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:

All rights reserved. No part of this manual may be reproduced, stored in a retrieval system, or transmitted in any form or 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 registered trademarks of their respective owners. EPSON disclaims any and all rights in those marks.

Copyright © 2014 SEIKO EPSON CORPORATION

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, for 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 manual.

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 Operation 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	Overview ....................................................................................................................		.............................................	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 series 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	Overview ....................................................................................................................		.............................................	57
	4.1.1	Tools ...............................................................................................................................................................		57
	4.1.2	Jigs ......................................................................................................................	............................................	57
4.2	Disassembly/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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Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series					Revision D
		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		Details 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		Overview ...............................................................................................................................................................			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	WP-4590	WP-4540	WP-4530	WP-4520	WP-4510	WP-4090	WP-4020	WP-4010
		series	series	series	series	series	series	series	series
	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

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)*1	Weight*2
WP-4540 series		461.0 mm x 419.5 mm x 420.0 mm	16.50 kg
WP-4590 series			TBD
WP-4530 series		460.0 mm x 419.5 mm x 340.9 mm	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			TBD
WP-4020 series		460.0 mm x 419.5 mm x 283.2 mm	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.

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 300
			• 600 x 600		• 600 x 1200
			• 1200 x 600		• 4800 x 1200
	Control code		• ESC/P Raster command
			• ESC/P-R (RGB) command
	Input buffer size		132 KBytes
	Paper feed method		Friction feed
	Paper feed amount*1		• 1st cassette:		250 pages (plain paper), 30 pages (Legal)
			• 2nd cassette*2:		250 pages (plain paper)
			• Rear MP Tray (rear ASF): 80 pages (plain paper)
	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/m2
*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/m2
Maximum number of documents which can be set	30 sheets or 3 mm at maximum (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)

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

Revision D

1.4 Control Panel

1.4.1 Operation Buttons & LEDs

The operation buttons, touch panel (WP-4540 series only), LEDs, and LCD are shown below. See Table 1-6 and Table 1-7 for the functions.

Touch panel

WP-4540 series

LCD

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

LCD

WP-4510 series

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

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

LCD

Button/ touch panel

-,,

(	(
(
	(

LED

	Name	Function
		Indicates the printer status, error, and menu screen.
	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*1	Shows next or previous menus.
		• Selects menus.
	Arrows*2	• 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.
	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	• Loads or ejects paper.
					• Resumes printing after a paper out error, multiple page feed error.
				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				Power	• Lights when the printer is on.
					• Flashes when the printer is in process.
				Network	Indicates the network connection status.
				Maintenance box	Indicates error status for maintenance box.
				Paper	Indicates error status for paper.
				Ink*	Indicates error status for ink.
Note :	See "1.4.2 LEDs and LCD Indications (p17)" for more details about the LEDs.
Note *:	The corresponding color LED is indicated.

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

WP-4090/4020/4010 series

WP-4590/4540/4530/4520/4510

series

Status

LED status

Power

Wi-Fi*1

Ethernet

Mainte-

Paper

Ink

LCD message*2

nance

(BK/C/

box

M/Y)

Operating

Printer error. Turn power off and

then on again. For details, see your

documentation or visit Epson.com.

Flash at

Flash at

Flash at

Flash at

Flash at

Flash at

Printer fatal

Paper jam inside, in back, or in

high

high

high

high

high

high

ADF. Press [OK] to see to see how

error

speed

speed

speed

speed

speed

speed

to remove jammed paper.

Remove while and orange

transportation locks by following

instructions.

Scanner fatal

Scanner error. Turn power off and

---

---

---

---

---

---

then on again. If the error is not fixed,

error*3

visit Epson.com for technical support.

ADF fatal

---

---

---

---

---

---

Automatic Document Feeder

error*4

(ADF) error.

Fax error*4

---

---

---

---

---

---

Fax error. Turn power off and then

on again.

Maintenance

Flash*5

Maintenance box is at the end of

---

---

ON

---

---

its service life. You need to replace

box full

it. <Maintenance Box> XXXXX*6

Maintenance

Flash*5

Cannot recognize maintenance

---

---

ON

---

---

box. Install it correctly.

box CSIC error

<Maintenance Box> XXXXX*6

No

Flash*5

Cannot recognize maintenance

maintenance

---

---

ON

---

---

box. Install it correctly.

box error

<Maintenance Box> XXXXX*6

Paper jam

Flash*5

---

---

---

Flash

---

Paper jam. Press OK to see how to

error*7

remove jammed paper.

Paper jam error

Flash*5

Paper jam. Press OK to see how to

(front cover

---

---

---

Flash

---

remove jammed paper.

open)*7

Flash*5

Paper out or paper jam. Check

Paper out error

---

---

---

ON

---

paper size and load paper in paper

cassette XX*6.

Paper out error

Flash*5

Paper out or paper jam. Check

(front cover

---

---

---

ON

---

paper size and load paper in rear

open)

MP tray.

No paper

Flash*5

---

---

---

ON

---

Load Cassette XX*6 correctly and

cassette error

press

(

(

or

(

(

.

Multi-feed

Flash*5

Multi-page feed error. Remove

---

---

---

ON

---

and reload the paper, then press

error

(

(

or

(

(

.

Paper length

Incorrect paper size detected. Load

mismatch error

Flash*5

---

---

---

ON

---

correct paper size and press

(

(

for duplex

or

(

(

.

printing

Product description

Control Panel

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Revision D

Table 1-8. LEDs and LCD Indications

WP-4090/4020/4010 series

WP-4590/4540/4530/4520/4510

series

Status

LED status

Power

Wi-Fi*1

Ethernet

Mainte-

Paper

Ink

LCD message*2

nance

(BK/C/

box

M/Y)

Operating

Paper size

No paper source matches paper

Flash*5

---

---

---

ON

---

size setting. Load appropriate

mismatch error

paper in Rear MP Tray. Press

(

(

or

(

(

.

Printer/printer

Flash*5

Flash at

Flash at

Error. Press .

driver

---

---

---

high

high

mismatch error

speed

speed

Front cover

Flash

---

---

---

Flash2

---

Front cover is open.

open error

Flash*5

---

---

---

---

Flash/

You need to replace the following

Ink end error

ink cartridge(s).

ON*8

<Ink Cartridges> XXX*6

Ink cartridge

Flash*5

Flash/

Cannot recognize the following

---

---

---

---

cartridge(s). Try installing them

detection error

ON*8

again. <Ink Cartridges> XXX*6

Ink cartridge

Ink cartridge is not recognized.

detection error

Flash*5

---

---

---

---

Flash/

Please replace the cartridge.

(non-Epson

ON*8

<Ink Cartridges> XXX*6

cartridge)

The cartridge is installed

No ink

Flash*5

---

---

---

---

Flash/

incorrectly. Press it until it clicks

cartridge error

ON*8

into place.

<Ink Cartridges> XXX*6

Starting

Install ink cartridges that came

initialization

Flash

---

---

---

---

---

with this product. Close front

(starting initial

cover. Initialization starts.

filling of ink)

Initializing

Initializing. Please wait... Do not open

front cover and do not turn power off

(during initial

Flash

---

---

---

---

---

until initialization completes. This

filling of ink)

takes about 12 minutes.

Requiring ink

Open front cover and replace

cartridges for

Flash

---

---

---

---

---

cartridge(s).

initial filling

Checking ink

Flash

---

---

---

---

---

Checking the ink cartridges...

cartridges

Drying 1st side

Printing 2-sided document. Do not

(printing from

Flash

---

---

---

---

---

touch the paper in the output tray

PC)

until printing is complete.

Printing (PC)

Flash

---

---

---

---

---

Printing...

Printing nozzle

Flash

---

---

---

---

---

Printing...

check pattern

Printing printer

Flash

---

---

---

---

---

Printing...

status sheet

Printing (UPNP)

Flash

Flash

Flash

---

---

---

Printing...

Receiving data

Flash

Flash

Flash

---

---

---

Receiving data...

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Control Panel

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				Table 1-8. LEDs and LCD Indications
				WP-4090/4020/4010 series					WP-4590/4540/4530/4520/4510
									series
		Status			LED status
			Power	Wi-Fi*1	Ethernet	Mainte-	Paper	Ink	LCD message*2
						nance		(BK/C/
						box		M/Y)
	Operating	Canceling	Flash	---	---	---	---	---	Canceling...
		Cleaning (PC)	Flash	---	---	---	---	---	Cleaning print head. Please wait...
									Do not open front cover.
		Print head	Flash	---	---	---	---	---	Cleaning print head. Please wait...
		cleaning							Do not open front cover.
		Canceling							Canceling...
		nozzle check	Flash	---	---	---	---	---
		pattern print
		Canceling							Canceling...
		printer status	Flash	---	---	---	---	---
		sheet print
		Initializing	Flash*5	Alternate	Alternate	---	---	---	Processing... Please wait.
		network		Flash2	Flash1
		Waiting for	Flash*5
		network		---	---	---	---	---	---
		initialization
		Network	OFF*5	ON	ON	---	---	---	---
		initialization
		(LED ON)
		Network	OFF*5	OFF	OFF	---	---	---	---
		initialization
		(LED OFF)
		Configuring		Alternate	Alternate				Establishing a Wi-Fi connection
		wireless	ON			---	---	---	with Push-Button mode...
				Flash2	Flash1
		LAN*9
		Configuring		Simulta-	Simulta-				Establishing a Wi-Fi connection
			ON	neous	neous	---	---	---	with WPS PIN code mode...
		PINCODE*9
				Flash	Flash				PIN Code XXXXXXXX*10
		Preparing to		Simulta-	Simulta-				Preparing to update...
		update	ON*5
				neous	neous	---	---	---
		firmware
				Flash	Flash
		(cancel)
		Updating	ON to						Updating firmware... Do not turn
				OFF	OFF	OFF	OFF	OFF	power off. It turns off and on
		firmware	flash
									automatically when complete.
		Preparing to	ON*5	Simulta-	Simulta-				Preparing to update...
		update		neous	neous	---	---	---
		firmware		Flash	Flash
		Canceling	ON*5	Simulta-	Simulta-	---	---	---	Canceling...
		firmware		neous	neous
		update		Flash	Flash
			Flash at						Turning off...
		Powering OFF	high	---	---	---	---	---
			speed

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Control Panel

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				Table 1-8. LEDs and LCD Indications
				WP-4090/4020/4010 series					WP-4590/4540/4530/4520/4510
									series
		Status			LED status
			Power	Wi-Fi*1	Ethernet	Mainte-	Paper	Ink	LCD message*2
						nance		(BK/C/
						box		M/Y)
	Operating		Flash at						Restarting product from other
		Resetting	high	---	---	---	---	---	device...
			speed
		Powering ON	Flash	Alternate	Alternate	---	---	---	---
				Flash2	Flash1
		Feeding a paper	Flash	---	---	---	---	---	---
		(load/eject)
	Standby	No error	ON	---	---	---	---	---	---
		Maintenance	ON*5	---	---	Flash	---	---	Maintenance box is nearing end of
		box near full							its service life.
		Ink level low	ON*5	---	---	---	---	Flash*8	Ink low.
		Front cover	Flash	---	---	---	Flash2	---	Front cover is open.
		open error
		Maintenance	ON*5						Maintenance box is at the end of its
				---	---	ON	---	---	service life. You need to replace it.
		box full
									<Maintenance Box> XXXXX*6
		Maintenance	ON*5						Cannot recognize maintenance
				---	---	ON	---	---	box. Install it correctly.
		box CSIC error
									<Maintenance Box> XXXXX*6
		No	ON*5						Cannot recognize maintenance
		maintenance		---	---	ON	---	---	box. Install it correctly.
		box error							<Maintenance Box> XXXXX*6
		Ink end error	ON*5	---	---	---	---	ON*8	You need to replace the following
									ink cartridge(s).
									<Ink Cartridges> XXX*6
									The cartridge is installed
		No ink	ON*5	---	---	---	---	ON*8	incorrectly. Press it until it clicks
		cartridge error							into place.
									<Ink Cartridges> XXX*6
		Ink cartridge	ON*5	---	---	---	---	ON*8	Cannot recognize the following
									cartridge(s). Try installing them
		detection error
									again. <Ink Cartridges> XXX*6
		Ink cartridge							Ink cartridge is not recognized.
		detection error	ON*5	---	---	---	---	ON*8	Please replace the cartridge.
		(non-Epson							<Ink Cartridges> XXX*6
		cartridge)
		Access point							Security error while setting Wi-Fi
		setting error			Flash at				with your access point. Try again.
		(security	ON	---	high	---	---	---
		information			speed
		exchange)*9
		Access point							Error while setting Wi-Fi with
		setting error	ON	---	Flash	---	---	---	your access point. Try again.
		(general)*9

Product description

Control Panel

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Revision D

Table 1-8. LEDs and LCD Indications

WP-4090/4020/4010 series

WP-4590/4540/4530/4520/4510

series

Status

LED status

Power

Wi-Fi*1

Ethernet

Mainte-

Paper

Ink

LCD message*2

nance

(BK/C/

box

M/Y)

Standby

Access point

Registration error.

setting error

ON

---

Flash

---

---

---

The access point is busy. Try

(registration)*9

again.

Access point

PIN code authentication error.

setting error

ON

---

Flash

---

---

---

Make sure the PIN code is correct.

(PINCODE

authentication)*9

Wireless LAN

The Wi-Fi/network connection

connection

ON

---

Flash

---

---

---

failed.

error*9

Print the check report?

Network

The Wi-Fi/network connection

connection

ON

---

Flash

---

---

---

failed.

time out error*9

Print the check report?

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

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Revision D

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*/Rear MP Tray).
		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	Wi-Fi Setup	Selects a connection method for wireless LAN.
	Settings
		Manual Wi-Fi/Network Setup	Configures the connection setting for manual setup.
		Wi-Fi/Network Connection	• Checks the network connection status.
		Check	• Prints the connection check result.
		Confirm Wi-Fi/Network	• Displays the network information.
		Settings	• Prints a network status sheet.
	File Sharing Setup	USB	Sets the access priority when accessing the storage device
		Wi-Fi/Network	connected to the USB host port to USB or Wi-Fi/Network.
	Fax Settings	Send Settings	Configures fax send settings.
		Receive Settings	Configures fax receive settings.
		Communication	Configures the details of the fax communication.
		Check Fax Connection	Prints the fax connection settings.
	Print Status Sheet	---	Prints a printer status sheet.
	Lock Settings	On	Changes the setting of the panel operation lock. (See "1.5.1.2
		(“Off” when panel operation	Panel Operation Lock Setting (WP-4590/4540/4530/4520/4510
		is locked)	series only) (p23)".)
		Change Password	Changes the password. (See "1.5.1.2 Panel Operation Lock
			Setting (WP-4590/4540/4530/4520/4510 series only) (p23)".)
	Restore Default	Fax Send/Receive Settings	Initializes the fax send/receive settings.
	Settings
		Fax Data Settings	Deletes the fax data settings.
		Wi-Fi/Network Setting	Initializes the Wi-Fi/network settings.
		All except Wi-Fi/Network &	Initializes the settings except Wi-Fi/network/fax settings.
		Fax Settings
		All Settings	Initializes the all settings.
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	Description
		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	Select characters with the arrow buttons. When a
		password is already set, the following three	password is already set, the following three
		password entries are required: “Enter Current	password entries are required: “Enter Current
		Password”, “Enter New Password”, and “Verify	Password”, “Enter New Password”, and “Verify
		New Password”.	New Password”.

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

2:If the entries “Enter New Password” and “Verify New Password” are different, the message “Password is incorrect. Enter correct password.” is displayed and the menu screen returns to the password entering screen.

3:If the entries up to “Verify New Password” are complete successfully, the change will be reflected and the LCD display returns to the setup menu.

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

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

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Revision D

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-4590/4540/4530/4520/4510/4090/4020/4010 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

1.

Press the setup button.

series

2.

Select “Print Status Sheet” from the setup menu.

3.

Press the start button.

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

(

(

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

WP-4090/4020/4010 series:

Press the “network status sheet” button. (See "1.4.1 Operation Buttons & LEDs (p14)".)

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Various Settings

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CHAPTER 2

OPERATING PRINCIPLES

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Revision D

2.1 Overview

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.

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.

						2.3707
						(14/150 inch
							5.9267
							(35/150 inch
	A#152	B#152 C#152			D#152 E#152		F#152	G#152
	A#151	B#151 C#151			D#151 E#151		F#151	G#151
	A#150	B#150 C#150			D#150 E#150		F#150	G#150	direction
	Column A		Column C			Column E
	Column B			Column D			Column F	Column G	Paper feed
0.0847	A#3	B#3			D#3		F#3
			C#3			E#3		G#3
		B#2
1/300 inch	A#2		C#2		D#2	E#2	F#2	G#2
									0.169
		B#1
	A#1		C#1		D#1	E#1	F#1	G#1
							Yellow		1/150 inch
0.0423
		Black				Magenta		Cyan
1/600 inch

Carriage movement direction

Figure 2-1. Nozzle Layout

Operating Principles

Overview

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Revision D

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
	A	1
		Printhead
B
		3

6

4	2

5

C

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

Operating Principles

Motors and Sensors

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Revision D

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
	1

A

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

2

3

A

1

Figure 2-4. Motors & Sensors (ADF)

Operating Principles

Motors and Sensors

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Revision D

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

1

2

A

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

Operating Principles

Motors and Sensors

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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	PF Timing Belt
Front ASF mechanism				ASF Timing Belt
(1st cassette)
Rear ASF mechanism
Carriage mechanism	CR Motor	CR Scale	CR Encoder	CR Timing Belt
Front ASF mechanism	ASF Motor	ASF Scale	ASF Encoder	Gear
(2nd cassette*1)
ADF mechanism*2	ADF Motor	ADF Scale	ADF Encoder	Gear

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.

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 light-receiving device 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. According 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 Encoder	PF Scale	PF Encoder
	With cover

Light passes

Light does not pass

Without cover (light-emitting and receiving devices)

Left side of Printer Mechanism

PF Timing Belt

PF Motor

Figure 2-6. PF Drive Control Section

Operating Principles

Optical Sensor Control

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