIONS

1.2.1

1.2.2

1.2.3

1.2.4

1.2.5

1.2.6

1.2.7

1.2.8

1.2.9

1.3 INTERFACE SPECIFICATION

1.4 PRINTER OPERATIONS

1.4.1

1.4.2

1.4.3

1.4.4

1.4.5

Printing Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Paper Handling Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. ...1-4

Paper Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............1-4

Ink Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ......1-6

Environmental Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. ....1-7

Electrical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ......1-7

Reliability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .........1-8

SafetyApproval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..............1-8

Physical Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..........1-8

control

Panel Operation at PowerOn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Default Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. ...1-12

1.4.3.1 Default Setting Item . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. ...1-12

Initial Ink Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. ..1-13

Error Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .....1-13

panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . ~

.

................1-1

1-1

1-2

.1-2

1-9

1-11

..1-12

1

1.5 MAIN COMPONENTS

1.5.1

Main Control Board (C106 MAIN BOARD) . . . . . . . . . . . . . . . . . . . . . .. .1-14

1.5.2 Power Supply Unit

1.5.3

Printer Mechanism

Figure 1-1.
Figure l-2.

Figure 1-3.
Figure 1-4.
Figure 1-5.
Figure 1-6.
Figure 1-7.
Figure 1-8.
Figure 1-9.
Figure l-10.
Figure 1-11. Printer Mechanism

View of the Stylus 800 . . . . . . . . . . . . . . . . . . . . . ...............1-1

Nozzle Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ......1-2

Printable Area - Cut Sheet (Built-in Sheet Feeder) . .............1-5

Printable Area - Cut Sheet/ Envelope (Manual Insertion Slot) .. ...1-5

Adjust Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..........1-6

Temperature

Data Transmission Timing . . . . . . . . . . . . . . . . . . . . . .........-..1-9

Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..1-11

C106 MAIN BOARD Component Layout . . . . . . . . . . . . . . . . . . . . .1-14

C106

PSB/PSE

(C106

(M-481O)

/

Humidity Range . . . . . . . . . . . . . . . . . . . . . ........1-7

1-14

PSB/PSE

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .....1-15

BOARD) . . . . . . . . . . . . . . . . . . . . .1-15

List of Figures

BOARD Component Layout . . . . . . . . . . . . .....1-15

(M-481O)

. . . . . . . . . . . . . . . . . . . . . . . . .....1-15

Rev.

A

l-i

List of Tables

Table 1-1. Print Speed and Printable Columns . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Table 1-2. Character Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Table l-3. Adjust Lever Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ......1-6

Table l-4. Environmental Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...1-7

Table l-5. Electrical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. ...1-7

Table l-6. Signal and Connector Pin Assignments . . . . . ..................1-9

Table l-7. Default Setting Item . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .....1-12

Table l-8. Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .....1-13

I-ii

f“”-”’-

Rev. A

STYLUS 800 Service Manual

1.1 FEATURES

The Stylus 800 is a serial inkjet printer that uses a newly developed inkjet technology to accomplish
a superb quality output with high-speed printing. The major features of this printer are:

Ll

High print quality from a new inkjet technology.
Cl Fast printing of LQcharacters at 150 cps.

Cl

Compact design saves precious work space.

Ci

Built-in auto sheet feeder with a capacity fora maximum of 100 cut sheets (either A4 or Letter).

D

Equipped with 4 scalable fonts and 15 bit-mapped fonts, standard.

CI

8 character tables for the U.S.

6 character tables for Pacific countries.

16 character tables for European countries.

The figure below shows a view of the printer.

General Description

printer cover

paper separator

Figure 1-1. View of the Stylus 800

panel

paper feeder cover

Rev. A

1-1

General Description

1.2 SPECIFICATIONS

STYLUS 800 Service Manual

This section provides detailed statistics for this printer.

1.2.1 Printing Specification

Print system:

Nozzle configuration:

On-demand ink jet system
48 nozzles (12 nozzles x 4 staggered columns)

II

.

.

II

i

i
II
i i

#45

II
I

,,

II

Qi

.

I

i

0

Paper feed

direction

{

i’

..., *

Printer direction:
PMt speed:
Printable columns:

Character Pitch

(l

Ocpi/Condensed)

(12

Figure 1-2. Nozzle Configuration

Bidirectional printing with logical seeking control

See Table 1-1.
See Table 1-1.

Table 1-1. Print Speed and Printable Columns

Print Speed (LQ)

150

Cps

180

CPS

225 CPS

257 Cf)S

300

Cps

10

cpi

12

cpi

15

cpi

17

cpi

20

cpi

cpVCondensed)

Printable Columns

80

96

120

137

160

1-2

Rev.

,,

f’

-..

A

STYLUS 800 Service Manual

Geneml

Descri@ion

Character sets:
Character tables:

Character Table US Version European Version Pacific Version

ITALIC

PC437 (U.S./Standard Europe)
PC850 (Multilingual)
PC860 (Portuguese)
PC863 (Canadian-French)
PC865 (Nodic)
PC437 Greek
PC851

(Greek)

PC852 (East Europe)
PC853 (Turkish)
PC855
PC857 (Turkish)

(Cyrillic)

Legal and 14 international character sets.
See Table 1-2.

Table 1-2. Character Tables

o

0
o 0
o
o

0

0
o 0

I
I

o

I

x

x
x
x
x
x

I

o

o

o

o

o

o

o

0
0

0

0

0

I
I

o

x

x
x
x
x

x

PC866 (Russian)
ABICOMP
BRASCII

Fonts:

Print mode:

x

I

o
o

[Bit-mppedfonts]

-

EPSON Roman

- EPSON %ns serif

- EPSON Courier

- EPSON Prestige

- EPSON Script

IScaldlefmtsl

-

EPSON Roman

- EPSON %ns serif

- EPSON Roman T

- EPSON

[For

Bit-mppedfontsl

Selection ~-d

- Print quality (LQ)

- Character pitch (10/12/15

- Condensed (not available with 15

- Double width

- Emphasized

- Italic

- Double underline

- Strike through

!%IIS

&xture

%rif

(lOcpi/12cpi/15cpi/Proportional)

(10/12/15/Proportional)
(10/12/15)
(10/12)
(10/12)

8-32 points (Unit= 2 points)
8-32 points (Unit= 2 points)
8-32 points (Unit= 2 points)

H

8-32 points (Unit= 2 points)

of the following mode are allowed.

cpi

or proportional)

- Double height

- Double strike

- Underline

-

Overscore

- Shadow / outline

o

I

cpi

x

x

character pitch)

x

I

x

x

Control codes:

Rev.

A

IForscalablefonts]

-

Emphasized

- Italic

- Double underline

- Strike through

EC,~//~~

- Double

- Underline

-

Overscore

- Shadow / outline

stike

1-3

General Description

1.2.2 Paper Handling Specification

STYLUS 800

Sewice Manual

Feeding system:

Feeding pitch:
Paper path:

Feeding speed:

Friction feed from built-in sheet feeder or manual insertion slot.

Notes: The following operation are not al/owed.

1. Reverse feeding within

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

1/6, 1/8 inch feed or progra
Built-in sheet feeder (front entry)

Manual insertion slot (Top-rear entry)
87

msec.

(at 1/6 inch feed pitch)

1.2.3 Paper Specification

Usable paper:

~ith

Cut sheet

Built-in sheet feeder]

Size:

Thickness:

Wighk

Quality:

3

mm (O. 12 inches) from the top edge
of the paper or 16 mm (0.63 inches) from the bottom edge of
the paper.

mmable

For European/Pacific version:
A4

(wX

L

:210mm (8.3”)X 297mm

For U.S. version:
Letter (W x L: 216 mm (8.5”) x 279 mm (11.0”))

0.065-0.14

-

90g/m2

64
Bond Paper, Photocopier paper

nun

with a 1/360 inch minimum increment.

(11.7”))

(0.0026 - 0.0055”)

(18 -24 lb./55 - 78 Kg)

.:

f“”

. .. . .

.

i.:,,-

<Envelope>

[With manual insertion]
Width:

Length:
Thickness:
Wight:
Quality:

Size:

Thickness:

Note:

Weight:
Quality:

Notes 1. Envelopes are usable only with manual insertion feed.

The variation in paper thickness within the printable area must be 0.25

mm (0.0098~ or less.

2. Printing with envelopes

3. Insert envelopes into the manual insertion slot sideways.

182-216 mm (7.2 - 8.5”)

257-

297mm

0.065-0.11 mm (0.0026- 0.0043”)
52-

90g/m2 (14

Bond Paper, Photocopier paper
#6 (W

X

#10

(Wx

0.16-0.52 mm (0.0063 - 0.0197”)

45-90 g/m2 (12 -24 lb.)

Bond paper, Airmail, Photocopier paper

and humidity condition.

(10.1 - 11.7”)

-24 lb / 45- 78 Kg)

L : 166 mm

L:

240

mm

(6%”) X

92 mm (35/8”))

(914”)

x 104 mm

guaranteedonly under normal temperature

(4%”))

f’

1-4

Rev.

,. ,.

A

STYLUS 800 Service Manual

Geneml

Description

Printable area:

B
(Left marain)>

Cut Sheet (with built-in sheet feeder)

c

—

4

(Right marain]~

.

r

Printable area

Figure 1-3. Printable Area - Cut S~eet

(Built-in Sheet Feeder)

r

A

!

(Top margin)

ID

I

(Bottom margin)

1

Note:

Cut

Sheet

/ Envelope (with the manual insertion

B
(Left

marain) ~.

Figure 1-4. Printable Area - Cut Sheet/ Envelope

A:

The minimum top margin=

B: The minimum left margin= 3 mm (O. 12”)

C:

The minimum right margin is:

D: The minimum bottom margin= 13 mm (0.51’)

*

Printable area

(Manual Insertion Slot)

3 mm (0.12”)

c

A4 size= 3.8
Letter size = 9.7mm (0.38’)
Manual

mm (O.

insettion

slot)

A
(Top margin)

L

&ottom margin)

15”)

= 3 mm (O.

12’9

Rev. A

1-5

General Description

SNLUS

800 Service Manual

Adjust lever settings:

Lever

Plain

paper,

The adjust lever, attached to the carnage unit, must be set to proper
position for the paper thickness, as shown in Table 1-3.

Table 1-3. Adjust Lever Settings

Position Paper Type

LEFT

RIGHT

I

Cut Sheets

Envelopes

I

Figure 1-5. Adjust Lever

Paper Thickness

~;%26--00~iO!$

0.16-

(0.0063- 0.020”)

/1

\

-

. . . . . . . . . . . - . . . . . . . .

0.52 mm

I

-.

.-

(-..

1.2.4 Ink Cartridge

Type:
Ink color:
Print capacity:

Ink Capacity:
Life:

Temperature conditions:

Dimension:

Exclusive cartridge

(S020025)

Black

0.7 million characters (LQ)

Note: This figure is equivalent to a 700page print volume when

printing is performed at 1000 characters perpage on letter or

A4-size

+0.5/-1.0

29.0

effective life from the indicated production date is:

The

paper.

CC

-2 years (total period of time in package and after unpacking)

-6 months (after unpacking)
[Storage]

[Transport] ~36- 60“C (-22 -140 “F)

Note: The ink inside the ink cartridge freezes if it kept below

(26.6”F). It requires several hours to unfreeze at room tem-

perature (25

Width
Depth
Height 38.5

-30- 40“C (-22 -104 ‘F)

(UDto1monthat40‘C

(Up to 1 month at40“C

(140 ‘F))

‘C (77°~).

28.5 mm (1.12”)

54.5 mm (2.15”)

mm(l.52”)

(140

(104

“F))

““

“F) or 120 hoursat60“C

-3’C

STYLUS 800 Service Manual

1.2.5 Environmental Conditions
Table 1-4. Environmental Conditions

Genera/

Descriptim

Description

Temperature

Humidity
Resistance to shock
Resistance to vibration

●

Note:

1 = Operating conditions must be in this range.

*2= When the printer is in the shipping container.

●

3 = Without condensation.

Humidity

(%RH)

80Y0

55~o

20?/0

. . . . . . .

Operating

10-35 ‘c (50 - 95 ‘I=)(*1)

20- 80% RH (*1,*3) 5-

1 G, within 1

0.15 G, 10-55 Hz 0.50 G, 10-55 Hz (*2)

msec.

. . . . . . . .

/

-20- 60

2 G, within 2

Print assured range

Storage

“C

(-4 - 140 ‘F) (*2)

85~0

RH (*2,*3)

msec.

(*2)

10” C

(50” F) (80” F)

Figure 1-6. Temperature/ Humidity Range

1.2.6 Electrical Specifications
Table 1-5. Electrical Specifications

Item

Rated voltage

Input voltage range
Rated frequency range
Input frequency range
Rated current

Power consumption

Insulation resistance

Dielectric strength

(self test with 10

10

(applying

10OOVAC

1200VAC rms

(between AC line and chassis)

27°

C 35°C

(95” F)

120V Version

120V AC

103.5- 132V
50- 60 Hz

49.5- 60.5 Hz 49.5- 60.5 Hz

0.5 A 0.3 A

Approx. 13W

cpi

LQ characters)

MQ,

minimum

500VDC

between AC line

and chassis)

rms

-1 minute or

-1 second

‘c

(“F)

220- 240V Version

220- 240V AC

198- 264V
50- 60 Hz

Approx. 13W

cpi

(self test with 10

MQ,

10

(applying 500VDC between AC line

and chassis)

1500VAC

(between AC line and chassis)

LQ characters)

minimum

rms

-1 minute

Rev. A

1-7

General Description

1.2.7 Reliability

STYLUS 800 Service Manual

MTBF:

MCBF:

Printhead

Total print volume:

life:

4000 power on hours
3 million lines (excluding the

1

billion dots per nozzle

75000

pages (with A4 or Letter size paper)

1.2.8 Safety Approval

Safety standards:

Radio frequency interface

US version:

European version:

(RFI):

US version: FCC part 15, subpart B,

European version:

1.2.9 Physical Specification

Size (W x D x H):
Weight

435 X 264X

Approx. 5.0 Kg (excluding ink cartridge)

(POH)

at a duty cycle of

printhead)

UL1950

CSA22.2

EN 60950
IEC 950

Vfg.

EN 55022

i~

(mm) (17.1X 10.4X 6.1 (inch))

with D3

%220

(~V)

(SEMKO,

243

(VDE

(CISPR Pub.22)

0878 part 3, part 30)

10%

DEMKO,

Ck.S

class B

NEMKO,

B

SETI)

1-8

Rev.

,

(“”

.

.

. . .

A

SNLUS

800 Service

Manual

1.3 INTERFACE SPECIFICATION

The Stylus 800 is equipped with an 8 bit parallel interface, standard.

GenemlDescription

Data format:
Synchronization:
Handshaking:
Signal level:
Adaptable connector:
Data transmission timing:

DATA

STROBE—

Figure 1-7. Data Transmission Timing

8 bit parallel
STROBE pulse

By BUSY and

TTL-compatible

swchronization

ACKNLG

level
36-pin 57-30360
See Figure 1-7.

\

—

L-

L!&

signals

(Amphenol)

O. SuS(Min.)

SuS(Min.)

O.

SuS(Min.)

O.

or equivalent

i’b--

Table 1-6 shows the connector pin assignments and signal functions of the 8-bit parallel interface.

Table 1-6. Signal and Connector Pin Assignments

Pin No.

1

2-9 DATA 1-8

10

11

12 PE

Signal Name

STROBE

ACKNLG

BUSY

1/0

The STROBE pulse is used to read data from the host

I

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

DATA 1-8 are parallel data bits. When one of these signals is
HIGH, the data bit is 1; when LOW, the
significant bit

I

maintained for 0.5 pS on either side of STROBE signal’s active
edge.

ACKNLG

approximately 10 vS. This signal goes LOW upon the

o

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

The BUSY signal informs the host computer of the

o

status. When this signal is HIGH, the printer cannot accept

further data.
This signal indicates whether paper is available in the printer

o

or not. A HIGH level indicates a no paper condition.

(MSB)

is an acknowledge pulse with a width of

Description

data

bit is O. The most

is DATA 8. The signal state must be

printe~s

Rev.

13

14

15

Pulled up to

SLCT

AFXT

NC

A

o

If this signal is set to LOW, the printer automatically performs

one line feed upon receipt of a CR (carriage return) code. The

I

status of this signal is checked only at power on and

initialization.

Not

USed.

+5V

through a 1.0 KQ resistor in the printer.

1-9

General Description

Table 1-6. Signal and Connector Pin Assignments (Continued)

SNLUS

800 Service

Manual

Pin No.

16

17

18

19-30

31

Signal Name

GND

CHASSIS-GND

NC

GND

INIT

32 ERROR

33
34

35

36

Note: The direction of the signal is as viewed from the printer.

GND

NC

+5V

-

I/o

Signal ground.
Chassis ground. (Both chassis ground and signal ground are

­connected in the

Not

USed.

Twisted-pair return signal ground.

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

I

width of this signal must be 50
This signal goes LOW if the printer:

o

.
.

.

.

-

has a fatal error.

- runs out of paper.
Signal ground.
Not

USed.

Pulled up to +5
Not used. (* Reserved.)

ptinter.)

Vthrough

Description

pS or more.

1.0 KW resistor in the printer.

(-

1-1o

Rev. A

STYLUS 800 Service Manual

General

DescriWion

1.4 PRINTER OPERATIONS

This section describes the basic operations of the printer.

1.4.1 Control Panel

The control panel of this printer contains five non-lock type push buttons and nine LED indicators
for easy operation of the various printer functions.

r

O

PAPER OUT

O

INK OUT

I

o

ECONOMY

II

/10

1’

I

I

CONDENSED [

r

000

Courier

Romm

T PS)

~:a:

Saris

Prestige

script

Ii3

$

(

Sarif

s)

,,

FONT

LOAD
EJECT

[

5

h.

1

,

D

/

5

jALT

1

r

R E SET

ju

\

I

I

I

J

Q

[Buttons]

PAUSE

ECONOMY/CONDENSED

FONT

LOAD/EJECT

ALT

[Indicators]

PAUSE
DATA
PAPER OUT

INK OUT

ECONOMY/CONDENSED

FONT

Figure 1-8. Control Panel

Switches printer status between printing and no printing, if any
print dataexists in the input

Selects ECONOMY printing mode or CONDENSED printing mode
alternately. Also works as a reverse micro feed button, if the
button has been pressed.

Selects one of the available fonts. Also works as a forward micro
feed button, if the

When you press this button, the printer either loads new paper into

the printer or ejects paper currently in the printer paper path. Also

works as a RESET button, if the
This button alternates the function of certain buttons. When you

hold down this button in PAUSE mode for 5 seconds, the printer
moves the carriage to the ink cartridge installation/replacement
position.

Lights when the printer is in PAUSE mode.
Lights when there is print data in the input buffer.
Lights when the printer is out of paper. Blinks if a paper jam has

occurred.
Lights when the printer detects ink end in the ink cartridge. Blinks

when the ink level becomes low.
This LED shows the currently selected mode.

lndicatw

the currently selected font.

ALT

button has been pressed.

ALT

button has been pressed.

buffer:

- - - -

ALT

Rev.

A

1-11

General Description

STYLUS 800 Service Manual

1.4.2 Panel Operation at Power On

The following functions can be activated at power on by holding down the specified button on the

control panel.
Self-test mode:

Start the self-test printing mode by turning the printer on while

holding down the FONT button.

Hex dump mode:

Start the built-in hexadecimal data dump print mode by returning
the printer on while holding down the FONT and LOAD/EJECT
buttons. Once this mode is selected, the printer prints all received
print data in hexadecimal form.

Demonstration mode:

Start printing of a demonstration page by returning on the printer
while holding down the ALT button.

Other functions that can be activated with the control panel at power on, such as the default setting
mode and the initial ink charge mode, are described in the sections that follow.

1.4.3 Default Setting

The printer can memorize certain number of printer setting parameters that defines its functions at
the initialization. You can change these parameters with the default setting mode for your specific
preference of the printer setting.

1.4.3.1 Default Setting Item

The settings listed in the table below can be made with the default setting mode. The default-setting
mode can be activated
printer. (Refer to the

by

hold down

use~’s

guide for the detail operation of the default-setting mode.)

the

ECONOMY/CONDENSED button while turning on the

Table 1-7. Default Setting Item

Menu

Contents

Character Table

Auto Print Direction

Network l/F Mode

Mixed Text/Graphics

Mode

Auto Line Feed

Note:

*1= If set to ON, the capacity of input buffer is limited to 8

Description

Select the character table
ON: Print direction is automatically selected as to maintains

optimal print quality (alignment).

OFF: Depends on the command ‘ESC U’.
ON: For network environment, such as LocalTalk.

(Time-out printing is disabled.)

ON: For normal environment.
ON: To ensure proper printing of the image containing

graphics and scalable font, with certain applications,
such as MS Word, WordPerfect

OFF: For normal use.

ON: Line feed operation is automatically performed by CR

code input.

OFF:NO line feed operation with single CR code.

(llme-out

V.5. I

printing is enabled.)

or earlier. ● 1

Kbyte,

Facto~

Setting

ON

OFF

OFF

OFF

. .. .

.

f

SWLUS

800 Service

Manual

General Description

1.4.4 Initial ink Charge

When the printer is to be set up for primary use, whole ink supply path of the printer must be filled
with a new ink, by performing the initial ink charge operation.

[Step 1]
[Step

[Step 3]

[Step 4]

The PAUSE LED blinks while the initial ink charge operation is in progress, and when it completes,

the printer automatically becomes ready state.

W
H

Turn the printer on and press the PAUSE button to pause the printer.
Open the printer cover and hold down the

2]

ink cartridge replace position.
Install the ink cartridge on the

printhead

Turn the printer on while holds down the
charge operation.

The ink cartridge must be installed just after unpacking the package.
The initial ink charge operation should not be

printer. It, otherwise, consumes too much ink in the ink
ink tank life.

to capping position. Then, turn off the printer.

printhead,

ALT

button until the

and press the

ALT

and the PAUSE buttons to start the initial

pe@ormed

ALT

more than

carh”dge

printhead

button again to move the

trm”ce

and shorten the waste

moves to the

on the same

1.4.5 Error Conditions

he

printer detects various errors and indicates them with the LED indicators and the buzzer.

Table 1-8. Error Codes

Error

Paper out

Paper jam

Ink low ● 1

Inkend I OFF

Waste ink tank

over-flow

PAPER

LED

ON

BLINKS

I

OFF

I

OFF

INK END

LED

OFF

OFF

BLINKS

ON

ON

OFF

ON

PAUSE

LED

OFF

OFF [ V4 x 3 times

=t==

=-l--==

BLINKS

Buzzer

V4

x 3 times

No beeps

V+

x 3 times

Load the paper and press the
buttons as follows:

1. PAUSE

2. LOAD/EJECT
Same as above.
Press PAUSE button and

replace the ink cartridge with

a new one. Then, press

PAUSE button again to
resume printing. ● 2

Replace the ink cartridge and

press

Install the ink cartridge and

mess

Turn off the printer, and turn
it on again.

Service

required. (Replace the waste
ink absorbing material and
reset the protect counters.)

Recovery

PAUSE button.

PAUSE button.

maintenance

Notes: V :

+ :

‘1:

*2:

Rev. A

0.1 second beep

0.1 second

This is

not treated as an error.

It

is not necessary to replace the ink cartridge until the printer detects the ‘Ink

End’ error.

4 :

intetval +

0.5 second beep

0.2 second interval

:

1-13

General Description

STYLUS 800 Service Manual

1.5 MAIN COMPONENTS

The main components of this printer are:

O

Printer mechanism (M-481O)
Q Main control board

~

Power supply unit

Cl

Control panel
Cl Housing

1.5.1 Main Control Board (C106 MAIN BOARD)

The

C106

MAIN BOARD is the main

the host computer and processing of received print data, as well as control of the whole printer

mechanism. This board consists of the following components.

(C106

MAIN BOARD)

(C106PSB/PSEBOARD)

conboller

of the Stylus 800. It takes charge of interfacing with

,. ..,,

.!

(.

CPU

(IC1):

Gate-array

Program ROM

CG

ROM

RAM

EEPROM

CR Motor driver

PF

Motor driver

(IC3):

(IC4):

(IC7/8):

(IC5):

(IC1O):

(IC13):

(QM1):

8-bit CPU

19.6608 MHz operating clock

Includes the following functions:

- MMU (Memory Management Unit)

-

IFU

- BMU (Bit Manipulation Unit)

- PCU (1/0 Port Control Unit)

- Head control unit (2 channel:
1 Mbit EPROM

4 Mbit Mask ROM
8 Mbit Mask ROM

1 Mbit
1 Kbit (64

3 lines serial bus
Hybrid

Constant current
Hybrid IC

Constant voltage

(TMP96C141F-20)

(Interface Control Unit)

(IC8

/ for US, Pacific version)

(IC7

/ for European version)

PSRAM

x

16

Bit)

EEPROM

IC

SMA7024MEL

unipolar

SMA6501

unipolar

drive

drive

HCU1, HCU2)

.,.

c

1-14

I

Un

Figure 1-9. C106 MAIN BOARD Component Layout

u

u

n

Rev. A

STYLUS 800 Service Manual

General Description

1.5.2 Power Supply Unit (C106

The power supply unit converts input AC voltage and generates different DC voltages required by

the printer mechanism and other electrical
and the

C106 PSE

/-

BOARD is for 220 to 240VAC input.

PSBIPSE

circuities.

—

BOARD)

The

C106 PSB

BOARD is for 120VAC input,

o

Figure 1-10. C106 PSBIPSE BOARD Component Layout

1.5.3 Printer Mechanism

This printer mechanism

carriage assembly, which includes the printhead and the ink supply system, the carriage motor, the
paper feed motor, the paper feeding mechanism, and the pump mechanism.

M-481O

(M-481O)

is specifically designed for the Stylus 800, and it consists of the

Rev.

Figure 1-11. Printer Mechanism

.—. —.—.

A

(M-481O)

1-15

,. . . . .

f.:,’

.

Chapter 2

Operating Principles

Table of Contents

2.1 OVERVIEW

2.2 OPERATING PRINCIPLES OF THE PRINTER MECHANISM

2.2.1 Printer Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .2-2

2.2.2 Carriage Drive Mechanism . . . . . . . . . . . . . . . . . . . . . . ...............2-4

2.2.2.1 Platen Gap Adjust Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4

2.2.3 Paper Feed Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .......2-5

2.2.4 Ink System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..................2-6

2.2.5 Pump Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..........2-7

2.2.6 Cap Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........2-9

2.3 OPERATING PRINCIPLES OF THE ELECTRICAL

2.3.1 Operating Principles of the Power Supply Circuit . . . . . . . - . . . . . .....2-10

2.3.2 Operating Principles of the Main Control Circuit . . . . . . . . . . . . . . .....2-12

2.3.2.1 Reset Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .....2-13

2.3.2.2 Sensor Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .....2-13

2.3.2.3 Ink End Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .....2-14

2.3.2.4 Carriage Motor Drive Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3.2.5 Paper Feed Motor Drive Circuit . . . . . . . . . . . . . . . . . . . . . .....2-16

2.3.2.6

Printhead

Drive Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...2-17

CIRCUITRIES

2-1

2-1

2-1o

.2-15

2.4 INK SYSTEM MANAGEMENT

2.4.1 Ink Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .....2-19

2.4.1.1 PowerOn Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...2-19

2.4.1.2 Cleaning Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .....2-19

2.4.1.3 Standby Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .....2-20

2.4.1.4 Initial Charge Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . .....2-20

2.4.1.5 Refresh Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .....2-20

2.4.1.6 Cleaner Blade Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4.1.7 l/C

2.4.1.8 Disengage On Operation . . . . . . . . . . . . . . . . . . . . . . . . . . .. ...2-22

2.4.1.9 Micro Absorbing Operation . . . . . . . . . . . . . . . . . . . . . . . . .. ...2-22

2.4.2 Counter and Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .....2-22

2.4.2.1 Refresh-l Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .....2-22

2.4.2.2 Flushing Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .....2-22

2.4.2.3

2.4.2.4 Protect Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .....2-23

Replacefnent

CLCounter K . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .....2-22

Operation . . . . . . . . . . . . . . . . . . . . . . . . .....2-21

2-18

.2-21

Rev.A

2-i

Figure 2-1.
Figure 2-2.
Figure 2-3.
Figure 2-4.
Figure 2-5.
Figure 2-6.
Figure 2-7.
Figure 2-8.
Figure 2-9.
Figure 2-10
Figure 2-11
Figure 2-12

Figure 2-13

Figure 2-14

Figure 2-15
Figure 2-16.
Figure 2-17.
Figure 2-18.
Figure 2-19.
Figure 2-20.

List of Figures

Functional Block Diagram of the Printer Mechanism . ...........2-1

Structure of Printhead . . . . . . . . . . . . . . . . . . . . . ...............2-2

ofthe

Principles

Carriage Drive Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4

Platen Gap Adjust Lever . . . . . . . . . . . .......................2-4

Paper Feed Mechanism . . . . . . . . . . . . . . . . . . . . . .............2-5

Diagram ofthelnkSystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..2-6

Pump Mechanism Block . . . . . . . . . . . . . . . . . . . . . .............2-7

Pump Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .........2-8

Cap Mechanism . . . . . . . . . . . . . . . . . . . . . ..................2-9

Block Diagram of the Electrical

~D•Œ

Power Supply Circuit Block Diagram . . . . . . . . . . . . . . . . . .....2-11

Main Control Circuit Block Diagram . . . . . . . . . . . . . . . . . . .....2-12

ResetCircuit Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . .....2-13

Sensor Circuit Block Diagram . . . . . . . . . . . . . . . . . . . . . . . .....2-13

Ink End Detection Sequence . . . . . . . . . . . . . . . . . . . . . . . .....2-14

Carriage Motor Drive Circuit Block Diagram . . . . . . . . . . . . .....2-15

Paper Feed MotorDriveCircuit Block Diagram . . . . . . . . . .....2-16

Printhead Drive Circuit Block Diagram . . . . . . . . . . . . . . . . .....2-17

Relation oflnkSystem Operation and Carriage Position . . .....2-18

Printing Operation . . . . . . . . . . . . . . . . . . . . . ....2-3

Circuities . . . . . . . . . . . . . . .....2-10

~...,,

~:

(,:

,

Table 2-1.
Table 2-2.
Table 2-3.
Table 2-4.
Table 2-5.
Table 2-6.
Table 2-7.

List of Tables

Carriage Drive Motor Specification . .........................2-4

Platen

Paper Feed Drive Motor Specification . .......................2-5

Pump Mechanism Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8

DC Voltage Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. ..2-10

Carriage Motor Drive Modes . . . . . . . . . . . . . . . . . . . . . . . . . ....-2-15

Paper Feed Motor Drive Modes . . . . . . . . . . . . . . . . . . . . . . . .....2-16

-

Gap Adjust Lever Position . ..........................2-4

2-ii

., .,

Rev.A

STYLUS 800 Service Manual

2.1 OVERVIEW

This section describes the operating principles of the printer mechanism and the electrical circuits of
the Stylus 800.

2.2 OPERATING PRINCIPLES OF THE PRINTER MECHANISM

The Stylus 800 printer mechanism is composed of the printhead unit, paper feed mechanism,
carriage drive mechanism, pump mechanism, and various sensors. The figure below shows a

functional block diagram of the printer mechanism.

Operating Principles

w.

i

Garr

CR

Motor

D

age

Printhead/

Filter/
Driver circuit

I

%“’einkdrain

m

n

i

Un t

1

m
m

~. . . . . . . . . .

MecK

*

mism ]

I

ASF

(Auto Sheet
Feeder)

n

Figure 2-1. Functional Block Diagram of the

Printer Mechanism

Rev.

A

2-1

Operating Principles

2.2.1 Printer Mechanism

STYLUS 800 Service Manual

The printer mechanism of this printer uses a drop-on-demand ink jet system similar to the system

used on all other Epson ink jet printers.
redesigned to make it compact and highly reliable.
printhead and ink supply system.

■ MLP

■ Cavity

■ Nozzles

Cartridge needle

MLP is the abbreviation for Multi-Layer Piezoelectric element. When a drive pulse
(voltage) is applied, this element pushes the vibration plate, compressing the cavity
for ink injection from the nozzle.

Ink supplied from the ink cartridge is stored in this space and is injected from the
nozzles when the vibration plate compresses this area.

These inject ink against the paper’s surface in response to the application of the
print signal. There are 48 individual nozzles making up this printhead.

\

However, the printhead in this system is completely

The figure below shows the structure of the

Printhead driver board

I

f-”

Filter

Cavity set
(Nozzle)

Nozzle plat

(Multi-Layer

Piezo)

A7’Nozz’e

tank

supply

nk

,,, . . .

f

‘

2-2

Viblation

p

Figure 2-2.

\

MLP
(Multi-byer Piezo)

Structure of Printhead

-. . .

Rev. A

STYLUS 800 Service Manual

Principles of the Printing Operation

Operating Principles

The operation of the

printhead

to inject ink from each nozzle is:
(1) Normal state
No electrical charge is applied to the

MLP

(Multi-Layer

Piezoelectric)

element attached to the back

of the cavity, and pressure inside the cavity is kept at constant level.

Nozzl

(2) Injecting state
The head data signal is applied to the specific nozzle control line to select the active nozzle for

printing, and the

MLP

element is gradually charged by the drive voltage. By charging the

MLP

element, the vibration plate is bent to compress the cavity. Then, ink is injected from the nozzle.

@

Figure 2-3. Principles of the Printing Operation

When the ink charge or
vacuumed out with the pump mechanism.
simultaneously supplied from the ink
change of volume in the cavity.

printhead

cleaning operation is performed, the ink in the cavity is

During printing, on the other hand, the ink is

cartridge

and

injected from the nozzle, according to the

A thermistor is attached to the

printhead

drive board to monitor the temperature, because the
viscosity of the ink varies, depending on the temperature.
back to the

Rev.

A

printhead

drive voltage control circuit to regulate the drive voltage to a proper level.

The detected temperature level is fed

2-3

Operating Principles

2.2.2 Carriage Drive Mechanism

The timing belt attached to the base of the carriage unit is driven by the carriage motor, causing the
carriage unit to
motor on this printer is a 4-phase, 200-pole, hybrid-type stepping
printer to stop the carriage or change the carriage movement at any position. The position of the
carriage is recognized by the home position sensor and position information is fed back to the
carriage drive control circuit to determine the motor phase switching mode.

move

along

the

carriage

Table 2-1. Carriage Drive Motor Specifications

guide shaft left to right, or vice versa. The carriage

STYLUS 800 Service Manual

drive

motor mechanism, allowing the

(’

‘-i.,

.

Item

Motor Type
Drive Voltage
Coil Resistance
Drive Frequency
Excitation Mode

I

4-phase
35 V f 10Yo (31.5 -38.5 V)

10.0 Qt 7%/ pole (at 25° C, 77°

960

1-2 phase excitation

Figure 2-4. Carriage Drive Mechanism

/

200-pole hybrid-type stepping motor

-5400 pps

Description

F)

I

2.2.2.1 Platen Gap

Set the platen gap adjust lever, attached to the carriage unit, to an appropriate position for the
paper thickness used for printing.

Plain paper, Bond paper

Adjust Lever

Table 2-2. Platen Gap Adjust Lever Position

Paper Type

Cut sheet
Envelope

Figure 2-5. Platen Gap Adjust Lever

Lever Position

Horizontal (A)
Vertical (B)

\

\

(gn~

r

>

:,

: .

P

<.~j

-..

/

)

-. . . . . . . . . . . . . . . --

Platen Gap

—

+0.7 mm

. . .

. . . . .

: : :

,,

,. .:

, . . . .

::

::

::

::

‘L

:,

. . . . . . . . . . . . .

.

.

;:

/

:

.’

Envelope

/

. .,