Epson WP 4590, WP 4540, WP 4530, WP 4520, WP 4510 Service Manual

...

SERVICE MANUAL

Color Inkjet Printer

Epson WP-4590 series/ Epson WP-4540 series Epson WP-4530 series/ Epson WP-4520 series Epson WP-4510 series/ Epson WP-4090 series Epson WP-4020 series/ Epson WP-4010 series

CONFIDENTIAL

SEMF11-002

Notice:

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

 All effort have been made to ensure the accuracy of the contents of this manual. However, should any errors be

detected, SEIKO EPSON would greatly appreciate being informed of them.

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

Note :Other product names used herein are for identification purpose only and may be trademarks or r egistered

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

Printer CS Quality Assurance Department

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Safety Precautions

All safety procedures described here shall be strictly adhered to by all parties servicing and maintaining this product.

DANGER

Strictly observe the following cautions. Failure to comply could result in serious bodily injury or loss of life.

1. Always disconnect the product from the power source and peripheral devices when servicing the product or performing maintenance.

2. When performing works described in this manual, do not connect to a power source until instructed to do so. Connecting to a power source causes high voltage in the power supply unit and some electronic components even if the product power switch is off. If you need to perform the work with the power cable connected to a power source, use extreme caution to avoid electrical shock.

WARNING

Strictly observe the following cautions. Failure to comply may lead to personal injury or loss of life.

1. Always wear protective goggles for disassembly and reassembly to protect your eyes from ink in working. If any ink gets in your eyes, wash your eyes with clean water and consult a doctor immediately.

2. When using compressed air products; such as air duster, fo r cleaning during repair and maintenance, the use of such products containing flammable gas is prohibited.

PRECAUTIONS

Strictly observe the following cautions. Failure to comply may lead to personal injury or damage of the product.

1. Repairs on Epson product should be performed only by an Epson certified repair technician.

2. No work should be performed on this product by persons unfamiliar with basic safety knowledge required for electrician.

3. The power rating of this product is indicated on the serial number/rating plate. Never connect this product to the power source whose voltages is different from the rated voltage.

4. Replace malfunctioning components only with those components provided or approved by Epson; introduction of second-source ICs or other non-approved components may damage the product and void any applicable Epson warranty.

5. The capacitors on the Main Board may be electrically charge right after the power turns off or after driving motors which generates counter electromotive force such as when rotating the PF Roller or when moving the CR Unit. There is a risk to damage the Main Board if the Head FFC is short-circuited with the capacitors on the Main Board electrically charged, therefore, after the power turns off or after motors are driven, leave the printer untouched for approximately 30 seconds to discharge the capacitors before starting disassembly/ reassembly.

6. To prevent the circuit boards from short-circuiting, be careful about the following when handing FFC or cables.

When handling FFC, take care not to let the terminal section of FFC touch metal parts.

  When connecting cables/FFC to the connectors on circuit board, connect them straight to the connectors to avoid

slant insertion.

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7. In order to protect sensitive microprocessors and circuitry, use static discharge equipment, such as anti-static wrist straps, when accessing internal components.

8. Do not tilt this product immediately after initial ink charge, especially after performing the ink charge several times. Doing so may cause ink to leak from the product because it may take some time for the waste ink pads to completely absorb ink wasted due to the ink charge.

9. Never touch the ink or wasted ink with bare hands. If ink comes into contact with your skin, wash it off with soap and water immediately. If you have a skin irritation, consult a doctor immediately.

10. When disassembling or assembling this product, make sure to wear gloves to avoid injuries from metal parts with sharp edges.

11. Use only recommended tools for disassembling, assembling or adjusting the printer.

12. Observe the specified torque when tightening screws.

13. Be extremely careful not to scratch or contaminate the following parts.

Nozzle plate of the printhead

  CR Scale  PF Scale  ASF Scale  Coated surface of the PF Roller  Gears  Rollers  LCD  Scanner Sensor  Exterior parts

14. Never use oil or grease other than those specified in this manual. Use of different types of oil or grease may damage the component or give bad influence on the printer function.

15. Apply the specified amount of grease described in this manua l .

16. Make the specified adjustments when you disassemble the printer.

17. When cleaning this product, follow the procedure described in this manual.

18. When transporting this product after filling the ink in the printhead, pack the printer without removing the ink cartridges in order to prevent the printhead from drying out.

19. Make sure to install antivirus software in the computers used for the service support activities.

20. Keep the virus pattern file of antivirus software up-to-date.

21. When disassembling/reassembling this product, if you find adhesive power of the double-sided tape which secure the parts or FFC is not enough, replace the tape with new one and attach it correctly to the specified points where the parts or FFC should be secured.

22. Unless otherwise specified in this manual, the labels attached on the returned product should be transferred to the corresponding attachment positions on the new one referring to the labels on the returned product.

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About This Manual

This manual, consists of the following chapters, is intended for repair service personnel and includes information necessary for properly performing maintenance and servicing the product.

CHAPTER 1. PRODUCT DESCRIPTIONS

Provides a general overview and specifications of the product.

CHAPTER 2. OPERATING PRINCIPLES

Describes the theory of mechanical operations of the product.

CHAPTER 3. TROUBLESHOOTING

Describes the step-by-step procedures for the troubleshooting.

CHAPTER 4. DISASSEMBLY / REASSEMBLY

Describes the disassembly/reassembly procedures for main parts/units of the product.

CHAPTER 5. ADJUSTMENT

Describes the required adjustments for servicing the product.

CHAPTER 6. MAINTENANCE

Describes maintenance items and procedures for servicing the product.

Symbols Used in this Manual

Various symbols are used throughout this manual either to provide additional information on a specific topic or to warn of possible danger present during a procedure or an action. Pay attention to all symbols when they are used, and always read explanation thoroughly and follow the instructions.

Indicates an operating or maintenance procedure, practice or condition that, if not strictly observed, could result in serious injury or loss of life.

Indicates an operating or maintenance procedure, practice, or condition that, if not strictly observed, could result in bodily injury, damage or malfunction of equipment.

May indicate an operating or maintenance procedure, practice or condition that is necessary to accomplish a task efficiently. It may also provide additional information that is related to a specific subject, or comment on the results achieved through a previous action.

For Chapter 4 “Disassembly/Reassembly”, symbols other than indicated above are used to show additional information for disassembly/reassembly. For the details on those symbols, see "4.2 Disassembly/Reassembly

Procedures (p58)".

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Revision Status

Revision Date of Issue Description

A June 17, 2011 First Release B March 12, 2013 Revised Contents

 All Chapter

 Description about WP-4590/WP-4090 has been added.

 Chapter 1

 Description about WP-4590/WP-4090 has been added in " Differences between the

Models (p10)".

 Description about WP-4590/WP-4090 has been added in " Dimensions (p11)".

 Chapter 3

 Description about WP-4590/WP-4090 has been added in " Error Message List (p41)".

 Chapter 4

 Part code has been added in " Jigs (p57)".  Description about WP-4590/WP-4090 has been added in " Parts/Units whose

Configuration is Different between Models (p60)".

 Made change for description in " Ink Supply Unit (p72)".  Description about " PCL Sub Board (p65)"has been added in Disassembly Flowchart.  Added Description of " PCL Sub Board( WP-4590/4090 series ) (p71)".  Description about WP4590/WP-4090 has been added in " Connector Diagram (p81)".

 Chapter 5

 Part code has been added in " Ink Leak Check (p101)".

C November 7, 2013 Revised Contents

 Chapter 5

 Made change for description in "5.2.1 PF Timing Belt Tension Check (p88)".  Made change for description in "5.2.2 Rear ASF Timing Belt Tension Check (p89)".

D April 9 , 2014 Revised Contents

 Chapter 5

 Made change for description in "5.2.2 Rear ASF Timing Belt Tension Check (p89)".  Made change for description in "5.2.7 Ink Leak Check (p101)".

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Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D

Contents

Chapter 1 Product description

1.1 Features ................................................................................................................................................................... 10

1.2 Printing Specifications ............................................................................................................................................ 12

1.2.1 Basic Specifications........................................................................................................................................ 12

1.3 Scanner Specifications (WP-4590/4540/4530/4520/4510 series only)................................................................... 13

1.3.1 Basic Specifications........................................................................................................................................ 13

1.4 Control Panel........................................................................................................................................................... 14

1.4.1 O peration Buttons & LEDs ............................................................................................................................ 14

1.4.2 LEDs and LCD Indications ............................................................................................................................ 17

1.5 Various Settings ............................................................................................................ .......................................... 22

1.5.1 Panel Operation .............................................................................................................................................. 22

1.5.1.1 Setup Menu Configuration (WP-4590/4540/4530/4520/4510 series only)........................................... 22

1.5.1.2 Panel Operation Lock Setting (WP-4590/4540/4530/4520/4510 series only) ...................................... 23

1.5.1.3 Forced Power OFF................................................................................................................................. 24

1.5.1.4 Printer Status Sheet................................................................................................................................ 24

Chapter 2 Operating Principles

2.1 O verview ................................................................................................................................................................. 26

2.2 Printhead.................................................................................................................................................................. 26

2.3 Motors and Sensors ................................................................................................................................................ 27

2.4 Optical Sensor Control........................... ......................................................................... ........................................ 30

2.5 Ink Supply Mechanism............................................................................................................................................ 31

2.6 Ink System Mechanism ........................................................................................................................................... 32

2.7 Power-On Sequence ................................................................................................................................................ 33

Chapter 3 Troubleshooting

3.1 Troubleshooting....................................................................................................................................................... 41

3.1.1 Error Message List....................................... ................................................................................................... 41

3.1.2 Troubleshooting Workflow ............................................................................................................................ 44

3.1.3 Fatal Error Code ............................................................................................................................................. 46

3.1.4 FAX Troubleshooting (WP-4590/4540/4530/4520 seri es only) .................................................................... 49

3.1.4.1 FAX Log ................................................................................................................................................ 49

3.1.4.2 Error Code/Superficial Phenomenon-Based Troubleshooting .............................................................. 54

Chapter 4 Disassembly/Reassembly

4.1 O verview ................................................................................................................................................................. 57

4.1.1 Tools ............................................................................................................................................................... 57

4.1.2 Jigs .................................................................................................................................................................. 57

4.2 D isassembly/Reassembly Procedures ..................................................................................................................... 58

4.2.1 Caution when Replacing the Printhead/Ink Supply Unit................................................................................ 58

4.2.2 Parts/Units Need to be Removed in Advance ................................................................................................ 59

4.2.3 Disassembly Flowchart................................................................................................................................... 60

4.2.3.1 Parts/Units whose Configuration is Different between Models in the Flowchart ................................. 60

4.2.3.2 Exterior Parts ......................................................................................................................................... 62

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4.2.3.3 Printer Mechanism.................................... ..................................... ........................................................ 64

4.2.3.4 Printhead/Ink Supply Unit ..................................................................................................................... 66

4.2.3.5 2nd Cassette Unit ................................................................................................................................... 67

4.3 Detailed Disassembly/Reassembly Procedure for each Part/Unit........................................................................... 68

4.4 Routing FFCs/cables ............................................................................................................................................... 77

4.5 Connector ................................................................................................................................................................ 81

Chapter 5 Adjustment

5.1 Required Adjustments ............................................................................................................................................. 83

5.2 D etails of Adjustments ............................................................................................................................................ 88

5.2.1 PF Timing Belt Tension Check ...................................................................................................................... 88

5.2.2 Rear ASF Timing Belt Tension Check........................................................................................................... 89

5.2.3 PG Adjustment ............................................................................................................................................... 90

5.2.4 Checking the Platen Gap ................................................................................................................................ 96

5.2.5 MAC Address Setting............................................................................... ...................................................... 97

5.2.6 Touch Panel Adjustment (WP-4540 series only) ........................................................................................... 98

5.2.7 Ink Leak Check........................................................................................................................ ..................... 101

Chapter 6 Maintenance

6.1 O verview ................................................................................................................................................... ............ 105

6.1.1 Cleaning........................................................................................................................................................ 105

6.1.2 Lubrication.................................................................................................................................................... 105

6.2 Lubrication Points and Instructions......................................................................................... .............................. 106

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CHAPTER 1

PRODUCT DESCRIPTION

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Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D

1.1 Features

In this manual, the product name is abbreviated to such as “WP-4510 series”, however, the last digit of the actual name may differ. Identify your product with the first three digits and refer to the appropriate sections in this manual.

WP-4590/4540/4530/4520/4510/4090/4020/4010 series are color inkjet printers that achieve high quality and high speed printing with a new printer mechanism. The main features are as follows.

 Common futures

 Printer

• Maximum print speed: 16 ppm (A4, monochrome, draft printing mode)

• F7-Mach Turbo 2 Printhead (Black: 152 nozzles x 4, Color: 152 nozzles x 1 per color)

• Maximum print resolution: 4800 x 1200 dpi

• Duplex printing available using the Duplex Unit that can be removed/installed by users

• Equipped with a panel operation lock function that improves security

• Auto switching for paper trays

The paper tray to use is automatically selected from the 1st cassette, 2nd cassette* or the Rear MP Tray (rear ASF) depending on the paper size

• Four newly developed independent ink cartridges are installed (pigment inks)

• Borderless printing is not available

 Consumables

• Maintenance box (the user can replace the waste ink pad when maintenance error occurs)

Note"*": When the optional 2nd cassette is installed for WP-4590/4530/4520/4510/4090/4020/4010 series.

 Differences between the models

WP-4590/4540/4530/4520/4510/4090/4020/4010 series are different as shown below.

Table 1-1. Differences between the Models

Item

LCD display size 2.5 inch 3.5 inch 2.5 inch 2.5 inch 2.5 inch --- --- --Panel operation Button Touch panel Button Button Button Button Button Button Scanner Yes Yes Yes Yes Yes --- --- --ADF Yes Yes Yes Yes --- --- --- --Copy Yes Yes Yes Yes Yes --- --- --USB host Yes Yes Yes Yes Yes --- --- --FAX Yes Yes Yes Yes --- --- --- --Wi-Fi --- Yes Yes --- --- --- Yes --PCL Yes --- --- --- --- Yes --- --2nd cassette Option Yes Option Option Option Option Option Option

WP-4590

series

WP-4540

series

WP-4530

series

WP-4520

series

WP-4510

series

WP-4090

series

WP-4020

series

WP-4010

series

Product description Features 10

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Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D

WP-4540 series

WP-4590 series/WP-4530 series/WP-4520 series

WP-4510 series

WP-4090 series/WP-4020 series/WP-4010 series

Figure 1-1. External View

Table 1-2. Dimensions

Model Dimensions (W x D x H)

WP-4540 series 461.0 mm x 419.5 mm x 420.0 mm 16.50 kg WP-4590 series WP-4530 series 11.20 kg WP-4520 series 13.77 kg WP-4510 series 460.0 mm x 419.5 mm x 298.5 mm 12.60 kg WP-4090 series WP-4020 series 10.90 kg WP-4010 series 10.87 kg

Note *1: Paper support for rear ASF and stacker are closed. Rubber feet are included.

*2: Excluding the weight of ink cartridges and power cable.

460.0 mm x 419.5 mm x 340.9 mm

460.0 mm x 419.5 mm x 283.2 mm

Weight

TBD

Product description Features 11

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Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D

1.2 Printing Specifications

1.2.1 Basic Specifications

Table 1-3. Printer Specifications

Item Specification

Print method On-demand ink jet Nozzle configuration Black: 608 nozzles (152 nozzles x 4)

Color: 456 nozzles (152 nozzles x 1 per color) Color Black, Cyan, Magenta, Yellow Print direction Bi-directional minimum distance printing, Unidirectional printing Print resolution Horizontal x Vertical (dpi)

• 300 x 300

• 600 x 600

• 1200 x 600

Control code • ESC/P Raster command

• ESC/P-R (RGB) command

Input buffer size 132 KBytes Paper feed method Friction feed Paper feed amount

• 1st cassette: 250 pages (plain paper), 30 pages (Legal)

• 2nd cassette

• Rear MP Tray (rear ASF): 80 pages (plain paper)

: 250 pages (plain paper)

• 600 x 300

• 600 x 1200

• 4800 x 1200

Paper path • Front feed, front out

• Rear feed, front out

PF interval 0.01693 mm (1/1500 inch)

Note *1: For paper thickness: 0.10 mm, 75 g/m

*2: When the optional 2nd cassette is installed for WP-4590/4530/4520/4510/4090/4020/4010 series.

Product description Printing Specifications 12

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Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D

1.3 Scanner Specifications (WP-4590/4540/4530/4520/4510 series only)

1.3.1 Basic Specifications

Table 1-4. Basic Specifications

Item Specification

Scanner type Flatbed, color Scanning method Moving carriage, stationary document Home position The rear left corner Photoelectric device CIS Light source LED Maximum document sizes A4 or US Letter Scanning range 8.5” x 11.7” (216 mm x 297 mm) Maximum resolution Main scan: 1,200 dpi

Sub scan: 2,400 dpi Maximum effective pixels 10,200 x 14,040 pixels (1200 dpi) Pixel depth Color 48 bit per pixel (input) and 24 bit per pixel (output)

Monochrome 16 bit per pixel (input) and 1 bit or 8 bit per pixel (output)

Table 1-5. ADF Specifications (WP-4590/4540/4530/4520 series only)

Item Specification

Document loading Face-up Maximum document sizes A4, US Letter or Legal Supported paper type Plain paper only Paper thickness 64 to 95 g/m Maximum number of documents which can be set 30 shee ts or 3 mm at max imum (A4, US Letter) / 10 sheets (Legal) Document path Feeds from upper tray and ejects to lower tray Document set position Rear

Product description Scanner Specifications (WP-4590/4540/4530/4520/4510 series only) 13

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Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D

WP-4540 series

WP-4590 series/WP-4530 series/WP-4520 series

/WP-4090 seriesWP-4020 series/WP-4010 series

WP-4510 series

Note 1: The WiFi logo on the control panel is for WP-4540/4530/4020 series only.

2: WP-4090/4010 series do not have the WiFi button.

Touch panel

LCD

1.4 Control Panel

1.4.1 Operation Buttons & LEDs

The operation buttons, touch panel (WP-4540 series only), LEDs, and LCD are sho wn below. See Table 1-6 and

Table 1-7 for the functions.

Figure 1-2. Control Panel

Product description Control Panel 14

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Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D

The available buttons and LEDs differ between models. Refer to Figure1-2 for available buttons and LEDs for your model.

Table 1-6. Operation Buttons, LEDs and LCD (WP-4590/4540/4530/4520/4510 series)

Item Icon Name Function

LCD Indicates the printer status, error, and menu screen. Button/

touch panel

Power Turns the power on/off. Copy Enters copy mode. Scan Enters scan mode. Fax Enters fax mode. Auto Answer Turns on/off auto answer mode.

Redial/Pause

• Displays the last number dialed.

• Inserts a pause symbol (-) when entering numbers in fax mode.

Speed Dial Displays speed dial/group dial list in fax mode. Setup Enters setup mode. Help Displays help for solutions to problems.

Arrows

Shows next or previous menus.

• Selects menus.

Arrows

• Specifies the number of copies.

• Moves the cursor in fax mode.

OK Activates the setting you have selected. Menu Displays detailed settings for each mode. Back Cancels/returns to the previous menu.

• Specifies the date/time

Ten key

• Specifies the number of copies

• Specifies fax numbers

Stop/Reset Stops printing/copying/scanning/faxing or resets the setting.

(

Start (B&W) Starts copying/scanning/faxing in black and white.

(

Start (Color) Starts copying/scanning/faxing in color.

LED

Power

• Lights when the printer is on.

• Flashes when the printer is in process.

Error On when error has occurred. Network Indicates the network connection status. Auto Answer On when the fax is in auto answer mode.

Note : See "1.4.2 LEDs and LCD Indications (p17)" for more details about the LCD. Note *1: WP-4540 series only.

*2: WP-4590/4530/4520/4510 series only.

Product description Control Panel 15

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Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D

Table 1-7. Operation Buttons, LEDs (WP-4090/4020/4010 series)

Item Icon Name Function

Button Power Turns the power on/off.

Network status sheet Prints a network status sheet. Wi-Fi Configures the wireless network.

Paper feed/eject

Head cleaning (monochrome) Starts head cleaning (black only). Head cleaning (color) Starts head cleaning (all except black). Cancel Cancels printing during a print job.

LED

Note : See "1.4.2 LEDs and LCD Indications (p17)" for more details about the LEDs. Note *: The corresponding color LED is indicated.

Power

Network Indicates the network connection status. Maintenance box Indicates error status for maintenance box. Paper Indicates error status for paper.

Ink

• Loads or ejects paper.

• Resumes printing after a paper out error, multiple page feed error.

• Lights when the printer is on.

• Flashes when the printer is in process.

Indicates error status for ink.

Product description Control Panel 16

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Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D

1.4.2 LEDs and LCD Indications

Table 1-8. LEDs and LCD Indications

Operating

Status

Printer fatal error

Scanner fatal

error

ADF fatal

error

Fax error

WP-4090/4020/4010 series

WP-4590/4540/4530/4520/4510

series

LED status

Power Wi-Fi*1Ethernet

Mainte-

nance

box

Paper

Ink

(BK/C/

M/Y)

LCD message

Printer error. Turn power off and then on again. For details, see your documentation or visit Epson.com.

Flash at

high

speed

Flash at

high

speed

Flash at

high

speed

Flash at

high

speed

Flash at

high

speed

Flash at

high

speed

Paper jam inside, in back, or in ADF. Press [OK] to see to see how to remove jammed paper.

Remove while and orange transportation locks by following instructions.

Scanner error. Turn power off and

--- --- --- --- --- ---

then on again. If the error is not fixed, visit Epson.com for technical support.

--- --- --- --- --- ---

Automatic Document Feeder (ADF) error.

Fax error. Turn power off and then on again.

Maintenance box full

Maintenance box CSIC error

Flash

No maintenance

Flash

box error Paper jam

error

Flash

Paper jam error (front cover

open)

Flash

Paper out error Flash

Paper out error (front cover

Flash

open) No paper

cassette error

Flash

--- --- ON --- ---

--- --- --- Flash ---

--- --- --- ON ---

Maintenance box is at the end of its service life. You need to replace it. <Maintenance Box> XXXXX

Cannot recognize maintenance box. Install it correctly. <Maintenance Box> XXXXX

Paper jam. Press OK to see how to remove jammed paper.

Paper out or paper jam. Check paper size and load paper in paper cassette XX*6.

Paper out or paper jam. Check paper size and load paper in rear MP tray.

Load Cassette XX

(

press or .

(

correctly and

(

Multi-feed error

Paper length mismatch error for duplex

Flash

--- --- --- ON ---

Multi-page feed error. Remove and reload the paper, then press

(

or .

(

Incorrect paper size detected. Load correct paper size and press

(

or .

(

printing

Product description Control Panel 17

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Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D

Table 1-8. LEDs and LCD Indications

Operating

Status

Paper size mismatch error

Flash

Printer/printer driver

Flash

mismatch error Front cover

open error

Ink end error Flash

Ink cartridge detection error

Flash

Ink cartridge detection error (non-Epson

Flash

cartridge)

WP-4090/4020/4010 series

LED status

Power Wi-Fi*1Ethernet

--- --- --- ON ---

--- --- ---

Mainte-

nance

box

Paper

Flash at

high

speed

Ink

(BK/C/

M/Y)

Flash at

high

speed

Flash --- --- --- Flash2 ---

--- --- --- ---

Flash/

WP-4590/4540/4530/4520/4510

series

LCD message

No paper source matches paper size setting. Load appropriate paper in Rear MP Tray. Press

(

or .

(

Error. Press .

Front cover is open.

You need to replace the following ink cartridge(s).

<Ink Cartridges> XXX Cannot recognize the following

cartridge(s). Try installing them

again. <Ink Cartridges> XXX Ink cartridge is not recognized.

Please replace the cartridge.

<Ink Cartridges> XXX

No ink cartridge error

Starting initialization (starting initial filling of ink)

Initializing (during initial filling of ink)

Requiring ink cartridges for initial filling

Checking ink cartridges

Drying 1st side (printing from PC)

Printing (PC) Printing nozzle

check pattern

The cartridge is installed

Flash

--- --- --- ---

Flash/

incorrectly. Press it until it clicks

into place. <Ink Cartridges> XXX

Install ink cartridges that came

Flash --- --- --- --- ---

with this product. Close front cover. Initialization starts.

Initializing. Please wait... Do not open

Flash --- --- --- --- ---

front cover and do not turn power off until initialization completes. This takes about 12 minutes.

Open front cover and replace

Flash --- --- --- --- ---

cartridge(s).

Checking the ink cartridges...

Printing 2-sided document. Do not

Flash --- --- --- --- ---

touch the paper in the output tray until printing is complete.

Flash --- --- --- --- --- Printing...

Flash --- --- --- --- ---

Printing...

Printing printer status sheet

Printing (UPNP)

Flash --- --- --- --- ---

Flash Flash Flash --- --- --- Printing...

Printing...

Receiving data Flash Flash Flash --- --- --- Receiving data...

Product description Control Panel 18

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Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D

Table 1-8. LEDs and LCD Indications

Operating

WP-4590/4540/4530/4520/4510

Status

WP-4090/4020/4010 series

LED status

Power Wi-Fi*1Ethernet

Mainte-

nance

box

Paper

Ink

(BK/C/

M/Y)

Canceling Flash --- --- --- --- --- Canceling...

Cleaning (PC) Flash --- --- --- --- ---

Print head cleaning

Flash --- --- --- --- ---

Canceling nozzle check

Flash --- --- --- --- ---

Cleaning print head. Please wait... Do not open front cover.

Canceling...

pattern print Canceling

printer status

Flash --- --- --- --- ---

Canceling...

sheet print Initializing

network Waiting for

network

Flash

Alternate

Flash2

Alternate

Flash1

--- --- ---

--- --- --- --- --- ---

Processing... Please wait.

initialization

series

LCD message

Network initialization (LED ON)

Network initialization (LED OFF)

Configuring wireless

LAN

Configuring PINCODE

Preparing to update firmware (cancel)

Updating firmware

Preparing to update firmware

Canceling firmware update

OFF

ON to

flash

ON ON --- --- --- ---

OFF OFF --- --- --- ---

Alternate

Flash2

Simulta-

neous

Flash

Simulta-

neous

Flash

Alternate

Flash1

Simulta-

neous Flash

Simulta-

neous Flash

--- --- ---

Establishing a Wi-Fi connection with Push-Button mode...

Establishing a Wi-Fi connection with WPS PIN code mode...

PIN Code XXXXXXXX Preparing to update...

Updating firmware... Do not turn

OFFOFFOFFOFFOFF

power off. It turns off and on automatically when complete.

Simulta-

neous

Flash

Simulta-

neous

Flash

Simulta-

neous Flash

Simulta-

neous Flash

Preparing to update...

--- --- ---

Canceling...

--- --- ---

*10

Powering OFF

Flash at

high

--- --- --- --- ---

Turning off...

speed

Product description Control Panel 19

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Table 1-8. LEDs and LCD Indications

WP-4590/4540/4530/4520/4510

series

LCD message

Restarting product from other device...

Operating

Status

Resetting

WP-4090/4020/4010 series

LED status

Power Wi-Fi*1Ethernet

Flash at

high

--- --- --- --- ---

Mainte-

nance

box

Paper

Ink

(BK/C/

M/Y)

speed

Powering ON Flash

Feeding a paper (load/eject)

Flash --- --- --- --- --- ---

Alternate

Flash2

Alternate

Flash1

--- --- --- ---

Standby No error ON --- --- --- --- --- ---

Maintenance box near full

Ink level low ON Front cover

open error

Maintenance box full

Flash --- --- --- Flash2 ---

--- --- Flash --- ---

--- --- --- --- Flash

--- --- ON --- ---

Maintenance box is nearing end of its service life.

Ink low. Front cover is open.

Maintenance box is at the end of its service life. You need to replace it. <Maintenance Box> XXXXX

Maintenance box CSIC error

No maintenance

box error

Ink end error ON

No ink cartridge error

Ink cartridge detection error

Ink cartridge detection error (non-Epson

ON cartridge) Access point

setting error (security information exchange)

ON ---

--- --- ON --- ---

--- --- --- --- ON

Cannot recognize maintenance box. Install it correctly. <Maintenance Box> XXXXX

You need to replace the following

ink cartridge(s). <Ink Cartridges> XXX

The cartridge is installed

--- --- --- --- ON

incorrectly. Press it until it clicks

into place. <Ink Cartridges> XXX

Cannot recognize the following

cartridge(s). Try installing them again. <Ink Cartridges> XXX

Ink cartridge is not recognized.

--- --- --- --- ON

Please replace the cartridge.

<Ink Cartridges> XXX

Security error while setting Wi-Fi

Flash at

high

--- --- ---

with your access point. Try again.

speed

Access point setting error (general)

ON --- Flash --- --- ---

Error while setting Wi-Fi with your access point. Try again.

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Table 1-8. LEDs and LCD Indications

WP-4590/4540/4530/4520/4510

series

LCD message

Registration error. The access point is busy. Try

again. PIN code authentication error.

Make sure the PIN code is correct.

The Wi-Fi/network connection failed.

Print the check report? The Wi-Fi/network connection

failed. Print the check report?

Standby

Status

Access point setting error (registration)

Access point setting error (PINCODE authentication)

Wireless LAN connection

error Network

connection time out error

WP-4090/4020/4010 series

LED status

Mainte-

Power Wi-Fi*1Ethernet

nance

Paper

box

ON --- Flash --- --- ---

Ink

(BK/C/

M/Y)

ON --- Flash --- --- ---

Note : -- No change

Flash: turns on and off at intervals of 1.25 seconds. Flash 2: On for 0.5 sec., Off for 0.5 sec., On for 0.5 sec. and Off for 1.0 sec. Flash at high speed: turns on and off at intervals of 0.5 seconds. Simultaneous Flash: same as “Flash” Alternate flash 1: same as “Flash” Alternate flash 2: turns on and off at intervals of 1.25 seconds.

Note *1: WP-4020 series only

*2: The message WP-4540 series indicates is different but the meaning is the same. *3: WP-4590/4540/4530/4520/4510 series only *4: WP-4590/4540/4530/4520 series only *5: Flashes if the status arises when printing starts or when the printer starts up, but lights if the status arises when printing is

complete. *6: The corresponding maintenance box, ink cartridge product number or cassette number is indicated. *7: Occurs in any paper path. *8: The corresponding ink LED flashes after the ink falls in the ink low status, and lights when it reaches the ink end status. *9: WP-4540/4530/4020 series only *10: The corresponding PIN number is indicated.

Product description Control Panel 21

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1.5 Various Settings

1.5.1 Panel Operation

1.5.1.1 Setup Menu Configuration (WP-4590/4540/4530/4520/4510 series only)

The following explains the setup menu structure and the outline of the menu functions.

Table 1-9. Menu Configuration

Menu Description

Setup Ink Levels --- Displays the status of ink cartridges and maintenance box.

Maintenance Nozzle Check Prints a nozzle check pattern.

Head Cleaning Runs a print head cleaning. Head Alignment Adjusts the alignment of the printhead.

Printer Setup Paper Size Loaded Selects the paper size (1st cassette/2nd cassette

Thick Paper Turn this on when printing on thick paper. Dry Time Sets the dry time when duplex printing. Sound Turns the sound on/off. Date/Time Selects display format for data/time. Daylight Saving Time Selects daylight saving time. Country/Region Selects country/region. Language Selects the language displayed on the LCD. Paper Size Notice Checks the paper size and selects whether to alert users when an

error occurs (Off/On).

Wi-Fi/Network Settings

File Sharing Setup USB

Fax Settings Send Settings Configures fax send settings.

Print Status Sheet --- Prints a printer status sheet. Lock Settings On

Restore Default Settings

Wi-Fi Setup Selects a connection method for wireless LAN. Manual Wi-Fi/Network Setup Wi-Fi/Network Connection

Check Confirm Wi-Fi/Network

Settings

Wi-Fi/Network

Receive Settings Configures fax receive settings. Communication Configures the details of the fax communication. Check Fax Connection Prints the fax connection settings.

(“Off” when panel operation is locked)

Change Password Changes the password. (See "1.5.1.2 Panel Operation Lock

Fax Send/Receive Settings Initializes the fax send/receive settings. Fax Data Settings Deletes the fax data settings. Wi-Fi/Network Setting Initializes the Wi-Fi/network settings. All except Wi-Fi/Network &

Fax Settings All Settings Initiali ze s the all settings.

Configures the connection setting for manual setup.

• Checks the network connection status.

• Prints the connection check result.

• Displays the network information.

• Prints a network status sheet.

Sets the access priority when accessing the storage dev ice connected to the USB host port to USB or Wi-Fi/Network.

Changes the setting of the panel operation lock. (See "1.5.1.2

Panel Operation Lock Setting (WP-4590/4540/4530/4520/4510 series only) (p23)".)

Setting (WP-4590/4540/4530/4520/4510 series only) (p23)".)

Initializes the settings except Wi-Fi/network/fax settings.

/Rear MP Tray).

Note : The setting items for Wi-Fi is for WP-4540/4530 series only. Note *: When the optional 2nd cassette is installed for WP-4590/4530/4520/4510/4090/4020/4010 series.

Product description Various Settings 22

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1.5.1.2 Panel Operation Lock Setting (WP-4590/4540/4530/4520/4510 series only)

For WP-4590/4540/4530/4520/4510 series, the panel operation for the following can be locked after setting the password.

 The same password is also required when configuring the printer settings through

EPSON NetConfig.

 All settings will be initialized when resetting the password.

Table 1-10. Panel Operation Lock Setting

ON The password is required for the following settings.

• Lock settings

• Printer setup

• Wi-Fi/Network settings

• File sharing setup

• Restoration of individual settings such as network setting (except initializing the all settings)

OFF Entering the password is not required to go to the setting screen even the password is registered.

 Password setting method

1. Select “Setup” - “Lock Settings” - “On”, and then press “OK”.

2. Enter the password, and then press “OK”.

3. To verify the password, enter the password again and press “OK”.

Table 1-11. Password Setting

Item

WP-4540 series WP-4590/4530/4520/4510 series

Digit of the password Within 1 to 20 Available characters Space, !”#$%&'()*+,-./, 0-9, ;<=>?@ A-Z, \]^_`, a-z, {|}~ Method Select characters with arrows or ten key. When a

password is already set, the following three password entries are required: “Enter Current Password”, “Enter New Password”, and “Verify New Password”.

Note 1: The password is not set when shipping from the factory.

2: If the entr ies “Enter New Password” a nd “Verify Ne w Password” are diffe rent, the message “Passw ord is in correct. Enter cor rect

password.” is displayed and the menu screen returns to the password entering screen.

3: If the entries up t o “Verify New Password” are com plete successfully, the change will be reflecte d and the LCD display returns to

the setup menu.

4: The password is stored on the EEPROM, and kept even the power is off.

Description

Select characters with the arrow buttons. When a password is already set, the following three password entries are required: “Enter Current Password”, “Enter New Password”, and “Verify New Password”.

 Panel operation lock method

1. Select “Setup” - “Lock Settings” - “On”, and then press “OK”.

2. Enter the password, and then press “OK”.

3. When “Free access limited” displays, press “OK”. Then the panel lock setting becomes valid.

Product description Various Settings 23

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 Resetting the password/unlocking the panel operation lock

If you need to reset the password or unlock the panel operation because of forgetting the password and such, follow the steps below to reset them.

 Resetting/unlocking method

1. Select “Setup” - “Restore Default Settings” - “All Settings”, and press “OK”.

2. When “Restore all settings to defaults” displays, select “Yes”.  Settings after reset

• Password: Not set

• Panel operation lock: OFF

1.5.1.3 Forced Power OFF

For WP-4590/4540/4530/4520/4510/4090/4020/40 10 series, the power can be turned off forcibly by the following panel operation. If the power is turned off forcibly, the same process of the normal power-off is executed.

 Operation method

1. Press the power button and then stop button, and hold down the buttons for seven seconds or more.

2. When the LCD display changes, release the buttons.

1.5.1.4 Printer Status Sheet

WP-4590/4540/4530/4520/4510/4090/4020/4010 series print the printer status sheet by the following operation.

Table 1-12. Status Sheet

Model Procedure

WP-4590/4540/4530/4520/4510 series

WP-4090/4020/4010 series Turn the power on while pressing the paper feed/eject button.

Note : When printing the network status sheet to check the network information, follow the procedure below.

WP-4590/4540/4530/4520/4510 series: Select “Wi-Fi/Network Settings” - “Confirm Wi-Fi/Network Settings”, and press or

WP-4090/4020/4010 series: Press the “network status sheet” button. (See

1. Press the setup button.

2. Select “Print Status Sheet” from the setup menu.

3. Press the start button.

(

.(See "1.5.1.1 Setup Menu Configuration (WP-4590/4540/4530/4520/4510 series only) (p22)".)

"1.4.1 Operation Buttons & LEDs (p14) "

(

Product description Various Settings 24

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CHAPTER 2

OPERATING PRINCIPLES

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A#3 A#2 A#1

A#152 A#151

A#150

B#152 B#151

B#150

B#3 B#2 B#1

C#3 C#2 C#1

C#152 C#151

C#150

D#152 D#151

D#150

D#3 D#2 D#1

E#3 E#2 E#1

E#152 E#151

E#150

F#152 F#151

F#150

F#3 F#2 F#1

G#3 G#2 G#1

G#152 G#151

G#150

0.169 ｍｍ

1/150 inch）

5.9267 ｍｍ

(35/150 inch

）

2.3707 ｍｍ

(14/150 inch）

）

0.0423 ｍｍ 1/600 inch）

）

0.0847 ｍｍ 1/300 inch）

）

Black CyanMagenta

Yellow

Column A

Carriage movement direction

Paper feed direction

Column B

Column C

Column D

Column E

Column F Column G

2.1 Overview

This chapter describes the operating principles of WP-4590/4540/4530/4520/4510/4090/4020/4010 series printer mechanism.

2.2 Printhead

This section describes the printhead.  Print method: On-demand inkjet

(F7-Mach Turbo 2)

 Nozzle configuration

Color Bk, C, M, Y (4 colors) Number of nozzles 1064 nozzles (Bk: 152 nozzles x 4, C, M, Y: 152 nozzles per color) Nozzle pitch 0.169 mm (1/150 inch)

The nozzle layout as seen from behind the Printhead is shown below.

Operating Principles Overview 26

Figure 2-1. Nozzle Layout

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Printhead

2.3 Motors and Sensors

The following table lists the motors and sensors of WP-4590/4540/4530/4520/4510/4090/4020/4010 series.  Printer Mechanism

Table 2-1. List of Motors & Sensors (Printer Mechanism)

Mechanism Motor or Sensor No.

Printhead --Carriage mechanism CR Motor A

CR Encoder 1 PW Sensor 2

Cover Open Sensor 3 Ink supply mechanism Decompress Pump Motor B Paper loading/feed mechanism PF Motor C

PF Encoder 4

PE Sensor 5

Paper Stopper Lever Sensor 6

Figure 2-2. Motors & Sensors (Printer Mechanism)

Operating Principles Motors and Sensors 27

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 Scanner (WP-4590/4540/4530/4520/4510 series only)

Table 2-2. List of Motors & Sensors (Scanner)

Mechanism Motor or Sensor No.

Scanner mechanism Scanner Motor A

CIS Unit 1

Figure 2-3. Motors & Sensors (Scanner)

 ADF (WP-4590/4540/4530/4520 series only)

Table 2-3. List of Motors & Sensors (ADF)

Mechanism Motor or Sensor No.

ADF mechanism ADF Motor A

PE Sensor 1

Document Sensor 2

ADF Encoder 3

Figure 2-4. Motors & Sensors (ADF)

Operating Principles Motors and Sensors 28

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 2nd cassette This unit is installed for WP-4540 series, and option for WP-4590/4530/4520/4510/4090/4020/4010 series.

Table 2-4. List of Motors & Sensors (2nd Cassette)

Mechanism Motor or Sensor No.

2nd cassette ASF Motor A

Paper Stopper Lever Sensor 1

ASF Encoder 2

Figure 2-5. Motors & Sensors (2nd Cassette)

Operating Principles Motors and Sensors 29

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PF MotorPF Timing Belt

Left side of Printer Mechanism

PF Encoder

With cover

Without cover (light-emitting

and receiving devices)

PF Encoder

Light passes

Light does not pass

PF Scale

2.4 Optical Sensor Control

WP-4590/4540/4530/4520/4510/4090/4020/4010 series uses the optical sensor to control itself. The following describes the operating principles of optical sensor control.

 Control method To ensure accurate printing, each part must be controlled to make an adequate amount (time) of movement. The

optical sensors read the amount (time) of movements as follows to printer to control it for achieving accurate printing.

1. Rotates the motors for control of the printer, and transmits drive force to the each part via the gear or the timing belt.

2. The encoder reads the drive amount of each part from the scale one by one to printer to monitor that the part drives for an adequate amount (time).

 Controlled parts The following table lists where the optical sensor control is used.

Table 2-5. Controlled Parts

Item Motor Scale Encoder Transmission method

 Paper feed/load mechanism

PF Motor PF Scale PF Encoder

 Front ASF mechanism

(1st cassette)

 Rear ASF mechanism

Carriage mechanism CR Motor CR Scale CR Encoder CR Timing Belt Front ASF mechanism

(2nd cassette ADF mechanism

Note *1: Installed on WP-4540 series, and option for WP-4590/4530/4520/4510/4090/4020/4010 series.

)

*2: WP-4590/4540/4530/4520 series only.

ASF Motor ASF Scale ASF Encoder Gear

ADF Motor ADF Scale ADF Encoder Gear

 Operating principles The following describes the paper feed mechanism drive control as an example of the actual operation for the

optical sensor. The PF scale consists of light-passing and light-blocking portions on its surface, and runs through the slit between

the encoder’s light-emitting and light-receiving devices. While the printer is operating, the encoder always emits light from light-emitting device toward the light-receiving device, and the ligh t-receiving dev ice detects light when the light is transmitted through the light-passing portion of the scale, and does not detect light when the light is blocked by the light-blocking portion of the scale. Accord ing to the counts of light-detected and non detected times, the printer controls paper feed drive direction and amount. When the encoder cannot read light-emitting/blocking counts correctly due to the misalignment, broken or contaminated scale, paper jam, foreign object and increasing a load, the fatal error occurs and the printer stops.

 PF Timing Belt  ASF Timing Belt

Figure 2-6. PF Drive Control Section

Operating Principles Optical Sensor Control 30

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