Epson Stylus Pro 5000 Service Manual

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EPSON Stylus Pro 5000

4008867

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NOTICE

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



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



All effort have been made to ensure the accuracy of the contents of this manual. However, should any errors be deteced, SEIKO EPSON would greatly

appreciate being informed of them.



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

EPSON is a registered trademark of SEIKO EPSON CORPORATION. General Notice: Other product names used herein are for identification purpose only and may be trademarks or registered trademarks of their respective

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

Page 3

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 THE POWER SOURCE AND PERIPHERAL DEVICES PERFORMING ANY MAINTENANCE OR REPAIR PROCEDURES.

2. NOWORK SHOULD BE PERFORMED ON THE UNIT BY PERSONS UNFAMILIER 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. W HEN THE POWER SUPPLY CABLE MUST BE CONNECTED, USE EXTREME CAUTION IN WORKING ON POW ER SUPPLY AND OTHER ELECTRONIC COMPONENTS.

WARNING

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

2. MAKE CERTAIN THAT THE SOURCE VOLTAGES IS THE SAME AS THE RATED VOLTAGE, LI STED ON T HE SERIAL NUMBER/RATING PLAT E. IF THE EPSON PRODUCT HAS A PRIMARY AC RATING DIFFERENT FROM AVAILABLE POW ER SOURCE, DO NOT CONNECT IT TO THE POW ER SOURCE.

3. ALWAYS VERIFY THAT T HE EPSO N PRODUCT HAS BEEN DI SCONNECT ED FRO M 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 SECONDSOURCE ICs OR OTHER NONAPPROVED COMPONENTS MAY DAMAGE THE PRODUCT AND VOID ANY APPLICABLE EPSON WARRANTY.

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PREFACE

This manual describes basic functions, theory of electrical and mechanical operations, maintenance and repair procedures of Stylus Pro5000. The instructions and procedures included herein are intended for the experienced repair technicians, and attention should be given to the precautions on the preceding page. The chapters are organized as follows:

CHAPTER 1. PRODUCT DESCRIPTIONS

Provides a general overview and specifications of the product.

CHAPTER 2. OPERATING PRINCIPLES

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

CHAPTER 3. TROUBLESHOOTING

Provides the step-by-step procedures for troubleshooting.

CHAPTER 4. DISASSEMBLY AND ASSEMBLY

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

CHAPTER 5. ADJUSTMENTS

Provides Epson-approved methods for adjustment.

CHAPTER 6. MAINTENANCE

Provides preventive maintenance procedures and the lists of Epson-approved lubricants and adhesives required for servicing the product.

APPENDIX

Provides the following additional information for reference:

• Connector pin assignments

• Electric circuit boards components layout

• Exploded diagram

• Electrical circuit boards schematics

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REVISION STATUS

Rev. Date Page(s) Contents

A 1998/01/23 All First release B 1998/03/10

4-68∼4-93 4-8 4-59

4-60 Chapter4

• Added “Disassembly and Assembly for ASF Unit”.

• Modified flow chart for disassembling the mechanism

according to addition of “Disassembly and Assembly for ASF Unit”.

• Added “CAUTION”.

• Added sentences to “CHECKPOINT”.

• Word “phase” is replaced by “alignment”.

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TABLE OF CONTENTS

PRODUCT DESCRIPTION

1.1 FEATURES....................................................................................................................................................................1-1

1.2 SPECIFICATIONS.........................................................................................................................................................1-4

1.3 ADDING PAPER GUIDE ROLLER UNIT.....................................................................................................................1-46

OPERATING PRINCIPLES

2.1 FEATURE......................................................................................................................................................................2-1

2.1.1 Operating Principles of Printer Mechanism.....................................................................................................................................2-1

2.1.1.1 Printing Mechanism...................................................................................................................................................................2-2

2.1.1.2 Carriage Mechanism.................................................................................................................................................................2-3

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

2.1.1.4 Upper Surface Sensor Mechanism ...........................................................................................................................................2-7

2.1.1.5 Paper Return Mechanism..........................................................................................................................................................2-8

2.1.1.6 Lifter Gear Train Mechanism.....................................................................................................................................................2-9

2.1.1.7 Hopper 5mm Down Mechanism..............................................................................................................................................2-10

2.1.1.8 Sub Roller Gear Train Mechanism..........................................................................................................................................2-13

2.1.1.9 Gear Train Change with Hopper installed ...............................................................................................................................2-14

2.1.1.10 Ink Engage/Disengage Mechanism.......................................................................................................................................2-16

2.1.1.11 PG Disengage Mechanism....................................................................................................................................................2-18

2.1.1.12 Ink Valve Mechanism............................................................................................................................................................2-20

2.1.1.13 Friction Release Mechanism.................................................................................................................................................2-21

2.1.1.14 Gear Train Block Diagram.....................................................................................................................................................2-23

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2.1.2 Outline of Electrical Circuit..............................................................................................................................................................2-24

2.1.2.1 C228 PSB Board.....................................................................................................................................................................2-24

2.1.2.2 C228 DRV Board.....................................................................................................................................................................2-26

2.1.2.3 C228 Main Board ....................................................................................................................................................................2-27

TROUBLESHOOTING

3.1 FEATURES....................................................................................................................................................................3-1

3.1.1 Problems relating to the printer mechanism....................................................................................................................................3-1

ASSEMBLY AND DISASSEMBLY

4.1 OVERVIEW....................................................................................................................................................................4-1

4.1.1 Precautions.........................................................................................................................................................................................4-1

4.1.2 Tools....................................................................................................................................................................................................4-2

4.1.3 Screws.................................................................................................................................................................................................4-2

4.2 DISASSEMBLY................................................................................................................ .............................................4-2

4.2.1 Housing Upper Removal....................................................................................................................................................................4-3

4.2.2 Housing Front Unit Removal .............................................................................................................................................................4-5

4.2.3 Mechanism Unit Removal ..................................................................................................................................................................4-6

4.2.4 MB Rear Unit Removal .......................................................................................................................................................................4-7

4.2.5 Disassembling the Mechanism..........................................................................................................................................................4-8

4.2.5.1 Discharge Brush Removal.........................................................................................................................................................4-9

4.2.5.2 Paper Guide Assembly, Cover Removal.................................................................................................................................4-10

4.2.5.3 Print Head Removal................................................................................................................................................................4-11

4.2.5.4 MB Front Unit Removal...........................................................................................................................................................4-13

4.2.5.5 Fan Assembly Removal ..........................................................................................................................................................4-15

4.2.5.6 PS Unit Removal.....................................................................................................................................................................4-16

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4.2.5.7 Motor Assembly, PF Removal.................................................................................................................................................4-16

4.2.5.8 Motor Assembly, CR Removal ................................................................................................................................................4-17

4.2.5.9 Motor Assembly, ASF Removal ..............................................................................................................................................4-18

4.2.5.10 Carriage Unit Removal..........................................................................................................................................................4-19

4.2.5.11 Frame, Main, Paper Eject Removal ......................................................................................................................................4-22

4.2.5.12 Paper Guide Upper Unit Removal.........................................................................................................................................4-26

4.2.5.13 Pump Frame Removal ..........................................................................................................................................................4-27

4.2.5.14 Frame, Main, PF Removal ....................................................................................................................................................4-28

4.2.5.15 ASF Unit Removal.................................................................................................................................................................4-31

4.2.5.16 Upper Surface Sensor Removal............................................................................................................................................4-32

4.2.5.17 PE Sensor Removal..............................................................................................................................................................4-33

4.2.5.18 PR Sensor Removal..............................................................................................................................................................4-34

4.2.5.19 HP Sensor Removal..............................................................................................................................................................4-36

4.2.5.20 Cable Assembly, Sensor FPC Removal................................................................................................................................4-37

4.2.5.21 Interlock Assembly Removal.................................................................................................................................................4-37

4.3 DISASSEMBLY AND ASSEMBLY FOR GEAR TRAIN...............................................................................................4-38

4.3.1 Disassembly of Gear Train...............................................................................................................................................................4-38

4.3.2 Assembling Gear Train.....................................................................................................................................................................4-46

4.4 DISASSEMBLY AND ASSEMBLY FOR ASF UNIT ....................................................................................................4-68

4.4.1 Disassembly of ASF Unit..................................................................................................................................................................4-69

4.4.2 Assembling ASF Unit........................................................................................................................................................................4-75

ADJUSTMENT

5.1 OVERVIEW....................................................................................................................................................................5-1

5.1.1 Conditions which adjustment is required ........................................................................................................................................5-1

5.1.1.1 Resetting Initial Ink Charge Flag ...............................................................................................................................................5-3

5.1.1.2 Re-input the Model Name .........................................................................................................................................................5-6

5.1.1.3 Head Voltage Value Adjustment ...............................................................................................................................................5-8

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5.1.1.4 Head Angular Adjustment .......................................................................................................................................................5-11

5.1.1.5 Head Height Adjustment .........................................................................................................................................................5-18

5.1.1.6 Head Gap Adjustment.............................................................................................................................................................5-22

5.1.1.7 Bi-D Adjustment ......................................................................................................................................................................5-27

5.1.1.8 Uploading of Firmware............................................................................................................................................................5-32

5.1.1.9 Parallelism Adjustment............................................................................................................................................................5-34

5.1.1.10 Upper Surface Sensor Positioning Adjustment.....................................................................................................................5-37

MAINTENANCE

6.1 CLEANING ....................................................................................................................................................................6-1

6.2 MAINTENANCE.............................................................................................................................................................6-2

6.2.1 Head cleaning .....................................................................................................................................................................................6-2

6.2.2 Maintenance Request.........................................................................................................................................................................6-3

6.3 LUBRICATION AND ADHESION ..................................................................................................................................6-4

APPENDIX

7.1 CONNECTOR SUMMARY.............................................................................................................................................7-1

7.2 EEPROM ADDRESS MAP ............................................................................................................................................7-5

7.3 COMPONENT LAYOUT ..............................................................................................................................................7-10

7.4 CIRCUIT DIAGRAM.....................................................................................................................................................7-13

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PRODUCT DESCRIPTION

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EPSON Stylus Pro 5000 Chapter1 Product Description

1.1 FEATURES

EPSON Stylus Pro 5000 is a 6-color ink jet printer , which can output colors for the professional level. Major features are following.



Professional color print quality



1440(H) x 720(V) dpi printing at the highest resolution setting.



Photo reproduction quality(6 color printing, C.M, Y, K, LC, LM)



By micro dot + super micro dot, super fine printing equivalent to Comoro Wide is available.



PostScript printing(option)



High speed printing

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Color 360 dpi A4: 1.1 PPM

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Color 720 dpi A4: 0.39 PPM



Built in 3 types of interfaces



Bi-directional parallel interface (IEEEP1284.4/ECP support)



Mac. Serial interface(up to approx. 1.8M bps)

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Type-B interface (SIM for copying up to approx. 98M is available to install on the same board;C228 main board)



Low running cost



Long life ink cartridge; Black: 3200 papers, Yellow: 3200 papers, Cyan/Magenta:3000 papers (5% ECOMA duty printing)



Independent 4 colors ink cartridges: Black, Yellow, Cyan including with light cyan, Magenta including light magenta.



Ink quantity sensor.

Note)

After ink near end is detected by the mechanical switch, the

firmware counts the determined absorbing quantity.



Paper handling



Double bin ASF(second bin option)



Manual feeding from the top cover of first bin and from the rear with opened rear cover.

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Paper volume for ASF/Paper size sensor/Paper type sensor

Note)

Those sensors do not work correctly, if users set the paper size

or media type lever wrong.



Increased paper loading capacity in the paper tray (55 g/m sheets/ Standard, option ASF)



Windows/Macintosh exclusive

250 cut

Rev.A

Note)

Cyan/Magenta ink is united as one, which light color and ordinary color ink are separated. The reason why that ink life span is not so different from others even though they are separated is that users are usually unable to perform printing which require strict separation of light color and ordinary color. Therefore, since light color and ordinary color inks are adjusted to be used alternately on the application, the life span of Cyan/Magenta does not become simply half life span of the other inks.

1-1

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EPSON Stylus Pro 5000 Chapter1 Product Description

Following table shows optional items for Stylus Pro 5000.

CHECK POINT

Since there are many kinds of exclusive papers, please refer to “Special Media” on the Reference Guide for Stylus Pro 5000.

Table 1-1. Optional Items and Available Consumable

Name Remark Code No.

Ink cartridge Black ink cartridge S020118

Cyan (including light cyan) Magenta(including light

magenta)

Yellow S020122

Paper tray unit

Exclusive Paper Refer to the reference SIMM memory Max.96MB(32MB x3), 72 Type-B I/F Card 32KB Serial interface

B5 ∼A3 (55g/m2:250 sheet)

guide pins card

LocalTalk Co-ax interface card C82314* Twin-ax interface card C82315* Ethernet interface card C82357* Bi-directional Parallel interface card

interface card C82312*

S020147

S020143

C81275*(lower paper

cassette) C81276*

---

C82307*/C82308*

C82345*

Note) *

Rev.A

The asterisk is a substitute for the last digit, which varies by country.

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EPSON Stylus Pro 5000 Chapter1 Product Description

1.2 SPECIFICATIONS

PRINTING SPECIFICATION



Print method: On demand MACH ink jet



Nozzle configuration Black - 64 nozzles

Color(5 colors) - 64 nozzles for each color(total: 320 colors, Y, M, C, LM, LC)

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Print direction Bi-direction with logic seeking



Print speed See the tables below

Table 1-2. Character Mode

Item Content

Character quality High quality Character pitch 10 CPI (Pica) Printable columns 127 columns LQ speed 200 CPS*

Note*)

This value is the speed of one print-pass in which the ¼ of character

matrix is printed.

Table 1-3. Raster Graphics Mode

CHARACTER SPECIFICATION



Character tables: 2 international character sets;

PC437(US, Standard Europe) PC850(Multilingual)



Type face: Bit map LQ font

EPSON courier 10 CPI

CONTROL CODE



ESC/P Raster



EPSON Remote command

PAPER FEED SPECIFICATION



Feeding method: Friction feed with ASF



Line spacing: 1/6 inch or programmable at 1/360 inch



Paper path: Cut-sheet ASF



Paper feeding: Standard cassette, optional lower paper

cassette, front manual feeding, rear manual feeding.(All friction feeding)



Feed speed 79 ms. (1/6 inch paper feeding)

6 inch/sec.(Continuous paper)

Horizontal

Resolution

360 dpi 323mm(12.7 inch) 4578 20 IPS 720 dpi 323mm(12.7 inch) 9156 20 IPS

Note)

20 IPS is equivalent to 200 CPS at printing 10 CPI.

Printable Area Available dot CR speed (IPS)

Rev.A

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EPSON Stylus Pro 5000 Chapter1 Product Description

PAPER SPECIFICATION

Table 1-4. Cut sheet specification

Item Remark

Paper size

Thickness Weight Quality Exclusive paper, Bond paper, PPC, Special

Paper

Note1)

No curled, wrinkled, scuffing or torn paper be used.

•Super A3 327 mm(W) x 483 mm(L)

•A3 297 mm(W) x 420 mm(L)

•A5 148mm(W) x 210 mm(L)

•B4 257 mm(W) x 364 mm(L)

•Letter 216 mm(W) x 279 mm(L)

•A4 210 mm(W) x 297 mm(L)

•B5 182 mm(W) x 257 mm(L)

•Legal 216 mm(W) x 356 mm(L)

•Statement 139.7 mm(W) x 215.9 mm(L)

•Exclusive 190.5 mm(W) x 254 mm(L)

0.08 mm(0.003”) ∼ 0.11 mm(0.004”) 64 g/m2 (17lb.) ∼ 90 g/m2 (24lb.)

papers.

•Regular plain paper

•EPSON Photo Quality Ink Jet Paper

•EPSON Photo Paper

Table 1-5. Transparency and Glossy film and paper specification

Item Remark

Paper size

Thickness 0.075 mm(0.003”) - 0.085 mm(0.0033”) Paper

Note) Note**)

Size

Thickness Less than 0.23 mm(0.0091”) Paper

Transparency printing is only available at normal temperature.

Glossy film only.

Item Remark

•Super A3/B 13”(W) x 19”(L)

•A3 297 mm(W) x 420 mm(L)

•A4 210 mm(W) x 297 mm(L)

•Letter 216 mm(W) x 279 mm(L)

•A6 105 mm(W) x 148 mm(L)**

•EPSON Photo Quality Glossy Film

•EPSON Photo Quality Glossy Paper

•EPSON Ink Jet Transparencies

Table 1-6. Index card specification

•A6 Index card: 105 mm(4.1”)(W) x 148 mm(5.8”)(L)

•5x8” Index card 127 mm(5.0”)(W) x 203 mm(8.0”)(L)

•10x8” Index card 127 mm(5.0”)(W) x 203 mm(8.0”)(L)

•EPSON Photo Quality Ink Jet Card

•EPSON Photo Card

Rev.A

Table 1-7. Envelope specification

Item Remark

Size

Thickness 0.16 mm(0.006”) - 0.52 mm(0.02”) Weight 45 g/m2 (12lb.) - 75 g/m2 (20lb.) Quality Bond paper, Plain paper, Air mail

Note) Note)

Envelope printing is only available at normal temperature. Keep the longer side of the envelope horizontally at setting.

•No.10 241 mm(9 1/2”)(W) x 104.8 mm(4 1/8”)(L)

•DL 220 mm(8.7”)(W) x 110 mm(4.3”)(L)

•C6 162 mm(6.4”)(W) x 114 mm(4.5”)(L)

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EPSON Stylus Pro 5000 Chapter1 Product Description

INK CARTRIDGE

Table 1-8. Black, Yellow Ink Cartridge

Item Specifications

Type Exclusive ink cartridge Color Black, Yellow Print capacity 3200 pages/A4 (360 dpi, ECOMA 5% duty) Validity 2 years from production date(sealed in package, or

being installed to the printer) Environmental conditions

Dimension 25.1 mm(W) x 139.6 mm(D) x 105.3 mm(H) Weight Approximately 200g

Item Specifications

Type Exclusive ink cartridge Color Magenta +Light magenta(I/C1), Cyan + Light

Print capacity 3000 pages/A4 (360 dpi, 5% duty) Validity 2 years from production date(sealed in package, or

Environmental conditions

Dimension 35.1 mm(W) x 140.9 mm(D) x 105.3 mm(H) Weight Approximately 200g

•Transit: −30°C ∼ 60°C

(within 120 hours at 60°C, and within a month at

40°C)

•Package storage: −30°C ∼ 40°C

(within a month at 40°C)

•Storage(installed to the printer):−20°C ∼ 40°C

(within a month at 40°C)

Table 1-9. Magenta and Cyan Ink Cartridge

cyan(I/IC2)

being installed to the printer)

•Transit: −30°C ∼ 60°C

(within 120 hours at 60°C, and within a month at

40°C)

•Package storage: −30°C ∼ 40°C

(within a month at 40°C)

•Storage(installed to the printer):−20°C ∼ 40°C

(within a month at 40°C)

Note1) Note2)

Note3)

INPUT DATA BUFFER



ELECTRIC SPECIFICATION

1) 120V version

    

 



2) 220-240V version

     



Ink cartridge can not re-fill, only ink cartridge is prepared for article of

consumption. Do not use the ink cartridge which was passed away the ink life. Ink will be frozen under -15°C environment, however it will be

useable after placing it more than 3 hours at room temperature.

6 K-byte

Rated voltage: AC 120 V Input voltage range: AC 99 V - 132 V Rated frequency range: 50 - 60 K Hz Input frequency range: 49.5 - 60.5 Hz Rated current: 1.0A (Max.1.6A)

Energy Star compliant Power consumption: Approx. 32W(ISO/IEC 10561 Letter pattern) Insulation resistance: 10 M ohms min. (between AC line and chassis,

DC 500 V) Dielectric strength: AC 1000 V rms. 1 minute or AC1200 V rms.

1 second(between AC line and chassis) Sneak current: Less than 0.25 mA

Rated voltage: AC 220 V - 240 V Input voltage range: AC 198 V - 264 V Rated frequency range: 50 - 60 Hz Input frequency range: 49.5 - 60.5Hz Rated current: 0.5 A(Max.0.8 A) Power consumption: Approx. 32 W(ISO/IEC 10561 Letter pattern)

Energy Star compliant Insulation Resistance: 10 M ohms min.(between AC line and chassis,

DC 500 V)

Rev.A

Page 16

EPSON Stylus Pro 5000 Chapter1 Product Description



Dielectric strength: AC 1500 V rms. 1 minute(between AC line and

ENVIRONMENT CONDITION

chassis)



Temperature: Operating: 10°C ∼ 35°C

RELIABILITY

Storage: −20°C ∼ 40°C Non-operating: −20°C ∼ 60°C



Total print volume: 75,000 pages (A4, letter)



Print head life: 2000 million dots/nozzle

SAFETY APPROVALS

Note)

Within 1 month at 40°C, within 120 hours at 60°C



Humidity: Operating: 20% ∼ 80% RH (without condensation)

Storage: 20% ∼ 85% (without condensation) Non-operating: 5% ∼ 85% (without condensation)

1)120 V version



Safety standards: UL1950 with D3

CSA22.2 No.950 with D3



EMI: FCC part15 subpart B class B

Note)

Refer to the figure below.

Humidity (% RH)

CSA C108.8 class B

2)220-240 V version



Safety standards: EN 60950 (VDE, NEMKO)



EMI: EN 55022 (CISPR Pub.22) class B

AS/NZS 3548 class B

ACOUSTIC NOISE



Level: Approx.47dB(A) (According to ISO 7779)

CE MARKING



220-240 V version



Low Voltage Directive 73/23/EEC :EN60950



EMC Directive 89/336/EEC :EN55022 Class B

EN61000-3-2 EN61000-3-3 EN50082-1

IEC801-2 IEC801-3 IEC801-4

Rev.A

10 20 30 40

Tem perature ( C )

Figure 1-1. Temperature/Humidity Range

Page 17

EPSON Stylus Pro 5000 Chapter1 Product Description



Resistance to vibration: Operating: 0.15G, 10 ∼ 55 Hz X,Y,Z directions

Non-operating: 0.50G, 10 ∼ 55 Hz X,Y,Z directions



Resistance to shock: Operating: 1G, within 1 ms X,Y,Z directions

Non-operating:2G, within 2 ms X,Y,Z directions

Note1) Note2)

Note3)

Note4)

During non-operating, make sure that the cap is capped. During the transport, make sure that the head is capped and ink cartridge is installed to the printer. If the head is not capped at the power-off state, turn the printer on while the ink cartridge is installed, and turn off the power after capping the head. Ink will be frozen under −15°C environment, however it will be useable after placing it more than 3 hours at 25°C.

SERIAL INTERFACE SPECIFICATION

Table 1-10. Serial Interface

Item Content

Transmission mode Based on RS-423 Synchronization Synchronous Transfer speed About 1.8M bps Data format Start bit: 1bit

Data bit: 8bit Parity bit: none

Stop bit: 1bit Handshaking X-ON/X-Off, DTR protocol Adaptable connector 8-pin mini circular connector Recommended I/F cable Apple system peripheral-8cable

PHYSICAL SPECIFICATION



Weight: 22 Kg (only a main frame)



Dimension: 640 mm(W) x 439 mm(D) x 224 mm(H)(Body only)

640 mm(W) x 704 mm(D) x 224 mm(H)(Printing on A3 size paper tray) 640 mm(W) x 584 mm(D) x 318 mm(H)(Printing on A4 size paper, optional cassette installed)

PARALLEL INTERFACE

[Compatibility Mode]

Table 1-11. Compatibility Mode

Item Content

Transmission mode 8-bit Parallel, IEEE-1284 compatibility

mode Synchronization By STROBE pulse Handshaking By BUSY and ACKLG signal Logic Level TTL compatible level (IEEE-1284 Level 1

device) Adaptable connector 57-30360(amphenol) or equivalent

Note1): Note2):

Note)

Recommend to use short interface cable according to your necessity. Use the twist pair line for each control signal of input connector and connect the return side to the signal ground.

BUSY signal is set high before setting either /ERROR low or PE high and held high until all these signals return to their inactive state.

Rev.A

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EPSON Stylus Pro 5000 Chapter1 Product Description

Busy signal is at high level in the following cases;



During data entry(see Data transmission timing)



When input data buffer is full



During /INT signal is at low level or during hardware initialization



During printer error (See /ERROR signal)



When the parallel interface is not selected

ERROR signal is at low level when the printer is one of the following states.



Printer hardware error (fatal error)



Paper out error



Paper jam error



Ink out error

Note)

PE signal is at high level during paper-out error.

[Nibble Mode]

Table 1-12. Nibble Mode

Item Content

Transmission mode Synchronization Refer to IEEE-1284 specification Handshaking Refer to IEEE-1284 specification Signal level TTL level (IEEE-1284 level 1 device) Adaptable connector Data transfer timing Extensibility request data

IEEE-1284 nibble mode

See forward channel Refer to IEEE-1284 specification The printer responds affirmatively when the

extensibility request values are 00H or 04H, that mean, 00H :Request nibble mode reverse channel

transfer.

04H :Request device ID; Return Data using Nibble

Mode Rev channel transfer. The printer sends following device ID string when it is requested.

[00H] [3BH]

MFG : EPSON

CMD : ESCPL2, BDC

MDL : Stylus[SP]Pro[SP]5000;

CLS : PRINTER

Note)

[00H] denotes a hexadecimal value of zero.

MDL value depends on the EEPROM setting.

Rev.A

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EPSON Stylus Pro 5000 Chapter1 Product Description

PARALLEL INTERFACE (CONT.)

[ECP Mode]

Table 1-13. ECP Mode

Item Content

Transmission mode IEEE-1284 ECP mode Synchronization Refer to IEEE-1284 specification Handshaking Refer to IEEE-1284 specification Signal level TTL level (IEEE-1284 level 1 device)

See forward channel Adaptable connector See forward channel Data transfer timing Refer to IEEE-1284 specification Extensibility request data The printer responds affirmatively when the

extensibility request values are 10H or 14H,

that mean,

10H :Request ECP mode reverse

channel transfer.

14H :Request device ID; Return Data

using ECP Mode Rev channel

transfer. The printer sends following device ID string when it is requested.

[00H] [3BH]

MFG : EPSON

CMD : ESCPL2, BDC

MDL : Stylus[SP]Pro[SP]5000

CLS : PRINTER

Note)

[00H] denotes a hexadecimal value of zero. MDL value depends on the EEPROM setting.

TYPE B OPTIONAL INTERFACE SPECIFICATION

Type-B interface level 2 is supported.



Reply message (Short version):



Case of using Co-ax / Twin-ax I/F card:

Main Type: MTP48p, PW127cl10cpi, PGR(KAxxxx)rev,

AP1200ma Product Name: Stylus[SP]Pro[SP]5000 Emulation Type: ESCPL2-00 Entity Type: EPSONLQ2



Reply message



Case of using except Co-ax / Twin-ax I/F card

Main Type: MTP48p, PW127cl10cpi, PGR(KAxxx)rev,

AP1200ma, SPD0fast Product Name: Stylus[SP]Pro[SP]5000 Emulation Type: ESCPL2-00 Entity Type: ESPONLQ2

BUFFER OPERATION

Stylus Pro5000 starts sending BUSY signal when it acknowledges no available area left in the buffer. When the host keeps receiving this signal for a long time, it acknowledges as time out and stops sending data.

INTERFACE SELECTION

The printer has 3-built in interfaces; the parallel interface and serial interface, and has 1 optional Type-B interface card slot. These interfaces are selected manually by the default setting mode or selected automatically. (However, it is necessary to set these settings within the maintenance mode level 1 of the panel operation.)



Manual Selection:

One of three interfaces can be selected by the default setting mode.

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EPSON Stylus Pro 5000 Chapter1 Product Description



Automatic Selection:

The automatic interface selection is enabled by the default setting mode. In this automatic interface selection mode, the printer is initialized to the idle state scanning which interface receives data when it is powered on. Then the interface that receives data first is selected. When the host stops data transfer and the printer is in the stand-by state for the seconds, the printer is returned to the idle state. As long as the host sends data or the printer interface is busy state, the selected interface is let as it is.

Following explains conditions of other interfaces when a particular interface is selected.



When the parallel interface is not selected, the interface gets into BUSY state. At this time, LH signal is set to “L”. That means blocking power supply and no responds from 1284. Therefore, it is necessary for the host, which requires Reverse transfer, to check LH state.



When the serial interface is not selected, the interface sets the DTR signal MARK.



When the optional interface is not selected, Off-Line bit is set to Main Status Register(MNSTS).



When the printer is initialized or returned to the idle state, Parallel interface becomes the ready condition and DTR of serial interface becomes SPACE(Low) condition and reset off-line bit of Main Status Register(MNSTS)to, option interface.



/INIT signal on the parallel interface is not effective while that interface is not selected or nibble Mode, ECP Mode.

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EPSON Stylus Pro 5000 Chapter1 Product Description

CONTROL PANEL

There are 4 non-lock push buttons and 8 LEDs. Each button function and indicator are explained briefly below and on your right.

A B

O perate

C leaningReset

3 se c 3 sec

2 3 4

Eject

C ontinue

Figure 1-2. Control Panel

Table 1-14. Control Panel Function

No. Button / Indicator Function

1 Operate button

(power)

Power source switch on the secondary side.

Note)

Current is constantly flowing

in the primary side.

2 Reset button(Pressing for

Printer reset. Buffer clear.

3 sec.)

3 Cleaning button(Pressing

for 3 sec.)

4 Eject(Error recover)

button (2 sec.)

A Black I/C out indication

LED

B Cyan I/C out indication

LED

C Paper out indication LED

for cassette (paper tray) 1

D Paper out indication LED

for manual feed slots

Perform cleaning all heads of both sides. Ejects the paper, or recovers from error. Blinks for low ink quantity and light is on for out of ink. Blinks for low ink quantity and light is on for out of ink. Indication for paper out or paper loading miss of cassette 1. All 3 LEDs (C, D, G) blink at the same time for paper loading miss.

E Magenta I/C out LED Blinks for low ink quantity, and light

is on for out of ink.

F Yellow I/C out LED Blinks for low ink quantity, and light

is on for out of ink.

G Paper out indication LED

for optional lower

Indication for paper out or paper loading miss of cassette 2.

cassette (paper tray) 2.

H Operate LED

(power)

Green light is on while the current is flowing, or receiving data, or CL operation.

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EPSON Stylus Pro 5000 Chapter1 Product Description

Following table shows function when the power is turned on.

Table 1-15. Functions with power on

No. Name of switch Function

1 Reset Perform status printing (Refer to

Note1) 2 Cleaning Changes paper size, type verification. 3 Eject/Continue Changes platen gap adjustment for

the manual feed slots. 4 Reset + Cleaning Changes parallel I/F ECP mode 5 Reset + Eject/Continue Enters print head alignment mode. 6 Cleaning +

Eject/Continue

7 Reset +Cleaning +

Eject/Continue (All SW)

Note1)

Note2):

mode.

:This status printing prints firmware version, ink counter, selected

code page and nozzle check patterns. Since the value of the waste ink counter is indicated by HEX, it is recommended to use the exclusive service program for checking the counter value. Refer to Table1-17 for Download of Firmware and Maintenance

Enters the maintenance mode,

level1.(Factory use only)

Enters the Firmware uploading mode.

(Factory use only)

Following table shows LED indications.

Table 1-16. Printer condition and Panel status

No. Printer Status Indicators (Figure 1-2) Priority

H AB

1 Power On On --- --- --- --- 9 2 Performing Ink

sequence 3 Receiving Data blink --- --- --- --- 8 4 Paper jam --- --- blink blink blink 3 5 Cassette 1/paper out,

wrong paper feeding 6 Out of paper in

Cassette 1(paper

tray1) 7 Cassette(Paper tray)2 --- --- --- --- On 5 8 Paper out in

Cassette(Paper tray)2 9 SIMM copy error

(over flow)

10 Ink end, No I/C --- On --- --- --- 7 11 Ink low --- blink --- --- --- 7 12 Reset, Timer IC reset,

EEPROM clear

13 Maintenance request

(waste ink counter

over flow)

14 Fatal error blink All

Note):

“---“ means no changes.

blink --- --- --- --- 6

--- --- --- blink --- 5

--- --- --- On --- 5

-- --- --- --- On 5

blink On On On On 4

--- On

blink AllOnblink blink blink 2

blink

D C G No.

---

(1 sec.)

blink blink blink 1

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EPSON Stylus Pro 5000 Chapter1 Product Description

Name of

Switch

All switches + Power on

Cleaning + Eject Switch + Power on (Level1)

Table 1-17. Download/Maintenance Mode

Function

1.Manual feed LED turns on when the printer enters this mode correctly. Exclusive starting command( is transmitted on the DOS (or DOS prompt). Black ink LED blinks during this transmission and Cyan ink LED will be turned on when the transmission is completed correctly.

2.Wait 2 or 3 seconds after the Cyan ink LED is turned on. Firmware time, Magenta ink LED is turned one during this transmission, and Yellow ink LED is turned on when it is completed.

3.Turn off the power. I/F Diseng age

Hexade cimal dump

(KEYWEST.HEX

1. After the operation written in the left column is performed, press Reset switch until the black ink LED is turned on. During entering this mode, black, Cyan, Magenta and Yellow LEDs are turned on alternatively, every time the reset switch is pressed.

2.When the black ink LED turns on, press Eject switch to determine.

3.Press the Reset switch until the corresponding LED turns on, according to the following explanation. Black ink LED→Automatic, Cyan ink LED→Parallel, Magenta ink LED→Serial, Yellow ink LED→Option

4.Press either Eject switch or turn the power off for registering to EEPROM.

1.After the operation written in the left column is performed, press Reset switch until the Magenta ink LED is turned on. During entering mode, black, Cyan, Magenta and Yellow LEDs are turned on alternatively, every time the Reset switch is pressed. Press Eject switch to determine after Magenta LED turns on.

2.Turning power off is the only way to escape.

) is transmitted. At this

IPL2.HEX

Table 1-18. Download/Maintenance Mode(Cont.)

Name of Switch Function

Cleaning + Eject Switch + Power on

)

P-I/F receiving speed

CG Disenga ge

1.After the operation written in the left column is performed, press Reset switch until the Cyan ink LED is turned on. During entering this mode, black, Cyan, Magenta and Yellow LEDs are turned on alternatively, every time the reset switch is pressed.

2.Press Eject switch to determine after Cyan ink LED is turned on.

3.Press the Reset switch until the corresponding LED turns on, according to the following explanation. Black ink LED→High speed, Cyan ink LED→Standard

4.Press Eject switch to register in the EEPROM. Note)It is not registered to EEPROM, if power is turned off without pressing Eject switch.

1. After the operation written in the left column is performed, press Reset switch until the Yellow ink LED is turned on. During entering this mode, black, Cyan, Magenta and Yellow LEDs are turned on alternatively, every time the reset switch is pressed.

2.Press Eject switch to determine after Yellow ink LED is turned on.

3. Press the reset switch until the corresponding LED turns on, according to the following explanation. Black ink LED→PC437, Cyan ink LED→PC850

4. Press Eject switch to register in the EEPROM.

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EPSON Stylus Pro 5000 Chapter1 Product Description



Table 1-19. Download/Maintenance Mode(Cont.)

Name of Switch Function

After inputting modes written in the previous page, press Cleaning, then, Reset switch. (Level 2)

INITIALIZATION

Stylus Pro 5000 has following 3 initializations.

Note)After entering maintenance mode level1, it becomes EEPROM reset function by pressing Cleaning switch, then, Reset switch.

1.Make sure that black ink LED is on. If it is not on, press Reset switch until the black ink LED turns on.

2.After black ink LED turns on, press Eject switch and confirm the reset.

3.To end this operation, turn the power off.

Operator(Panel) initialization

This printer is initialized when pushing the panel reset switch, or printer recognized the /INT signal(negative pulse) of parallel interface. When printer is initialized, following action is performed.

1. Caps the print head

2. Ejects a paper

3. Clears input data buffer

4. Clears print buffer

5. Resets default values

SETTING VALUES BY INITIALIZATION

By performing initialization, the following items return to the initial values. Also, the panel setting, default setting, and item that can be saved on the remote command will be default values.



Power on (Hardware) initialization:

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

1. Initializes printer mechanism

2. Clears input data buffer

3. Clears print buffer

4. Resets default values



Software initialization

The ESC@ command also initializes the printer. When printer is initialized, following action is performed.

1. Clears print buffer

2. Resets default values

1. Page position: Page heading location as present paper location

2. Line spacing: 1/6 inch

3. Right margin position: 127 lines

4. Left margin position: First line

5. Word pitch: 10 CPI

6. Printing mode: Text mode(Not raster graphics mode)

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EPSON Stylus Pro 5000 Chapter1 Product Description



ERROR CONDITION

Stylus Pro5000 goes to error condition when it falls to the following conditions. Out of Centronics interface signals, BUSY signal is set High and /ERROR signal is set LOW. Then, the printer goes to unprintable state, stopping data input from outside. Once the error happens, the printer can go back to the standby position or ready status for printing again by removing the error causes.



Ink near end and Ink out Error When the printer runs out the most part of the ink of any one color, it warns ink-low and keeps printing. When the printer runs out the whole ink of any one color, it stops printing and indicates ink-out error. User is requested to install a new ink-cartridge in this state. A ink-cartridge once taken out should never be used again. Reinstallation of the cartridge not filled fully upsets the ink level detection and may cause a serious problem in the print head as a result.

Paper out sensor When there is no paper in the paper tray, or paper tray itself is not installed, this sensor detects and goes paper out error.



Paper loading miss: When printer fails to load a sheet or PE sensor does not detect the paper on the path, it goes paper out error.



Paper Jam Error Even when the paper feeding is performed at the power on, if the PE sensor detects the paper on the paper path or fails to eject a paper by FF command or Eject button, the printer considers it as paper jam and goes to the error condition. In the Stylus Pro5000, the linear encoder monitors detection of paper jam in the carriage running range.



No ink-cartridge When the printer detects that ink cartridge comes off or is not installed, it goes to the error condition.

CAUTION

Rev.A

Although there is no worry of bubble invasion by pulling out or installing the ink cartridge, it is necessary to pay attention to the following points.

1)If the ink cartridge is once removed and installed again in the condition that the ink out(end) sensor detects the ink is still in, ink consumption based on the previous ink life will be kept counting.

2)If the ink cartridge is once removed and the ink cartridge whose left ink quantity is little is installed again in the condition that the ink is still in, Stylus Pro5000 goes to the ink out error condition, even though there is still enough ink in it.



Maintenance Request When the total quantity of ink wasted through the cleanings and flushing reaches to the limit, printer indicates this error and stops. The absorber(waste ink pad) in the printer enclosure is needed to be replaced with new one by a service person. This error does not recover until the waste ink pad is replaced and “0” is written to the particular address in the EEPRON by a service man.



Fatal Errors When fatal errors such as carriage control error or CG access error are detected, the printer goes to error condition and stops. Repair service is required for this error.

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EPSON Stylus Pro 5000 Chapter1 Product Description

PANEL SETTING FUNCTION

Here explains input method for each panel setting.



Printing nozzle check pattern and printer configuration

•Operation: Reset SW + Power On

•Exit: Power Off

•Function: (Power LED blinking while in this mode)

1)Reset SW + Power on →2)Position change to thick→3)Starts printing pattern→

4)Printing 1-page→5)Eject paper→6) Stand by mode in self-test by pressing →Refer to followings.

[Pressing Cleaning SW: in standby mode only]

1)Execute cleaning→2)Eject paper 3)Reprint self test page→4)self-test stand by mode.

[Pressing Eject SW: in standby mode only]

1)Feed paper→2)Reprint self test page→3)self-test stand by mode.

Note)

Ignore Cleaning SW while printing and Power off to exit this mode.

K 00227A A :0D 95 B :0D A F D :002C E 2C 0

Current Settings P a p e r S iz e /T y p e C h e c k : O n P a r a lle l I/F E C P M o d e : O ff Platen G ap A djustm ent for M anual Feed S lots : Fixed (thick paper)

CHECK POINT



Even if Cleaning or Eject switch is pressed



during printing, the panel operation is ignored.



You can escape from the self-test mode only by



turning the power off.

Printing Pattern: Print nozzle test pattern, firmware version, the value

of wasted ink count and current setting values are printed. Following shows printing pattern.

Rev.A

Figure 1-3. Printing Sample

[Explanation]

K00227A: Firmware version. A:0D95 : The present counting value of ink absorber only for

dark colors head.

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EPSON Stylus Pro 5000 Chapter1 Product Description

B:0DAF : The present counting value of ink absorber for light

color head only.

D: 002CE2C0 : The present counting value of waste ink absorber for

flushing.

Note)

By referring to the printing pattern on the previous page, it becomes possible to check ink discharge conditions (or dot missing or alignment failure) from all nozzles in each color. As an example, refer to “A” ∼ “D” lines shown on the black nozzle pattern. “A” line is printed by black nozzle #1 to #16, “B” line is by #17 to #32, “C” line is by #33 to #48, and “D” is #49 to #64. Since the nozzle for different colors is also aligned in the same way, you can consider in the same way.

Maintenance Error occurs at the point either A or B becomes full counter condition. In other words, it occurs when A becomes 46650, or B becomes 47200. Since the value is indicated by HEX indication, it is recommended to use the exclusive program to check the counter value.

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EPSON Stylus Pro 5000 Chapter1 Product Description



Paper check mode

This setting decides to turn the paper check function on or off. For Stylus Pro5000, it is necessary to match the lever located paper feed cassette(tray) above to the presently used paper type (media type) and its size. If the PC which supports bi-directional communication is used, it is not necessary to make this paper check setting effective(on), because the user can change the lever positions on the cassette, according to the error message on the PC screen. However, if the user uses the PC which does not support the bidirectional communication, it is necessary to set this mode on the printer body, since he/she can not check the error message on the computer screen.

[After completing the setting, if the power is turned off]

1)Printer escapes from the selected paper check mode.→2)Printer goes to the power off condition.

•Setting and LED indicator: ECP mode off→Cyan LED on ECP mode on→Black ink LED on.

•Function: 1)Reset SW+ Cleaning SW+ Power on to enter this mode→2)Power LED turns on and Cassette1LED blinks→

3)Indicate the current setting by blinking ink LED.→4)Change ECP On/Off by Reset SW.

•Operation: Cleaning SW + Power on to enter this mode.

•To change paper check mode setting On/Off:

Reset SW

•Save setting: Press Eject switch or turn off the power.

•Setting and LED indicator:

Paper check On→ Black ink LED On. Paper check Off→ Cyan ink LED On.

•Function: 1)Cleaning SW +Power on to enter this mode→2)Power LED blinks, Cassette1 LED turns on→3)Ink LED indicates current setting→ 4)Change paper check On/Off by Reset SW.

[After completing the setting, if the power is turned off]

1)Save setting→2)Exit mode→3)Power off

[After completing the setting, if Eject switch is pressed]

1)Save setting→2)Exit mode→3)Idle state



ECP Mode

•Operation: Reset SW + Cleaning SW + Power On to enter this mode.

•To change ECP mode On/Off: Reset SW

•Save setting : Turn off the power or press the Eject SW

[After completing the setting, if Eject switch is pressed]

1)Printer escapes from the selected paper check mode. →2)Printer goes to the ordinal printing mode(idle state).

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EPSON Stylus Pro 5000 Chapter1 Product Description



Manual feed slots paper thickness - Auto mode

The setting for Manual feed thick paper and auto mode is the function only to deal with using manual feed slots(front/rear). After checking the result of the printing by the manual feeding, this function becomes effective when the printing is blurry or faint. The reason why there is this kind of function only for manual feeding is that the printer can not recognize the paper thickness, unlike the other paper feed cassettes. There is no influence on the other paper feeding path(or standard cassette or optional cassette), when this function becomes effective. Also, unless this function is set effective, manual paper feeding always make PG(platen gap) big or wider and perform printing. Following shows conditions when the PG becomes wider(big).

Table 1-20. Setting conditions when PG becomes thick paper mode

Setting No. Conditions

Setting on the Driver side.

Lever setting on the cassette side.

Special Panel setting.

1 In case A4 size paper (landscape) is set. 2 In case SF exclusive paper (landscape) is set.

3 In case Media type is the combination of

ordinary paper and paper size A4(landscape).

4 In case Media type is the combination of SF

exclusive paper and A4 size(landscape).

5 In case of thick paper mode for the manual

feed.

CAUTION



Paper Feed from Manual Paper Feed Slot



Priority order1.:PG is wider(big) if thick paper mode is set. Priority order2.:In case, media type is set to the envelope.

•Operation: Eject switch + Power on to enter this mode.

•To change setting Manual/Auto mode:

Reset SW

•Save setting: Turn off the power or press the Eject switch.

•Setting and LED indication: *Auto→Black ink LED On. Platen gap

is defined by platen gap command ‘PG’. *Manual feed(thick paper)→Cyan ink LED on. Platen gap ignores PG command and uses platen gap thick position.

•Function: 1)Eject SW + Power On to enter this mode→2)Power LED blinks and Cassette 2 LED turns on→3)Ink LED indicates current setting→4)Automatic or manual (thick paper) is changed over everytime the Reset SW is pressed.

Rev.A

CAUTION

According to the Table above, priority order for each setting is determined as follows.



Paper Feed from paper feed cassette



(standard/option). Priority order1.:In case the media type is set to “Thick Paper”. Priority order2.:In case there is mis-matching between driver and lever position on the printer, the priority is given to the driver setting, if “Ignore” button is selected on the screen.

[After completing the setting, if the power is turned off]

1)Save setting→ 2)Exit setting mode →3)Printer goes to the power off condition.

[After completing the setting, if Eject switch is pressed]

1)Save setting→ 2)Exit setting mode →3)Printer goes to the ordinary printing mode.(idle state)

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EPSON Stylus Pro 5000 Chapter1 Product Description



Select I/F mode(Cont1. from Maintenance mode)



Maintenance Mode 1



• Operation: Cleaning SW + Eject SW + Power ON to enter this mode.

• To change maintenance item: Reset SW

• Determine the selection(maintenance item): Eject SW

• Maintenance item and LED indicator: I/F selection → Black ink LED is on. Parallel input speed→Cyan ink LED is on. HEX dump→Magenta ink LED is on. Character set→Yellow ink LED is on.

• Function: 1)Cleaning SW + Eject SW+ Power ON to enter this mode→2)Power LED blinks. Manual cassette(tray), Cassette1 and 2 turn on→3)Ink LED indicates current setting→4) Paper check, I/F selection, Parallel input speed, Hex change is changed over everytime the Reset SW is pressed. Ink LED turn on in the order of left to right and returns to left side.

[In case of pressing Eject SW]

1)Select item(Data registration)→2)Exit this mode→3)Enter each setting

mode.

CAUTION

Following explains setting of each item in the maintenance mode selection.

• Operation: After Eject SW + Power ON, turn the black ink LED on by pressing Reset SW, and determine that selection by pressing Eject SW.

• To select I/F mode: Reset SW(Parallel→Serial→Option)

• Save setting: Eject SW or Power off

• Setting item and LED indicator: Auto selection setting→Black ink LED is on. Parallel I/F mode→Cyan ink LED is on. Serial I/F mode→Magenta ink LED is on. Option I/F mode→Yellow ink LED is on.

• Function: 1)Select “Black” in maintenance mode to enter this mode.→2)Power LED blinks. Cassette1 and 2 turn on →3)Ink LED indicates current setting. →4)By pressing Reset SW, Auto, Parallel, Option is selected in this order. Ink LED moves left to right and return to left.

[After completing the setting, if power is turned off]

1)Save setting(Data registration)→ 2)Exit setting mode →3)Printer goes

to the power off condition.

[After completing the setting, if Eject switch is pressed

1)Save setting(Data registration)→ 2)Exit setting mode →3)Printer goes

to the ordinary printing mode(idle state).

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EPSON Stylus Pro 5000 Chapter1 Product Description



HEX dump mode (Cont2. from Maintenance mode)



• Operation: After pressing Eject SW + power on, turn on the Magenta ink LED by pressing Reset SW and determine by Eject SW. After that, HEX dump and ordinary mode is changed over by pressing Reset SW.

• Save setting: Press Eject SW.

• Function: 1)Enter HEX dump mode →2)Hex dump idle →3)HEX

dump printing. Exit mode by power off.



Parallel I/F speed(/ACK plus width) (Cont3. from Maintenance mode)



• Operation: After pressing Cleaning SW + Eject SW + Power on, turn on the Cyan ink LED by pressing Reset SW and determine by Eject SW. After that, High speed and standard is changed over by pressing Reset SW.

• Save setting: Press Eject SW.

• Setting item and LED indicator:

/ACK with short(0.5us)→Black ink LED is on. /ACK with standard(2us)→Cyan ink LED is on.

• Function: 1)Select “Cyan” in maintenance mode to enter this mode. →2)Power LED and Cassette 1 blink. Cassette2 LED turns on. →4) Ink LED indicates current setting. →

5)Short or Standard is changed over everytime Reset SW is pressed.



PC437-PC850 Code Page select(Cont4.from Maintenance mode)



• Operation: After pressing Cleaning SW +Eject SW +Power on, turn on the Yellow ink LED by pressing Reset SW and determine by Eject SW. After that, PC-437 and PC-850 is changed over by pressing Reset SW.

• Save setting: Power off or Eject SW

• Setting item and LED indicator:

PC437→Black ink LED is on. PC850→Cyan ink LED is on.

• Function: 1)Select maintenance mode “Yellow” to enter this mode. →2)Power LED and cassette 2 LED blink. →3)Ink LED indicates current setting. →4)PC437 and PC850 is changed over every time Eject SW is pressed.

[In case of turning power off]

1)Save setting(Data registration)→2)Exit this mode→3)Power off

[In case of pressing Eject SW]

1)Save setting→2)Exit this mode→3)Ordinary printing mode(idle state)

[In case of turning power off]

1)Save setting(Data registration)→2)Exit this mode→3)Power off

[In case of pressing Eject SW]

1)Save setting→2)Exit this mode→3)Ordinary printing mode(idle state)

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EPSON Stylus Pro 5000 Chapter1 Product Description



Maintenance Mode 2



Reset EEPROM (Cont. from Maintenance Mode2)

This operation is to input particular address “0” in the EEPROM.

• Operation: In maintenance mode, press Cleaning SW and then Reset SW to enter maintenance mode2.

• Select maintenance mode2 setting item: Reset SW

• Select item: Eject SW

• Setting item and LED indicator: Reset EEPROM→Black ink LED is on.

• Function: 1)In maintenance mode, press Cleaning SW and then

press Reset SW to enter this mode. →2)Power LED and manual tray LED blink. Cassette 1 and 2 turn on. →3)Ink LED indicates current setting. →

4)Ink LED moves left to right and return to left by every Reset SW.

[In case of pressing Eject SW]

1)Save setting→2)Exit this mode→3)Execute one of setting mode.

CAUTION

There is only one available item in the maintenance

2. See the item on your right.

There is only one item that you can actually operate in the maintenance mode2. This function is the same reset as other EEPROM reset of other EPSON printer products.

• Operation: After entering maintenance mode, press Cleaning SW, then, press Reset SW to enter maintenance mode2. At this time, black ink LED is on. Select maintenance mode 2 “BLACK” to clear EEPROM.

• Execute: Eject SW

• Function: Pressing Eject SW clears only particular address in

the EEPROM.

• Exit: Exit this mode by power off.

Following shows items which are actually cleared by this operation.

CHECK POINT

Following items are reset forcefully by executing

maintenance mode2.



Waste ink counter (protect counter) is cleared.

 

Total power off time(timer IC) is cleared.

 

Cleaning counter is cleared.

 

The value of Auto I/F returns to Auto(initial value).



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EPSON Stylus Pro 5000 Chapter1 Product Description



Gap Adjustment Mode

This adjustment is Bi-D adjustment and head gap adjustment. By turning on power, pressing Cleaning SW and Eject SW, the printer enters to the gap adjustment mode and prints out the present adjustment values.

• Select: Select most appropriate No. of line from the

samples by referring to the table below. In this selection, LED moves from 1→7 direction by Reset SW, and 7→1 direction by Eject SW.

CAUTION

In this gap adjustment mode, 4 printing patterns are printed out; 1. Normal dot, 2.Micro dot, 3.BiD printing of Super micro dot, 4.Head Gap pattern. However, in this present model, Bi-D printing by other dots except normal dot is not performed. The reason why Bi-D adjustments for micro and super micro are included is for the future use, in case of specification changes.

• Operation: Rese SW+ Eject SW + Power On to enter this mode. After entering to the gap adjustment mode, 4 patterns(#1∼#4) of Bi-D sample with present values is printed out. At this time, set the sample number you want to adjust by referring to the Table below.

Table 1-21. Number selection after entering adjustment mode

No. Ink LED #1 #2 #3 #4

1 Black On Off Off Off 2 Cyan Off On Off Off 3 Magenta Off Off On Off 4 Yellow Off Off Off On

• Select setting item: Number is changed from #1 to #4

everytime Reset SW is pressed.

• Determination: Press Eject SW, and the next pattern (1∼7) is

printed out.

Table 1-22. Selecting Adjustment values after selecting number

No. Ink LED #1 #2 #3 #4 #5 #6 #7

1 Black On Blink Off Off Off Off Off 2 Cyan Off Off On Blink Off Off Off 3 Magenta Off Off Off Blink On Off Off 4 Yellow Off Off Off Off Off Blink On

• Determination: Determine No. by Cleaning SW and perform printing again.

• Exit: Exit this mode by power off. Also, it is written to EEPROM at this time. By pressing Eject SW, the printer exits from this mode and stores the memory of adjustment values.



Firmware uploading

If any changes occur on the firmware after the products are sent, it is possible to perform uploading from the PC without changing ROM of Stylus Pro5000.

• Operation1: Turn on the power, pressing Cleaning SW, Reset SW

and Eject SW, in order to enter the firmware uploading mode. IPL2.HEX file in the FD for uploading, which will be distributed, is transferred first. IPL2 file is the program to make the next firmware to transfer. Without performing this operation, following uploading program can not get started.

Rev.A

1-2

Page 34

EPSON Stylus Pro 5000 Chapter1 Product Description

CHECK POINT

• Opeation2: Check if the operation is completed correctly and wait

CHECK POINT

• Exit: Exit this mode by power off.



Type the following sentence on DOS screen or



on the DOS prompt for transmission. Copy X :IPL2.HEX_LPT1



During transmission, black ink LED turns on



and Cyan ink LED turns on when the transmission is completed correctly.

2 or 3 seconds. Main firmware K0xxxx.HEX is transferred.



Type the following sentence on DOS screen or



on the DOS prompt for transmission. Copy X: K0xxxx.HEX_LPT1



During transmission, Magenta ink LED turns on



and Yellow ink LED turns on when the transmission is completed correctly.

Rev.A

1-2

Page 35

EPSON Stylus Pro 5000 Chapter1 Product Description

1.3 ADDING PAPER GUIDE ROLLER UNIT

Here explains installing and removing Paper Guide Roller Unit, which can be installed to the paper feed cassette. Paper Guide Roller Unit is designed to improve the credibility of paper feeding for large exclusive papers (especially glossy paper), such as A3 or Super A3/B,.

Table 1-23. Parts Code List

Parts Name Parts Code

Paper Guide Roller Unit 1040445

[Installing Paper Guide Roller Unit]

Step1. As it is shown in Figure1-4, insert the yellow side of the unit, which is

located at left side of Paper Guide Roller Unit, into the yellow spaced of paper feed cassette, and insert the other hook into the hole on the paper feed cassette. (Refer to Figure1-4)

WARNING

When installing Paper Guide Roller Unit to the paper feed cassette, be careful not to involve the protection board for signal cable of paper type/size sensor.

Protection board for signal cable of paper type/size sensor

Paper Guide Roller Unit

Paper Feed Cassette

Hook

Figure 1-4. Installing Paper Guide Roller Unit

Step2. Push the Paper Guide Roller Unit hard until it clicks and the unit is

attached completely.

Rev.A

1-2

Page 36

EPSON Stylus Pro 5000 Chapter1 Product Description

Minus DriverBig Hook

[Removing Paper Guide Roller Unit]

Step1. Looking at the front side of paper feed cassette from its bottom,

release the big hook, which is located under its right side(paper type lever), as it is shown in Figure1-5. (Refer to Figure1-5)

Step2. Looking at the front side of paper feed cassette from its bottom,

release the hook by inserting a minus driver into 2 small hooks from their sides, which are located under the left side of paper feed cassette(paper size lever), and remove Paper Guide Roller Unit. (Refer to Figure1-6)

Figure 1-5. Paper Guide Roller Unit Removal (1)

Minus Driver

Rev.A

2 small hooks

Figure 1-6. Paper Guide Roller Unit Removal (2)

1-2

Page 37

OPERATING PRINCIPLES

&+$37(5



Page 38

Stylus Pro5000 Chapter2 Operating Principles

2.1 FEATURE

This section explains mechanical and electrical operating principles for Stylus Pro5000.

2.1.1 Operating Principles of Printer Mechanism

The printer mechanism of Stylus Pro5000 consists of the following mechanism parts.

Table 2-1 . Mechanism Components

No. Mechanism Motor Function(Purpose)

1 Printing Mechanism ----2 Carriage Mechanism CR

3 Paper Load/Paper Feed

Mechanism

4 Upper Surface Sensor

Mechanism

5 Paper Return Mechanism 6 Lifter Gear Train

Mechanism

7 Hopper 5mm Down

Mechanism

8 Sub Roller Gear Train

Mechanism

PF+ASF

-----

Pump,

ASF

•Ink Discharge

•Driving Carriage

•Input or Output trigger

to ink mechanism

•Paper transport.

•Open or close the ink

valve.

•Load adjustment of the Paper Load Roller, according to the paper volume.

•Prevention of multifeeding.

•Lifter Up/Down.

•Prevention of folding

paper on the paper skew.

•Improvement of credibility of paper loading.

•Big roller for paper transport.

Table 2-2. Mechanism Components(Con.)

No. Mechanism Motor Function(Purpose)

9 Gear Train Changes with

Hopper installed

10 Ink Engage/Disengage

Mechanism

11 PG Engage/Disengage

Mechanism

12 Ink Valve Mechanism PF

13 Friction Release

Mechanism

----PF

CR+PF

Pump,

ASF

•Engaging to the Lifter Gear Train.

•Changes over Paper Load line/ Pump line

•Changes PG according to the paper type.

•Prevention of ink leaking during the retransportation.

•Friction Release Mechanism in the range 10cm of the paper end edge.

Rev. A

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Stylus Pro5000 Chapter2 Operating Principles

2.1.1.1 Printing Mechanism

Printing method for Stylus Pro5000 uses EPSON original’s MACH method, like the previous models. Although 2 color heads which are the same ones used for Stylus Color 800, are used for Stylus Pro500, auto color calibration function is added to the heads used for Stylus Pro5000. Therefore, since the ID contents written in the head is completely different from the ones of Stylus Color 800,

can not be used for Stylus Pro5000 on the service.

Table 2-3. Head Code

Head Name Parts Code

IJ192-AD(Left Head) F055040

IJ192-AE(Right Head) F055050

CAUTION



Head shape of 2 heads mentioned above look



same. Therefore, when replacing 2 heads at the same time, do not get confused which is right head and which is left head.



It is possible to use the right head as left head,



but left head can not be used as right head. If

you ignore this, it gives bad influence directly on the printing quality.

the color heads of Stylus Color 800

[Nozzle Component]

Nozzle component is shown in the figure 2-1. It is one of the major characteristics that black nozzles are included as a part of the color nozzles. Also, 2 head are divided into either dark colors or light colors. In the dark colors, there are black, Cyan, Magenta. In the light colors, there are light cyan, light magenta, and yellow.

Each head: < (64 nozzles / Color x 3 lines) x 2 heads = Total 384 nozzles >

N ozzle C onfiguration for S tylus Pro5000

144/360"

32/360"

320/360"

#64

#63

[Cleaning Operation]

Also, 2 printing heads are mounted on the carriage, but black head or color head are not divided in this Stylus Pro5000. Therefore, there is no cleaning function that clean the black head or color head respectively. So, when the cleaning command is input from the printer body or from the driver, these 2 heads are cleaned with the same ink absorbing quantity.

Rev. A

4/360"

Black

(L ig h t C y a n )

(V ie w fro m th e to p )

Figure 2-1. Nozzle Configulation

Cyan

(Light M agenta)

M agenta

(Y e llo w )

R ight H ead (For Light C olors)

L e ft H e a d (D a rk C o lo rs )

2/360"

Page 40

Stylus Pro5000 Chapter2 Operating Principles

2.1.1.2 Carriage Mechanism

The carriage unit of Stylus Pro5000 performs on/off of D/E lever not only to control motive power transmission to the pump mechanism(at “0” digit side), but also to change the platen gap(at “137” digit side).

Head for Light Colors

Head for Dark Colors

Figure 2-2. Carriage Mechanism

D/E Mech anism for PG change

[Carriage Unit]

3 sensors are mounted on the carriage unit and each sensor detects the following printer conditions.

Table 2-4. Sensors on the carriage and their function

No. Name of Sensor Function

1 Carriage Home Position Sensor Detects paper jam and

acknowledges the standard position when the carriage is driven.

2 Encorder Pulse Sensor PTS compensation signal to

PZT driving trapezoidal waveform.

3 Paper width sensor Detects the paper width

every time the paper is loaded. (Prevention of printing on the platen)

Rev. A

Page 41

Stylus Pro5000 Chapter2 Operating Principles

[Carriage Guide Axis]

Unlike the previous EPSON ink jet printer models, 2 carriage guide axes support the whole carriage in the Stylus Pro 5000. Also, since eccentric shafts are used for both guide axes, more sophisticated PG changes are possible. Following picture shows its concept.

PG C oncept in the previous m odels

Ex1:

Stylus C olor3000

PG is wider

Ex2:

Stylus C olor

P G is n a rro w e r

PG is wider

PG C oncept in the Stylus Pro5000

P G is n a rro w e r

Figure 2-3. Concept of PG Mechanism

As it is shown in the figure above, it is understandable that the PG mechanism of Stylus Pro5000 equals the flying time for all nozzles.(Flying time means the time span that ink is discharged and until it reaches to the paper.)

Rev. A

Page 42

Stylus Pro5000 Chapter2 Operating Principles

2.1.1.3 Paper Feed Mechanism

There are 4 paper feed paths in the Stylus Pro5000; 1) Standard Paper Tray, 2)Optional Paper Cassette, 3)Front Manual Feed, 4)Rear Manual Feed. Following figure shows the paper feed path from the standard paper tray. In case of the rest of other paper feed paths, the same operation is done, except a point that the Paper Load Roller does not rotate.

C ro s s S e c tio n D ia g ra m fo r P a p e r P a th

Paper Pick U p S ensor

Size, P aper type sensor

Front M anual Feed P ath

Paper Tray 1

N o M anual Feeding!

O ptional Paper C a s s e tte

Paper Eject S upport R oller

Platen

PF Motor

(P aper) Left Q uantity Sensor

Pow der C oated R oller

Support R oller

H opper B ottom P late

Figure 2-4. Paper Feed Path

PE Sensor

Paper Load Roller(Sem icircle roller)

PF Support R oller(2)

Pum p,A SF Motor

PR Sensor (R ear M anual Feed)

Sub R oller

Flap (Fixed)

M anual F eed P ath (R e a r)

R oller for optional paper c a s s e tte

PF Support Roller(1)

Paper Return R oller

P S ensor 1(Front M anual F eed) + Paper Tray1

L ifte r fo r c a s s e tte

[Paper Loading from the Standard Paper Tray]

1. While the printer is turned on, Papers in the tray are always monitored by 3 sensors; Left Quantity Sensor, Paper size sensor and Paper type sensor.

2. When the printing command is input from the PC, the paper load roller, which is at the waiting mode, rotates half circle towards left direction and stops once in this position.

3. While the Paper Load Roller maintains this position, the lifter pushes up the hopper in the paper tray. This makes the paper on the hopper up. (Refer to “Lifter Gear Train Mechanism”)

4. At this time, when the Upper surface sensor detects THLD(THLD value: almost On or Off condition) by the Paper Pick Up mechanism, lifter operation is stopped. (Refer to “Paper Pick Up Mechanism”)

5. By rotating the Paper Load Roller again, the top paper on the paper pile is separated, and picked up from the rest of the other papers on the separation pad.

6. While the top paper is separated from the other papers, the credibility of this paper separation is improved, and also the problem that the paper edge is bent or folded at the skew removal operation can be avoided by moving the hopper 5mm down. (Refer to “5mm Down Mechanism”) The skew removal operation is to correct the skew part by colliding the loaded paper to the surface of PF Support Roller(1).

7. The head edge of the loaded paper is collided to the edge of the PF Support Roller for skew removal.

8. Sub roller is rotated and the loaded paper is transported to the printing start position.

9. When the Step 8 operation is completed, the Paper Load Roller returns to the waiting mode.

10. Lifter returns down and hopper returns to the waiting position. (Refer to “Lifter Gear Mechanism”)

Rev. A

Page 43

Stylus Pro5000 Chapter2 Operating Principles

[Paper Feeding From the Optional Cassette]

Although inside of the optional cassette is composed of same parts as you can find in the standard cassette, there is some distance from the optional cassette to the standard cassette. Therefore, paper load roller for optional cassette mounted on the printer becomes impossible to pick up the tip of the paper correctly in case of relatively short paper and paper type, which rolls back, and causes paper jam. Therefore, paper type that can be used for optional cassette is limited.

[Paper Feeding from Front Manual Feed Slot]

1. When the user insert a paper directly from the manual feed slot, the heading tip of the paper motivates P sensor(1), then, stops by colliding with edge of PF support roller. This sensor is in charge of detecting the heading tip of the paper in both cases, paper feeding from the front manual feed slot and from the standard cassette.

2. When this P sensor(1) works, the printer enables the sub roller to rotate without rotating the paper load roller, and carry the paper with friction between sub roller and paper support roller(1) up to the point that the heading tip of the paper can be completely hold.(Actually, the paper is fed only a few mm) Also, in case of front manual feeding, since the distance between the paper setting positing and P sensor(1) is very long, relatively short paper becomes impossible to make its heading tip to touch with this sensor. Therefore, like the optional cassette, paper size for using the front manual feed slot is limited.

3. After that, the printer rotates the sub roller again by inputting the printing command, and carries the paper’s heading tip to the platen quickly.

4. When the paper is carried to the platen, the paper is fixed completely by the friction between powder coated roller(paper feed roller) and support roller, and also between sub roller and PF support roller. As s result, the printer tries to release the friction between the sub roller and PF support roller(1), and to prevent kick back at the end of printing operation.

[Paper Feeding from Rear Manual Feed Slot]

In case of paper feeding from rear manual feed slot, exclusive PR sensor is mounted. This sensor enables the printer to carry the paper to the inside of the printer in the same process as front manual feeding does but without driving the paper load roller. Refer to “Paper Feeding from Front Manual Feed Slot” for the rest of operations. If you select this paper path, since paper loading is almost straight loading, the printer supports paper sizes from A6 to 22 inches, as it is mentioned in the specification.

Rev. A

Page 44

Stylus Pro5000 Chapter2 Operating Principles

2.1.1.4 Upper Surface Sensor Mechanism

As printing operation goes on, of course, the number of paper in the paper tray decreases. Unlike the previous ink jet printer models, since the lifter supports the hopper directly in the Stylus Pro5000, if the height which this lifer rises is always constant, the credibility of paper loading decreases by the change of the paper volume in the paper tray. In order to avoid this symptom, the Paper Load Roller itself moves up and down with its axis.

Paper Load R oller

Paper P ick U p S ensor

Flag

Paper

L ifte r

Flag is up

[Explaining the operation]

As it is shown in the figure 2-5, since the lifter does not rise at the waiting mode, the hopper in the paper tray does not contact with the Paper Load Roller. After the printer receives the printing order, the lifter rises up for paper loading and the hopper is also pushed up together. When the flag which is fixed to the unit reaches the upper surface sensor, C228 main control board stops the rotation of the gear train so that the lifter does not keep rising up any more. Also, this timing to stop the rotation of gear sets the best height for Paper Load Roller to pick up the top paper from the paper pile.

H opper

Seperation P ad

[W aiting C ondition]

[Paper Loading Condition]

L ifte r is u p

Figure 2-5. Transition of Paper Load Roller Unit Condition at Paper

Rev. A

Page 45

Stylus Pro5000 Chapter2 Operating Principles

2.1.1.5 Paper Return Mechanism

The purpose of paper return mechanism is to return the second paper, or papers after the first paper to the paper tray by force, in case the multifeeding happens. When the Paper Load Roller rotate, this mechanism is performed by conveying motive power to the transmission gears in order to drive the Paper Return Lever by the timing belt .

Sub R oller

PF S upport R oller

Paper R eturn Lever

Second Paper

First P aper

It pops out at paper loading

P a p e L o a d R o lle r in w a itin g c o n d it io n

Seperarion Pad Paper Load R oller in the paper

lo a d in g c o n d itio n

[Explaining the operation]

As it is shown in the figure2-6, when the paper loading starts, the Paper Load Roller which was in the waiting mode rotates left and loads the top paper from the pile of papers. Since paper loading is performed on the Separation Pad, in many cases, even if multiple feeding occurs, the different distance occurs between the head of the first(top) paper and second one.

The head of the first paper reaches the friction between the Sub Roller and Paper Feed Support Roller, and as soon as it goes to the state that the paper is about to be transferred not by the rotation of Paper Load Roller but the rotation of Sub Roller, the Paper Return Lever jumps out as it is shown in the figure and kicks back the following paper(s), which is(are) attached to the first(top) paper by static electricity, to the tray inside.

Rev. A

Figure 2-6. Paper Return Lever Operation

Page 46

Stylus Pro5000 Chapter2 Operating Principles

2.1.1.6 Lifter Gear Train Mechanism

Lifter Gear Train Mechanism is the mechanism to control the lifter, which operates the hopper up or down. Unlike the previous paper trays, the hopper of Stylus Pro5000 does not go up automatically, even the user installs the tray to the printer body. Therefore, the lifter pushes up the hopper forcefully from the hole located under the paper tray.

Figure 2-7. Lifter Gear Train Mechanism

[Explaining the operation]

Power source is pump/ASF motor. This motive power is conveyed from the transmission gear located under pump frame to the top surface of the sun gear, which has 3 planetary gears. (See “A” in the figure 2-7)

When the pump/ASF motor rotates right, the motive power is conveyed from “A” to “I” shown in the figure and in that alphabetic order, and the lifter goes up. At this time, semicircle gear “I” moves the axis of the lifter up and down directly, and maintains reverse rotation at paper loading and upper surface sensor operation so that the lifted up lifter does not return to the opposite direction by One-way Roller. (When the paper is actually loaded, refer to the next section, since hopper 5mm Down mechanism works.)

Rev. A

Page 47

Stylus Pro5000 Chapter2 Operating Principles

2.1.1.7 Hopper 5mm Down Mechanism

Hopper 5mm down is to improve the paper loading credibility and to prevent the head of paper from being folded at the moment that the Paper Load Roller picks up the top of the paper in the paper tray.

5 m m M e c h a n is m O u tlin e

Paper Load R oller

Paper Tray

H opper

Tim ing that touches the 2 points

Seperation Pad

L ifte r

[Explaining the operation]

At the moment that Paper Load Roller rotates and picks up the top paper on the paper pile, there is a timing that the loading of Paper Load Roller touches both hopper and separation pad. At this time, since the head of paper might be folded by the rotation of Paper Load Roller because of different angles and locations of the separation pad and hopper, this phenomenon is controlled by pushing the lifter 5mm down at the moment that the paper is picked up.

Rev. A

D ire c tio n to r o ta te

5mm Down

Figure 2-8. Concept of Hopper 5mm Down Mechanism

2-1

Page 48

Stylus Pro5000 Chapter2 Operating Principles

[Outline of Paper Gear Train]

Power source is Pump/ASF motor. Also, refer to section 2.1.1.6 Lifter Gear Train Mechanism for the transmission of motive power. Figure 2-9 shows important gear train of 5mm down mechanism.

Return Sprin

Clutch Gear for 5mm Down

Lifter Transmission Gear

One-way Roller

Even when One-way Roller release the gear train, since the stopper lever of clutch gear is stopping rotation of clutch gear forcefully, the clutch gear does not rotate in reverse completely and only the gear shown in the figure 2-9, whose upper clutch gear is removed, rotates in reverse(left rotation) by the power of the return spring located inside. Only the range that this return spring located in the clutch gear rotates in reverse enables the lifter to go down 5mm. The movement that only this One-way Roller releases is performed by rotating the paper return transmission cam with 2-step clutch gear, which is the transmission gear for rotating the paper load roller.

Cam pushes the pin and One-way Roller goes up.

Stopper Lever

Figure 2-9. 5mm Mechanism Gear Train

[Explaining the operation]

Like lifter gear train mechanism explained in the section 2.1.1.6, the motive power from pump/ASF motor is transmitted to the transmission gear for driving the lifter. At the moment which the paper is loaded by the rotation of Paper Load Roller, only One-way Roller moves away from the lifter transmission gear.

Rev. A

Pin for controlling One-way Roller up and down

Paper Return Transmission Cam

Figure 2-10. Controlling One-way Roller Up and Down

2-11

Page 49

Stylus Pro5000 Chapter2 Operating Principles

[Explaining the operation(Con.)]

After the Paper Load Roller loads the paper and performs hopper down 5mm, lifter returns to the original position and the hopper is reset. In order to perform this operation, the stopper lever which fix the clutch gear must leave to downward. In order to perform this, the lever for lifter release

needs to be pushed to right side by the rotation of Cam gear. (See ① in the figure2-11) Cam gear is released by laying down the lever for lifter release toward right

direction.(See ② in the figure2-11)

Lever for Lifter Release

Cam Gear

As a result, the stop lever, which stops the clutch gear, releases the connection with the clutch gear. On the other hand, since the tension spring of the semicircle gear for driving the lifter is always trying to reset, the lifter goes back the original position immediately after the stop lever is released.

Rev. A

Stopper Lever

Figure 2-11. Conceptual Figure for Lifter Reset

Semicircle Gear

Tension Spring

Figure 2-12. Position of Tension Spring

2-1

Page 50

Stylus Pro5000 Chapter2 Operating Principles

2.1.1.8 Sub Roller Gear Train Mechanism

The sub roller of Stylus Pro5000 is the big roller which always rotates, no matter which paper tray is used to load the paper. This roller rotates only while the pump/ASF motor rotates in reverse. Figure 2-13 shows motive power transmission.

Sub Roller Driven Gear

[Explaining the operation]

Pump/ASF motor rotates in reverse, then the sun gear marked “A” in the figure2-13 also performs reversed rotation. By this reverses rotation of this sun gear, the planetary gear 3 makes the transmission gear, which is located rear side of Gear B. rotate in reverse. (Since Gear 3 is located behind the planetary gear2, it is not shown in the figure2-13) By this, the planetary gear 4(Gear “C” in the figure), which is hiding itself in the below, comes up as it is shown in the figure, and makes it possible to have engagement with Sub Roller Driven gear.

Figure 2-13. Conveying Motive Power in the Sub Roller Gear Train

Rev. A

2-1

Page 51

Stylus Pro5000 Chapter2 Operating Principles

2.1.1.9 Gear Train Change with Hopper installed

Gear train of Stylus Pro5000 is controlled so that it is not until the user install the paper tray that the motive power becomes available for the lifter gear train. However, if the user removes the paper tray while the printer is performing the paper loading, the lifter which has been lifted up, returns to the reset position. Also, if the paper tray is not installed, C228 main control board prevents the lifter from being lifted up by the feedback signal from the logical line in order to avoid accidents. Figure2-14 shows all parts which changes their conditions, when the hopper is installed.

Sun Gear

Protrusion Part

Small Cam Gear rotates left.

[Explaining the operation]

Flag, which collides with paper tray, is sticking out in the mechanism frame. By installing the paper tray to the printer body, this flag moves to rear side (to right direction in the figure2-14). Along with this, the slider plate moves

to right side. (See ① in the figure2-14) On this plate, the small cam gear always engages with the notched part, which looks like the gear teeth.

(See ② in the figure2-14). This cam gear is located under the sun gear, and is usually located behind planetary gear 2(Refer to figure2-13). Therefore, when the slider plate moves to the right side, cam gear rotates left . As a result, the protrusion side of the cam gear faces upward.

Rev. A

Slider Plate: Moves to the right side when the paper tray is installed.

Figure 2-14. Gear Train Transmission(1)

Gear part also moves to right side.

2-1

Page 52

Stylus Pro5000 Chapter2 Operating Principles

[Explaining the operation]

Figure 2-15 and 2-16 shows 2 conditions; one is the case that pump/ASF motor rotates right without installing paper tray and the planetary gear2 does not fall to right side, being unable to convey the motive power, and the other case that pump/ASF motor rotates forward (rotates right) with the paper tray installed.

Planetary Gear 2 does not fall to right side without installing the Paper tray.

Therefore, the planetay gear2 can not convey the motive power to the next transmission gear.

Planetary Gear2 falls to the right side with Paper tray installed

As a result, Planetary Gear2 can transmit the motive power to the next transmission gear.

Figure 2-16. Condition of Planetary Gear 2 with Paper Tray Installed

Figure 2-15. Condition of Planetary Gear 2 without Paper Tray

Rev. A

Also, the planetary gear 2 mentioned in the figure above is not the only one part, which gear train changes by installing the paper tray to the printer body. The lever to release the lifter gear train mounted on the printer rear side is also influenced. Refer to section 2.1.1.7 Hopper 5mm Down Mechanism for the details about this operation.

2-1

Page 53

Stylus Pro5000 Chapter2 Operating Principles

2.1.1.10 Ink Engage/Disengage Mechanism

The ink disengage mechanism for Stylus Pro5000 is called D/E(disengage/engage mechanism). This determines to conveys the motive power from paper load/eject line to the pump line for absorbing ink or not. Figure 2-17 shows the exterior view of pump frame.

Slider

Pump Unit

Planetary Gear 1

Return Spring 1

Transmission Gear for pump driving Planetary Gear 2

Semicircle Cam Gear2

Return Spring 2

Figure 2-18. Gear Train Condition at transmitting power to the Pump

[Explaining Operation1]

Figure 2-17. Exterior View of Pump Frame

[Explaining Figure2-17]

The major parts mounted on the pump frame above consists of various gears, which determines whether to convey the motive power from pump/ASF motor, cap unit and pump unit to the paper load/eject line gear train, or to the pump only. Out of these gears, the gear train for engaging or disengaging the motive power is the same as the one of Stylus Color 800.

Rev.A

Figure 2-18 shows the condition that motive power of pump/ASF motor is transmitted only to the pump unit. When the printer performs the pump operation, the planetary gear 1 moves to left direction, since the carriage collides with the slider, as it is shown in the figure2-17. While the carriage collides with the slider, the return spring 1 on the same axis, which the planetary gear 1 is also on, is compressed. When this spring expands, it moves the planetary gear 1 to left direction. In this condition, when the pump/ASF motor rotates forward, the motive power charged on the planetary gear 1 is transmitted to the semicircle cam gear. Then, as this cam gear goes up, the planetary gear 2 is pushed out to the notch of the right frame. (Refer to Figure2-19)

2-1

Page 54

Stylus Pro5000 Chapter2 Operating Principles

Transmission gear for pump driving and Planetary Gear 2 after the gear train is released.

Motive power goes to Paper Load/Eje ct Gear Train

Semi circle gear after its direction changed

Figure 2-19. Gear Train Condition at transmitting power to the Paper

Load/Eject Line

[Explaining Operation2]

The planetary gear1 gets engaged with the cam gear and pump/ASF motor is rotated forward, the motive power to the transmission gear(black) for driving pump is shut off, but instead, the motive power is conveyed to the transmission gear, which transmits the power to the paper load/eject line.

Rev.A

2-1

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Stylus Pro5000 Chapter2 Operating Principles

2.1.1.11 PG Disengage Mechanism

Stylus Pro 5000 performs automatic control to change the platen gap, which the users were controlling the platen gap manually in the previous models. Usually, the printer perform this operation automatically, according to the paper type setting from the driver.

Clutch Roller

PF Motor (CW)

Transmission Gear

Flag for colliding with carriage

PF Motor (CCW)

PG Driven Gear

[Explaining the operation]

When the printing command is input in the conditions that plain paper or Photo Quality Ink Jet paper (landscape) is selected on the driver, or the media type lever is set to Thick Paper, or manual feed thick paper mode is selected by the alternative function on the control panel, the carriage lets the flag, which is waiting at the most left edge with the paper width sensor, collide with the protrusions on the carriage. Once the flag collides with the carriage, although the positions of the transmission gear and PG driven gear match as it is shown in the figure 2-20, they can not be really engaged with each other, since there is still gap between them. Therefore, the whole transmission gear falls into the PG driven gear side by rotating the PF motor counterclockwise, then, the PG driven gear rotates. The figure 2-21 shows the condition of small(narrow) platen gap before the PG driven gear rotates, and figure2-22 shows the condition of the gear train after the PG gap becomes wider.

Carriage Guide Axis(Rear)

Carriage Guide Axis(Front)

Rev.A

Figure 2-20. PG Changes

Powder Coated Roller Driving Gear (High precision gear)

PG Driven Gear

Clutch gear by statical friction torque

Figure 2-21. Gear Train Condition when PG is narrow(small)

2-1

Page 56

Stylus Pro5000 Chapter2 Operating Principles

[Explaining the operation(Con.)]

Once the transmission gear is engaged with the PG driven gear, PG driven gear is rotated counterclockwise by the forward rotation of PF motor, and PG mechanism starts its operation. (See figure 2-20) The figure 2-22 shows the gear train condition, when the platen gap becomes big(wider).

Middle Transmission Gear

Down

No gear teeth

Figure 2-22. Gear Train Condition when PG is wider(big)

[Explaining the operation]

When the PG driven(clutch) gear starts rotating right direction, each lever with gear located on both sides of the transmission gear, changes the condition. Also, as it is shown in the figure2-22, since the some portions of gear teeth are removed on the surface of the driving gear and on the lever with gear on the right side, the rotation by the PF motor can not be transmitted more than necessary. Since the PG driven gear itself is the clutch gear applied with static friction torque, even the motive power tries to go to the other areas except for the area of controlling PG(2.1mm) and small PG(1.2mm), the PG driven gear loses its clutch and can not transmit the power.

Rev.A

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Stylus Pro5000 Chapter2 Operating Principles

2.1.1.12 Ink Valve Mechanism

The purpose of ink valve mechanism is to prevent ink leaking during retransport after the serve is completed. Stylus Pro5000 does not have the waste ink sequence like Stylus Color 3000 had, instead, this ink valve mechanism prevents leaking from the ink pack. Also, in case of Stylus Color 3000, when the waste ink sequence is performed, the program performs initial ink charge automatically by turning the printer on after installing each ink cartridge. On the other hand, in case of Stylus Pro5000, since the printer itself does not have the function to perform initial ink charge, it is recommended not to remove the ink cartridge from the printer during the retransport.

Valve is opened by CW PF motor rotation

CW(Valve is opened)

CCW(Valve is closed)

Transmission Gear

Protrusion of cam faces out by CW PF motor rotation

Clutch Gear

Valve is closed by CCW PF motor rotation

Protrusion of Cam faces the valve side by CCW PF motor rotation

Figure 2-24. Ink Valve Mechanism when the Valve is closed

[Explaining the operation]

The motive power source of ink valve mechanism is PF motor. When the PF motor is rotating, although ink valve mechanism is always receiving the motive power, the cam loses its clutch in the clutch unit so that the cam to operate the valve does not rotate more than 180 degree. In the actual operation, when the printer is turned on, the valve is opened by rotating the PF motor forward with initialization operation, and the valve mechanism stays open, but stays always close in the non-printing condition.

Rev.A

Figure 2-23. Ink Valve Mechanism when the Valve is opened

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Stylus Pro5000 Chapter2 Operating Principles

2.1.1.13 Friction Release Mechanism

In the previously used paper feed mechanism, which was applied for Stylus Color 1520 and Stylus Color 3000, the paper feed roller always contacts with the paper feed support roller located under the paper feed roller. In this condition, as the printing on the presently moving the paper gets closer to the end, since the friction between paper feed roller and the paper feed support roller is all released at the paper ending edge, strictly speaking, there is a possibility that the paper feed pitch varies slightly.

Paper Feed R oller

F r ic tio n is released

Paper Feed Support R oller

[P revious M odels]

Figure 2-25. Concept of Friction Release

[Explaining the operation]

The gear train, which sets or releases the friction with paper feed support roller, depends on the sub roller driven gear train. As it is mentioned in the section 2.1.1.7 Hopper 5mm Down Mechanism, when the pump/ASF motor rotates, the cam gear always rotates too, regardless the motor’s rotational direction. This cam gear not only pushes or pulls the lever in order to encourage the lifter gear train to be released, but also conveys the motive power to the transmission gear to encourage the paper feed support roller to move up and down in the frame inside.

[P revious M odels]

Down

Sub Roller Driven Gear

Cam Gear

Sun Gear

Planetary Gear

Figure 2-26. Transmitting the motive power to the Cam Gear

Since the sub roller is not supposed to rotate forward, this gear train are not able to rotate in reverse, unless the pump/ASF motor rotates backward, using planetary gears and conveys the motive power. On the other hand, when the pump/ASF motor rotates forward, the motive power is not transmitted to the Sub Roller Driven gear but only to the cam gear. If this cam gear keeps rotating, it will come off eventually, since there is a limit for up and down operation by the paper feed support roller. In order to prevent this, a part of gear teeth of the cam gear is removed and this avoids conveying the unnecessary motive power from the planetary gears.

Rev.A

2-21

Page 59

Stylus Pro5000 Chapter2 Operating Principles

Cam for driving Paper Feed Support Roller

Transmission Gear 1

Transmission Gear 2

Cam Gear

Sub Roller

Paper Feed Support Roller

Figure 2-27. Transmitting motive power to Paper Feed Support Roller

[Explaining the operation(Con.)]

Table 2-5. Relation between Rotational Direction of Motive Power and

Gear Train Changes

Rotational

direction for

Sub Roller

condition

Cam Gear

condition

PF Support

Roller

Pump/ASF motor

CW(right) rotation Not operate Right rotation

(It stops after

Release

condition the certain rotation)

CCW(left) rotation Left rotation

(Paper

transportation)

Left rotation (It stops after the certain

Friction

condition rotation)

Figure2-27 shows transmission of motive power, which the motive power of pump/ASF motor is conveyed to the paper feed support roller. The cam gear must rotate, as a condition to set or release the paper feed support roller. However, while the sub roller is rotating in reverse, the cam gear loses motive power and stops, after setting the paper feed support roller in the friction condition. Also, while the pump/ASF motor rotates forward, since the planetary gear in the figure2-26 does not engage with the Sub Roller Driven gear, the motive power is not transmitted to the sub roller, and the paper feed support roller is set in the release condition by rotating the cam gear clockwise. The table 2-5 shows the relation between the rotation of pump/ASF motor and operation of each mechanism.

Rev.A

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Page 60

Stylus Pro5000 Chapter2 Operating Principles

2.1.1.14 Gear Train Block Diagram

Diagram below shows the most complicated mechanism in the Stylus Pro5000; the Gear Train for Paper Load/Eject line control.

Stylus P ro5000 M echanism Flow

Sub R oller G ear Train B lock

Friction R elease M echanism

Lifter G ear Train

State0

Clutch Roller for 5 m m dow n

State2

Cam Roller R otating Forw ard

(PF S upport R oller: R eleased)

Cam Roller Rotating Backw ard

(PF S upport R oller: S et)

Lifter

State1

State2

Stopper Cam for 5 mm down

Hopper Reset

Hopper Set

Sub R oller D riven

H opper 5 m m dow n

State1

O ne-w ay R o lle r

Lifter Transm ission G ear

F o rw a rd R o ta tio n

Planetary G ear 5 C am R oller Line

B a c k w a rd R o ta tio n

M otive pow er goes to planetary gear4, only in the back rotation

Planetary G ear 4 Sub R oller Line

Planetary G ear 2 Lifter G ear Train Line

Lifter S tops

Lifter Drive G ear

Lifter M iddle G ear

O ne-w ay R o lle r

M o tiv e p o w e r is tra n s m itte d to planetary gear 5, regardless of its rotational direction.

Planetary G ear 3 Sub R oller Line

Backw ard Rotation

C ondition 1

Planetary G ear 2 can tra n s m it m o tiv e p o w e r o n ly w ith fo rw a r d ro ta tio n

C ondition 2

Planetary gear 2 can n o t tra n s m it m o tiv e pow er w ithout installing the paper tray.

Valve M echanism

PF M echanism

ASF/Pump Motor

B a c k w a rd R o ta tio n

R eversing G ear

Paper R eturn G ear Train

M ovem ent on the C R

B a c k w a rd R o ta tio n (P F )

D /E M echanism

Forward Rotation (P F )

CR,PF M otor

Pum p Fram e

S a m e a s fo r Stylus C olor 800

D /E M echanism

ASF

Sun G ear R otating F o rw a rd /B a c k w o rd

Planetary G ear 1 One-way Control

Forward R o ta tio n

D ouble C lutch G ear R otating Forw ard O nly

2nd O n

Tim ing B elt

Forw ard /B ackw ard R otation (PF )

PG M echanism

In k

Pum p M echanism

2nd

Solenoid

1st On

1st O n

Paper Load R oller H opper S tate

Rev.A

Lifter G ear Train B lock

H o pp er G ear Train B lock

Figure 2-28. Flow Chart for Paper Load/Eject Line Gear Train

2-2

Page 61

Stylus Pro5000 Chapter2 Operating Principles

2.1.2 Outline of Electrical Circuit

Here explains outline of various electric circuit boards.

2.1.2.1 C228 PSB Board

In the power supply circuit of Stylus Pro5000, the switching power supply called C228 PSB board is used, and plays role of generating various driving voltages. Table below shows the voltage, which C228 PSB board generates, and its usage.

Table 2-6. Output Voltages of C228 PSB Board and their Usage

No. Output Voltages Usage or Roles

1 +42V

2 +5V

3 +28V

•Driving Pump/ASF motor.

•Driving PF motor.

•Driving CR motor.

•Driving Paper Load Solenoid (Driving

Optional solenoid)

•Source of the print head common voltage.

•Source of the Fan driving voltage.

•Logical signal of C228 Main Board.

•Current setting signal of various motor

drivers.

•Source of nozzle selector for head driving.

•Control Panel LED driving voltage.

•Reset IC standard monitoring voltage.

•Timer IC driving voltage, etc.

•Standard voltage of comparator for

generating head driving voltage.

Full W ave R e c tif ic a tio n Circuit

Input Filter C ircuit

CN1

Figure 2-29. C228 PSB Power Supply Circuit Block

Sm oothing Circuit

Switching Circuit

Drop Circuit

Delay Circuit

Drop Circuit

+42V + 5V

GND

- 2 V

+28V

PSC

CN2

Figure 2-29 shows circuit block for C228 PSB board.

Rev.A

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Page 62

Stylus Pro5000 Chapter2 Operating Principles

[Various Protection Circuits]

Each output power source from *1 through *4 numbered in the figure2-29 has protection circuit, as it is explained below.

*1) 5 VDC Stabilization Circuit

IC51(L4960), which is also HIC for drop circuit, outputs +5 VDC, as +42 V line power supply voltage. If the switching circuit on the primary side gets shorted by any malfunctions, the output voltage level on the secondary side gradually increases and may damage C228 main board and C228 DRV board. Therefore, +5 V output line is always monitored by ZD94, and output will be stopped completely, if the voltage level exceeds 9 VDC.

*2) +42 VDC Line Stabilization Circuit

+42 V consists of 2 stabilization circuits. It is the control circuit to vary the On/Off timing of the switching circuit located on the primary side by 7 Zener diodes, which are from ZD51 to ZD86 on the circuit. If +42V lines falls to +38V by the influence of overloading, electromagnetic induction on the primary side is encouraged to be stopped periodically by turning the main switching FET(Q1) off. This circuit is called constant voltage control circuit.

The other one is the over voltage protection circuit. If the voltage of +42 V line falls into the abnormal situations, especially assuming the malfunction on the switching circuit on the primary side, this protection circuit stops all the operations on the C228 PSB board so that the abnormally increased voltage is not output. This circuit is called the over voltage protection circuit.

*4) Delay Circuit

Since the power supply switch is on the secondary side, even if the power is turned off on the control panel, the exclusive power off sequence still operates. Following shows various power off sequences, which are always performed, when the power is turned off from the control panel.



Closing ink valve



Carriage lock set



Paper eject operation(if the printer is still printing)



ASF load paper system reset (If it is operating)

*3) +28 VDC Line Stabilization Circuit This circuit is mounted on the same line as the +42 V line over voltage protection circuit is on, which is mentioned above. It stops all the operations on the C228 PSB board, when +28V line falls to the abnormal situations by malfunctions of the switching circuit on the primary side, etc., and the voltage level exceeds 33V. This circuit is also called over voltage protection circuit.

Rev.A

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Stylus Pro5000 Chapter2 Operating Principles

2.1.2.2 C228 DRV Board

In the C228 DRV board, E05B48(IC9) plays its central role. On this board, 2 printing heads, 3 motors and solenoids, and all sensor circuits are mounted. These driving/stop signal, monitoring the conditions of all sensors in the motive power line, and the control in the driving line according to the conditions are determined by E05B48 through communication with C228 main board. Figure below shows block diagram of C228 DRV board.

Left H ead

COM

CN10

R ight H ead

COM

CN11

VH4

CN14

CN15

VH2

M 65X X (IC 80)

VH2

CXD2308Q(IC8)

IC 2

IC 3

IC 4

E05B 48 XX (IC 9)

(P aper)Left Q uantity Sensor

CN19

CN3

CN13

O perate

Paper Size/Type Sensor

I/C O u t, In k O ut S ensor

Paper P ick U p S ensor

CN18

PTS Encoder

CN12

C o o lin g Fan

C leaning

3 sec

Eject

Continue

CN9

Reset

3 sec

CN6

CN21(C,c)

CN20(M,m)

CN22(Y)

CN23(Bk)

Rev.A

Pum p ASF

ASF

CN16

CN8

IC 5

CN8

S o le n o id

Figure 2-30. C228 DRV Board Block

CN7

PR Sensor PE Sensor

CRHP

P S ensor

S o le n o id

CN4

CN17

2-2

Page 64

Stylus Pro5000 Chapter2 Operating Principles

2.1.2.3 C228 Main Board

In the C228 Main board, mainly, memory control (Flash/DRAM/SRAM/PDRAM), taking CPU as its center, optional SIM control and Bus control are performed, and this board plays the major role for the whole circuit. Also, this board plays role of sending or receiving information between interfaces(Parallel/Type-B/Mac.) and various exterior parts. Figure below shows block diagram for C228 main board.

CN1

R elay C onnector

TM P 95C 063 (IC 3 )

Address Bus

Data Bus

IC 2

Transceiver

E05B 47 (IC 7 )

IC 10-12 B us D R V

CN3 S e ria l I/F

Figure 2-31. C228 Main Board Block

CN2 P a ra lle l I/F

SIM 1

SIM 2

SIM 3

Rev.A

2-2

Page 65

TROUBLESHOOTING

&+$37(5



Page 66

Stylus Pro5000 Chapter3 Troubleshooting

3.1 FEATURES

This chapter describes how to troubleshoot abnormal operations of Stylus Pro5000.

3.1.1 Problems relating to the printer mechanism

In this section, problems which may occur in the printer mechanism and their remedies are described in each table.

Table 3-1. Phenomenon:

Cleaning does not solve the problem in print quality.

Step Remedy

1 Connect the printer and the PC with a cable and turn them on. If

any error condition is found, the cause of the error must be eliminated.

2 Start the service program “Stylus Pro5000.EXE” and select

“Head cleaning” from the menu ‘Maintenance”. (Repeat the cleaning 5, 6 times or more to remove severe head clogging. (See Chapter 5 for details.) If this operation does not recover the head condition, go to Step 4.

3 Select “Ink charge flag reset” from the same menu. Note that

this operation does not start initial charge operation. 4 Turn the printer off. 5 Turn the printer back on, and the initial charge operation starts. 6 Run the self-test to check the output. If the problem is not

solved yet, go back to Step 1 and repeat the operation.

WARNING

CAUTION

The servicing program runs on DOS program only. Therefore, do not run the program on Mac. ®PC.



In the cleaning operation by the servicing



program, always CL2(strong cleaning) is forcibly performed. Therefore, make sure to perform printing test every time CL is performed.



Note that “Ink charge flag reset” in the servicing



program does not reset the initial charge flag by itself. For this reason, be sure to turn the printer off and then back on after the operation.



Be careful no to perform initial ink charge more



than necessary as it spends a considerable amount of ink. In case you need to repeat the operation to solve the head clogging problem, make sure that you have an extra cartridge ready, since you can not repeat the operation three times at a time. (The ink usually ends before the second operation is complete. )

Rev. A

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Stylus Pro5000 Chapter3 Troubleshooting

Table 3-2. Phenomenon:

Cleaning does not solve the problem in print quality. (Continued)

Step Remedy

7 Remove the upper case and then the cover on the carriage.

(Refer to Chapter4) 8 Check the damper inserted in the needle for each color. If it is

loose, fix it securely. 9 Check that hexagon nuts connecting the pipes and ink supply

tubes for all colors routed out to the front side of the printer are

securely tightened.

10 Check that the hexagon nuts securing the ink supply port at the

back of the ink cartridge holders are securely tightened.

11 When the printhead is at the home position, check the rubber on

the cap and the head surface, which should be in tight contact

with each other, for the correct position. If they are not properly

positioned, following conditions can be assumed:



Lack of parallelism due to bad repair or severe shock.



Incorrect engagement of the parts around the cap, such as the spring dislocated and the cap supporting shaft unhooked.



Ink tube has come off or deformed.



Small concavities on the cap rubber surface

12 Using the tester, check the signal change in on and off for that

the detected signal is properly fed back from the ink out sensor.

13 Head driver common voltage and the nozzle selector control

signals may not be sent to the printhead. Therefore, check that

the FFCs are correctly connected to CN10 and CN11 on the

C228 DRV board.

14 Check that the FFCs for the printheads are correctly connected.

If it is not connected completely, there is a possibility that excess

current already flew into PZT in the head, damaging the head.

15 Waveform for the head driver voltage output from the C228DRV

board may be abnormal. Therefore, replace the C228DRV board.

16 C228MAIN board may be bad. Replace the C228MAIN board. 17 If the problems is not solved through the steps, replace the

printhead.

WARNING

Step Remedy

1 When the printer ejects ink in a improper direction, that

condition is considered “improper alignment”. The possible causes other than head clogging are failure in any of the following adjustments:

Referring to Chapter 5, print a check pattern to see the current adjustment condition.

WARNING

Mind that 2 printhead used for the printer, the dark color version (left) and light color version (right), have different ordering codes. Therefore, be sure to install the head of the correct code, as a wrong head has a direct effect on print quality.

Table 3-3. Phenomenon:

Printer ejects ink but prints badly.

Bi-D adjustment, Head gap adjustment, Head angle adjustment, Head vertical adjustment

The adjustments mentioned above must be performed in the specified order. Make sure that you perform the adjustments in the order specified in Chapter 5.

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Stylus Pro5000 Chapter3 Troubleshooting

Table 3-4.Phenomenon:

Printer Fails to Load Paper Frequently.

Step Remedy

1 Paper types available and the way to set vary depending on the

cassette types; standard cassette or optional cassette. Look into

the User’s Guide and set the paper which is not available to the

optional cassette to the standard one. 2 Check that the paper set in the cassette does not exceed the

capacity. 3 Check that the edge guides in the cassette are properly aligned

with the paper sides. 4 A separation pad in the paper cassette must be kept to have

proper friction with paper. If the user touches the pad surface, it

affects paper separation. Therefore, when this problem occurs

wipe the paper separation pad surface with a cloth moistened

with alcohol. 5

If a PF roller is used for many years, it starts losing proper µ due

to friction built up on its surface. In stand by status, the roller can

not be cleaned as it is facing upward. Therefore, clean the roller

in the following order when this problem occurs:

1. Remove the paper cassette.

2. Turn the printer off and back on, and the ASF resets.

3. Using the cloth moistened with alcohol, wipe the PF roller as the roller rotates.

Table 3-5.Phenomenon:

Printer Loads Multiple Paper Frequently.

Step Remedy

1 The hopper 5-mm down mechanism may not be properly

functioning. Referring to Section 2.1.1.7 in Chapter 2, check the mechanism in the following step.

2 Check that the spring in the clutch gear which acts to bring the

lifter down by 5 mm is properly set. To check it, hold one gear (either inner one or outer one) and then turn the other gear manually. If the turned gear spins back with the tension of the spring, it means the spring is set properly.

Table 3-6.Phenomenon:

Hopper does not Reset after Paper Is Loaded.

Step Remedy

1 The tension spring is dislocated form the lifter driving gear (a

crescent gear). Therefore, mount it properly.

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Stylus Pro5000 Chapter3 Troubleshooting

Table 3-7. Abnormal Phenomenon: LED Indicates “Paper Out (tray 1)”.

Step Remedy

1 Remove the paper cassette and check the paper left quantity

sensor actuator (an acting pole with a roller attached on it) for the proper function. If it is dislocated or not functioning properly, reinstall it to the correct position. (Refer to Chapter 4.)

2 The LED status may remain the same after the cassette is

properly reinstalled to the printer. It is because the LED indication

also shows “No Tray” condition. 3 Check that the CN6 on the C228DRV board is properly set. 4 Referring to Table 3-3, perform the adequate cleaning. 5 Check that each connector connecting the paper cassette with

the printer is properly connected. 6 C228DRV board is not feeding back the cassette presence status

properly. Therefore, replace it. 7 C228MAIN board may be defective. Therefore, replace it.

Table 3-8. Abnormal Phenomenon: LED Indicates “Paper Out (tray 2)”.

Step Remedy

1 Remove the paper cassette and check the paper left quantity

sensor actuator (an acting pole with a roller attached on it) for the

proper function. If it is dislocated or not functioning properly,

reinstall it to the correct position. (Refer to Chapter 4.) 2 The LED status may remain the same after the cassette is

properly reinstalled to the printer. It is because the LED indication

also shows “No Tray” condition. 3 Check that the CN9 on the C228DRV board is properly set. 4 Referring to Table 3-3, perform the adequate cleaning. 5 Check that each connector connecting the paper cassette with

the printer is properly connected. 6 C228DRV board is not feeding back the cassette presence status

properly. Therefore, replace the C228DRV board. 7 C228MAIN board may be defective. Therefore, replace it.

Table 3-9. Abnormal Phenomenon:

LED Indicates “Paper Out (manual feed)”.

Step Remedy

1 If the P sensor does not come on despite the manual feed is

selected in the printer driver, the printer assumes that no paper is loaded in the manual feed paper entrance. In this case, following problems may be considered.

2 A sheet is set but the front edge has not reached the P sensor,

and the sheet is not loaded into the printer as the result. In this case, push the sheet further until it meets resistance.

Note: Paper types and setting directions available to manual

feed are limited. Look into the User’s Guide, and if you find the paper not available to manual feed, set the paper to the cassette. Also, be sure to switch the paper source from manual feed to cassette feed in the printer driver.

3 Check the P sensor, since it is disconnected or defective. 4 Check that the CN4 on the C228DRV board is securely

connected.

5 Replace C228DRV board is not detecting the signal from the P

sensor. Therefore, replace it.

6 C228MAIN board may be defective. Therefore, replace it.

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Stylus Pro5000 Chapter3 Troubleshooting

Table 3-10. Abnormal Phenomenon:

LED Indicates “Paper Jam”.

Step Remedy

1 The same LEDs come on when the rear cover is open. Therefore,

check that the rear cover is securely closed to the printer side. 2 The printer refers to the points below to determine ‘Paper Jam”

condition:



Point where the P sensor comes on. (Right after a sheet is picked up from the paper cassette.)



Point where the PE sensor comes on.



Point where the PR sensor comes on. (Comes on at manual rear insertion only.)



In the CR scanning area (Paper jam is detected based on the

change in the pulse output from the encoder belt.) The printer monitors the conditions for these sensors and determines if any paper or paper debris is remaining.

3 Check that the following connectors on the C228DRV board are

properly connected.

CN4 (P sensor), CN7(PE,PR sensors), CN12(PTS)

4 C228DRV board may not be detecting the signals from the

sensors. Therefore, replace it.

5 C228MAIN may be defective. Therefore, replace it.

Table 3-11. Abnormal Phenomenon:

Any of the Ink End LEDs Stays On or Blinking.

Step Remedy

1 Check that the life of the ink cartridge currently installed as a

repair tool almost expires, or check that the ink cartridge is installed to the printer.

2 Check that the ink out sensor and I/C out sensor are properly

functioning. Also, check if they are securely set to the specified positions.

3 Check that the following connectors for the ink out sensor and

I/C out sensor on the C228DRV board are properly connected.

CN23(Bk), CN22(Y), CN20(Mm), CN21(Cc)

4 C228DRV board may not be detecting the signals from the

sensors. Therefore, replace it.

5 C228MAIN board may be defective. Therefore, replace it.

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Stylus Pro5000 Chapter3 Troubleshooting

Table 3-12 .Abnormal Phenomenon:

LED indicates “Fatal Error”.

Step 1: Summary

The printer indicates “Fatal Error” condition by bringing all LEDs on. This is caused by the troubles occurred in the driver lines including electrical circuit, as shown below:



Trouble occurred in the CR motor control mechanism



Trouble occurred in the PF motor control mechanism



Trouble occurred in the pump/ASF drive mechanism (Occurs when an abnormally excess force applied to a specific gear train or mechanism is preventing the motor from rotating.)

To find out the cause of the problem, follow the steps and isolate the defective part. Exceptionally, you can go straight to the corresponding step for a quick solution when you notice the following problem:

The printer operates at power on and then indicates “Fatal Error” when it enters a specific sequence. (Ex.: The PF motor rotates normally at power on but enters “Fatal Error” condition when the CR starts moving.)

Therefore, be sure to refer to the following steps when “Fatal Error” occurs at power on only.

Note: Following steps correspond to the sequence which the mechanisms operate.

Step 2: Checking the PF motor drive line

At power on, the PF motor is driven first. If you notice “Fatal Error” immediately after power on, you are to check the following parts to see the condition of the PF motor drive line:



Check internal coil resistance for the PF motor. If the result does not meet the specification, replace the motor.

− Specification: 2.8 Ω ± 10% (each phase)

− Check points: Between Pins 1 and 3 or Pins 2 and 4 for CN15

on the C228DRV board



Replace the C228DRV board and check for the proper operation.



Replace the C228MAIN board and check for the proper operation.

Table 3-13 .Abnormal Phenomenon:

LED indicates “Fatal Error”. (Continued)

Step 3: Checking the CR motor drive line

When the PF motor drives and releases the CR lock and ink valve mechanisms, the CR motor comes in operation. The printer then checks that the CR shifts in the scanning area normally. Therefore, if “Fatal Error” occurs while the CR is in operation after PF motor drive is complete, check the following for the correct operation of the CR motor line:



Check internal coil resistance for the CR motor. If the result does not meet the specification, replace the motor.

− Specification: 4.3 Ω ± 10% (each phase)

− Check points: Between Pins 1 and 3 or Pins 2 and 4 for CN14

on the C228DRV board



Replace the C228DRV board and check for the proper operation.



Replace the C228MAIN board and check for the proper operation

Step 4: Checking the Pump/ASF motor (1)

After the CR moves normally and returns to the home position, the printer starts ink absorbing operation (Timer-CL) for the period determined based on the power off time. To enter this operation, the D/E mechanism (Disengage Mechanism), or the switch for the pump gear train, crashes into the carriage to transmit torque from the Pump/ASF motor to the gear train on the pump side. If “Fatal Error” occurs during this operation, following must be checked:



Check internal coil resistance for the Pump/ASF motor, and replace the motor if the result does not meet the specification.

− Specification: 3.9 Ω ± 10% (each phase)

− Check points: Between Pins 1 and 3 or Pins 2 and 4 for

CN16 on the C228DRV board



Check the D/E switch, a slider switch on the home position side, manually for the proper operation. (Push the switch into the HP side and see if it bounds with spring tension.)



Rotate the transmission gear (white) next to the motor pinion gear manually and check that each transmission gear for pump drive turns smoothly.



Replace the C228DRV board and check for the proper operation.



Replace the C228MAIN board and check for the proper operation.

Rev. A

Page 72

Stylus Pro5000 Chapter3 Troubleshooting

Table 3-14 .Abnormal Phenomenon:

LED Indicates “Fatal Error”. (Continued)

Step 5: Checking the Pump/ASF Motor (2)

After ink is absorbed properly from the printhead by the pump mechanism, the built-in ASF resets. When drive is not properly transmitted to the ASF, it causes the motor to rotate abnormally because of lack or excess of drive produced in the mechanism. If “Fatal Error” occurs as a result, check the following:



Check that the gear (white) sticking out from the bottom the pump frame is properly set so that torque is transmitted to the root of the basic rack (See Chapter 2.) in the gear train at the right of the mechanism frame. Note that gears in the gear train must be engaged with each other at right phases, as listed below, and a wrong phase may stop the whole gear train mechanism at worst.

*Phase: Enables the gears with specified notches on them to

engage with each other so that they drive properly.

1. Between the paper load roller driving transmission gear and the double clutch gear

2. Between the double clutch gear and the paper return transmission gear (white)

3. Between the white and cream paper return transmission gears

4. Between the paper return transmission gear on the timing belt and the paper return transmission cam

5. Between the paper return transmission cam and the paper return drive roller

6. Between the cam gear in the friction release gear train, 2 transmission gears inside the frames, and the paper return driving cam gears (for both frames)



Check internal coil resistance for the solenoid.

− Specification: 115 Ω

− Check points: Between Pins 1 and 3 or Pins 2 and 4 for CN16 on

the C228DRV board (Between Pins 5 and 11 for CN8 for the option.)

If resistance is infinitive, replace the motor.

Table 3-15. Abnormal Phenomenon: LED Indicates “Maintenance Error”.

Remedy

One of the waste ink counters has passed the limit. Refer to Chapter 1 or Chapter 6 and clear the error.

WARNING

The printer is equipped with the following 3 different waste ink counters A, B and D, which can be found in the self-test. Be careful not to replace the corresponding waste ink pad only, since all the counters reset at a time when the “Maintenance Error” is reset.

Rev. A

Page 73

Stylus Pro5000 Chapter3 Troubleshooting

Table 3-16. Abnormal Phenomenon:

Color Gradation Differs Among the Printers

Step Remedy

1 If 2 or more Stylus Pro5000 are used in an office of by an

individual user, they may print the same data in different color gradations. Generally, sine the printer is equipped with the Auto Color Calibration, it only creates different color graduations at an unnoticeable level. However, if the PC does not support a Bi-directional parallel interface, it does not write the adjusted value stored in the C228DRV board into the driver. Therefore, it is required to register the adjusted value in the driver forcibly by following the steps below.

2 Connect the printer with the PC with the cable and turn them

on.

3 Select “Utility” and next “Printer and Option Information (P)”

from the menu.

4 The windows for ‘Printer ID” are ineffective. Select ‘Setting

Sheet” so that the printer prints the adjusted values stored in the EEPROM.

5 See the values output and input them to the 6 windows for

“Printer ID”.

Rev. A

CAUTION

Each of 2 printheads consists of 2 rows of head nozzles for each color, and ink ejected differs in weight from nozzle to nozzle. Therefore, Ink ejected from each nozzle is weighed in the manufacture and the data is stored in the driver as the Printer ID. As a result, the printer manages to equalize ink ejected from each nozzle in weight, referring to the IDs.

Page 74

ASSEMBLY AND DISASSEMBLY

&+$37(5



Page 75

Stylus Pro5000 Chapter4 Assembly and Disassembly

4.1 OVERVIEW

This section explains disassembly and assembly of the printer. Basically, the disassembled components can be re-assembled by reversing the disassembly procedure, but we explains procedure of assembling the gear trains for ASF control since it is complicated part. “Caution” and “Check Point” are mentioned for the procedures which requires extra attention. “Adjustment” is for required adjustments resulted by assembly or disassembly. Also, read the precautions below before disassembling and assembling in this chapter.

4.1.1 Precautions

The lithium battery, which is necessary for managing the ink system, is mounted on the main control board of this printer. Since mishandling the lithium battery may cause explosion at the worst case, read the warning and caution below carefully and start disassembly or assembly.

WARNING



Plug off and disconnect the power cable before disassembling or assembling the printer.



If ink gets in your eye, flush the eye with fresh water and see a doctor immediately.



A lithium battery is installed on the main board of this printer. Be sure to observe the following instructions.

1. Keep the battery away from any metal or other batteries so that electrodes of the 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)

WARNING

CAUTION

WARNING

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

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

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

Remove any accessories such as paper cassettes or tray before starting disassembly.

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

Rev.B

4-1

Page 76

Stylus Pro5000 Chapter4 Assembly and Disassembly

4.1.2 Tools

Use only specified tools to maintain quality of the printer.

Table 4-1. Required Tools

Name Supplier EPSON parts code

Phillips Screw Driver (No.1) EPSON B743800400 Phillips Screw Driver (No.2) EPSON B743800200 Minus Driver (−) Cutting pliers Commercially

Thickness gauge set EPSON B776702201 Tweezers EPSON B741000100 Exclusive pliers for C-ring for shaft ST-0 Exclusive pliers for C-ring for shaft ST-1 Paper pick up detector adjust tool Positioning pin Commercially

Torque Wrench EPSON B765106901

EPSON B74300100

−

available

EPSON 103983900 EPSON 103984000 EPSON 103983200

Use nail whose

available

diameter is φ1.8∼2.

4.2 DISASSEMBLY

This section describes disassembly procedure until mechanism and “MB Rear Unit” are removed. Refer to section 4.3 to disassemble more fine parts on the mechanism. Refer to flow chart below for items explained on section4.2.

Start

4.2.1 “Housin Removal

4.2.2 “Housin Removal

Upper”

Front“

4.2.4 “MB Rear Unit” Removal(C228 Main)

4.1.3 Screws

Following abbreviation for screws are used in the explanation for disassembly and assembly.

Table 4-2. Screw Abbreviation

Abbreviation Name

CBS Cross/Bind/S-tight screw CBP Cross/Bind/P-tight screw

CP Cross/Pan-head screw CB Cross/Binding Screw

Rev.B

4.2.3 “Mechanism Unit“ Removal

Figure 4-1. Flowchart of Disassembly

CAUTION



The MB rear unit, which C228 main board is mounted on, can be removed directly, without disassembling other parts in advance.



Refer to sections from Section 4.3 for disassembly and assembly which are not mentioned on the flow chart above.

Page 77

Stylus Pro5000 Chapter4 Assembly and Disassembly

4.2.1 Housing Upper Removal

1. Open the rear tray.

2. Remove the “Cover, printer”, releasing 2 hooks on the “Cover, printer”.

3. Remove 5 CBS screws(3x8) securing “Housing Upper” to the mechanism unit. The rest of one CBS screw(3x6) does not effect on removing “Housing Upper”.

4. Open “Paper Guide Assembly, Cover” united with rear tray completely and remove one CBS screw(2x6) located on the left side of AC cable.

2 Hooks

5 CBS Screws(3x8)

1 CBS(3x6) screw

Figure 4-3. Positions of fixing screws for Housing Upper(1)

Paper Guide Assembly, Cover

1 CBS screw(3x6 )

Rev.B

Rear Tray

Figure 4-2. Cover, Printer Removal

Figure 4-4. Position of fixing screw for Housing Upper(2)

Page 78

Stylus Pro5000 Chapter4 Assembly and Disassembly

5. Insert a minus driver to 3 airspace (A), located upper paper eject of “Housing Front Unit”, and remove hooks which are connecting “Housing Upper” and “Housing Front Unit”. (Refer to Figure 4-5)

6. Insert a minus driver to 2 airspace (B), located both right and left of the front printer and remove the hooks which are connecting “Housing Assembly Upper” and “Housing Lower”. (Refer to Figure 4-6)

7. Release one hook connecting with “Housing Lower” at the rear side of

“Housing Assembly, Upper”. (Refer to Figure4-7)

2 Hooks

WARNING

8. Remove “Housing Assembly Upper”, lifting it up.

If you try to remove “Housing Assembly, Upper” forcibly from the front direction, the rib located inside of “Housing Assembly, Upper” may be broken. So, be careful of removing it.

3 Hooks

Housing Front Unit

Housin

Figure 4-6. Position of Hooks(located both right and left side)

Upper

Housin

Front Unit

One hook on the "Housin

Assem bly,

Upper".

Rev.B

Figure 4-5. Location of Hooks

Figure 4-7. One hook at back of the printer

Page 79

Stylus Pro5000 Chapter4 Assembly and Disassembly

4.2.2 Housing Front Unit Removal

1. Remove “Housing Upper”.(See Section4.2.1)

2. Remove “Cable, Panel” connecting to “Board Assembly, Panel” from

connector on the board.

3. Remove 2 CBS screws(3x6) securing “Grounding plate, Panel” to

“Frame, Paper Eject”. (Refer to Figure4-8)

4. Release 2 hooks securing “Housing Front Unit” located front bottom side

of “Housing Lower”. (Refer to Figure4-9)

5. Remove “”Housing Front Unit”.

2 CBS screws(3x6)

"Cable, Panel"

"Groun din

"Housin

Front Unit"

Figure 4-8. Housing Front Unit Removal

Plate, Panel"

Rev.B

Hook under "Housin Lower"(located at both right and left side)

Figure 4-9. Discharge Brush Removal

Page 80

Stylus Pro5000 Chapter4 Assembly and Disassembly

4.2.3 Mechanism Unit Removal

"Frame, Main, Rear"

1. Remove “Housing Upper”. (See section 4.2.1)

2. Remove “Housing Front Unit”. (See section 4.2.2)

3. Looking from back side of printer, insert the plus screw driver into the

notch which is located at “Frame, Main, Rear” and remove 2 CBP screws(4x12) securing the mechanism to “Housing Lower”. (Refer to Figure4-10)

4. From the printer front, remove 2 CBP screws(4x12) securing the

mechanism to “Housing Lower”. (Notice that the fixing screw at the left side is also securing reinforcing frame.)

Notched parts to insert the driver

WARNING

CHECK POINT

5. Lift up the mechanism and remove it from “Housing Lower”.

When installing the mechanism to “Housing Lower”, it is recommended to do so by 2 service men. And connect 2 waste ink tubes of right and left head into each holes of waste ink absorber. Failing to do so causes ink leaking.

When installing the mechanism to “Housing Lower”, install them matching 2 dimples of “Housing Lower” to 2 notched parts on the mechanism frame, as it is shown in the figure 4-

11.

Figure 4-10. MB Rear Unit Removal (1)

Positioning Notches

Reinforcin

Frame

Rev.B

2 CBP screws(4x12)

Figure 4-11. Mechanism Removal (2)

Page 81

Stylus Pro5000 Chapter4 Assembly and Disassembly

4.2.4 MB Rear Unit Removal

CAUTION

$'-8670(17

1. Remove 2 fixing screws securing “MB Rear Unit” to “Frame, Main, PF” of

the mechanism unit.

2. Remove 2 CBS screws(3x12) securing “Cover, Connector, Upper”, and

remove “Cover, Connector, Upper”.

3. Remove 2 CBS screws(3x12) securing “Cover, Rear” and remove “Cover,

Rear”. (Refer to Figure4-12)

4. Insert the driver into 2 bail locks on the I/F connector and remove “MB

Rear Unit” toward back. (Refer to Figure4-13)



The MB rear unit, which C228 main board is mounted on, can be removed directly, without disassembling other parts in advance.



When installing this unit again, push in hard so that it can be firmly connected to the connector on the C228 DRV board.

EEPROM ,which various adjustment values are registered, is not mounted on C228 main board. In the flash memory of spare part C228 main board, the program is not registered. Therefore, refer to “Firmware uploading”(page 1-23) and perform reinstallation of the program.

Fixing screws

"Cover,Connector,Upper"

CBS (3x12)

CBS (3x8)

"Cover, Rear"

Figure 4-12. Cover, Rear Removal

MB Rear Unit

Rev.B

Bail Lock

MB Rear Unit

Figure 4-13. MB Rear Unit Removal

Page 82

Stylus Pro5000 Chapter4 Assembly and Disassembly

4.2.5 Disassembling the Mechanism

Here explains procedure to disassemble the removed mechanism to more fine pieces.

Start

4.4 Disassembly and Assembly for ASF Unit

4.3. Disassembly and Assembly for GearTrain

4.2.5.1 Discharge Brush Removal

4.2.5.5 Fan Assembly Removal

4.2.5.9 Motor Assembly, ASF Removal

4.2.5.13 Pump Frame Removal

4.41. Disassembly of ASF Unit

4.3.1. Disassembly of Gear Train

4.2.5.2 Paper Guide Assembly, Cover, Removal

4.2.5.6 PS Unit Removal

4.2.5.10 Carriage Unit Removal

4.2.5.14 Frame, Main, PF, Removal

4.4.2. Assembling ASF Unit

4.3.2. Assembling Gear Train

4.2.5.3 Print Head Removal

4.2.5.7 Motor Assembly, PF Removal

4.2.5.11 Frame, Main,Paper Eject, Removal

4.2.5.15 ASF Unit Removal

4.2.5.4 MB Front Unit Removal

4.2.5.8 Motor Assembly, CR, Removal

4.2.5.12 Paper Guide Upper Unit Removal

4.2.5.16 Upper Surface Sensor Removal

Rev.B

4.2. 5.17 PE Sensor Removal

4.2.5.21 Interlock Assembly Removal

Figure 4-14. F low Chat for Disassembling the Mechanism

4.2.5.18 PR Sensor Removal

4.2.5.19 HP Sensor Removal

4.2.5.20 Cable Assembly,Sensor FPC Removal

Page 83

Stylus Pro5000 Chapter4 Assembly and Disassembly

4.2.5.1 Discharge Brush Removal

1. Remove 3 CBS Sems W2 screws(3x8) securing “Discharge brush” to

“Frame, Main, Paper Eject” of the mechanism unit, and remove “Discharge Brush”.

CAUTION

It is necessary to remove the discharge brush when performing “Head Angular Adjustment” or “Head Height Adjustment”.

CBS Sems W2(3x4)

"Discharge Brush"

Rev.B

Figure 4-15. Discharge Brush Removal

Page 84

Stylus Pro5000 Chapter4 Assembly and Disassembly

4.2.5.2 Paper Guide Assembly, Cover Removal

1. Remove “Housing Upper”. (See section 4.2.1)

2. Remove “Housing Front Unit”. (See section 4.2.2)

3. Remove the mechanism. (See section 4.2.3)

4. Push hard “Paper Guide Assembly, Cover” toward right or left direction

releasing it from the protrusion at the side you pushed, and remove “Paper Guide Assembly, Cover” from the mechanism. (Refer to Figure4-16)

CAUTION

When removing “Paper Guide Assembly, Cover”, do not lose a plain washer and “U” shaped spring washer; a plain washer and “U” shaped spring washer come off from right side.

CHECK POINT

Paper G uide Assem bly, C over

Since the “U” shaped spring washer has a determined direction to be installed, install the washer so that concave side of the spring washer faces to the “Assembly Cover” side. (See figure 4-

17)

Fram e A ssem bly, M iddle, Left

Rev.B

Plain was her

"U" shaped sprin (leaf sprin

"Paper Guide Assembly, Cover"

Figure 4-16. Paper Guide Assembly, Cover Removal

"U "shaped S pring W ahser

Plain W asher

Figure 4-17. Installation of Spring Washer

washer

)

4-1

Page 85

Stylus Pro5000 Chapter4 Assembly and Disassembly

4.2.5.3 Print Head Removal

WARNING

1. Remove “Mechanism Unit”. (Refer to section 4.2.7)

2. In case of replacing the head, if the carriage is fixed at the home

position, that makes difficult to replace the head. Therefore, it is necessary to rotate the paper feed roller driven gear(Gear,80), holding 2 protrusions on the gear surface and release the carriage lock. (Refer to Figure4-18)

WARNING

This printer uses left head for dark colors and right head for light colors, and each head has different parts code. Therefore, in case of exchanging right and left heads at the same time, make sure to follow the points below. Failing to do so gives bad influence on the printing quality.



It is prohibited to use the left head(for dark colors) as right head(for light colors).



It is allowed to use the right head as left head.



In case of replacing both right and left heads, make sure to install each head at proper position.

Do not touch the teeth part of “Gear,80” by your fingers. Since it is a high precision gear, touching the gear with bare hands gives bad influence on paper feeding and printing quality.

Gear,80

Protrusions

Figure 4-18. Releasing Carriage Lock

CBP(3x8)

Fixin

Hooks

Position of carriage lock

3. Release the “Cable, head, left/right” for head control located on the

carriage from the hook.

4. Move the carriage unit to the center of the mechanism, and remove one

CBP screw(3x8) securing “Cover, CR, Rear” over the carriage, and remove “Cover, CR, Rear”. (Refer to Figure4-19)

Rev.B

Cable, Head, Right

Figure 4-19. Cover, Carriage, Rear, Removal

Cable, Head, Left

4-11

Page 86

Stylus Pro5000 Chapter4 Assembly and Disassembly

5. Release each 2 fixing parts of “Cover, CR, Front” located rear and front,

and release “Cover, CR, Front”. (Refer to Figure4-20)

6. Pull out each 6 dampers from the head needle.

CAUTION

WARNING

7. Remove each one CBB screw(2.5x6) securing left and right head to the

carriage and plain washer(3.4x1.0x8.2x2).

8. Remove “Compression Spring,9.9” pressing left and right head to the

carriage side. (Refer to Figure4-21)

CHECK POINT

Total 6 dampers are fixed in the order(from left); Bk→→Cyan→→Magenta→→Light Cyan→→Light Magenta

→→Yellow.

Since the print head is not strong against static electricity, wear rubber glove.

Even after releasing the fixing part of head, if the head can not be removed easily, pull the parts marked with arrow in the figure 4-21 so that the head can be removed easily.

"Cover, CR, Front"

"Compression Spring,9.9"

Hooks(each at both right and left sides)

Fixin

Figure 4-20. Releasing "Cover, CR, Front"

Rev.B

Screw with plain washer for fixin left head.

Figure 4-21. Print Head Removal(1)

Screw with plain washer for fixin right head.

4-1

Page 87

Stylus Pro5000 Chapter4 Assembly and Disassembly

9. Remove FFC inserted in each right and left head, and remove the print

head. (Refer to Figure4-22)

4.2.5.4 MB Front Unit Removal

CHECK POINT

$'-8670(17

"O" is marked onl y on the FFC for lleft head



When replacing heads to new ones, connect FFC correctly. Only the FFC which should be installed for left head is marked with “O”.

After replacing the print head, refer to Table5-1 of Chapter5, and perform necessary adjustment items according to the procedure order.

Left Head (for dark colors)

Ri (for li

ht Head

ht colors)

1. Remove the mechanism unit.(Refer to section 4.2.7)

2. Remove one CBS screw(3x6) securing “Grounding plate, DB2” to “Shield plate, M/B, Front”.

3. Remove one CBS screw(3x6) securing “Grounding plate, DB2” to “Frame Assembly, Left”.

4. Remove “Grounding plate, DB2”. (Refer to Figure4-23)

"Frame Assembly, Left"

2 CBS screws(3x6)

"Grounding P late, DB2"

Rev.B

"Shield Plate, M/B, Front"

4-1

Figure 4-22. Print Head Removal(2)

Figure 4-23. Grounding Plate, DB2 Removal

Page 88

Stylus Pro5000 Chapter4 Assembly and Disassembly

5. Disconnect all connectors on C228 DRV board.

CHECK POINT

Following shows connectors on C228 DRV board, which is necessary for installing MB front unit

CHECK POINT

As it is shown in the figure4-23, the FFC to install

again. to connector CN10 is marked with “O” on the cable surface.(FFC for left head)

$'-8670(17

After replacing C228 DRV board, refer to Table5-1

of Chapter5, and perform necessary adjustment

WARNING

Since the same connectors are used for CN14,

items according to its procedure order. CN15 and CN16, the mechanism might get damaged by wrong connector insertion. Since 1pin of each cable corresponding to these 3 connectors are marked red, black, and blue respectively, check red, black and blue printed on the connector location and install them correctly.

6. Looking from the printer front, remove 2 CBS screws(3x6) securing “MB Front Unit” to “Frame Assembly, Left”, and remove “MB Front Unit”. (Refer to Figure below)

CBS (3x6)

"MB Front Unit"(Front side)

Figure 4-24. MB Front Unit Removal

"MB Front Unit"(Rear side)

Connector

No.

CN1 Black MB rear unit(C228 Main:Only when CN2 White Board Assembly, P/S

CN3 White Fan Assembly CN4 Black Harness, sensor, P CN5 White Harness, sensor, HP CN6 White Mounting board, connector(Standard paper

CN7 White Harness sensor, PE(cable for PE/PR CN8 Black Harness, option connector, B(for optional CN9 White Harness, option, connector

CN10 White Cable, Head, Right(for dark colors) CN11 White Cable, Head, Left(for light colors) CN12 Black Cable, Sensor FFC(for both PTS, paper

CN13 Black Cable, Panel (control panel) CN14 White Motor Assembly, CR CN15 White Motor Assembly, PF

Table 4-3. Connectors on C228 DRV Board

Connector

Color

Name of Harness / Destination of

Connection

removing MB rear unit)

type/size sensor) sensor) motor, solenoid, P sensor) sensor(Optional paper type/size)

width sensor)

Rev.B

4-1

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Stylus Pro5000 Chapter4 Assembly and Disassembly

Table 4-4. Connectors on the C228 DRV Board(Cont.)

Connector

No.

CN16 White Motor Assembly, ASF CN17 Yellow Solenoid, ASF(standard side) CN18 Yellow Harness, Upper Surface Sensor(standard

CN19 Black Left quantity sensor(paper level sensor at CN20 Red Holder Assembly, Ink cartridge, M

CN21 Blue Holder Assembly, Ink cartridge, C CN22 Yellow Holder Assembly, Ink cartridge, Y CN23 Black Holder Assembly, Ink cartridge, BK CN24 White Case, Open sensor(CR/Pump for rear

Connector

Color

Name of Harness / Destination of

Connection

paper surface sensor) standard side)

manual feed, Turn on or off ASF motor)

4.2.5.5 Fan Assembly Removal

CAUTION

1. Remove the mechanism unit.(Refer to section 4.2.7)

2. Remove connector CN3 on the “Board assembly, Driver, C228 DRV”.

3. Release a harness of “Fan Assembly” from locking wire saddle”(Lead wire cramp).

4. Remove 3 CBS screws(3x30) securing “Fan assembly” to “Shield Plate, P/S, Cover” of PS unit, and remove “Fan Assembly”. (Refer to Figure below)

It is necessary to remove the fan assembly before removing PS unit(Power supply unit).

PS unit

CBS (3x30)

Rev.B

Fan Assembly

Figure 4-25. Fan Assembly Removal

4-1

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Stylus Pro5000 Chapter4 Assembly and Disassembly

4.2.5.6 PS Unit Removal

1. Remove “Fan assembly” (Refer to section 4.2.8.3)

2. Remove “AC cable” from connector CN1 of “Board Assembly, P/S”.

Note)

Remove AC cable, pressing the hook located under the

connector.

3. Remove connector CN2(white) on the “MB Front Unit”

4. Remove 2 CBS screws(3x6) securing “PS Unit” to “Frame, Main, Rear”. (Refer to Figure below)

5. Remove 2 CBS screws(3x6) securing “PS Unit” to “Frame, Main, PF”, and remove “PS Unit”. (Refer to Figure below)

CBS(3x6)

CN1

4.2.5.7 Motor Assembly, PF Removal

1. Remove the mechanism unit.(Refer to section 4.2.7)

2. Remove MB Front Unit. (Refer to section 4.2.8.2)

3. Remove PS Unit. (Refer to section 4.2.8.4)

4. Remove the harness of “Motor Assembly, PF” from the connector (CN15, white) of “MB Front Unit” and also remove it from “Locking Wire Saddle” on the “Frame, Main, PF”.

5. Remove 2 CBS screws(3x6) securing “Mounting board, Motor, PF” to “Frame, Left”, and remove “Motor Assembly, PF” with “Mounting Board, Motor, PF”. (Refer to Figure below)

CBS (3x6)

"Gear,80"

"Combination Gear, 9,6,36"

Rev.B

Figure 4-26. PS Unit Removal

WARNING

Lockig Wire Saddle

Figure 4-27. Motor Assembly, PF Removal

When you try to touch the tip of the drive to 2 fixing screws for “Motor Assembly, PF”, be careful not to let the tip or shank of the driver to touch the gear teeth of “Gear,80” or “Combination gear,9,6,36”. Since these gears are high precision gears, small impact can damage them.

Pinion for PF motor

4-1

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Stylus Pro5000 Chapter4 Assembly and Disassembly

4.2.5.8 Motor Assembly, CR Removal

1. Remove the PS Unit. (Refer to section 4.2.5.6)

2. Remove the timing belt hanging on the pinion of “Motor Assembly, CR”. (Refer to Figure4-28)

3. Remove 4 CBS screws(3x6) securing “Mounting board, CR” to “Frame, Main, Rear”, and remove “Motor Assembly, CR” with “Mounting board, Motor, CR”. (Refer to Figure4-29)

$'-8670(17

In case of replacing “Motor Assembly, CR”, refer to Chapter5 and perform “Bi-D Adjustment”.

Timing Belt

Figure 4-28. Timing Belt Removal

Pinion

"Motor Assembly, CR"

Rev.B

CBS (3x6)

Figure 4-29. Motor Assembly, CR Removal

4-1

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Stylus Pro5000 Chapter4 Assembly and Disassembly

4.2.5.9 Motor Assembly, ASF Removal

1. Remove PS unit. (Refer to section 4.2.5.6)

2. Remove a harness of “Motor Assembly, ASF” from the connector(CN16, white) of “MB Front Unit”, and remove it from locking wire saddles located at 3 locations(around PS unit was installed) on the “Frame, Main, PF”.

3. Remove a harness of “Motor Assembly, ASF” from lead cramp on the “Paper Guide, Upper”.

4. Remove one CBS screw(3x6) securing pump unit and “Frame Assembly, DE, Left”. (Refer to Figure4-30)

5. Remove 2 CBS screws(3x6) securing “Mounting board assembly, Cap” and “Frame Assembly, DE, Left”, and remove “Mounting board assembly, Cap”. (Refer to Figure4-30)

6. Remove 3 “Axis, damper, CR”s securing “Motor Assembly, ASF” to “Frame Assembly, Pump, ” by inserting the driver to notched part on the mechanism frame, and remove “Motor Assembly, ASF” with “Mounting board, Motor, ASF” from the frame rear side. (Refer to Figure4-31)

CAUTION

Washers are attached to each “Axis, damper, CR”. Be careful not to lose them.

"Frame Assembly,

3 CBS scr ews(3x 6)

"Mounting Board Assembly, Cap"

Figure 4-30. Mounting Board Assembly, Cap Removal

DE, Left"

"Motor Assembly, ASF"

"Frame, Assembly, DE, Left" "Axis, damper, ASF"

Figure 4-31. Motor Assembly, ASF Removal

Rev. B 4-1

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Stylus Pro5000 Chapter4 Assembly and Disassembly

4.2.5.10 Carriage Unit Removal

1. Remove print head. (Refer to section 4.2.5.3)

2. Remove “Motor Assembly, CR”. (Refer to section 4.2.5.8)

3. Remove “C” shaped ring securing “Gear,80” by a pair of tweezers or stop ring pliers. (Refer to Figure4-32)

4. Remove “Gear,80”.

"Gear,80"

WARNING

5. Remove “E” shaped ring (#6) pressing “Combination gear, 36,36”, and remove “Combination gear, 36,36”.

6. Remove one CBS screw(3x8) pressing “Bush, Parallelism, Adjustment” and remove “Bush, Parallelism, Adjustment”. (Refer to Figure4-33)

CHECK POINT

CAUTION

Never use “Gear,80”,which is once removed, again. Failing to do so can not guarantee normal paper feeding. Also, when installing a new “Gear,80”, attach it by pushing its surface and do not touch the gear teeth.

There is alignment between “Combination Gear, 36,36” and “Gear,49”. When assembling them, install them to each axis, matching “O” marked on the both gear surface(red circle in the figure4-33).

When removing “Bush, Parallelism, Adjustment”, “Reinforcing board, Axis, CR” attached behind of “Bush, Parallelism, Adjustment” can easily come off. Be careful not to lose this board. (Refer to Figure4-34)

"C" shaped ring

CBS(3x6)

Stop ring Pliers

Figure 4-32. Releasing Gear

"E" shaped ring

"Gear,49"

"Combination Gear,36,36"

"Bush, Parallelism, Adjustment"

Figure 4-33. Releasing Carriage Guide Axis at left side

Rev. B 4-1

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Stylus Pro5000 Chapter4 Assembly and Disassembly

7. Remove “E” shaped ring(#6) and one CBS screw(3x8) securing “Bush, Parallelism, Adjustment” at the right side of mechanism, and remove “Bush, Parallelism, Adjustment”.

CAUTION

8. Remove “Axis, CR” from the notched part for “Bush, Parallelism, Adjustment”, which is removed at Step7. At this time, do not lose one leaf spring and a plane washer.

CHECK POINT

When installing “Axis, CR” again, install leaf spring(8.2x0.15x15) first, then install plane washer(8.2x0.15x15). When installing the leaf spring, convex side should face inside.

$'-8670(17

After removing “Axis, CR”, make sure to perform “Platen Gap Adjustment”, referring to Chaper5.

"Bush, Parallelism, Adjustment" "E" shaped ring(#6)

CBS(3x8)

Figure 4-35. Removal of “Bush, Parallelism, Adjustment” at right side

"Bush, Parallelism, Adjustment"

(8.2x0.15x15)

Plain Washer (8.2x0.15x15)

Leaf Spring

"Reinforcin

Figure 4-34. Back of “Bush, Parallelism, Adjustment”

board, Axis, CR"

Figure 4-36. Axis, CR Removal

Rev. B 4-2

"Axis, CR"

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Stylus Pro5000 Chapter4 Assembly and Disassembly

9. Remove “Tension spring,28.76” located back of the belt pulley unit at the left side of the mechanism, and release the timing belt.

10. Remove “Timing belt” from the pulley unit, and remove “Tension spring,2.44” for linear scale from the frame. (Refer to Figure4-37)

11. Remove the connector for paper width sensor on the carriage unit.

12. Release engagement between the carriage unit and timing belt.

CHECK POINT

When installing “Timing belt” to the carriage unit again, match the inside surface of the belt, which has no ditches, to “A” part in the figure 4-38.

Belt Pulle

"Tension Spring, 28.76"

"Tension Spring,

2.44"

"Frame, Main, Rear"

Figure 4-37. Tension spring, Timing Belt and Linear Scale Removal

"Timin

"Linear Scale"

Belt"

Connector for paper width sensor

No ditches

"A" part

"Timing Belt"

Figure 4-38. Carriage Unit Removal

Rev. B 4-21

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Stylus Pro5000 Chapter4 Assembly and Disassembly

4.2.5.11 Frame, Main, Paper Eject Removal

1. Remove print head. (See section4.2.5.3)

2. Remove each 2 CBS screws(3x30) securing “Holder, Fixing, Tube, B”, and remove “Holder, Fixing, Tube, B” from the mechanism. (Refer to Figure4-39)

CHECK POINT

3. Perform prevention for ink leakage to 6 dampers, which are removed from print head.

WARNING

“Holder, Fixing, Tube, B” located both right and left sides are exclusive ones. Therefore, before reinstalling them, check “L”(for left) and “R”(for right) written on the surface of “Holder, Fixing, Tube, B” and install them correctly.

Removing “Tube, Locking Screw” in the condition that the print head is removed has a risk of ink leakage from damper side. This may make clothing or mechanism dirty. In order to prevent this, have a container in advance, which can absorb ink leakage from the damper, and put the damper in it. (See Figure4-40)

"Holder,Fixin

CBS(3x30)

Figure 4-39. “Holder, Fixing, Tube, B” Removal

,Tube, B"

CBS(3x30)

Figure 4-40. Preventing Ink Leakage

Rev. B 4-2

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Stylus Pro5000 Chapter4 Assembly and Disassembly

4. Remove only 6, which are located inside, out of 12 “Tube, Locking Screw”s securing 6 ink tubes respectively, and remove ink tubes. (Refer to Figure4-41)

"Tube, Locking Screw"

CBS(3x6)

"Tube, Lockin

Screw"

WARNING

After removing each ink tube from “Relay, Tube”, handle it so that the tip of the tune does not face down but face up. Otherwise, ink charged in the tube may leak out.

4. Remove 2 CBS screws(3x6) securing “Reinforcing board, Fixing, FFC” to the mechanism, and remove ink tubes for each color with dampers.

5. From left side of the printer mechanism, remove “E” shaped ring securing “Combination gear,36.36.67”, and remove “Combination gear, 36.36.67”. (Refer to Figure4-42)

CHECK POINT

There is alignment between “Combination Gear, 36,36.67” and “Gear,49”. When assembling them, install them to each axis, matching “O” marked on the both gear surface(red circle in the figure4-42).

"Relay, Tube"

"Reinforcin

Figure 4-41. “Tube, Locking Screw” Removal

, Fixing, FFC"

Gear,49

"Relay, Tube"

"E" shaped ring(#6)

Combination Gear,36. 36.67

Figure 4-42. “Combination Gear,36.36.67”

Rev. B 4-2

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Stylus Pro5000 Chapter4 Assembly and Disassembly

7. From right side of the printer mechanism, remove one “E” shaped ring securing “Axis, CR, Support”.

8. Rotate a bush for fixing an axis(shaft) toward right direction and remove the bush. (Refer to Figure4-43)

9. Remove “Axis, CR, Support” from the mechanism.

"E" shaped rin

CHECK POINT

When re-installing “Axis, CR”, set a leaf spring(8.2x0.15x15) to the axis first, then, install a plain washer(8.2x0.15x15). Also, when installing a leaf spring, convex side should face to inside. (Refer to Figure4-44)

Fixing bush for "Axis, CR, Support"

Figure 4-43. Removing a fixing bush for Axis, CR Support

Plain Washer (8.2x0.15x15)

"Axis, CR, Support"

Leaf Spring(8.2x0.15x15)

Figure 4-44. Axis, CR, Support Removal

Rev. B 4-2

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Stylus Pro5000 Chapter4 Assembly and Disassembly

10. Release various harness from 3 “Mini-cramp(small cramp)”s located at the front side of “Frame, Main, Paper Eject”. (Refer to Figure4-45)

11. Remove one CBS screw(3x6) securing “Tank, Absorber”, and remove “Tank, Absorber”.

12. Remove 8 CBS screws(3x6) securing “Frame, Main, Paper Eject”, and remove “Frame, Main, Paper Eject”. (Refer to Figure4-46)

"Mini Cram p"

Figure 4-45. Releasing Harness at the front side of “Frame, Main, Paper

Eject”

"Tank, Absorber"

CBS(3x6)

"Frame, Main, Paper Eject"

CBS(3x6)

Figure 4-46.”Frame, Main Paper Eject” Removal

Rev. B 4-2

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Stylus Pro5000 Chapter4 Assembly and Disassembly

4.2.5.12 Paper Guide Upper Unit Removal

Tension Spring, 11.7

1. Remove carriage unit.(See section 4.2.5.10)

2. Remove a connector of carriage home position sensor from CN5(white,3pin) located on the “MB Front Unit”.

3. Remove a connector of PE sensor including PR sensor from CN7(white, 5-pin) located on the “MB Front Unit”.

4. Remove “Tank, Absorber”. (See section 4.2.5.11)

5. Remove “Tension spring,11.7” which is pulling “Lever, PF roller, Pressing”. (Refer to Figure4-47)

6. Remove 8 CBS screws(3x6) and 4 CBP screws(3x8) securing “Paper Guide Upper Unit” to the mechanism, and remove “Paper Guide Upper Unit”. (Refer to Figure4-48)

CHECK POINT

When re-installing “Paper Guide Upper Unit”, assemble it so that the slider to disengage the motive power to the pump system is inserted correctly to the notched parts on the unit. (See Figure4-48)

"Lever, PF Roller, Pressing"

Figure 4-47.”Tension Spring,11.7” Removal

Notched part and Slide r position

CBS(3x6)

Figure 4-48. Paper Guide Upper Unit Removal

CBP(3x8)

CBS(3x6)

Rev. B 4-2