Epson Stylus Photo RX500, Stylus Photo RX510 Service Manual. Parts List

SERVICE MANUAL IMAGE

Scanner • Printer • Copier

EPSON Stylus PHOTO RX500/510

SEOT03007

Notice:

mechanical, photocopying, recording, or otherwise, without the prior written permission of SEIKO EPSON CORPORATION.

 The contents of this manual are subject to change without notice.  All effort have been made to ensure the accuracy of the contents of this manual. However, should any errors be detected, SEIKO EPSON would greatly

appreciate being informed of them.

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

EPSON is a registered trademark of SEIKO EPSON CORPORATION.

General Notice: Other product names used herein are for identification purpose only and may be trademarks or registered trademarks of their

respective owners. EPSON disclaims any and all rights in those marks.

I&I CS Quality Promotion Dept. (Printer Technical Support Grp.) Imaging & Information Products Div.

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 MANUFACTURE; 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

• Electric circuit boards components layout

• Electrical circuit boards schematics

• Exploded diagram & Parts List

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.

A D J U S T M E N T

R E Q U I R E D

C A U T I O N

C H E C K

P O I N T

W A R N I N G

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 proced ure, p ractice or condition that is necessary to accomplish a task efficiently. It may also provide additional information that is related to a specific subject, or comment on the results achieved through a previous action.

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 September 16, 2003 First release B February 2, 2004 CHAPTER 1 PRODUCT DESCRIPTION

• Outside Drawing is added to 1.2.7 Weight and Overall Dimensions (p.11). CHAPTER 2 OPERATING PRINCIPLES

• 2.2.1.2 Printerhead Specification (p.15) is added.

• 2.2.1.3 Paper Feeding Motor Specification (p.15) is added.

• 2.2.1.4 PW Detector Specification (p.15) is added.

• Figure 2-3. Scanner Mechanism (p.16) is altered. CHAPTER 3 TROUBLESHOOTING

• 3.3 Troubleshooting for Printer / Faulty paper ejection (p.30) is modified.

• 3.4 Troubleshooting for Scanner / Carriage unit does not operate (p.33) is modified.

• 3.4 Troubleshooting for Scanner / Fluorescent lamp does not turn on (p.33) is modified.

• 3.6 Troubleshooting for Motors and Sensors (p.35) is modified. CHAPTER 4 DISASSEMBLY AND ASSEMBLY

• 4.1.5 Stylus PHOTO RX500/510 Disassembly (p.40) is modified.

• 4.5 Disassembly and Assembly of Printer Unit (p.49) is modified.

• 4.5.3 Printhead (p.53) is added.

• 4.5.7 Front Frame Assembly (p.57) is added.

• 4.5.8 Front Paper Guide (p.57) is added.

• 4.5.9 Waste Liquid Pad (p.58) is added. CHAPTER 5 ADJUSTMENT

• 5.1 Overview (p.63) is altered.

• 5.2 Adjustments by Adjustment Program (p.65) is added.

• 5.3 Firmware Uploading (p.78) is modified. CHAPTER 6 MAINTENANCE

• 6.1.1 Maintenance of the Printer (p.80) is modified. CHAPTER 7 APPENDIX

• 7.1 Connectors / 7.1.1 Connector Assignments (p.86) is modified.

• 7.1 Connectors / Figure 7-1 Connector Assignments of Circuit Boards (p.86) is modified.

• A figure is added to 7.3 Exploded Diagrams (p.94).

• A list is added to 7.4 ASP List (p.101).

C September 24. 2004 Revision of 5.3 Firmware Uploading (p.78)

EPSON Stylus PHOTO RX500/510 Revision B

CONTENTS

Chapter 1 Product Description

1.1 Overview .............................................................................................................. 9

1.1.1 Basic Functions ........................................................................................... 9

1.2 Common ............................................................................................................ 10

1.2.1 Electrical Specifications ........................................................................... 10

1.2.2 Interface .................................................................................................... 10

1.2.3 Conformance with Safety and EMC Standards ........................................ 10

1.2.4 Environmental Conditions ........................................................................ 11

1.2.5 Reliability ................................................................................................. 11

1.2.6 Acoustic Noise .......................................................................................... 11

1.2.7 Weight and Overall Dimensions ............................................................... 11

1.3 Ink Cartridge ......................................................... ........................................... 12

Chapter 2 Operating Principles

2.1 Overview ............................................................................................................ 14

2.2 Mechanism ........................................................................................................ 14

2.2.1 Printer Mechanism .................................................................................... 14

2.2.1.1 Carriage Motor Specification ............................................................ 15

2.2.1.2 Printerhead Specification .................................................................. 15

2.2.1.3 Paper Feeding Motor Specification ................................................... 15

2.2.1.4 PW Detector Specification ................................................................ 15

2.2.2 Scanner Mechanism .................................................................................. 16

2.3 Electric Circuit .................................................................................................. 17

2.3.1 C544 Main Circuit Board ......................................................................... 18

2.3.1.1 Feature ............................................................................................... 18

Chapter 3 Troubleshooting

3.1 Overview ............................................................................................................ 20

3.1.1 Specified Tools ......................................................................................... 20

3.1.2 Preliminary Checks ................................................................................... 20

3.2 Troubleshooting at Unit Level ......................................................................... 21

3.2.1 Printer / Scanner does not operate at all

even with power turned on ........................................................................ 22

3.2.2 Error is detected ........................................................................................ 23

3.2.3 Trouble related to Print ............................................................................. 23

3.2.4 Paper feeding is not normally carried out ................................................. 24

3.2.5 Operation Panel faulty .............................................................................. 24

3.3 Troubleshooting for Printer ............................................................................ 25

3.4 Troubleshooting for Scanner ........................................................................... 32

3.5 I/F Concerned Troubleshooting ...................................................................... 34

3.6

Troubleshooting for Motors and Sensors ................................................ 35

Chapter 4 Disassembly and Assembly

4.1 Overview ............................................................................................................ 37

4.1.1 Precautions ................................................................................................ 37

4.1.2 Tools ......................................................................................................... 38

4.1.3 Screws ....................................................................................................... 38

4.1.4 Service Dispatch Standard ........................................................................ 39

4.1.5 Stylus PHOTO RX500/510 Disassembly ................................................. 40

4.2 Main Unit Removal .......................................................................................... 41

4.2.1 Panel Unit Removal .................................................................................. 41

4.2.2 Scanner Unit Removal .............................................................................. 42

4.2.3 Middle Housing Removal ......................................................................... 43

4.3 Disassembly and Assembly of Panel Unit ....................................................... 45

4.3.1 Panel Circuit Board Removal ................................................................... 45

4.4 Disassembly and Assembly of Scanner Unit .................................................. 46

4.4.1 Upper Housing Assembly Removal ......................................................... 47

4.4.2 CCD Module ............................................................................................. 48

4.4.3 Motor Assembly ...................................................................................... 48

EPSON Stylus PHOTO RX500/510 Revision B

4.4.4 HP Sensor Circuit Board .......................................................................... 48

4.5 Disassembly and Assembly of Printer Unit .................................................... 49

4.5.1 CR Scale ................................................................................................... 50

4.5.2 Carriage Unit ............................................................................................ 51

4.5.3 Printhead ................................................................................................... 53

4.5.4 ASF Unit Removal ................................................................................... 54

4.5.5 Disassembly of ASF Unit ......................................................................... 55

4.5.6 Power Unit ................................................................................................ 56

4.5.7 Front Frame Assembly ............................................................................. 57

4.5.8 Front Paper Guide ............ ....................................... .................................. 57

4.5.9 Waste Liquid Pad ...................................................................................... 58

4.6 Disassembly and Assembly of Other Parts .................................................... 59

4.6.1 Damper Assembly .................................................................................... 59

4.6.2 Stacker ...................................................................................................... 59

4.6.3 Main Board Unit ....................................................................................... 60

Chapter 5 Adjustment

5.1 Overview ............................................................................................................ 63

5.1.1 Adjustment Items for Individual Units and Components ......................... 64

5.2 Adjustments by Adjustment Program ............................................................ 65

5.2.1 Overview ................................................................................................... 65

5.2.1.1 Installing the Adjustment Program .................................................... 65

5.2.1.2 Starting the Adjustment Program ...................................................... 65

5.2.2 Adjustment ................................................................................................ 66

5.2.2.1 Market Setting (EEPROM initialization) .......................................... 66

5.2.2.2 USB ID Input ..................................................................................... 67

5.2.2.3 Head ID Input .................................................................................... 68

5.2.2.4 Head Angular Adjustment ................................................................. 68

5.2.2.5 1st Dot Position Adjustment .............................................................. 69

5.2.2.6 Bi-D Adjustment ............................................................................... 70

5.2.2.7 PW Adjustment ................................................................................. 71

5.2.2.8 Calorific Limitation Input ................................................................. 72

5.2.3 Maintenance .............................................................................................. 73

5.2.3.1 Head cleaning .................................................................................... 73

5.2.3.2 Ink charge .......................................................................................... 73

5.2.3.3 Refurbishment For DOA ....................................... ............................ 74

5.2.3.4 Waste ink pad counter ....................................................................... 74

5.2.3.5 EEPROM data copy .......................................................................... 75

5.2.4 Check Pattern print ................................................................................... 76

5.2.4.1 Normal Paper Pattern ........................................................................ 76

5.2.4.2 Photo Quality Paper Pattern .............................................................. 76

5.2.4.3 Nozzle check pattern ......................................................................... 76

5.2.5 Appendix .................................................................................................. 77

5.2.5.1 Save all of EEPROM data ................................................................. 77

5.3 Firmware Uploading ........................................................................................ 78

5.3.1 Firmware Program File ............................................................................. 78

5.3.2 Firmware Update Procedure ..................................................................... 78

5.3.3 Update Error List ...................................................................................... 78

Chapter 6 Maintenance

6.1 Overview ............................................................................................................ 80

6.1.1 Maintenance of the Printer ....................................................................... 80

6.2 Cleaning ............................................................................................................. 80

6.3 Lubrication .................................... ....................................... ............................. 81

6.3.1 Designated Lubricant ................................................................................ 81

6.3.2 Lubrication Points of the Scanner ............................................................ 81

6.3.3 Lubrication Points of the Printer .............................................................. 82

Chapter 7 Appendix

7.1 Connectors .............................................................................. .......................... 86

7.1.1 Connector Assignments ......................................................... ................... 86

7.2 Electric Circuit Diagrams ...... ........................................ .................................. 87

7.3 Exploded Diagrams .............................................................................. ............ 94

7.4 ASP List ........................................................................................................... 101

PRODUCT DESCRIPTION

CHAPTER

EPSON Stylus PHOTO RX500/510 Revision C

1.1 Overview

This section describes the specifications for the SPC (Scanner, Printer, Copier) machine “Stylus PHOTO RX500/510”.

1.1.1 Basic Functions

The functions of Stylus PHOTO RX500/510 are as described below:

 Printer function

High quality and high speed printing, improved durability against lights, water, gas and rubbing on regular copy paper due to introduction of new dye ink, and has following features:

 Maximum printing resolution: 2880 (H) x 1440 (V) dpi  Six color independent ink cartridge  BorderFree print on Epson special paper  Low noise  Alarms to prevent paper jam when stacker (output tray) is closed  Print head

Black Ink : 90 nozzles Color Ink : 90 no zzles x 5 col ors (C, M, Y, LC, LM)

C H E C K

P O I N T

Ink cartridge is not compatible to previous model, Stylus CX3100/

3200. Refer to “ 1.3 Ink Cartridge (p12)”.

 Standalone Copier function

The latest six color dye type printer engine allows to make photo quality copies on the Epson special coated paper. Other features are as follows:

Copy Mode Margin Feature

Standard copy BorderFree copy Small margin copy

Repeat copy

Poster copy

2-up/4 up copy

Mirror copy

Wallet size photo copy (Only for EAI)

3mm Normal copy

N/A Full copy with no margin

1.5mm Margins are 1.5 mm in four sides Copies original size on multiple places in the media

(4/8/16).

Divides the original image into 4/8/16, and produces

poster size copy (A4 and Letter size only).

Reduces 2 pages/4 pages of the original image to

single page.

- Flips over the original left to right. Adjusts image to wallet size (3.5” x 2.5”), and

places (For EAI only) multiple images in single page (A4 and Letter size only)

 Print Function with Memory Card

Stylus PHOTO RX500/510 is equipped with built-in memory card slot, and print function with memory card at standalone. Other features are as follows:

 Supports index sheet print that allows you to simply select images by marking

on index sheet. Simplifies image selection by scanning or checking the

 Scanner function

The image can be easily acquired in the PC. Other features are as follows:

 The maximum optical resolution :2400 x 4800dpi  Reading gradations :16bit (Input) /1bit, 8bit, 16bit (Output)

Note “*”: Adapter required

Product Description Overview 9

marking sheet.

 Ten key allows you to select single image and print range, or all images and

all range print.

 Compatible to various memory cards.

Compact Flash / Microdrive Smart Media / xD-Picture Card Memory Stick / MagicGate Memory Stick / Memory Stick PRO /

Memory Stick Duo* / SD Memory Card / miniSD Card* /MultiMediaCard

EPSON Stylus PHOTO RX500/510 Revision C

1.2 Common

The specifications described below are common to the scanner and printer.

1.2.1 Electrical Specifications

Table 1-1. AC Input

100V model 120V model 220-240V model

Rated voltage (ACV) 100 120 220-240 Input voltage (ACV) 90-110 108-132 198-240 Rated current (A) 0.8A 0.8A 0.4A Rated frequency range (Hz) 50 ~ 60 Input frequency range (Hz) 49.5 ~ 60.5

Approx. 21 W (Standalone copying, ISO10561 Letter Patter,

Plain Paper - Text)

Power consumption (W)

Note 1: The product is Energy Star compliant.

2: The holding current to the motors is reduced when the printer has stayed in non-

operation status for 5 minutes.

3: The Scanner lamp is turned off when the Scanner has stayed in nonoperation status for

15 minutes.

Approx. 4 W (Sleep Mode)

Approx. 0.4 W (Power Off Mode)

Approx. 4 W

(Sleep Mode)

Approx. 0.5 W

(Power Off Mode)

1.2.2 Interface

USB 2.0 compatible. See Table 1-2. for details.

Table 1-2.

Item Descriptions

Standard “Universal Serial Bus Specifications Revision 2.0”

“Universal Serial Bus Device Class Definition for Pr inting Devices

Version 1.1” (printer unit)

“Universal Serial Bus Mass Storage Class Bulk-Only Transport

Revision 1.0”(storage unit) Data transfer speed 480Mbps (High Speed Device) Data format NRZI Conforming connecter USB Series B

1.2.3 Conformance with Safety and EMC Standards

 Conformance with EMC standard

Table 1-3.

120 V version 220-240 V version

Safety

EMI

• UL1950

• CSA 22.2 No.950

• FCC part15 subpart B class B

• CSA C108.8 class B

• EN 60950(VDE)

• EN 55022 (CISPR Pub.22) class B

• AS/NZS 3548 class B

Product Description Common 10

EPSON Stylus PHOTO RX500/510 Revision C

1.2.4 Environmental Conditions

Table 1-4.

Operating Storage Transporting

Temperature 10 ~ 35 °C*1 - 20°C ~ 40°C Humidity (no condensation) 20 ~ 80%, RH 20 ~ 85% 5 ~ 85%, RH

-3

Resistance to physical shock 1 G, 1 x 10 Resistance to physical

vibration

Note “*1”: 1 month at 40 °C or 120 hours at 60 °C

“*2”: 1 month at 40 °C “*3”: In the shipment container.

second 2 G, 2 x 10-3 second

0.15G 0.50G

-20°C ~ 60 °C

1.2.5 Reliability

5 years or following printable media volume whichever comes first:

 Total print volume

Black Ink : 50,000 pages (A4)§ Color Ink : 20,000 pages (A4)§

 Print head life

30 million dots/nozzle

 Scan hea d

MCBF 30,000 cycles

1.2.7 Weight and Overall Dimensions

 Weight:

9.8 kg (Excluding ink cartridge)

 Over al l Dimensions (mm):

455.9 x 439.1 x 256.0 (Width x Depth x Height)

NOTE:

Neither the rubber feet nor the paper tray is included.

Figure 1-1. External Appearance

1.2.6 Acoustic Noise

 Level

Approx.TBD dB (copy in use, ISO7779)

Product Description Common 11

EPSON Stylus PHOTO RX500/510 Revision C

1.3 Ink Cartridge

 Type: Ink cartridge  Suggested effective period: Period described on the product package,

or six months after opening.

 Storage tempe rature

 Storage: -30°C ~ 40°C (If 40°C, within 1 month)  Transporting: -30°C ~ 50°C (If 50°C, within 10 days)  When installed: -20°C ~ 40°C (If 40°C, within 1 month,

Temperature change must be within the specified ranges, but no higher than 45°C.)

 Other

Table 1-5.

Model Number

Color

Black Ink Cartridge T0481 T0491

Cyan T0482 T0492

Color Ink Cartridge

Magenta T0483 T0493 Yellow T0484 T0494 Light Cyan T0485 T0495 Light Magenta T0486 T0496

Europe,

EAI

Asia/Latin

Dimensions (mm)

(W x D x H)

12.7 x 73.46 x 55.25 *2

Life

*2 *2 *2 *2 *2

Note “*1”: 400pages/A4 (360dpi,5%duty each color)

“*2”: This value reflects continuous print

on numbers of cleaning, this value become smaller. The first ink cartridge installed in this product will be used to bring it to printable condition.

“*3”: Continuous print: Continuous printing without stopping action due to power ON/

OFF or head cleaning.

after replacing the ink cartridge. Depending

Note : Ink in the cartridge freezes if it is left in the temperature below -16°C. Once ink

is frozen, it takes approx. 3 hours to return to be usable condition if ink is in 20

°C and moved to in 25°C.

Product Description Ink Cartridge 12

OPERATING PRINCIPLES

CHAPTER

EPSON Stylus PHOTO RX500/510 Revision C

2.1 Overview

This Chapter describes the operating principles of the mechanism and electric circuits of EPSON Stylus PHOTO RX500/510. EPSON Stylus PHOTO RX500/510 mainly, basically consists of a printer and a scanner. The mechanism can be divided into the printer and the scanner. The electric circuit includes the Main Board circuit, Power Supply Board circuit, scanner carriage circuit and control panel circuit.

2.2 Mechanism

2.2.1 Printer Mechanism

The printer mechanism comprises the Carriage carrying the print head, the CR Motor for driving the carriage in the lateral direction in the printing range, the Capping Unit for preventing the print head from drying, the PF Motor for transporting the paper, the ASF Unit for loading paper by the driving force from the PF motor, and the Paper Eject Unit for ejecting the paper after printing.

Print Head

Capping Unit

PF Motor

Paper Eject Unit

ASF Mechanism

CR Motor

Figure 2-1. Outline of Printer Mechanism

Operating Principles Overview 14

EPSON Stylus PHOTO RX500/510 Revision C

2.2.1.1 Carriage Motor Specification

Table 2-1. CR Motor Specification

Item Specifications

Type DC Motor with brush Voltage + 42V (DC) ±5% (printable voltage to the driver) Resistance 22.65 Ω ± 10% Inductance 17.3 mH ± 25% Drive PWM system, rated current ch opping system Drive IC A6615

2.2.1.2 Printerhead Specification

 Black Ink : 90 nozzles

Color Ink : 90 no zzles x 5 colors (C, M, Y, LC, LM)

2.2.1.3 Paper Feeding Motor Specification

Table 2-2. PF Motor Specification

Item Specifications

Type 4-phase 200-pole HB stepping motor Voltage + 42V (DC) ±5% (printable voltage to the driver) Resistance 30 Ω ± 10% Inductance 3.5 mH ± 20% Drive Bipolar driving Drive IC A6615

2.2.1.4 PW Detector Specification

Stylus PHOTO RX500/510 has newly employed a PW (Paper Width) sensor that is described in detail below.

 Purpose of Detection

• To prevent printing with no characters on cut sheet.

 Detector Specification

Item Specification

Detecting method

Open-collector electric characteristic

 Switching Mode

Detected State Switching Mode Detector Output

Paper existent Open Voltage low

Paper non-existent Close Voltage high

Note: Paper head signals shall be converted by means of 8-bit A/D conversion.

 PW Detector Control

There are two controlling methods using PW detector as follows:

 Control of preventing print with no characters

Before start of print (immediately after paper head feed is complete) or during print, this control detects the existence of paper with PW detector, driving CR and PF motors and prevents print with no characters on paper sent to paper guide, which applies to only right and left edges of paper.

 Control of restriction to run-off

This control detect paper edges with PW detector at the time of printing with no margin, and restrict the printing run-off quantity. It detects 4 edges when no margins are set for 4 sides of paper. For each mode, run-off area thin-out control is set that further compensates for run-off mask area at the time of printing with no characters.

Photoelectric conversion method (reflection type) (SHARP GP2S40V)

Collector withstand-voltage: not more than 30V Sinc current : not more than 0.2mA Driving voltage : 3.3 ± 5%

Operating Principles Mechanism 15

EPSON Stylus PHOTO RX500/510 Revision C

Controlling of each detection

Detection Type

• Control of preventing print with no characters

• Control of restriction to runoff

Detection Direction

CR direction

PF direction

(Carriage bottom face)

Table 2-3.

CR Drive at Time of

Detection

Interrupt control (PID/load positioning control)

Stop

PF Drive at Time of

Detection

At stop or during drive

At time of interrupt control (PID or BS control)

Detection Timing

• After paper head feed or during print

• Acquisition of position with factory command at time of adjustment

2.2.2 Scanner Mechanism

The scanner consists of the Scanner Carriage Unit comprising the CCD for capturing images and the light source for illuminating the document, the Scanner Motor and Timing Belt for moving the scanner carriage unit along the document surface, and the Scan HP Detector for detecting the position of the scanner carriage unit.

Document

Scanner HP Detector

Scanner Carriage Unit

Scanner Motor

Figure 2-3. Scanner Mechanism

Printhead

PW detector

Figure 2-2. PW Detector Installing Position

Operating Principles Mechanism 16

EPSON Stylus PHOTO RX500/510 Revision C

2.3 Electric Circuit

The electric circuit boards of Stylus PHOTO RX500/510 are as follows:

 C544MAIN Board (main circuit board)  C543PSB Board / C543PSE Board (power supply circuit board)  CCD circuit board (Scanner circuit board)  Panel circuit board

Figure 2-4. Electric Circuit Block

Operating Principles Electric Circuit 17

EPSON Stylus PHOTO RX500/510 Revision C

2.3.1 C544 Main Circuit Board

2.3.1.1 Feature

 USB 2.0 with multi-end points allows high speed SPC without HUB  SOC with printer control, scanner control, PT control, CPU SuperMacro  1CPU (NA85E2C by NEC) controls printer, scanner and PT unit  256Mbit*16 SDRAM (2 units)  A6615 drives DC x 2 and DC x 2 with 1Chip to motor driver  SOC obtains wider band ranges by setting action frequency of local SDRAM

to 96MHz

 Copy function allows faster process with SOC to scan, and to generate 2-

values, microwave, image buffer instead of going through CPU bus.

 Low current allows LCD to reduce power consumption in low power mode as

follows:

• Lowering power supply voltage

• Shutting off optical current for optical sensor

• SLEEP mode for motor drive

• Saving the power for printer with no exciting motor

• Saving the power for scanner by turning off the lamp

• Equipped with printer tray open sensor

Table 2-4.

Main Element location Function

• Built-in NA85E2C core

• Built-in iLB RAM 12Kbyte, Built-in dLB RAM 4Kbyte Built-in iCACHE 8Kbyte, Built-in dCACHE 8Kbyte

• Action frequency

Built-in CPU core

SOC

(E01A49B*)

FLASH ROM

(MBM29PL32BM)

SDRAM

(K4S561632)

SDRAM

(K4S561632)

Card ASIC

(E09A49B*)

CF Socket Power

Controller

(TPS2041A)

RTC circuit (RTC9822)

Motor drive circuit

(A6615)

Head drive circuit

(E09A41RA)

IC6

IC2

IC14

IC15

IC1

IC12

IC11

CPU core :192MHz(SSCG) NPB macro (UART, TimerC/D, Prescaler) :48MHz User logic (scanner/photo print) :48MHz (SSCG) User logic (printer) :48MHz Local SDRAM :96MHz(SSCG) External bus clock :64MHz(SSCG)

• Power supply voltage : internal 1.5 V, external 3.3 V

•Firmware

• 32MB, 16bit bus, 48pin, 3.3V drive

• System Memory (for CPU)

• 256 Mbit, 16 bit bus, 54pin, 133M Hz (CL=2) minimum

• Work memory for copy function (image processing)

• 256 Mbit, 16 bit bus, 54pin, 133M Hz (CL=2) minimum

• Bus clock : 64MHz , internal clock : 48MHz

• 3.3V Single power supply

• 8 pin PSOP

• Power control 1CH with current limit

Multiple IC

• EEPROM ( Default value, store various parameters)

• RESET

•TIMER

• CR motor, PF motor, scanner motor drive circuit

• Drive motor: 42V ±5%

• Head drive control (control port for SOC)

Operating Principles Electric Circuit 18

TROUBLESHOOTING

CHAPTER

EPSON Stylus PHOTO RX500/510 Revision C

3.1 Overview

With this printer, almost all troubles can be coped with by using “EPSON Status Monitor 3” installed on the host personal computer.

Once an error occurs, the “EPSON Status Monitor 3” will appear as a pop-up window on the screen of the host PC. It will show details of how to cope with the trouble. In almost all cases, the user can recover the printer from the error, provided that the user follows the instructions indicated on the pop-up window.

In addition, the User's Manual for EPSON Stylus PHOTO RX500/510 describes detailed steps to be taken for recovery from typical errors.

3.1.1 Specified Tools

This printer does not require any specified tools for troubleshooting.

3.1.2 Preliminary Checks

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

 The power supply voltage must be within the specification limits. (Measure the

voltage at the wall socket.)

 The POWER CORD must be free from damage, short circuit or breakage, or

miswiring in the POWER CORD.

 The printer must be grounded properly.  The printer should not be located in a place where it can be exposed to too high or

low temperature, too high or low humidity, or abrupt temperature change.

 The printer should not be located near waterworks, near humidifiers, near heaters

or near flames, in a dusty atmosphere or in a place where the printer can be exposed to blast from an air conditioner.

 The printer should not be located in a place where volatile or inflammable gases

are produced.

 The printer should not be located in a place where it can be exposed to direct rays

of the sun.

 The printer must be located in a well-ventilated place.  The printer must be placed on a strong and steady level table (without an

inclination larger than 5 degrees).

 The paper used must conform to the specification.  There is no error in handling of the printer.  Check the inside of the printer, and remove foreign matters, if any, such as paper

clips, staples, bits of paper, paper dust or toner.

 Clean the inside of the printer and the rubber rolls.

Troubleshooting Overview 20

EPSON Stylus PHOTO RX500/510 Revision C

3.2 Troubleshooting at Unit Level

By following this troubleshooting procedure, when some trouble has occurred, you can easily identify the unit which is the cause of the trouble, from its observation. Table 3-1 and Table 3-2 list the observations of various troubles. Once the type of the trouble has been identified, refer to the flowchart for that trouble.

The flowchart shown in Table 3-1 outlines the troubleshooting procedure.

NOTE:

See

“3.6 Troubleshooting for Motors and Sensors” (p35)

for motors and sensors.

Identifying the Trouble

 Table 3-1, “LCD Indication”  Table 3-2, “Observations and Troubleshooting Flowcharts”

Repair at Unit Level

Repair at Parts

Level

Printer Mechanism

Figure 3-1. Troubleshooting Flowchart

Diagnosing the Following Units

Motor and Sensor Repair

Disassembly = Chapter 4

Adjustment = Chapter 5

for troubleshooting

Scanner Mechanism

Table 3-1. LCD Indication

LED Indication

Error Status LCD Indication

Printer fatal error Error

Printer error → See your documentation and call service if necessary.

Scanner fatal error Error

Scanner error → See your documentation and call service if necessary.

Scanner unit open Error

Scanner unit open → Close the scanner unit.

Paper out Error

Paper out → Load paper into the sheet feeder,then press the Color button.

Paper jam Error

Paper jam → Press the Color button. Remove any remaining jammed paper by hand.

No ink cartridge Error

No <No ink cartridge colors> ink cartridge → Press the Color button to install a new ink cartridge.

Ink end Error

<Ink out colors> ink out → Press the Color button to begin the ink cartridge replacement.

Ink cartridge error Error

<Ink cartridge error colors> ink cartridge error → Cartridge replacement is necessary.Press the Color button to begin.

Note "*1": The upper line shows “Error indication” and the lower line shows descriptive

character strings by scrolling.

Power

Lighting

‑

Lighting

‑

Lighting

‑

Lighting

‑

Lighting

‑

Lighting

‑

Lighting

‑

Lighting

‑

Error

LED

Troubleshooting Troubleshooting at Unit Level 21

EPSON Stylus PHOTO RX500/510 Revision C

Table 3-2. Observations and Troubleshooting Flowcharts

Observation Details Refer to

Power is on but not operating

Error is detected • LCD/LED panel shows error status. Figure 3-3 Trouble related to

Paper feeding is not normally carried out.

Faulty operation panel

Trouble related to scanner

• LED does not turn on at all.

• Printer mechanism does not operate at all.

Figure 3-2

• Scanner mechanism does not operate at all.

• Printing is not done.

• Print is abnormal (Dot missing, etc.).

Figure 3-4

• Print quality is bad.

• Paper feeding is not done.

• Paper jam occurs.

Figure 3-5

• Paper start up position is not correct.

• Pressing a button does not work. Figure 3-6

• Scanner does not operate normally. Refer to “3.4

Troubleshooting for Scanner” (p32)

3.2.1 Printer / Scanner does not operate at all even with power turned on

Start

AC power /

voltage

is normal?

Yes

Fuse (F1) of

Fuse (F1) of power

power board is

board is blown?

blown?

Check output voltage of

power board CN2.

Power board

output voltage is

normal?

Yes

Input normal

power.

Replace fuse.

Disconnect CN3 of

Disconnect CN10 of

main board and turn

power on again.

Fuse is blown

again?

Yes

Replace power board

Replace main board

Check motors, head

and other parts

End

Figure 3-2. Flowchart-1

Troubleshooting Troubleshooting at Unit Level 22

EPSON Stylus PHOTO RX500/510 Revision C

3.2.2 Error is detected

Start

Check error contents by LCD (See Table 3-1).

Yes

Printer error?

Yes

Ink cartridge out

error?

Maintenance error

Replace waste ink porous pad and reset counter. (Refer to “Disassembly and

Assembly” on page 36 and “Adjustment” on page 62)

Turn power off, unlock CR and move CR with hand.

Replace Ink cartridge with a new one by operation panel.

Ink cartridge

out error is

cleared?

Yes

CR cartridge can

move smoothly?

Yes

Check CR motor and if there is no problem, replace main board.

Yes

Carriage smoothly

moves?

3.2.3 Trouble related to Print

Start

Execute test printing

Printing was

successfully

done?

Yes

quality is

normal?

Execute cleaning

Problem is

solved?

Yes

Execute print adjustment (Refer to

“Adjustment” on page 62)

Replace Ink cartridge and execute test print.

Yes

Problem is

solved?

All the

cables are connected

properly to main

board?

Connect correctly

Problem is

solved?

Yes

Refer to Table 3-12

Problem is

solved?

Yes

Check whether Head FFC is connected properly to head.

End

Refer to Table 3-12

End

Refer to Table 3-12

Yes

Problem is

solved?

Replace main board

End End End

Figure 3-3. Flowchart-2

Figure 3-4. Flowchart-3

Troubleshooting Troubleshooting at Unit Level 23

EPSON Stylus PHOTO RX500/510 Revision C

3.2.4 Paper feeding is not normally carried out

Start

Paper is

correctly set in

ASF?

Yes

Paper loading

roller and PF roller

are correctly

rotating?

Yes

Remove foreign matters, if any, from paper route.

Clean rollers on paper route. (Refer to

“Maintenance” on page 79)

Set paper correctly.

PF motor is

Yes

driving?

Check whether connector of PF motor is connected to CN6 of main board. If it is connected properly, replace main board.

3.2.5 Operation Panel faulty

Start

Operation

Panel is connected

properly with

cable?

Yes

Replace operation

panel.

Problem is

solved?

Connect correctly Operation panel again.

Problem is

solved?

Yes

Replace main

board.

End

Problem is

solved?

Yes

End

Refer to Table 3-12

Figure 3-5. Flowchart-4

Yes

End

Figure 3-6. Flowchart-5

Troubleshooting Troubleshooting at Unit Level 24

EPSON Stylus PHOTO RX500/510 Revision C

3.3 Troubleshooting for Printer

This section describes repair / service of the Printer Mechanism. Listed below are various problems which may occur, observations of such problems, check point and remedies. For the pertinent observation, check the functions of the parts in question according to Check Point.

Table 3-3. Printer Errors

Observation Cause Remedy

Ink shortage / Ink out

Paper out • When Printer cannot load

Paper jam When paper is not ejected,

• If any ink cartridge comes close to Ink out, Printer continues printing in ink shortage status.

• If cartridge is completely empty, Printer indicates ink out error and stop printing.

paper, paper out error is indicated.

• Paper stops in front of PE detector or paper is not loaded.

• Paper is loaded without adjusting paper to right edge guide.

paper jam error is indicated.

• Start cleaning execution command on Panel or by Utility.

• Carriage automatically moves to replacement position.

• Replace ink cartridge with a new one.

1.Set paper on tray if paper is out.

2.If paper is stopped midway, pull paper out and check that paper is not folded. Loosen paper well and set it again with edge guide adjusted to paper width.

3.Execute “Load/Eject”.

• Clean paper loading roller. Or replace paper loading roller.

• Check that gears for ASF are engaged correctly.

• Select “Load/Eject” from menu and execute it.

1.Open the printer cover and remove with hand all the paper inside the printer and all the set paper if there is paper on the way of loading.

2.Check that there is no paper in the printer and set paper again and execute paper loading and paper ejection. Then, this error display will be cleared and if there is print data, print operation will start.

• Check whether Platen gap is correct

value. (Refer to “Adjustment” on

page -62)

Table 3-3. Printer Errors (continued)

Observation Cause Remedy

Ink cartridge out • If Ink cartridge is not correctly

set, printer indicates ink cartridge out error.

Maintenance error

Fatal error • Carriage error:

Waste ink overflow indication is displayed if the total amount of ink consumed by cleaning and/or flushing has exceeded the predetermined limit.

• Home of carriage can not be recognized.

• Abnormal external power was applied to carriage or carriage operation is obstructed during printing.

• PF error:

PF motor does not operate adequately to feed paper by the required distance.

• Check CSIC connection circuit.

• Replace ink cartridge.

After replacing waste ink porous pad, reset waste ink overflow counter.

• Several seconds or more after turning power off, press power switch to turn power on.

• Open maintenance cover and check that there is no obstacle in the carriage moving zone.

If the error is not cleared even by t he abo ve operation, check the followings:

• CR HP sensor/Harness

• CR Lock mechanism

• Main board

Troubleshooting Troubleshooting for Printer 25

EPSON Stylus PHOTO RX500/510 Revision C

Troubleshooting without error display on LCD. For Items and pages, refer the following:

• Faulty pump mechanism (p26)

• Ink is not absorbed at all or ink absorption is poor. (p26)

• Faulty carriage operation (p27)

• Printing is not carried out correctly. (p27)

• Faulty print (p28)

• Faulty paper loading (p30)

• Faulty paper ejection (p30)

• Printer stops during initialization (p31)

 Faulty pump mechanism

Table 3-4. Diagnostics when pump mechanism is abnormal

Condition Cause Check Point Remedy

When power is turned on, PF motor operation is abnormal.

There are foreign matters on the PF gear.

PF motor is faulty. Check whether the internal coil resistance is just as specified

Operate the platen drive gear by hand and check whether it rotates properly.

and whether the harness is connected properly. See Table 3-21

“Motor Resistance and Check Point” (p 35).

Remove foreign matters. Replace the printer mechanism.

Replace the printer mechanism or PF motor.

 Ink is not absorbed at all or ink absorption is poor.

Table 3-5. Diagnostics when ink is not absorbed

Condition Cause Check Point Remedy

Ejected ink does not flow into Ink Eject tube.

Ink is not absorbed from head to cap.

Pump tube is crashed. Check tube with the naked eye. Replace the printer mechanism or pump unit. Capping unit is faulty. Check capping rubber with the naked eye. Replace the printer mechanism or capping unit. Tube is projecting from cap. Check with the naked eye whether tube is projecting from cap. Connect the tube correctly. Pump tube is entangled in the pump

unit.

Dirt on cap Check whether any foreign matter is adhering to cap. Remove foreign matters from the cap and if the cap is

Faulty slide-up of cap Check whether two compression springs are set on cap

When cap assembly slides up completely, check whether there is a small slack in pump tube between cap assembly and pump unit.

assembly.

Remove the entangled pump tube carefully, correct the tube condition and connect it to the cap assembly.

damaged, replace it with a new one. Set the compression springs on the cap assembly.

Troubleshooting Troubleshooting for Printer 26

EPSON Stylus PHOTO RX500/510 Revision C



Faulty carriage operation

Table 3-6. Diagnostics when carriage action is abnormal

Condition Cause Check Point Remedy

When power is turned on, carriage operation is abnormal.

Abnormal carriage operation during printing

There is an obstacle in CR shift area. Check with the naked eye whether there is an obstacle. Remove the obstacle. CR lock is not released. Check that chan ge le ver is in the front of printer. Retu rn the change lever to the back of printer by tweeters or a

small driver.

Check whether the CN12 connector and coil resistance of the PF motor are as specified. See Table 3-21 “Motor Resistance

and Check Point” (p 35).

Check whether any gear is damaged on the torque transmission route of PF motor.

Faulty CR motor Check whether the internal coil resistance is just as specified

and whether the harness is connected properly. See Table 3-21

“Motor Resistance and Check Point” (p 35).

Carriage does not move smoothly. Operate the carriage by hand and check whether carriage

moves smoothly. Check tension of timing belt. Adjust tension or replace the belt. Check whether there is an obstacle in carriage route. Remove the obstacle.

Connect the PF motor to CN12 on the main board. Replace the printer mechanism or PF motor.

Replace the damaged gear with a new one.

Replace the CR motor.

Clean the CR guide shaft and lubricate.

 Printing is not carried out correctly.

Table 3-7. Diagnostics when printing is erratic

Condition Cause Check Point Remedy

Carriage moves correctly but printing is not normal.

Head FFC is not connected properly. Check whether Head FFC is connected properly to CN13 and

CN14 of main board.

Inside of FFC is not connected properly.

Faulty ink cartridge Set new ink cartridge and execute test printing. Replace the ink cartridge. Faulty head unit Repeat cleaning and test printing alternately several times. Replace the head unit. Faulty head cleaner Check whether dust is adhering to head cleaner. Clean or repla ce the head cleaner.

Check FFC by tester. Replace the FFC.

Connect the FFC correctly.

Troubleshooting Troubleshooting for Printer 27

EPSON Stylus PHOTO RX500/510 Revision C



Faulty print

Table 3-8. Diagnostics when printing is abnormal

Condition Cause Check Point Remedy

Faulty printing occurs at specific dots.

Sometimes dots are missing. Head surface is dirty.

Black points or dots are printed.

Vertical line is not straightly lined.

Head surface is dirty. (Dot missing occurs)

Faulty head FFC Check whether head FFC is damaged. Replace the head FFC with a new one. Faulty head unit Repeat cleaning and nozzle checking alternately several

Capping porous pad is in contact with head surface.

(Dot is missing occurs) Inside of FFC is not connected

properly. Head FFC is not connected. Check whether Board and Carriage FFC are connected. Connect the FFC correctly. Faulty Head unit. Execute cleaning several times, and Check nozzle. If the condition is not improved even after cleaning, replace

Faulty ink cartridge. Set new ink cartridge and check nozzle. Replace the ink cartridge. Head FFC is not connected. Check whether Board and Carriage FFC are connected. Connect the FFC correctly. Faulty head unit Check connection with head FFC. If connection with the FFC is not faulty, replace the head. Bi-D adjustment has not been made. Make Bi-D adjustment. Refer to “ Adjustment” (p62)

Repeat cleaning and test printing alternately several times. Clean with a swab fixed to a stick.

If the condition is not improved even after cleaning, replace

times. Check capping porous pad with the naked eye. Replace the capping porous pad, if its shape is deformed or it

Repeat cleaning and nozzle checking alternately several times.

Check FFC by tester. Replace the head FFC.

the head.

is damaged. Clean with a swab fixed to a stick.

the head.

Troubleshooting Troubleshooting for Printer 28

EPSON Stylus PHOTO RX500/510 Revision C

Table 3-8. Diagnostics when printing is abnormal (continued)

Condition Cause Check Point Remedy

White line appears in output data.

Dirt is adhering to CR guide shaft. Check whether dirt is adhering to the surface of CR guide

shaft.

Faulty CR guide shaft. Check that CR guide shaft is steadily installed in the

designated position. Check that CR guide shaft surface is flat.

Faulty slide operation of Carriage. Check whether sufficient oil is remaining on the surface in the

carriage slide area on the Paper Eject Frame. Paper feeding route is dirty. Check whether PF roller is dirty. Clean the surface of the PF roller carefully with a soft brush. Damaged gear Check whether the following parts are not damaged.

• Combination gear16, 21.6

• Combination gear 11.6, 36.8

• Spur gear 73.6

• Spur gear 25.6 Platen gap is not correct. Adjust platen gap. Refer to “ Adjustment” (p62) As head surface is dirty, dot jet

direction is slanting. Faulty ink cartridge Set new ink cartridge and execute test printing. Replace the ink cartridge.

Faulty head unit Clean several times, and execute test printing. Replace the head unit.

Repeat cleaning and test printing alternately several times. Clean with a swab fixed to a stick. Check whether dust is adhering to head cleaner. Clean or replace the head cleaner.

Clean the surface of CR guide shaft with a dry and soft cloth.

Reinstall the CR guide shaft on the mounting slats (wing boards) on both sides of the frame, and fix it with the rod spring.

Replace the CR guide shaft with a new one. Clean the surface in the carriage slide area and apply a

specified amount of G-26. Refer to “ Maintenance” (p79)

Replace the damaged part with a new one.

Troubleshooting Troubleshooting for Printer 29

EPSON Stylus PHOTO RX500/510 Revision C



Faulty paper loading

Table 3-9. Diagnostics when feeder is abnormal

Condition Cause Check Point Remedy

Paper is not loaded. Paper loading roller worn Check whether paper loading roller rotates when paper

feeding is not operating. Check whether paper loading roller is not slipping during

paper feeding. Check that Micro Pearl or oily substance is not adhering to the

paper loading roller

Faulty operation of ASF hopper Check ASF hopper operation with the naked eye. Replace the ASF. Faulty clutch mechanism Check whether clutch me chanism is damaged. Replace the clutch mechanism with a new one.

Multiple sheets of paper are always drawn in

Paper is loaded even without print job

Paper Return (preventive multiple feeding mechanism) does not operate correctly.

Faulty operation of ASF hopper Check whether the tip of change lever is damaged.

When paper is loaded, check whether Paper Return is correctly operating inside the ASF.

Check whether compression spring 1.47 is not off the change lever.

Clean the paper loading roller with the cleaning sheet. If this cleaning does not work to improve the condition, replace the paper loading roller.

In order to remove Micro Pearl from the surface of LD roller, install the cleaning sheet up side down inside ASF. Grasp the upper end of the sheet steadily and try paper loading from printer driver. In order to remove oily substance, staple a cloth soaked in alcohol to a post card and clean the roller by the same method.as above.

Check whether the gears for driving the PF roller are engaged correctly.

Reassemble the torsion spring 25.7 inside the ASF frame.

Replace the change lever with a new one. Set the compression spring 1.47 on the change lever correctly.

 F aulty paper ejection

Table 3-10. Diagnostics when paper ejection is abnormal

Condition Cause Check Point Remedy

Paper is jammed on the way of paper ejection.

Paper is ejected without being printed.

Faulty installation of Star Wheel Roller

Faulty operation of Paper Eject Roller Chec k whe the r Paper Eject Roller rotates correctly. Check whether the gears for driving the Paper Eject Rolle r are

Faulty HP/PE sensor Check whether CN10 Connector is not disconnected from HP/

Check that Star Wheel Roller is set on paper eject frame. Remove the jammed paper, set the Star Wheel Roller in the

paper eject frame steadily. If the hook of the Hook Roller is damaged, replace it with a

new one.

engaged correctly. Connect CN10 connector cable to CN10 on the main board.

PE sensor cable on main board or sensor.

Replace HP /PE sensor with a new one.

Troubleshooting Troubleshooting for Printer 30

+ 73 hidden pages