Epson Stylus Pro Service manual

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EPSON COLOR INKJET PRINTER

Stylus Pro

SERVICE MANUAL

EPSON

4004825

NOTICE

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

All efforts 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 notwithstanding SEIKO EPSON can assume no responsibility for any errors in this manual or the consequence thereof.

Epson is a registered trademark of Seiko Epson Corporation.

General Notice: Other productnamesused herein are for identication purposes only andmay be trademarks of their respective campanies.

-i-

PRECAUTIONS

Precautionary notations throughout the text are categorized relative to 1) personal injury and 2) damage to equipment.

DANGER

WARNING

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

DANGER

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

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

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

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

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

-ii-

PREFACE

This manual describes functions, theory of electrical and mechanical operations, maintenance, and repair of STYLUS-PRO. The instructions and procedures included herein are intended for the experience repair technician, and attention should be given to the precautions on the preceding page. The chapters are organized as follows:

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 and exploded diagram.

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

-iv-

REVISION SHEET

Revision Issue Date Revision Page

Rev. A May 30, 1995 - 1st issue

Rev. B June 5, 1995

1 - 2, 4-7

&4-10

Change Fig.1-2 and WARNINGs

-v-

CHAPTER 1. GENERAL DESCRIPTION CHAPTER 2. OPERATING PRINCIPLES CHAPTER 3. DISASSEMBLY AND ASSEMBLY CHAPTER 4. ADJUSTMENTS CHAPTER 5. TROUBLESHOOTING CHAPTER 6. MAINTENANCE APPENDIX

-vi-

Chapter 1 Product Description

Table of Contents

1.1 FEATURES 1-1

1.2 SPECIFICATIONS 1-2

1.2.1 Printing Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.2.2 Paper Handling Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

1.2.3 Paper Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

1.2.4 Ink Cartridge Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

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

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

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

1.2.8 Safety Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

1.2.9 Physical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

1.3 INTERFACE SPECIFICATIONS 1-9

1.3.1 Parallel Interface Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

1.3.2 Serial Interface Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

1.4 OPERATIONS 1-12

1.4.1 Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

1.4.2 Panel Operation at Power On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

1.4.3 Default Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

1.4.3.1 Default Setting Items. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

1.4.3.2 Changing the Default Settings . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

1.4.4 Error Conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17

1.4.5 Printer Initialization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17

1.4.5.1 Hardware Initialization. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17

1.4.5.2 Software Initialization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17

1.4.5.3 Panel Initialization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17

1.5 MAIN COMPONENTS 1-18

1.5.1 Main Control Board (C164 MAIN Board) . . . . . . . . . . . . . . . . . . . . . . . 1-18

1.5.2 Power Supply Board (C137 PSB/PSE Board) . . . . . . . . . . . . . . . . . . . 1-19

1.5.3 Control Panel (C137 PNL Board) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19

1.5.4 Printer Mechanism (M-4A11) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20

1.5.5 Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20

List of Figures

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

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

Figure 1-3. Printable Area for Cut Sheets . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Figure 1-4. Printable Area for Envelopes. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Figure 1-5. Adjustment Lever Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Figure 1-6. Temperature/Humidity Range . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Figure 1-7. Data Transmission Timing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Figure 1-8. Control Panel Appearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

Figure 1-9. C164 MAIN Board Component Layout . . . . . . . . . . . . . . . . . . . 1-18

Figure 1-10. C137 PSB/PSE Component Layout. . . . . . . . . . . . . . . . . . . . . 1-19

Figure 1-11. C137 PNL Board Component Layout . . . . . . . . . . . . . . . . . . . 1-19

List of Tables

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

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

Table 1-3. Cut Sheet Paper Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Table 1-4. Envelope Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Table 1-5. Adjust Lever Setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Table 1-6. Rated Electrical Ranges. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Table 1-7. Acceptable Environmental Conditions. . . . . . . . . . . . . . . . . . . . . 1-7

Table 1-8. Signal and Connector Pin Assignments for Parallel Interface 1-10

Table 1-9. DTR and X-ON/X-OFF Protocol . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

Table 1-10. Signal and Connector Pin Assignments for Serial Interface . 1-11

Table 1-11. Default Setting Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

Table 1-12. Characteristics of Print Direction Mode. . . . . . . . . . . . . . . . . . 1-14

Table 1-13. Printing Direction and ESC U Command . . . . . . . . . . . . . . . . . 1-14

Table 1-14. Language Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

Table 1-15. Feature Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

Table 1-16. Character Table Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

Table 1-17. Error Indications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17

Table 1-18. The Comparison between C164 MAIN and C162 MAIN . . . . . . 1-18

Stylus Pro Service Manual Product Description

1.1 FEATURE

The Stylus Pro is a high-performance color ink jet printer with a small footprint and low cost. The main components of this printer are similar to the Stylus Color. The main features are:

r High quality color print Super dot 720 dpi printing

Plain paper 720 dpi printing Special coated paper for 720 dpi printing

r High print speed LQ printing at 200 cps

r Built-in auto sheet feeder Holds 100 cut sheets (55 g/m

Holds 10 envelopes Holds 50 transparency film sheets Holds 70 sheets of special paper

r Three built-in I/F types Macintosh Serial interface

Parallel interface (I-EEE 1284-compatible) Type-B interface (optional)

Note :

Type-B interfaces are available, except C82324*(ETHERNET I/F CARD for NETWARE). * The asterisk represents the last digit, which varies by country.

r Easy to set up No DIP switches

Multilingual setting messages (5 languages)

r 4 scalable fonts,

5 LQ fonts

Roman T, Sans Serif H, Roman, Sans Serif (scalable), Roman, Sans Serif, Courier, Prestige, Script (LQ)

)

r Character Tables Italic, PC437, PC850, PC860, PC863, PC865, PC437 Greek, PC852,

PC853, PC855, PC857, PC866, PC869, PC861, BRASCII, Abicomp, MAZOWIA, Code MJK, ISO 8859-7, ISO Latin 1T, Bulgaria

The figure below shows the Stylus Pro.

Figure 1-1. Exterior View of Stylus Pro

Rev.B 1-1

Product Description Stylus Pro Service Manual

1.2 SPECIFICATIONS

This section provides statistical facts and other detailed information for the printer.

1.2.1 Printing Specifications

Print system: On demand ink jet system Nozzle configuration: 64 nozzles (16 × 4 staggered): monochrome

48 nozzles (16 × 3 staggered): color

Row CRow D

#16

MagentaCyanYellow

1/360"

1/90"

#16

#63

Figure 1-2. Nozzle Configuration

Printing direction: Bidirectional with logic-seeking The table below shows print speed and printable columns.

Table 1-1. Print Speed and Printable Columns

#62

Row B

#64

Row A

1/90"

#61

Character Pitch Printable Columns Print Speed (LQ)

10 cpi (pica) 80 200 cps 12 cpi (elite) 96 240 cps

15 cpi 120 300 cps 17 cpi (pica condensed) 137 340 cps 20 cpi (elite condensed) 160 400 cps

1-2 Rev.B

Stylus Pro Service Manual Product Description

Character sets: Legal and 21 international character sets. Character tables: See Table 1-2.

Table 1-2. Character Tables

Bitmap Fonts Scalable Fonts

EPSON Roman

Character Tables

Italic table mmm PC437

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

mSupported ×

EPSON Sans Serif

EPSON Courier

EPSON Prestige

EPSON Script

Not supported

EPSON Roman

EPSON Sans Serif

mmm

EPSON Roman T

EPSON Sans Serif H

Note: These character tables are not supported for EPSON Roman T and EPSON Sans Serif H

scalable fonts.

Fonts: Bitmap LQ fonts

r EPSON Roman (10 cpi/12 cpi/15 cpi/Proportional) r EPSON Sans Serif (10/12/15/Proportional) r EPSON Courier (10/12/15) r EPSON Prestige (10/12/15) r EPSON Script (10/12/15)

Scalable fonts

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

Control codes: ESC/P 2 and expanded raster graphics codes Input data buffer: 64K bytes

Rev.B 1-3

Product Description Stylus Pro Service Manual

1.2.2 Paper Handling Specifications

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

Notes: The following operations are not allowed:

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

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

Line spacing:

⁄6-inch feed,1⁄8-inch feed, or programmable in1⁄

-inch minimum increments.

360

Paper path: Cut sheets: Built-in auto sheet feeder (ASF). Front entry. Feeding speed:

89 msec. (at

⁄6-inch feed pitch).

1.2.3 Paper Specifications Table 1-3. Cut Sheet Paper Specifications

Legal: 216 mm (8.5 in.) × 356 mm (14.0 in.) Letter: 216 mm (8.5 in.) × 279 mm (11.0 in.)

Size (W × L)

Thickness 0.08 mm (0.003 in.) ∼ 0.11 mm (0.004 in.) Weight 55 g/m

Quality

Note : Printing on special coated paper for 720 dpi, special coated paper for 360 dpi,

transparency film, and high-quality glossy paper is only available at normal temperatures.

A4: 210 mm (8.3 in.) × 297 mm (11.7 in.) Executive: 184 mm (7.25 in.) × 267 mm (10.5 in.) Statement :140 mm (5.5 in.) × 216 mm (8.5 in.)

(17 lb) ∼ 90 g/m2(24 lb) Plain paper, special coated paper for 720 dpi, special coated paper for 360 dpi, transparency film, high-quality glossy paper

Table 1-4. Envelope Specifications

C5: 229 mm (9 in.) × 162 mm (6.4 in.)

Size (W × L)

No. 10: 240 mm (9 DL: 220 mm (8.7 in.) × 110 mm (4.3 in.)

Thickness Less than 0.52 mm (0.020 in.) Weight 75 g/m

(20 lb) ∼ 90 g/m2(24 lb)

Quality Plain paper

Note: Printing of envelopes is supported only at room temperature. When inserting envelopes,

keep the longer side horizontal.

⁄2in.) × 104 mm (41⁄8in.)

1-4 Rev.B

Top mar gin 3 mm (0.12 in.)

Left margin 3 mm (0.12 in.)

Right margin 3 mm (0.12 in.)

Bottom margin 14 mm (0.55 in.)

Printable area

Stylus Pro Service Manual Product Description

Printable area: Cut sheets

B (Left margin)

C (Right margin)

Printable area

A (Top margin)

D (Bottom margin)

Figure 1-3. Printable Area for Cut Sheets

Note: A: Mnimum top margin = 3 mm (0.12 in.)

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

A4 size: 3 mm (0.12 in.) Letter size: 9 mm (0.35 in.) Legal size: 9 mm (0.35 in.) Envelopes: 3 mm (0.12 in.)

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

Envelopes

Figure 1-4. Printable Area for Envelopes

Rev.B 1-5

Product Description Stylus Pro Service Manual

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

paper thickness, as shown in Table 1-5.

Table 1-5. Adjust Lever Setting

Lever Position LEFT

(Vertical) RIGHT

(Horizontal)

1.2.4 Ink Cartridge Specifications

Paper Paper Thickness

Cut Sheets

Envelopes Less than 0.5 mm (0.020 in.)

Cut Sheets

Carriage Unit

Figure 1-5. Adjustment Lever Settings

Black

0.08 ∼

(0.003

0.11 mm

∼

0.004 in.)

Envelopes

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

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

–30 ∼ 40° C (−22 ∼ 104° F) Storage under a month at 40° C (104° F)

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

−30 ∼ 60° C(−22 ∼ 140° F) Transit under 120 hours at 60° C (140° F)

Color

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

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

Notes:

Ink cartridge cannot be refilled; it is the only consumable article.

Do not use an ink cartridge that has exceeded the ink life.

Ink freezes below−3°C; however, it can be used after it returns to room

temperature.

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

–30 ∼ 40° C (−22 ∼ 104° F) Storage under a month at 40° C (104° F)

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

−30 ∼ 60° C(−22 ∼ 140° F) Transit under 120 hours at 60° C (140° F)

1.2.5 Electrical Specifications Table 1-6. Rated Electrical Ranges

1-6 Rev.B

Humidity (% RH)

˚C (˚F)

80%

55%

20%

10˚C (50˚F)

27˚C (80˚F)

35˚C (95˚F)

Guaranteed range

Stylus Pro Service Manual Product Description

Item Rated voltage

Input voltage range Rated frequency range Input frequency range Rated current

Power consumption

Insulation resistance

120 VAC 220 - 240 VAC

103.5 ∼ 50 ∼

49.5 ∼

0.6 A 0.4 A Approx. 20 W

(self-test with 10-cpi LQ characters) 10 MΩ,

(applying 500 VDC between

120 V Version 220 - 240 V Version

132 V

60 Hz

60.5 Hz

minimum

AC line and chassis)

1000 VAC rms - 1 minute or

Dielectric strength

1200 VAC rms - 1 second (between AC line and chassis)

1.2.6 Environmental Conditions Table 1-7. Acceptable Environmental Conditions

Description Temperature

Humidity Shock resistance Vibration resistance

10 ∼

35°C (50∼95°F)

20 ∼

80% RH

1G (within 1 msec.) 2G (within 2 msec.)

0.15 G 0.50 G

198 ∼

264 V

50 ∼

60 Hz

49.5 ∼

60.5 Hz

Approx. 20 W

(self-test with 10-cpi LQ characters)

10 MΩ

, minimum

(applying 500 VDC between

AC line and chassis)

1500 VAC rms - 1 minute

(between AC line and chassis)

Operating Non Operating

*1,3

−20∼60° 5 ∼

C (−4∼122°F)

85% RH

*2,3

*1 : For operating the printer, conditions must be in the range shown in the figure below.

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

: Without condensation.

Figure 1-6. Temperature/Humidity Range

Rev.B 1-7

Product Description Stylus Pro Service Manual

1.2.7 Reliability

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

1.2.8 Safety Approvals

Safety standards: 120V version: UL1950 with D3,

CSA22.2 # 950 with D3

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

NEMKO, SETI)

Radio frequency interference (RFI): 120 V version: FCC part 15 subpart B class B

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

EN55022 (CISPR PUB. 22) class B

1.2.9 Physical Specifications

Dimension (W × D × H): 482 × 530 × 192 mm (18.5 × 20.7 × 7.56 in.) Weight: Approximately 7.5 kg (16.5 lb)

1-8 Rev.B

Approx. 5 µs Approx. 5 µs

0.5 µs (minimum)

BUSY

ACKNLG

DATA

STROBE

Stylus Pro Service Manual Product Description

1.3 INTERFACE SPECIFICATIONS

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

1.3.1 Parallel Interface Specifications

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

STROBE pulse synchronization

ACKNLG signals

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

Figure 1-7. Data Transmission Timing

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

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

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

INIT input signal is active r During initialization r When the

ERROR or PE signal is active r During the self-test mode r During the demonstration mode r During the default setting mode r When a fatal error occurs

The

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

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

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

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

Rev.B 1-9

Product Description Stylus Pro Service Manual

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

Table 1-8. Signal and Connector Pin Assignments for Parallel Interface

Pin No.

2-9

12 13

32 35

17 16 19-30 33,36 15,18,34

Signal Name I/O* Description

The

STROBE pulse is used to read data from the host

STROBE I

DATA 1-8 I

ACKNLG O

BUSY O

PE O

SLCT O Pulled up to +5 V through a 1.0 KΩ resistor in the printer.

AFXT I

INIT I

ERROR O

+5 V — Pulled up to +5 V through 1.0 KΩ resistor in the printer.

CHASSIS — Chassis ground.

GND — Signal ground.

—— — — — Not used. —— —

computer. Pulse width must be 0.5 µs or more. Normally, it

is HIGH, and data is latched with the rising edge of this

signal.

DATA 1-8 are parallel data bits. When one of these signals is

HIGH, the data bit is 1; when LOW, the data bit is 0. The most

significant bit (MSB) is DATA 8. The signal state must be

maintained for 0.5 µs on either side of the

active edge.

ACKNLG is an acknowledge pulse with a width of

approximately 10 µs. This signal goes LOW upon

completion of data reception to indicate that the printer is

ready to receive further data.

The BUSY signal informs the host computer of the printer’s

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

more data.

This signal indicates whether paper is available in the printer or

not. A HIGH level indicates no paper.

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

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

status of this signal is checked only at power on and

initialization.

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

width of this signal must be 50 µs or more.

This signal goes LOW if the printer has a fatal error or runs out

of paper.

STROBE signal’s

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

1-10 Rev.B

Stylus Pro Service Manual Product Description

1.3.2 Serial Interface Specifications

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

Table 1-9. DTR and X-ON/X-OFF Protocol

State Busy

Ready

Word length

Start bits: Data bits: Parity bits:

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

Buffer Space DTR X-ON/X-OFF

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

1 bit 8 bit none 1 bit

System peripheral-8 cable

Table 1-10. Signal and Connector Pin Assignments for Serial Interface

Pin No. 1

2 3 4 5 6 7 8

Signal Name I/O* Description

DTR Out Data terminal ready

NC — No connection

TXD Out Transmit data

SG In Signal ground RXD In Receive data TXD Out Balanced transmit

NC — No connection RXD In Balanced receive

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

Rev.B 1-11

Product Description Stylus Pro Service Manual

1.4 OPERATIONS

This section describes the basic operations of the printer.

1.4.1 Control Panel

The control panel for this printer has 1 lock-type and 5 non lock-type pushbuttons, and 15 LED indicators for easy operation of the various printer functions.

Operate Alt

Font

Economy/ Condensed

Load/Eject

Pause

Figure 1-8. Control Panel Appearance

Buttons

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

3 seconds turns the Pause light to come on, and causes the printer to move the carriage to the ink cartridge installation position. Pressing Alt again causes the carriage to return to the home position.

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

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

Economy/Condensed Selects either economy printing or condensed printing mode. Pressing

the Economy/Condensed button while holding down the Alt button turns the Pause light on and starts the color printhead cleaning cycle.

Load/Eject Either loads a new sheet into the printer or ejects paper currently in

the paper path. Pressing the Load/Eject button while holding down the Alt button starts the black printhead cleaning cycle.

Pause Stops printing temporarily or resumes printing if it has been stopped

temporarily. Pressing Pause while holding down the Alt button for about three seconds, or until all LEDs light, resets the printer.

1-12 Rev.B

Stylus Pro Service Manual Product Description

Indicators

Operate On when the printer is on. Blinks during power on and off. Data On when print data is in the input buffer. Data and Pause lights blink if

an error occurs. Paper Out On when the printer is out of paper. Blinks when a paper jam occurs. No Ink Cartridge Onwhen the ink is out. Economy Onwhen economy printing mode is selected. Condensed On when condensed printing mode is selected. Font These LEDs indicate the selected font. Pause On when printing is paused.

1.4.2 Panel Operation at Power On

You can activate the modes below by doing the following: Self-test mode Turn on the printer while holding down the Load/Eject button.

Hex dump mode Turn on the printer while holding down the Font and Load/Eject

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

in hexadecimal format. Default setting mode Turn on the printer while holding down the Economy/ Condensed

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

buttons.

Rev.B 1-13

Product Description Stylus Pro Service Manual

1.4.3 Default Settings

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

1.4.3.1 Default Setting Items

In default-setting mode, you can change settings listed in the table below. Activate default-setting mode by holding down the Economy/Condensed button while turning on the printer.

Table 1-11. Default Setting Items

Menu Contents

Character table

Print direction

Network I/F mode

Auto line feed Loading position

Interface mode

Auto I/F wait mode

Table 1-12. Characteristics of Print Direction Mode

Item

Auto

Bi-D

Uni-D

Black and White Printing Color (CMYK) Printing

Throughput and quality is

Print quality may be down.

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

Auto Bi-D Uni-D

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

On: Valid Off: Invalid

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

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

10/30 seconds 10 sec.

better.

Throughput is best.

Throughput is worse. Print quality is better.

Description

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

Throughput is worse. Color quality is best.

Factory

Setting

—

Off

—

Table 1-13. Printing Direction and ESC U Command

Default Setting Mode

^ Character mode

(for MS-DOS Raster graphics mode (for Windows

™

)

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

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

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

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

1.4.3.2 Changing the Default Settings

To change the printer’s default settings:

1-14 Rev.B

Auto Bi-D Uni-D +

Stylus Pro Service Manual Product Description

a. Hold down the Economy/Condensed button and turn on the printer. The printer prints a sheet that

shows the firmware version and describes how to select the language used to print messages.

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

language corresponds to which font LED.

Table 1-14. Language Selection

Language English

Français Deutsch Italiana Español

c. Press the Alt button. The printer prints the current settings using the selected language. It also

prints a table showing how to change the printer settings.

d. Press the Font button to advance through the setting menu. The current printer settings are

indicated by the Courier, Roman T (PS), and San Serif H (PS) LEDs. Each time you press the Font button, you adance to the next setting, and the three font LEDs change according to the selection.

Font LED

Courier Roman T (PS) Sans Serif H (PS) Roman Sans Serif

Table 1-15. Feature Selection

Feature/Menu

Character table On On On See Table 1-16 + Print direction

Network I/F mode Auto line feed Loading position Interface mode

Auto I/F wait time

e. Change the setting value by pressing Alt button. Pressing the Alt button changes the setting for the

current menu. The status of the LEDs will be changed as the button is pressed.

Courier

LED

On Off Off

Off On Off On On Off Off Off On

On Off On

Off On On

Roman T (PS) LED

Sans

Serif H

(PS) LED

Setting

Auto On Off Off

Bi-D Off On Off

Uni-D On On Off

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

3 mm Off Off Off

8.5 mm On Off Off Auto On Off Off

Parallel Off On Off

Serial On On Off

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

Setting Value

Operate

LED

Data LED

Paper Out

LED

Rev.B 1-15

Product Description Stylus Pro Service Manual

Table 1-16. Character Table Selection

Version Settings Operate LED Data LED

Italic U.S.A. Off Off Off Italic France On Off Off Italic Germany Blinks Off Off Italic U.K. Off On Off

Common

Standard

NLSP

f. Repeat d and e to change other printer settings. The setting menu selection will return to the first menu

after the last menu selection is over.

g. Turn off the printer. The setting is stored into non-volatile memory.

Italic Denmark 1 On On Off Italic Sweden Blinks On Off Italic Italy Off Blinks Off Italic Spain 1 On Blinks Off PC437 Blinks Blinks Off PC850 Off Off On PC860 On Off On PC863 Blinks Off On PC865 Off On On PC861 On On On BRASCII Blinks On On Abicomp Off Blinks On PC437 Greek Off Off On PC853 Blinks Off On PC855 Off On On PC852 On On On PC857 Blinks On On PC866 Off Blinks On PC869 On Blinks On MAZOWIA Blinks Blinks On Code MJK Off Off Blinks ISO 8859-7 On Off Blinks ISO Latin 1T Blinks Off Blinks Bulgaria Off On Blinks

Paper Out

LED

1-16 Rev.B

Stylus Pro Service Manual Product Description

1.4.4 Error Conditions

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

Table 1-17. Error Indications

Error Data LED

Paper out Off On Off Off Off Off No ink cartridge Off Off On Off Off Off Paper jam Off Blinks Off Off Off Off Maintenance request Blinks Blinks Blinks Blinks Blinks Blinks Carriage error Blinks Off Off Off Off Blinks

Paper Out

LED

No Ink

Cartridge

LED

Economy

LED

Condensed

LED

Pause

LED

1.4.5 Printer Initialization

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

1.4.5.1 Hardware Initialization

Hardware initialization is performed by: r Turning on the printer. r Sending the parallel interface

(If the

INIT signal is active when the printer is turned on, hardware initialization is started when the INIT

signal becomes inactive.) When the hardware initialization is performed:

r The printer mechanism is initialized. r Input data buffer is cleared. r Downloaded character definitions are cleared. r Print buffer is cleared. r Default values are set.

INIT signal.

1.4.5.2 Software Initialization

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

r Print buffer is cleared. r Default values are set.

The last panel settings are kept.

1.4.5.3 Panel Initialization

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

r Input data buffer is cleared. r Print buffer is cleared. r Default values are set.

The last panel settings are kept.

Rev.B 1-17

Product Description Stylus Pro Service Manual

1.5 MAIN COMPONENTS

The main components of the Stylus Pro are:

o Main control board (C164 MAIN Board) o Power supply unit (C137 PSB/PSE Board) o Control panel board (C137 PNL Board) o Printer mechanism (M-4A10) o Housing

1.5.1 Main Control Board (C164 MAIN Board)

The main control board (C164 MAIN Board) consists of an H8/3003 16-bit CPU, E05A09 gate array, a program ROM (1/2/4Mb), a program/CG ROM (1/2/4/8Mb), 1 DRAM (4Mb), a mask ROM (4/8Mb), an EEPROM (1Kb), and a lithium battery for powering the protect counters. The reset IC (M51955 and PST 592) is equipped with both a logic system and a power system. The C164 MAIN Board is almost the same as the C162 MAIN Board, except that the C164 board has no solenoid driving circuit for the ADF. (The C162 MAIN Board has a solenoid driver to operate the document feeder. )

Table 1-18. Comparison between C164 MAIN and C162 MAIN

Main Board C164 MAIN Board C162 MAIN Board

DRAMs 1 2 ADF Plunger

Driving Circuit *

None Equipped

* The ADF plunger switches the PF motor operation from paper feed to paper pickup.

CPU (H8/3003)

RAM

Program ROM

Head Common Drive Tansistors

Lithium Battery

164

Gate Array (E05B09)

EEPROM

PF Motor Driver IC

CR Motor Driver IC

CG ROM

Figure 1-9. C164 MAIN Board Component Layout

1-18 Rev.B

CN1

CN2

IC51 (TL494)

C11

C51

C82

PC1

Q51

DB1

D51

SW6

LED1 / LED4

LED8 / LED14

LED5 LED6

LED7

SW4 / SW0

Stylus Pro Service Manual Product Description

1.5.2 Power Supply Board (C137 PSB/PSE Board)

The power supply board (C137 PSB/PSE Board) consists of an RCC switching regulator circuit. This board is equipped with a power switch, connected to the secondary circuit. Thus, if the printer is turned off, it can continue to operate to eject the paper and perform the head-capping operation. The power on/off signal is always monitored by the E05A09 gate array on the C164 MAIN Board, and the logic system recognizes the power switch status.

Figure 1-10. C137 PSB/PSE Component Layout

1.5.3 Control Panel (C137 PNL Board)

The 15 LEDs on this board indicate error status (there is no buzzer system). By using the 6 buttons in combination with one another, you can operate the printer in each protected mode (cleaning color or black ink systems, exchanging ink cartridges, running a self-test, setting default values, resetting the printer, and EEPROM clearing).

Figure 1-11. C137 PNL Board Component Layout

Rev.B 1-19

Product Description Stylus Pro Service Manual

1.5.4 Printer Mechanism (M-4A11)

The M-4A11 printer mechanism is equipped with a 64-nozzle black printhead and 48-nozzle color (CMY) printhead on the carriage unit. A resolution of 720 dpi is possible with special (non-absorbent) paper.

The ink system has both a black pump unit and a color pump unit. Waste ink from each printhead flows into individual caps. Power for the pump system and paper feed system is supplied by the paper feed motor. This printer mechanism is based on Stylus Color’s (M-4A10).

1.5.5 Housing

The Stylus Pro’s housing consists of the printer cover, upper case, and the lower case. Attached to the housing is the front paper tray, with paper separator.

1-20 Rev.B

Chapter 2 Operating Principles

Table of Contents

2.1 OVERVIEW 2-1

2.2 OPERATING PRINCIPLES OF THE PRINTER MECHANISM 2-1

2.2.1 Printer Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2.2.2 Principles of the Printing Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

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

2.2.3.1 Platen Gap Adjust Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

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

2.2.5 Ink System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

2.2.6 Pump Mechanism. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

2.2.7 Cap Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

2.2.8 Wiping Mechanism. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

2.3 OPERATING PRINCIPLES OF THE ELECTRICAL CIRCUITS 2-13

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

2.3.2 Operating Principles of the Main Control Circuit . . . . . . . . . . . . . . . . 2-14

2.3.2.1 Reset Circuits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

2.3.2.2 Sensor Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

2.3.2.3 Carriage Motor Drive Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

2.3.2.4 Paper Feed Motor Drive Circuit . . . . . . . . . . . . . . . . . . . . . . . . 2-18

2.3.2.5 Printhead Drive Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

2.3.2.6 DMA Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

2.3.2.7 DRAM Refresh Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

2.4 INK SYSTEM MANAGEMENT 2-21

2.4.1 Ink Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

2.4.2 Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23

2.4.2.1 Protect Counter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23

List of Figures

Figure 2-1. Printer Mechanism Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

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

Figure 2-3. Principles of the Printing Operation . . . . . . . . . . . . . . . . . . . . . . 2-3

Figure 2-4. Platen Gap Lever Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Figure 2-5. Platen Gap Lever Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Figure 2-6. Paper Feed Mechanism. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Figure 2-7. Ink System Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Figure 2-8. Pump Mechanism Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

Figure 2-9. Switch Lever Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

Figure 2-10. Paper Feed Mechanism. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Figure 2-11. Switch Lever Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Figure 2-12. Pump Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

Figure 2-13. Cap Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Figure 2-14. Wiping Mechanism. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Figure 2-15. Block Diagram of the Electrical Circuits . . . . . . . . . . . . . . . . . 2-12

Figure 2-16. Power Supply Circuit Block Diagram. . . . . . . . . . . . . . . . . . . . 2-13

Figure 2-17. Main Control Circuit Block Diagram . . . . . . . . . . . . . . . . . . . . 2-14

Figure 2-18. Reset Circuit Block Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

Figure 2-19. Sensor Circuit Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

Figure 2-20. Carriage Motor Circuit Block Diagram. . . . . . . . . . . . . . . . . . . 2-16

Figure 2-21. Serial Data Transfer Procedure . . . . . . . . . . . . . . . . . . . . . . . . 2-17

Figure 2-22. Paper Feed Motor Drive Circuit Diagram. . . . . . . . . . . . . . . . . 2-18

Figure 2-23. Normal/EPSON Micro Dot Switching Block Diagram. . . . . . . 2-19

Figure 2-24. Trapezoidal Drive Waveform. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

Figure 2-25. Printhead Drive Circuit Block Diagram . . . . . . . . . . . . . . . . . . 2-20

Figure 2-26. DMA Controller Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

Figure 2-27. Junction Method (CPU-DRAM) . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

List of Tables

Table 2-1. Carriage Drive Motor Specifications . . . . . . . . . . . . . . . . . . . . . . . 2-4

Table 2-2. Drive Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Table 2-3. Platen Gap Adjust Lever Position. . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Table 2-4. Paper Feed Drive Motor Specification . . . . . . . . . . . . . . . . . . . . . 2-5

Table 2-5. Drive Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Table 2-6. Pump Mechanism Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

Table 2-7. DC Voltage Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

Table 2-8. Serial Data Contents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

Table 2-9. Paper Feed Motor Drive Modes. . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

Stylus Pro Service Manual Operating Principles

2.1 OVERVIEW

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

2.2 OPERATING PRINCIPLES OF THE PRINTER MECHANISM

2.2.1 Printer Mechanism

The Stylus Pro is based on the Stylus Color printer. The Stylus Pro printer mechanism is composed of the printhead unit, paper feed mechanism, carriage drive mechanism, pump mechanism, and various sensors such as the Stylus Color’s. The figure below shows a functional block diagram of the printer mechanism.

Pickup Re lease Lever

ASF Mechanism

Pa per Feed Moto r

Carriage Motor

Figure 2-1. Printer Mechanism Block

Disengage Lev er

Paper Feed Mechanism

Pump Unit Drive Mechanism

Carriage Unit

Color Black

Rev.A 2-1

Cartridg e Needle

Piezo

Printhead Driver Board

Nozzle

Nozzle Plate

Piezo

Operating Principles Stylus Pro Service Manual

2.2.2 Principles of the Printing Operation

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

Figure 2-2. Structure of Printhead

2-2 Rev.A

Normal State

Ejection State

Vibration PlateNozzle

Vibration Plate

Cavit y

Nozzle

Piezo

Cavit y

Stylus Pro Service Manual Operating Principles

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

No electrical charge is applied to the piezoelectric element attached to the back of the cavity, and pressure inside the cavity is kept at a constant level.

r Ejecting state

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

Figure 2-3. Principles of the Printing Operation

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

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

2.3.2.5.)

EPSON Micro Dot Printing Mode (Super 720 dpi Printing Mode)

The Stylus Pro printer has a special printing mode, called the EPSON Micro Dot Printing mode. This printing mode can be selected on command from the host computer. Using this printing mode can improve the quality of output because it eliminates the banding that can sometimes occur in normal mode. In EPSON Micro Dot Printing mode, the ink dot size becomes smaller than the normal dot size.

Rev.A 2-3

Operating Principles Stylus Pro Service Manual

2.2.3 Carriage Drive Mechanism

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

Table 2-1. Carriage Drive Motor Specifications

Item Description

Motor Type 4-phase / 200-pole hybrid-type stepping motor Drive Voltage +35 VDC ± 5% Coil Resistance 10.0 Ω ± 7% Drive Frequency 960 ~ 4800 PPS Excitation Mode Constant current unipolar drive, micro step driving

Table 2-2. Drive Terms

Acceleration/

CR Speed Frequency Phase Drive Method

Deceleration

Steps

Mode 1 (200 CPS)

Mode 2 (100 CPS)

Mode 3 (40 CPS)

4800 (2400)

2400 (1200)

960 (480)

r Acceleration/Deceleration Area:

2W1-2 phase + 1-2 phase

r Constant Area: 1-2 phase

r Acceleration/Deceleration Area:

2W1-2 phase + 1-2 phase

r Constant Area: 1-2 phase r Acceleration/Deceleration Area:

2W1-2 phase

r Constant Area: 2W1-2 phase

Notes: 2W1-2 phase means the 1/8 2-2 phase drive control.

Values in parentheses ( ) are values of the 2-2 phase.

2.2.3.1 Platen Gap Adjust Lever

(A)

Platen Gap Adjust Lever

Acceleration

40 (5)+110 (55)

Deceleration

32( 4)+112 (56)

40 (5)+40 (20)

16 (2)

(B)

0.6 mm

Eject Frame

Platen

Printhead

Carriage Slide r

Figure 2-4. Carriage Drive Mechanism

2-4 Rev.A

Stylus Pro Service Manual Operating Principles

The platen gap adjust lever, which is attached to the carriage unit, needs to be set to the appropriate position for the paper thickness. To change the platen gap, put the printer in the PAUSE state, then press the Font button while holding down the Alt button. The carriage unit moves the platen gap adjustment position automatically. The platen gap adjustment mechanism consists of platen gap lever, carriage slider, and eject frame. When you set the lever for vertical or horizontal position, the carriage slider either pushes against the eject frame or does not push it. Then the platen gap is changed because of the up and down motion of carriage.

Table 2-3. Platen Gap Adjust Lever Position

Paper Type Lever Position

Cut sheets Horizontal (A) (± 0 mm) Envelopes Vertical (B) (+0.6 mm)

CR HP Sensor

CR Motor

Carriage Guide Shaft

Belt Pul ley

Car riag e Unit

Figure 2-5. Platen Gap Lever Operation

2.2.4 Paper Feed Mechanism

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

Table 2-4. Paper Feed Drive Motor Specification

Item Description

Motor Type 4-phase, 96-pole, hybrid-type Drive Voltage +35 VDC ± 5% Coil Resistance 11.5 Ω ± 1.1Ω Drive Frequency 300 ~ 1800 PPS Excitation Mode Paper feed / pump drive: 2-2 phase, 2W1-2 phase

Rev.A 2-5

Operating Principles Stylus Pro Service Manual

Table 2-5. Drive Terms

Current Value (mA)

Mode

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

PF Transmission Ge ar

Frequency

(pps)

Quenchi ng Roller

Acceleration/

Deceleration

PF Pinch Roller Unit

Constant Rush Hold

PF Motor Pinion Gear

Paper Pickup Lever

Pickup Roller

Platen Drive Gear

Carr iag e Lever

Tension Spring

Cam Roller

Hopper Frame

Figure 2-6. Paper Feed Mechanism

2-6 Rev.A

Air Valve

Black HeadColor Head

Pump 1

Pump 2

Ink Absorber

Waste In k Dra in Ta nk

Cleani ng B la de (for Color / Bla ck Head )

Pump Unit

Friction Clutch

Disengage Unit

Platen Roller

PF Motor

Stylus Pro Service Manual Operating Principles

2.2.5 Ink System

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

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

The figure below shows a diagram of the ink system.

Figure 2-7. Ink System Block Diagram

Rev.A 2-7

D/E Lever

D/E Set L ever

D/E Reset Le ver

Carria g e

Operating Principles Stylus Pro Service Manual

2.2.6 Pump Mechanism

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

Drive: Pump Mechanism

Carriage

Left Frame

Platen D rive Gear

PF Motor

Figure 2-8. Pump Mechanism Block Diagram

Drive: Switch Lever Set

Hook

Platen

Spring

Sub Frame

Disengage Lever

Release Clutch

Pump Drive Gear

Pump Unit

Right Frame

2-8 Rev.A

Figure 2-9. Switch Lever Set

Carriage

D/E Reset Lever

D/E Lever

Stylus Pro Service Manual Operating Principles

Drive: Pump Mechanism

Figure 2-10. Paper Feed Mechanism

Drive: Switch Lever Set

Figure2-11. Switch Lever Reset

Rev.A 2-9

Operating Principles Stylus Pro Service Manual

Table 2-6. Pump Mechanism Operation

PF Motor Rotational Direction Operation

Clockwise (CW)

forward rotation

Counterclockwise (CCW)

backward rotation

r Color absorption r Wiper reset r Carriage lock reset

r Monochrome absorption r Wiper set r Carriage lock set

The pump draws ink from the printhead nozzles and drains it into the waste ink drain tank. The printer performs this operation to eliminate dust or bubbles within the nozzles. The figure below illustrates pump operation. When the paper feed drive motor rotates CW (forward), the color pulley pumps in the wheel pump unit rotate in the direction of the arrow while squeezing the ink tube to push the ink inside the tube out to the waste ink drain tank. When the motor rotates CCW (backward), the black pulley pumps in the wheel pump unit rotate in the direction of the arrow while squeezing the ink tube to push the ink inside the tube out to the waste ink drain tank. There are 2 pump rollers in the pump unit, and the drive power is supplied from the paper feed motor via the pump drive gear (D/E gear), which is moved by carriage operation. In the pump unit, the transmission gear supplies both the black and color pulley, which are rotated by the rotation of each other.

Ink Draining

Vacuuming

Pump Motor (CW) : Color Pumping

No ink draining

No vacuuming

Pump Motor (CW): Black No Pump in g

Figure 2-12. Pump Operation

Vacuuming

Pump Motor (CC W) : Bla ck Pu mpin g

No ink draining

No vacuuming

Pump Motor (CCW): Color No Pumping

2-10 Rev.A

Color Cartridge Black Cartridge

Carriage

Air Tube

Cap Holder

Cap 1 Cap 2

Air Valve

Valve Spring

Stylus Pro Service Manual Operating Principles

2.2.7 Cap Mechanism

The cap mechanism prevents printhead nozzles from drying and keeps bubbles from forming inside the nozzle while the printer is not in use. The printer performs this operation automatically when print data is not received, when printer power is turned off, and during printing or ink system operations. (The power switch uses a secondary circuit that allows this operation to be performed.) Also this printer has 2 caps, 1 for the black head and 1 for the color head.

2.2.8 Wiping Mechanism

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

Platen

Figure 2-13. Cap Mechanism

Hook

Hook Lever

Wiper (Cleaning Blade)

Wiper Drive Gear

Clutch

Rev.A 2-11

Wipe r Drive Ge ar Frame

Figure 2-14. Wiping Mechanism

Operating Principles Stylus Pro Service Manual

2.3 OPERATING PRINCIPLES OF THE ELECTRICAL CIRCUITS

The Stylus Color Pro contains the following circuit board units:

r C164 MAIN Board (main control circuit board). r C137 PSB/PSE Board (power supply circuit board). This board is the same as Stylus Color’s r C137 PNL (control panel board). This board is the same as Stylus Color’s.

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

C137 PNL

C137 PSB/PSE

+5 VDC

+35 VDC

C164 MAIN

M-4A11 PRINTER MECHANISM

CR/PF Motor

Carriage Unit

YMC Head Driver

R-T02 Head R-T01 Head

Black Head Driver

Figure 2-15. Block Diagram of the Electrical Circuits

2.3.1 Operating Principles of the Power Supply Circuit

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

Table 2-7. DC Voltage Distribution

Voltage Application

+35 VDC

+5 VDC

2-12 Rev.A

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

C164 MAIN Board Sensors (home position, paper end, no ink cartridge, head thermistor) Control panel, head nozzle selector

Stylus Pro Service Manual Operating Principles

The figure below shows a block diagram of the power supply circuit (C137 PSB/PSE). The power switch is equipped with a secondary circuit that allows the CPU to remain active for a while after the printer is turned off. This allows the printhead to return to the capping position after power has been turned off. The CPU, which is mounted on the C164 MAIN Board, always monitors the PSC (Power On/Off) signal. If this signal goes LOW, the CPU resets each device after performing the head-capping sequence. Also, this board employs the RCC (Ringing Choke Converter) switching system. The AC voltage is first input to the filter circuit for higher harmonics absorption, and then input to the rectification and smoothing circuit, converting it into DC voltage. This DC voltage is then input to the switching circuit for the switching operation. Along with the switching operation on the primary side, +35 VDC is generated after passing through the +35 V line voltage detection circuit. This +35 VDC output level is stabilized. This +35 VDC is also input to the +5 VDC generation circuit to generate a stable +5 VDC.

DB1 C11 Full-wave

Rectifie r Circuit

L1,R1

C1-C4

Filter Circuit

Fuse

Smoothing Circuit

Main Switching Circuit

Feedback Circuit

C51

Smoothing Circuit

ZD51, 81-84

Transformer

P-OFF De te ctio n and Delay Circuit

ZD86, C82

Drop Protection Circuit

Over Voltage Protection Circuit

Photo Coupler

PC1

TL 494

ZD52

P-OFF Signal

Figure 2-16. Cap Mechanism

+35 VDC

ZD53

Over Voltage Protection Circu i t

C164 MAIN

+5 VDC

Power SW

on Panel

1. +5 VDC line over voltage protection circuit The output voltage level of +5 V line is monitored by Zener diode ZD53. If the voltage level exceeds +7 V,

the status is fed back to the primary switching circuit through a photocoupler (PC1) to stop the +35 V generation.

2. +5 VDC line over current / over voltage control circuit The output current is monitored by detection resistor R53 and fed back to +5 VDC generation switching

control IC51, which monitors the output voltage. This information is input to the internal comparator, which outputs a HIGH signal to turn off transistor Q51 when the voltage or current becomes abnormal.

3. +35 VDC line over voltage protection circuit The output level is monitored by Zener diode ZD36. If the voltage level exceeds +36 V, photocoupler PC1 is

activated. This stops primary switching circuit operation.

4. +35 VDC line drop protection circuit The output level of +35 VDC line is monitored by a detection circuit that consists of Zener diodes ZD51 and

ZD81 to 84. This circuit feeds back the output voltage level status through a photo- coupler to the primary switching circuit to control the ON/OFF time of the switching transistor for constant output voltage.

Rev.A 2-13

Operating Principles Stylus Pro Service Manual

2.3.2 Operating Principles of the Main Control Circuit

The main control circuit for this printer is the C164 MAIN Board. This circuit is controlled by a 16-bit H8/3003 CPU (IC1), running at 14.7456 MHz. The CPU has a unique architecture, capable of handling data on the data bus at either an 8-bit or 16-bit bus width. Because of this, a 16-bit or 8-bit data bus width-type ROM is used on this board, increasing the internal processing speed. Also, the CPU’s unique architecture is capable of the refresh control function. A 4M DRAM (2 CAS method) on the main board is controlled by the CPU itself. In addition, the CPU controls the serial interface control (RS-422 for Mac).

Gate array E05B06 (IC2) manages printhead drive control, the external Centronics CG board and the control panel, and the controls that create the 4-bit signal for the carriage or the paper feed motor. (The carriage and paper feed motor are controlled by the current duty data.)

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

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

parallel I/F, extension

Type B I/F

EEPROM

Reset (Power)

RS-422 Serial I/F

(IC12) 93C46

(IC8)

M51955B

C164 MAIN Board

PROM (4M) (IC3)

Note:1

Refresh

CPU H8/3003 (IC1)

SD I/O

(IC7)

NJU6355E (Timer Counter)

CG-ROM (IC4)

CLK

Carriage

DRAM

(IC5 )

DMAREQ

Battery

Note:2

CG-ROM (IC1 6) (8M or16M)

Address Bus

E05B09 (IC2)

To B

Pa ralle l I/F

(Centronics)

Drive S ignal

Carriage/Paper Feed

CG-ROM (IC 17)

Data Bus

(IC13)

PST592D

Panel

To A

Black/Color H ead

Com mon and Nozz le

Selector D rive Signal

(8M )

Reset (Logic)

From A

From B

Notes 1: 32-pin IC socket only 2: IC 17 is socket only. 16M (IC16), IC1 7 are only in stalled in JAPAN version .

Black/Color Head Common Driver Circuit

SLA7041MS (IC14,15)

Carriage/Paper Feed Motor Driver

SED5620 (U1,U2)

Black 64 Nozzles

Color 48 Nozzles

Figure 2-17. Main Control Circuit Block Diagram

2-14 Rev.A

+35 V

+5 V

NMI

P62

CPU (IC1)

+5 V

PST592D

(IC13)

E05B09 (IC2)

RES

RES ET

135

72 68

RST Type B

PA8

M51955B

(IC8)

1 2

1 2 3

+5 V

AN3

(CN12)

CCO

AN5

CPU (IC1)

AN1

AN0

+5 V

(CN8)

(CN9)

AN4

BCO

(CN11)

Stylus Pro Service Manual Operating Principles

2.3.2.1 Reset Circuits

The C164 MAIN Board contains 2 reset circuits: the +5 V monitor reset circuit and the +35 V monitor reset circuit. The +5 V monitor reset circuit monitors the voltage level of the +5 V line (logic line), using reset IC PST592D (IC13), and outputs a reset signal to the CPU (IC1) and the E05E09 gate array (IC2) when the voltage level drops below +4.2 V. The +35 V monitor reset circuit monitors the voltage level of the +35 V line, using reset IC M51955B (IC8), and outputs a reset signal to the CPU. The reset signal is generated when the voltage level drops below +28 V, and this causes a non-maskable interrupt (NMI).

Figure 2-18. Reset Circuit Block Diagram

2.3.2.2 Sensor Circuits

The following sensor circuits enable the C164 MAIN Board to monitor printer mechanism status: HP sensor A photocoupler-type HP (home position) sensor is attached to the surface of the printer

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

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

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

BCO sensor, CCO sensor

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

Micro switches (BCO sensor for the monochrome ink cartridge, CCO sensor for the color ink cartridge) are attached to the bottom of monochrome ink cartridge holder in the carriage unit. When the ink cartridge is installed, these switches are pressed and a LOW level from the signal indicates that the ink cartridge is installed into the ink cartridge holder.

thermistor’s resistance value (at 25° C (77° F) , approximately 10 KΩ ). The CPU changes the printhead drive signal’s pulse width (charge pulse width) based on the temperature level.

Rev.A 2-15

Figure 2-19. Sensor Circuit Block Diagram

NPN Tr (Q27, 28)

E05B09 (IC2)

CRB

CRSTB

CLKA

CRA

SLA7041MS (IC15)

CLKB STBA STBB

DATA A DATA B

CRVRF

REF A REF B

CRHLD (PA6)

RSA RSB

CRCLK

(PB0-PB7)

A B

8 11 18

2 3 4

+35V

(CN6)

31-38

Operating Principles Stylus Pro Service Manual

2.3.2.3 Carriage Motor Drive Circuit

The carriage motor drive IC SLA7041MS (IC15) outputs a constant current to drive the carriage motor for the printer mechanism. Gate array E05B09 (IC2) decides the motor phase and speed and then sends a signal to the carriage motor driver IC (SLA7041MS) using the 4-bit serial transmission line.

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

⁄

inches, minimum).

720

Figure 2-20. Carriage Motor Circuit Block Diagram

The SLA7041MS motor driver reads four-bit serial data using four clock counts from the E05B06 (IC2) clock. Each bit is read at the falling edges of these clock pulses. As a result of this, received serial data is set into the shift register and then shifts the latch register. When the strobe pulse becomes active from the E05B06 (IC2), serial data is moved into the reference voltage selection circuit and the voltage is changed. Therefore, when the printer is in the constant speed mode, this strobe pulse becomes inactive. The following table indicates the current duty of each carriage motor speed mode.

Table 2-8. Serial Data Contents

Mode c b a Vref (typical)

0 0 0 0 1 0 0 1 × 20% 2 0 1 0 × 40 % 3 0 1 1 × 55.5% 4 1 0 0 × 71.4% 5 1 0 1 × 83% 6 1 1 0 × 91%

2-16 Rev.A

7 1 1 1 × 100%

Vref × 1/3 (Vref = +5V)

× 0%

Stylus Pro Service Manual Operating Principles

The following figure shows 4-bit serial data and how this data is transferred by the SLA7041MS driver. The step time of the reference voltage is determined by the interval time of the strobe pulse.

Vref

+5 V

SLA7041

Vref

To Motor (Phase Signal)

STRB

4-bit Serial Data

CLK

STRB

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

Vref Voltage Selection Circuit

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

Phase a b c

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

Phase a b c

Reading of serial data from the phase signal in order

Latch

4-bit Shift Register

Figure 2-21. Serial Data Transfer Procedure

Rev.A 2-17

E05A96 (IC2)

41 40

PFB

PFSTB

CLKA

PFA

SLA7041MS (IC14)

CLKB STBA

STBB

DATA A DATA B

PFVRF

REF A REF B

PFHLD

RSA RSB

PFCLK

(PB8-PB13)

A A

11 18

1 2 3 4

+35V

(CN7)

NPN Tr (Q25, 26)

Operating Principles Stylus Pro Service Manual

2.3.2.4 Paper Feed Motor Drive Circuit

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

r Paper feed mechanism r Paper pickup mechanism r Pump mechanism

Driver IC SLA7041MS (IC14) drives the paper feed motor by a constant current. The operation principle is same as for the carriage motor drive circuit. But the paper feed motor drives not only the paper feed mechanism but also the pump unit. (Refer to Section 2.2.4.)

Table 2-9. Paper Feed Motor Drive Modes

Mode Phase Excitation Drive Frequency

Paper feed 2-2 phase or 2W1-2 phase 391 or 1600 pps Pump drive 2-2 phase 300 or 1800 pps

Figure 2-22. Paper Feed Motor Drive Circuit Diagram

2-18 Rev.A

Micro Dot Charge/Discharge Circuit

SELM

SELN

Normal Dot

Micro Do t

Resistor A rra y

Common Drive Signal

Printhead

Normal Dot Charge/Discharge Circuit

RM12, RM5

RM11, RM4

COM

GND BPWC

CPEC

BPWD CPED

Tc: Charge time Th: Idle time Td: Discharge time

Pc: Charge pulse Ph: Idle pulse Pd: Discharge pu lse

Head drive volt age (VH)

Stylus Pro Service Manual Operating Principles

2.3.2.5 Printhead Drive Circuit

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

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

The 64-bit thermal head driver SED5620D in the head drive circuit on the carriage is used as a nozzle selector to selectively drive the printhead nozzles. Print data is converted into serial data by gate array E05B09 (IC2) and is output from port BSO (pin 20) to the black head drive circuit or output from port CSO (pin 24) to the color head drive circuit. Then, head driver SED5620D latches the head data when gate array E05B09 outputs the BLAT or CLAT signal, and the latched data becomes 64-bit parallel data for the black head, or 48-bit parallel data for the color head. One bit corresponds to each nozzle.

When data transfer and nozzle selection are complete, gate array E05B09 outputs the common drive pulse BPWC or CPWC (charge pulse) and BPWD or CPWD (discharge pulse) to the common drive circuit. The common drive circuit then generates the trapezoidal pulse and applies it to the printhead as a common drive pulse. After this, the nozzle selected by the head data is activated to eject ink.

Normal Dot / EPSON Micro Dot Printing Mode

The Stylus Color Pro produces two types of ink ejection (normal print mode and EPSON Micro Dot Mode). The signals for switching ink ejection modes are “SELM” (for normal dot printing) and “SELN” (for EPSON Micro Dot printing). These signals are output from pin 49 and pin 50 of gate array E05B09 to IC11 and IC18.

In normal dot print mode, the common drive signals (BPWC, CPWC and BPWD, CPWD) are output to the register arrays (RM12 for black, RM5 for color). In the Micro Dot Mode, the signals (BPWC, CPWC and BPWD, CPWD) are output to the register arrays (RM11 for black, RM4 for color). The signals through the resistor array are output to the charge / discharge circuit that consists of Darlington connected transistors. Then the circuit generates printhead drive pulses.

Figure 2-23. Normal / EPSON Micro Dot Switching

Figure 2-24. Trapezoidal Drive Waveform

Rev.A 2-19

Operating Principles Stylus Pro Service Manual

E05B09 (IC2)

BPWC BPWD

BLAT BCLK BCLKIN BSO

CPWC CPWD

CLAT CCLK CCLKIN CSO

14 19

17 20

16 23

22 21 24

Common Driver

CN11

Common Driver

CN11

C164 MAIN

COM1-8

SED5620D (U1)

LAT

DO64-49

CN1

CLK

COM1-6

DO48-33

DO32-1 7 DO16-1

SED56 20D (U2)

68 69

CN1

On Carriag e (Head Driver B oard)

LAT CLK

DO64-49

DO48-3 3 DO32-1 7

DO16-1

Row A

Row B Row C Row D

Not Connected Row R (Magenta) Row S (Cyan) Row T (Yellow)

Figure 2-25. Printhead Drive Circuit Block Diagram

2.3.2.6 DMA Controller

Data from the host computer is received automatically by the STB signal via the external Centronics interface. The data is input to the input buffer on the DRAM (IC5). At this time, E05B09 detects the rising edge of the external detects this signal, the DMA controller in the CPU sends a bus request to the bus controller in the CPU, and then the CPU releases the bus line. Because of this, the external data is transported into the memory, bypassing the CPU.

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

STB

ACK

BUSY

E05B09 (IC2)

STBDMA

DMARQ

Figure 2-26. DMA Controller Operation

128 14

CPU H8 (IC1)

9129

DREQ1

DREQ2

BAREQ

BACDMAC

Memory

2-20 Rev.A

Stylus Pro Service Manual Operating Principles

2.3.2.7 DRAM Refresh Controller

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

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

CPU 2 CAS DRAM

HWR

LWR

CS3

UCAS

LCAS

RAS

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

UCAS

LCAS

RAS

Read Cycle

Writ e Cycle

(Read / Write Cycle)

UCAS

LCAS

RAS

(Refresh Cycle)

Figure 2-27. Junction Method (CPU - DRAM)

Rev.A 2-21

Operating Principles Stylus Pro Service Manual

2.4 INK SYSTEM MANAGEMENT

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

r Power On r Wiping Operation 1 r Cleaning Selection r Wiping Operation 2 r Micro Absorbing Cleaning r Rubbing Operation r Power Off r Disengage On r Print Start r Disengage Off r Refresh r Micro Absorbing r Standby r Carriage Lock Set r False Absorbing r Carriage Lock Reset r Ink Cartridge Replacement r Refresh (When loading or ejecting paper) r Adjust Lever Operation Position Moving Sequence r Transportation Sequence

These ink system operations are controlled by the following counter:

r Protect counter

2.4.1 Ink Operations

The various ink operations that can be performed selectively by the printer are described below:

1. Power On Operation

This operation is performed when power is turned on.

2. Cleaning Selection Mode

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

3. Micro Absorbing Cleaning Operation

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

4. Power Off Operation

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

5. Print Start Operation

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

6. Refresh Operation

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

7. Standby Operation

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

8. False Absorbing Operation

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

9. Ink Cartridge Replacement Operation

2-22 Rev.A

Stylus Pro Service Manual Operating Principles

This operation is performed when the Alt button is held down for more than 3 seconds (the Pause LED lights); the carriage then moves to the ink cartridge replacement position.

10. Wiping Operation 1

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

11. Wiping Operation 2

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

12. Rubbing Operation

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

13. Disengage ON Operation

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

14. Disengage OFF Operation

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

15. Micro Absorbing Operation

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

16. Carriage Lock Set

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

17. Carriage Lock Reset

This operation resets the carriage lock lever.

18. Refresh Operation (Performed when Loading or Ejecting Paper)

This operation prevents an increase in the viscosity of ink inside the black head surface when paper is being loaded or ejected. When just the black head is on, the color head is capped as paper is loaded or ejected. The printer performs the flushing operation for the black head only.

19. Adjust Lever Operate Position Moving Sequence

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

20. Transportation Sequence

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

Rev.A 2-23

Operating Principles Stylus Pro Service Manual

2.4.2 Counter

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

2.4.2.1 Protect Counter

The value of protect counter A is stored into the EEPROM on the main board, and while the printer is on, this data is stored in the RAM on the main board.

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

counter value is equal to or exceeds 40000, the printer indicates an error on the control panel that maintenance is required.

Notes for Service

Protect counter A is reset:

1. Upon shipment from the factory.

2. After maintenance is performed (when the ink drain tank is replaced).

2-24 Rev.A

Chapter 3 Disassembly and Assembly

Table of Contents

3.1 OVERVIEW 3-1

3.1.1 Precautions for Disassembling the Printer . . . . . . . . . . . . . . . . . . . . . . 3-1

3.2 DISASSEMBLY AND ASSEMBLY 3-2

3.2.1 Upper Case Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

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

3.2.3 Main Controller (C164 MAIN Board) Removal . . . . . . . . . . . . . . . . . . . . 3-5

3.2.4 Printer Mechanism (M-4A11) Removal. . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

3.2.5 Printer Mechanism Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

3.2.5.1 Printhead Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

3.2.5.2 Carriage Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

3.2.5.3 Pump Unit Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

3.2.5.4 Cleaner Head Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

3.2.5.5 CR Motor Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

3.2.5.6 PF Motor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

3.2.5.7 Carriage Home Position Sensor Removal. . . . . . . . . . . . . . . . 3-15

3.2.5.8 PE Sensor Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

3.2.5.9 Paper Feed Roller Assembly Removal . . . . . . . . . . . . . . . . . . 3-16

3.2.5.10 Upper Frame Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

3.2.6 Drain Ink Pad Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

LIST OF FIGURES

Figure 3-1. Disassembly Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Figure 3-2. C137 Control Panel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Figure 3-3. Upper Case Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Figure 3-4. Power Supply Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Figure 3-5. Main Controller Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Figure 3-6. Printer Mechanism (M-4A11) Removal . . . . . . . . . . . . . . . . . . . . . 3-7

Figure 3-7. Ink Cartridge Clamp Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Figure 3-8. Ink Carriage Holder Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Figure 3-10. Printhead Resistance Value. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Figure 3-11. Head Spacer Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Figure 3-12. Front Frame Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Figure 3-13. Carriage Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Figure 3-14. Pump Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Figure 3-15. Cleaner Head Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

Figure 3-16. CR Motor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Figure 3-17. PF Motor Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Figure 3-18. Carriage Home Position Sensor removal . . . . . . . . . . . . . . . . . 3-15

Figure 3-19. PE Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

Figure 3-20. Tension Roller Assembly Removal. . . . . . . . . . . . . . . . . . . . . . 3-16

Figure 3-21. Paper Feed Roller Assembly Removal . . . . . . . . . . . . . . . . . . . 3-16

Figure 3-22. Upper Frame Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

Figure 3-23. Attaching the Torsion Spring. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

Stylus Pro Service Manual Disassembly and Assembly

3.1 OVERVIEW

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

3.1.1 Precautions for Disassembling the Printer

See the precautions below when disassembling the printer.

WARNING

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

water and see a doctor immediately. If ink comes into contact with your skin, wash it off with soap and water. If irritation occurs, contact a physician. r A lithium battery is installed on the C164 MAIN Board of this printer. Be sure to observe the following instructions when servicing the battery:

1. Keep the battery away from any metal or other batteries so that electrodes of opposite polarity do not come in contact with each other.

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

3. Do not solder on any part of the battery. (Doing so may result in leakage of electrolyte from the battery, burning, or explosion. The leakage may affect other devices close to the battery.)

4. Do not charge the battery. (An explosive gas may be generated inside the battery, and cause burning or explosion.)

5. Do not dismantle the battery. (The gas inside the battery may hurt your throat. Leakage, burning, or explosion may also result.)

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

CAUTION

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

ATTENTION

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

CAUTION

r Never remove the ink cartridge from the carriage unless specified to do so. r When transporting the printer after installing the ink cartridge, be sure to pack the printer for

transportation without removing the ink cartridge.

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

Rev.A 3-1

Disassembly and Assembly Stylus Pro Service Manual

3.2 DISASSEMBLY AND ASSEMBLY

WARNING

Follow the precautions in Section 3.1.1 when disassembling the printer.

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

START

Upper Case Removal

3.2.1

Power Supply Unit (C137 PSB/PSE) Removal

3.2.2

Main Controller (C137 MAI N) Remo val

3.2.3

Printer Mechanism (M-4A10) Remo val

3.2.4

Page 3-3

Page 3-4

Page 3-5

Page 3-7

Pump Unit Removal

3.2.5. 3

PF Roller Assembly Removal

3.2.5. 9

Page 3-11

Page 3-15

Drain Ink Pad Rem oval

3.2.6

Printhead Unit Removal

3.2.5.1

Carriage Unit Removal

3.2.5.2

Page 3-18

Page 3-8

Page 3-10

Cleaner Head Removal

3.2.5.4

CR Motor Remova l

3.2.5. 5

Page 3-12

Page 3-13

Carriage Home Position Sensor Removal

3.2.5.7

PE Sensor Removal

3.2.5. 8

Page 3-14

Upp er Fra me Removal

3.2.5.10

Page 3-16

PF Motor Removal

3.2.5.6

Page 3-

Figure 3-1. Disassembly Flowchart

3-2 Rev.A

CBB(M3x11)

Stylus Pro Service Manual Disassembly and Assembly

3.2.1 Upper Case Removal

1.1. Remove the printer cover by releasing the 2 tabs holding it to the upper case.

2. Remove the paper support by releasing the 2 tabs holding it to the lower case.

3. Move the carriage to the center while pressing the carriage lock lever.

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

Carriage Lock Lever

1. Press

2. Move

Prin te r Co ver

Control Pa nel

Figure 3-2. C137 Control Panel Removal

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

6. Release 2 tabs by inserting a flathead screwdriver into the holes at the bottom of the lower case, as shown in the figure below.

7. Remove the upper case by lifting the front side.

DISASSEMBLY/ASSEMBLY POINT

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

Figure 3-3. Upper Case Removal

Rev.A 3-3

Locking Tab

CBS (M3x8)

C164 MAIN Board

C137 PSB/PSE Board

CN5

Shield Plate for C137 PSB/PSE Board

CBS(O) (M4x8)

CBB (M3x12)

CN1

Harnesses for Motors

Disassembly and Assembly Stylus Pro Service Manual

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

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

2. Disconnect the cables from connector CN1 on the C137 PSB/PSE Board and from CN5 on the C164 MAIN Board.

Remove 1 CBS (M3×8) screw and remove 4 CBB (M3×12) screws securing the shield plate to the lower case via the C137 PSB/PSE Board.

Remove 2 CBB (M3×12) screws and 1 CBS (M3×8) screw securing the C137 PSB/PSE Board to the lower case. Then remove 1 CBS (O) (M4×8) screw fixing the earth line from the AC cable to the earth plate.

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

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

CAUTION

As the shield plates of C164 MAIN and C137 PSB/PSE have sharp edges, so take care in handling them.

3-4 Rev.A

Figure 3-4. Power Supply Unit Removal

Stylus Pro Service Manual Disassembly and Assembly

3.2.3 Main Controller (C164 MAIN Board) Removal

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

2. Remove the P/S shield plate from the upper shield plate.

Remove 2 CBS (M3×8) screws securing the upper cover connector to the I/F grounding plate and remove the upper cover connector (Type-B interface cover).

Insert a screwdriver into the printer mechanism to remove the CBS (M3×8) screw securing the C164 MAIN Board and the printer mechanism to the lower shield plate.

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

Remove 2 CBB (M3×12) screws securing the main controller (C164 MAIN Board) to the lower case and remove it by pulling it upward, toward the back of the printer.

7. Disconnect the cables from the connectors CN5, CN6, CN7, CN8, CN9, CN10, CN11, and CN12 of the C164 MAIN board.

Lower G rounding Pl ate

CBB (M3x12)

CBS (M3x8)

Black Head

Color He ad

P/S Shield Plate

CBB ( M3x12)

FFC Form Black Head

Upper Shield Plate

Upper Connector Cover

CBS ( M3x12)

Figure 3-5. Main Controller Removal

Rev.A 3-5

Disassembly and Assembly Stylus Pro Service Manual

ASSEMBLY POINT

r When you replace the main board, initialize the EEPROM contents as follows;

1) Reassemble the printer.

2) Turn the printer ON while hold down [Alt], [Font], [Load/Eject] and [Pause] buttons on the control panel. r It is possible to misconnect the cables. When reconnecting the cables from the connectors CN6, CN7 and connectors CN11, CN12 of the C164 MAIN board, see the following instructions.

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

2. CN6 : Carriage motor cable (red color mark : Also the red color indicates the 1-pin of the

CN6.)

CN7 : Paper feed motor cable (black color mark : Also the black color indicates the

1-pin of the CN7.) r When you replace the main board, block resistances RM4, RM5, RM11 and RM12 must be re-installed at same position on new board.

REQUIRED ADJUSTMENT

r When replacing the main controller board, adjust both the head gap and the Bi-D adjustment alignment, and input the destination parameter into the EEPROM on the C164 MAIN Board. (See Chapter 4.) r When you replace the main board, the parameters in the internal timer are all reset. Therefore, it is possible that printing becomes abnormally. At this time, perform the cleaning operation by the control panel on command (Refer to Chapter 4) until the printing becomes normally.

CAUTION

As the shield plates of C164 MAIN and C137 PSB/PSE have sharp edge, take care of handling them.

3-6 Rev.A

CBS (M4x14)

Stylus Pro Service Manual Disassembly and Assembly

3.2.4 Printer Mechanism (M-4A11) Removal

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

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

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

Remove the 4 CBS (M4×14) screws and take out the printer mechanism.

DISASSEMBLY/ASSEMBLY POINT

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

mechanism.

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

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

Figure 3-6. Printer Mechanism (M-4A11) Removal

r When the printhead or the printer mechanism is replaced, the block resistor must be replaced at locations RM4, RM5, RM11 and RM12 on the C164 MAIN Board. (Every spare printhead or spare printer mechanism comes with a block resistor that is specifically selected for each printhead.) r Adjust both the head gap and the Bi-D alignment when replacing the printer mechanism.

CAUTION

Rev.A 3-7

Disassembly and Assembly Stylus Pro Service Manual

3.2.5 Printer Mechanism Disassembly

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

3.2.5.1 Printhead Unit Removal

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

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

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

CAUTION

r When removing the ink cartridge, always install a new cartridge immediately after removing the old one. r When the ink cartridge is replaced, the printer performs the ink cartridge replacement

operation automatically. Exclusive cartridge is as follows; Monochrome : 1020626

YMC: 1020627

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

Ink Cartridge Clamp (Monochrome)

Tweezers

Ink Cartridge Clamp (Color)

Ink Cartridge Holder

Carriage Base

Figure 3-7. Ink Cartridge Clamp Removal

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

Remove the 3 CBB (M3×11) screws and 3 plain washers securing the ink cartridge holder to the carriage base, and then lift the ink cartridge holder out of the carriage base sliding a little toward left.

Note : As the head FFC cables are secured to the ink cartridge holder with the adhesive tape,

tear off the cables from the ink cartridge holder before removing the ink cartridge holder from the carriage base.

3-8 Rev.A

Ink Cart ridge Holder

CR Cap Cover

CBB (M3x11)

Carriage Base

CBB (M3x11)

PRINTH EAD I J48- 0C 0 (COLOR)

PRINTH EAD I J48- 0A 0 (MONOCHROME)

Stylus Pro Service Manual Disassembly and Assembly

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

Figure 3-8. Ink Carriage Holder Removal

7. Pull the black or color head toward you and disconnect the head flexible flat cable (FFC) on the head driver board (nozzle selector). Then remove the black or color head.

Figure 3-9. Printhead Removal

CAUTION

r Take proper measures to protect the printhead unit from static electricity, because the driver IC is directly attached to the printhead unit. r Never touch the metallic nozzle surface cover of the printhead. Handle it only by holding the edges of the printhead. r When the printhead or the printer mechanism is replaced, the block resistor must be replaced at location RM4 (for Normal Dot R), RM5(for Micro Dot M), RM11 (for Normal Dot R), and RM12 (for Micro Dot M) on the C164 MAIN Board. (Every spare printhead or spare printer mechanism comes with a block resistor that is specifically selected for each printhead. And the resistance value of block resistor are written on the nozzle face of printhead. (Refer to Figure 3-10.)

Rev.A 3-9

Black Head

Head Nose

Spacer

Disassembly and Assembly Stylus Pro Service Manual

Printhead Nozzles

R, M

Color Printhead

R: Normal Dot Res istance Val ue M: Micro Dot Resistance Value

R, M

Monochrome Printhead

Figure 3-10. Printhead Resistance Value

REQUIRED ADJUSTMENT

r When removing or changing the black head, you need to make the following adjustments:

1. Black head angle adjustment (See Section 4.1.4)

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

3. Head gap adjustment (See Section 4.1.3)

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

r When removing or changing the color head, you need to make the following adjustments:

1. Color head angle adjustment (See Section 4.1.6)

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

3. Head gap adjustment (See Section 4.1.3)

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

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

1. Color head angle adjustment (See Section 4.1.6)

2. Black head angle adjustment (See Section 4.1.4)

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

4. Head gap adjustment (See Section 4.1.3)

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

WARNING

r When removing the color or black head, do not lose the spacer that is fixed to each head. This spacer modifies the angle error that occurs during manufacturing. Also, this spacer is different from the linear spacer or angular spacer. (See Chapter 4.)

Figure 3-11. Head Spacer Position

3-10 Rev.A

Grounding Wire

Parallelis m Adjustment Bushing

Pulley Lever

Stylus Pro Service Manual Disassembly and Assembly

3.2.5.2 Carriage Unit Removal

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

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

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

CBS(O) (M3x6)

Front Fra me

Hook

CBS(O) (M3x6)

Figure 3-12. Front Frame Removal

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

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

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

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

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

Rev.A 3-11

Figure 3-13. Carriage Unit Removal

CAUTION

ADJUSTMENT REQUIRED

r Platen gap adjustment (See Chapter 4.)

CBS (M3x6)

Bottom F rame

Pump Unit

(1)

(2)

Disassembly and Assembly Stylus Pro Service Manual

3.2.5.3 Pump Unit Removal

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

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

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

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

Figure 3-14. Pump Unit Removal

3-12 Rev.A

Cleaner Head

Hook

Cleaning Lever

Stylus Pro Service Manual Disassembly and Assembly

3.2.5.4 Cleaner Head Replacement

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

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

CAUTION

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

r Never touch the cleaner head with your bare hands. r When attaching the cleaner head to the pump unit, wear gloves and use clean tweezers to

handle it.

Figure 3-15. Cleaner Head Replacement

Rev.A 3-13

Disassembly and Assembly Stylus Pro Service Manual

3.2.5.5 CR Motor Removal

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

2. Release the timing belt. (See Section 3.2.5.2.)

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

3.2.5.6 PF Motor Removal

Screws

CR Mo tor

Figure 3-16. CR Motor Removal

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

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

CBS (M3x6)

PF Mo tor

Figure 3-17. PF Motor Removal

3-14 Rev.A

Sensor Cable

Carriage Home Position Sensor

Sensor Cable

PE Sensor

Botto m Frame

Stylus Pro Service Manual Disassembly and Assembly

3.2.5.7 Carriage Home Position Sensor Removal

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

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

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

Figure 3-18. Carriage Home Position Sensor Removal

3.2.5.8 PE Sensor Removal

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

2. Disconnect the connector for the PE sensor.

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

Figure 3-19. PE Sensor Removal

Rev.A 3-15

Disassembly and Assembly Stylus Pro Service Manual

3.2.5.9 Paper Feed Roller Assembly Removal

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

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

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

4. Remove the torsion spring on the side frame (L) holding the tension roller assembly to the left side frame.

Remove 1 CBS (M3×6) screw securing the tension roller assembly to the sub frame and remove the

tension roller assembly.

CBS (M3x6)

Tosion Spring

Tension Spring

Tens ion Rolle r Asse mbly

Figure 3-20. Tension Roller Assembly Removal

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

Paper Feed Roller Assembly

Figure 3-21. Paper Feed Roller Assembly Removal

3-16 Rev.A

CBS (M3x6)

E-ring

Tension Spring

Knob

CBS (M3x6)

Upper Frame

Driven Roller Support

Upper Frame

Torsion Spring 6700

Stylus Pro Service Manual Disassembly and Assembly

3.2.5.10 Upper Frame Removal

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

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

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

Remove the 5 CBS (M3×6) screws securing the upper frame to both side frames and the sub frame.

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

Figure 3-22. Upper Frame Removal

ASSEMBLY POINT

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

Figure 3-23. Attaching the Torsion Spring

Rev.A 3-17

Disassembly and Assembly Stylus Pro Service Manual

3.2.6 Drain Ink Pad Removal

The procedures described in this section explain how to remove the drain ink pad when the protect counter value reaches its maximum, and the printer displays a maintenance request error. (Refer to Section 2.4.2.)

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

2. Remove the drain ink pad.

ASSEMBLY POINTS

r After reassembling the printer, power it on while holding down the ALT, Font, Load/Eject and Pause buttons to reset the protect counter.(Refer to Section 2.4.2.) o The protect counter value is shown in the first line of printing in the default setting mode.

The first line consists of the ROM version number, the protect counter value, and nozzle check patterns. o At any time, if the protect counter value is more than 32000, replace the drain ink pad.

CAUTION

After resetting the protect counter, perform the destination data writing operation (Refer to Section 4.1.1.), the Bi-D alignment adjustment (Refer to Section 4.1.2.) and the Head Gap Adjustment. (Refer to Section 4.1.3.)

3-18 Rev.A

Chapter 4 Adjustment

Table of Contents

4.1 OVERVIEW 4-1

4.1.1 Destination Data Writing Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4.1.2 Bi-D (Bidirectional Printing) Alignment Adjustment. . . . . . . . . . . . . . . 4-3

4.1.3 Head Gap Adjustment (Black and Color Head). . . . . . . . . . . . . . . . . . . 4-4

4.1.4 Black Head Angle Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

4.1.5 Black - Color Head Vertical Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . 4-9

4.1.6 Color Head Angle Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

4.1.7 Platen Gap Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

4.1.8 Internal Timer Reset Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

List of Figures

Figure 4-1. Head Gap Adjustment Sample. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Figure 4-2. B-Head Angle and Linear, Angular Spacer. . . . . . . . . . . . . . . . . . 4-5

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

Figure 4-4. Black Head Angle Adjustment Sample . . . . . . . . . . . . . . . . . . . . . 4-6

Figure 4-5. Head Gap Adjustment Sample. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Figure 4-6. Removing the Rubber Cap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Figure 4-7. Spacer Angular Replacement Method . . . . . . . . . . . . . . . . . . . . . 4-8

Figure 4-8. Black-Color Head Vertical Adjust Conception. . . . . . . . . . . . . . . 4-9

Figure 4-9. Spacer Linear Selection Sample . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

Figure 4-10. Spacer Linear Replacement Method. . . . . . . . . . . . . . . . . . . . . 4-10

Figure 4-11. C-Head Angle and Spacer Angular Position . . . . . . . . . . . . . . 4-11

Figure 4-12. Color Head Angle Confirmation Sample. . . . . . . . . . . . . . . . . . 4-11

Figure 4-13. Relationship of the Shape and Thickness . . . . . . . . . . . . . . . . 4-12

Figure 4-14. Spacer Select Judgment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

Figure 4-15. Spacer Angular Replacement Method (YMC). . . . . . . . . . . . . . 4-13

Figure 4-16. Adjusting the Paper Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

Figure 4-17. Confirming the Gap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

List of Tables

Table 4-1. Required Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Table 4-2. Gap and Adjustment Direction. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

Stylus Pro Service Manual Adjustment

4.1 OVERVIEW

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

WARNING

r Always perform adjustments in the order indicated. r After performing destination setting, head angle adjustment, head vertical position adjustment,

head gap adjustment, or bidirectional adjustment, perform the cleaning operation for the black and color printheads. The cleaning operation is necessary because printing sample patterns for these adjustments increases the viscosity of the ink and the printer will not print the correct value. For instance if you replace the black head, you must perform the following adjustments in the order shown: (1) black head angle, (2) black-color head vertical, (3) head gap, (4) Bi-D alignment. r After removing an ink cartridge, always install a new cartridge immediately. During adjustments and testing, use the cartridges designed exclusively for service:

Monochrome: 1020626, CMY: 1020627.

Table 4-1. Required Adjustments

Work Contents Adjustment Contents

When replacing the M-4A11 printer mechanism

When replacing or disassembling the C164 MAIN board or printer mechanism

When replacing or disassembling the black head (board)

When replacing or disassembling the color head (board)

When replacing or disassembling both the color and black head

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

2. Head gap adjustment (See Section 4.1.3)

3. Internal timer reset operation (See Section 4.1.8)

1. Destination data writing operation (See Section 4.1.1)

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

3. Head gap adjustment (See Section 4.1.3)

1. Black head angle adjustment (See Section 4.1.4)

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

3. Head gap adjustment (See Section 4.1.3)

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

1. Color head angle adjustment (See Section 4.1.6)

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

3. Head gap adjustment (See Section 4.1.3)

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

1. Color head angle adjustment (See Section 4.1.6)

2. Black head angle adjustment (See Section 4.1.4)

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

4. Head gap adjustment (See Section 4.1.3)

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

When replacing or disassembling the carriage unit

Rev.B 4-1

1. Platen gap adjustment (See Section 4.1.7)

Adjustment Stylus Pro Service Manual

4.1.1 Destination Data Writing Operation

The setup value that specifies the destination setting is stored in the EEPROM on the C164 MAIN board. This setup value must be rewritten to the EEPROM when the main board or the EEPROM chip is replaced.

CAUTION

Before writing destination data, set the interface setting to the parallel interface•or the auto select setting.

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

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

1. Destination Setting

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

3. Head Vertical Position Confirmation

4. Head Gap Adjustment

5. Bi-D Adjustment

6. Internal Timer Reset

7. END

When the main menu appears, choose “Destination Setting” by typing

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

Choose “END” by typing

6. Turn off the printer.

7 and Enter. The following message appears on the display.

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

Turn the printer OFF, Now!

1 and Enter.

4-2 Rev.B

Stylus Pro Service Manual Adjustment

4.1.2 Bi-D (Bidirectional Printing) Alignment Adjustment

The bidirectional alignment is required when the printer mechanism, main board, or the printhead (board) is replaced. Performing this adjustment determines a compensation value to rectify any deviation in the print position. This deviation could be caused by the different print speeds, which are due to tolerances in the mechanical components, or to the differences in print timing between odd-numbered lines and even-numbered lines in bidirectional printing. The printer stores the compensation data in the EEPROM on the C164 MAIN Board and refers to this data when performing bidirectional printing.

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

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

1. Destination Setting

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

3. Head Vertical Position Confirmation

4. Head Gap Adjustment

5. Bi-D Adjustment

6. Internal Timer Reset

7. END

When the main menu appears, choose “Bi-D Adjustment” by typing the check pattern with a sample compensation value.)

4. The following menu appears on the display.

Input Bi-D value No. (If OK, input [Y] key.)? _

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

lines, enter a compensation value in the range from −30 to +30. r Positive compensation value: Shifts the 2nd line to the left

r Negative compensation value: Shifts the 2nd line to the right When the sample printing becomes vertically aligned in both lines, press

you to the main menu.

Choose “END” by typing

7 and Enter. The following message appears on the display.

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

Turn the printer OFF, Now!

5 and Enter. (The printer prints

Y and Enter; this returns

7. Turn off the printer.

Rev.B 4-3

Adjustments Stylus Pro XL

4.1.3 Head Gap Adjustment (Black and Color Head)

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

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

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

1. Destination Setting

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

3. Head Vertical Position Confirmation

4. Head Gap Adjustment

5. Bi-D Adjustment

6. Internal Timer Reset

7. END

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

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

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

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

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

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

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

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

All parameters that you have specified so far arewrittentoEEPROMuponpoweroff.

7. Turn off the printer.

Head Gap Adjustment No. 0

Color (Magenta ) Line

Turn the printer OFF, Now!

Black Line

Figure 4-1. Head Gap Adjustment Sample

4-4 Rev. A

Black Head

(Angle Adjustment Concept)

Black Head (Reverse Side)

Head Base

Carriage

Angular Spacer

Linear Spacer

(Spacer Setting Position)

Stylus Pro XL Adjustments

4.1.4 Black Head Angle Adjustment

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

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

Figure 4-2. Black Head Angular and Linear Spacers

Angular Spacers (For Black Head)

Spacer Name Spacer NameThickness Thickness

angular spacer BK

angular spacer BK:B

angular spacer BK:C

angular spacer BK:D

angular spacer BK:E

0.05

0.10

0.15

0.20

0.25

Shape

Linear Spacers (Only Use for Black Head)

linear spacer K

linear spacer J

linear spacer I

linear spacer

linear spacer B

linear spacer C

linear spacer D

linear spacer E

linear spacer F

Shape

0.05

0.12

0.19

0.26

0.33

0.40

0.47

0.54

0.61

Rev. A 4-5

linear spacer G

linear spacer H

0.68

0.75

Figure 4-3. Types of Spacers and Relationship between

Shape and Thickness

Black Head Angle Adjustment

Adjustments Stylus Pro XL

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

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

1. Destination Setting

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

3. Head Vertical Position Confirmation

4. Head Gap Adjustment

5. Bi-D Adjustment

6. Internal Timer Reset

7. END

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

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

WARNING

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

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

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

to insert an angular spacer if the pattern is incorrect.

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

Figure 4-4. Black Head Angle Adjustment Sample

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

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

Check p osit ion A.

Position A Position A

4-6 Rev. A

Replace the right angular spacer with a thinner one.

Figure 4-5. Spacer Selection

Replace the right angular spacer with a thicker one.

1: Push

Carriage Unit

Platen Gap Adjust Lev er

Linear Spac er

Black Head

Head Ba se

Angular Spacer

2: Replace

(Angular Spacer Replacement Position)

Stylus Pro XL Adjustments

7. Turn the printer power off now.

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

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

Figure 4-6. Removing the Rubber Cap

WARNING

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

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

Rev. A 4-7

1: Push

Carriage Unit

Platen Gap Adjust Lev er

Linear Spac er

Black Head

Head Ba se

Angular Spacer

2: Replace

(Angular Spacer Replacement Position)

Adjustments Stylus Pro XL

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

WARNING

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

changing the black head angle is correct.

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

Figure 4-7. Angular Spacer Replacement Method

4-8 Rev. A

#16

#1#2

#61

#62

#63

#64

Carriage Unit

Adjust

Color Head

Black Head

Vertical Position

Magenta

Cyan

Yellow

Stylus Pro XL Adjustments

4.1.5 Black - Color Head Vertical Adjustment

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

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

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

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

1. Destination Setting

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

3. Head Vertical Position Confirmation

4. Head Gap Adjustment

5. Bi-D Adjustment

6. Internal Timer Reset

7. END

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

WARNING

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

2-3 BLACK HEAD SPACER SELECTION

Magenta

-5 -4

-3 -2

-1

OK (0)

Black

+1 +2 +3 +4

Figure 4-9. Linear Spacer Selection Sample

Rev. A 4-9

Adjustments Stylus Pro XL

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

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

WARNING

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

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

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

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

same time.

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

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

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

5. Turn the printer off.

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

Rubber Cap

Screw 1

Screw 2

Screw 3

Figure 4-10. Removing the Rubber Cap

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

WARNING

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

4-10 Rev. A

1: Push

Carriage Un it

Platen G ap Adjust Lever

2: Replace

Black Head

Head Base

Linear Spacer x 2

(Linear Spacer Replacement Position)

Angular Spacer

Stylus Pro XL Adjustments

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

Figure 4-11. Linear Spacer Replacement Method

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

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

Rev. A 4-11

4.1.6 Color Head Angle Adjustment

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

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

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

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

1. Destination Setting

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

3. Head Vertical Position Confirmation

4. Head Gap Adjustment

5. Bi-D Adjustment

6. Internal Timer Reset

7. END

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

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

WARNING

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

0.30

0.35

0.40

0.45

0.50

Angular Spacer (for Color Head)

Spacer Name

Thickness

Shape

angular spacer YMC

angular spacer YMC-B

angular spac er YM C-C

angular spacer YMC-D

angular spacer YMC-E

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

Check

positions A, B

Positio n A, B

Position A, B

Replace the right angular spacer with a thicker one.

Replace the right angular spacer with a thinner one

Magenta

Cyan

Magenta

Cyan

Stylus Pro XL Adjustments

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

Figure 4-14. Relationship between the Shape and Thickness

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

5. Turn off the printer now.

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

Rev. A 4-13

Figure 4-15. Spacer Selection

Adjustments Stylus Pro XL

Rubber Cap

Screw 1

Screw 2

Screw 3

Figure 4-16. Removing the Rubber Cap

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

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

4-14 Rev. A

Stylus Pro XL Adjustments

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

Carriage Unit

1: Push

Head Base

Color H ead

Angular Spacer (one side on ly)

Platen Gap Adjust Lever

2: Replace

Figure 4-17. YMC Angular Spacer Replacement

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

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

Rev. A 4-15

Attach the thickness gauge under the PF pinch roller unit.

Left Adjustment Position

Right Adjustment Position

Paper Guide P late

Bushing

Pump Un it

Eject Frame

Thickness Gau ge

Thickness Gauge

Front

Fron t Frame

PF Pinch Roller Unit

Attach ment Point

Tension Roller

Thickness Gau ge

Paper G uide

Platen

Adjustments Stylus Pro XL

4.1.7 Platen Gap Adjustment

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

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

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

Table 4-2. Gap and Adjustment Direction

Gap between Head Nose and Gauge Surface Left Bushing Right Bushing

Narrow CW CCW Spread CCW CW

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

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

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

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

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

4-16 Rev. A

Figure 4-18. Adjusting the Platen Gap

0.04 mm

Carriage Roller

Thickness Gauge

Gap

Eject Frame

Stylus Pro XL Adjustments

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

Figure 4-19. Confirming the Gap

4.1.8 Internal Timer Reset Operation

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

1. Refresh timer

2. Timer (monochrome and CMY)

3. Flushing level decision timer

4. False absorbing timer

5. Total print timer

6. PAUSE timer

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

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

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

1. Destination Setting

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

3. Head Vertical Position Confirmation

4. Head Gap Adjustment

5. Bi-D Adjustment

6. Internal Timer Reset

7. END

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

resets the internal timer. The following message then appears.

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

4. Press Y and ENTER.

5. Press 7 and ENTER.

6. Turn off the printer.

Rev. A 4-17

Chapter 5 Troubleshooting

Table of Contents

5.1 OVERVIEW 5-1

5.2 UNIT LEVEL TROUBLESHOOTING 5-3

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

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

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

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

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

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

5.4 UNIT REPAIR - C164 MAIN BOARD 5-10

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

LIST OF FIGURES

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

LIST OF TABLES

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

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

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

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

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

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

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

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

Stylus Pro Service Manual Troubleshooting

5.1 OVERVIEW

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

START

UNIT LEVEL TROUBLESHOOTING

UNIT REPAIR OF C137 PSB/PSE BOARD

Motor

Connector

Number

UNIT REPAIR OF C164 MAIN B OAR D

ASSEMBLY

AND

ADJUSTMENT

END

UNIT REPAIR OF M-4A11 Mechanism

Figure 5-1. Troubleshooting Process Flowchart

Table 5-1. Motor Coil Resistance Test Points

Common

Number

Test Pin

Number

(Set Meter to Ohms. Disconnect

Motor from Main Board and Check it

Test Method

with Printer Power Off.)

Meter Reading

CR Motor (CN6)

PF Motor (CN7)

5 1, 2, 3, 4

Place one lead on pin 5 and the other lead on each of the 4 test pins to check the two motor phases.

10.0Ω± 10%(At 25 °C, 77 °F)

11.5 Ω± 10%(At 25 °C, 77 °F)

Rev.A 5-1

Troubleshooting Stylus Pro Service Manual

Table 5-2. Sensor Status

Sensor Point Signal Level Status

PE Sensor

BCO Sensor

CCO Sensor

HP Sensor

TH Sensor

Sensor

connector

Number

PE Sensor (CN8)

BCO Sensor (CN11)

CCO Sensor (CN12)

CN8 / Pin 1 to Pin 2

CN11 / Pin 8 to Pin 7

CN12 / Pin 8 to Pin 7

CN9 / Pin 3 to Pin 2

CN12/ Pin 10 to Pin 11

H (5 V) Paper exists L (GND) No paper (paper end) L (GND) Black cartridge exists

H (5 V) No black cartridge L (GND) Color cartridge exists

H (5 V) No color cartridge

L At home position (HP)

H Away from HP

Analog data

Table 5-3. Sensor Test Points

Test Method

(Set Meter to Ohms. Check Printer with

Power Off.)

Place one lead on pin 1 and the other lead on pin 2. Toggle the sensor by inserting and removing a sheet of paper.

Place one lead on pin 8 and the other lead on pin 1. Toggle the sensor by inserting and removing a monochrome ink cartridge.

Place one lead on pin 8 and the other lead on pin 1. Toggle the sensor by inserting and removing a color ink cartridge.

Change the pulse width of the charge pulse for the common driver circuit

Method Reading

Meter should toggle between open and short (open = active).

Meter should toggle between open and short.

Table 5-4. Error Codes

Error

Status

Paper out

No ink

cartridge

Paper jam — Blinks — — — —

Maintenance request

Carriage error

Data

Blinks Blinks Blinks Blinks Blinks Blinks

Blinks — — — — Blinks

Paper Out

—On — — — —

— — On — — —

No Ink Cartridge

LED

Economy Condensed Pause

Recovery

Load paper and press Pause and Load/Eject buttons. Install the new ink cartridge and press the Pause button. Load paper and press Pause and Load/Eject Buttons. Service maintenance request. (Change the waste ink drain tank and reset the counter.) Turn off the printer and turn it on again.

5-2 Rev.A

Stylus Pro Service Manual Troubleshooting

5.2 UNIT LEVEL TROUBLESHOOTING

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

Table 5-5. Symptom and Problem

Symptom Problem Flowchart No.

Printer does not operate at power on

Error is detected

Failure occurs during printing

Printer does not feed the paper correctly

Control panel operation is abnormal

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

❒ Error is indicated by LED indication. ❒ Printing is not performed.

❒ Abnormal printing (missing dots, etc.) ❒ Print quality is poor

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

❒ No response to button access.

1 2

Rev.A 5-3

START

Is the AC

input voltage

correct ?

Has fuse

(F1) on the C137

PSB/PSE

blown ?

Check the output voltage of the C137 PSB/PSE at CN2.

Is the output

voltage correct ?

Replace the C137 MAIN board.

Is the problem

corrected ?

END

Use the correct input voltage.

Replace the fuse and disconnect CN5 on the C164 MAIN board .

Replace the C137 PSB/PSE board.

Does the

fuse blow again

at power on ?

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

YES

Troubleshooting Stylus Pro Service Manual

5.2.1 Printer Does Not Operate at Power On

5-4 Rev.A

Flowchart - 1

Stylus Pro Service Manual Troubleshooting

5.2.2 Error is Detected

START

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

Carriage error

No ink cartridge

Waste ink drain tank overflow

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

YES

Turn the printer off and try to move the carriage manually.

Replace the ink cartridge with a new one.

Does error

occur again ?

YES

Does the

carriage move

smoothly ?

YES

Check CR moto r and drivers. If they are OK, replace the C164 MAIN bo ard.

Is the

problem

corrected ?

Check ink cartridge sensor and, if bad, replace.

END

Refer to the se ction describing repair of the printer mechanism.

END

Flowchart - 2

Rev.A 5-5

Troubleshooting Stylus Pro Service Manual

5.2.3 Failure Occurs During Printing

START

Run the self-test.

Does the self-

test print?

YES

Is print

quality bad ?

YES

Perform the cleaning.

Is the problem

corrected ?

YES

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

See the section describing repair of the printer mechanism.

YES

Are all cables

connected to C164

MAIN firmly ?

Connect the cables correctly.

Is the problem corrected ?

Check all motors, drivers, and printhead for shorts . If th ey are OK, replace the C164 MAIN board.

YES

Is the problem

corrected ? YES

Check all motors,

END END

drivers, and printhead for shorts . If th ey are OK, replace the C164 MAIN board.

Flowchart - 3

5-6 Rev.A

Stylus Pro Service Manual Troubleshooting

5.2.4 Printer Does Not Feed the Paper Correctly

START

Is paper loaded

in the sheet feeder

correctly ?

YES

Does a

paper jam

occur ?

Check the PF motor and drivers. If OK, replace the C164 MAIN board.

Is the problem

corrected ?

YES

END

YES

Load the paper correctly.

Verify that the paper path is clear. Also confirm that there are no foreign objects that may interfere with paper movement.

See the section describing repair of the printer mechanism.

Is the problem

corrected ?

YES

END

Flowchart - 4

Rev.A 5-7

Troubleshooting Stylus Pro Service Manual

5.2.5 Control Panel Operation is Abnormal

START

Is the control

panel connected

properly ?

YES

Replace the control panel.

Connect the control panel correctly.

Is the problem

corrected ?

YES

END

Is the problem

corrected ?

YES

Replace the C164 MAIN board.

END

Flowchart - 5

5-8 Rev.A

Epson Stylus Pro Service manual

Specifications and Main Features

Frequently Asked Questions

User Manual

PRECAUTIONS

PREFACE

REVISION SHEET

TABLE OF CONTENTS

Chapter 1 Product Description

1.2 SPECIFICATIONS

3.2 DISASSEMBLY AND ASSEMBLY 3-2