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EPL-5500W
SERVICE MANUAL
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EPSON TERMINAL PRINTER
EPL-5500W
SERVICE MANUAL
EPSON
4005668
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NOTICE
All rights reserved. Reproduction of any part of this manual in any form whatsoever without SEIKO EPSON's express written permission is forbidden. The contents of this manual are subjects to change without notice. All efforts have been made to ensure the accuracy of the contents of this manual. However, should any errors be detected, SEIKO EPSON would greatly appreciate being informed of them. The above notwithstanding SEIKO EPSON can assume no responsibility for any errors in this manual or the consequence thereof. Epson is a registered trademark of Seiko Epson Corporation. General Notice: Other product names used herein are for identication purposes only and may be trademarks of their respective campanies.
Copyright © 1995 by SEIKO EPSON CORPORATION Nagano, Japan
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PRECAUTIONS
Precautionary notations throughout the text are categorized relative to 1) personal injury and 2) damage to equipment.
DANGER
Signals a precaution which, if ignored, could result in serious or fatal personal injury. Great caution should be exercised in performing procedures preceded by DANGER Headings.
WARNING Signals a precaution which, if ignored, could result in damage to equipment.
The precautionary measures itemized below should always be observed when performing repair/ maintenance procedures.
DANGER
1. ALWAYS DISCONNECT THE PRODUCT FROM BOTH THE POWER SOURCE AND PERIPHERAL DEVICES PERFORMING ANY MAINTENANCE OR REPAIR PROCEDURE. NO WORK SHOULD BE PERFORMED ON THE UNIT BY PERSONS UNFAMILIAR WITH BASIC SAFETY MEASURES AS DICTATED FOR ALL ELECTRONICS TECHNICIANS IN THEIR LINE OF WORK. WHEN PERFORMING TESTING AS DICTATED WITHIN THIS MANUAL, DO NOT CONNECT THE UNIT TO A POWER SOURCE UNTIL INSTRUCTED TO DO SO. WHEN THE POWER SUPPLY CABLE MUST BE CONNECTED, USE EXTREME CAUTION IN WORKING ON POWER SUPPLY AND OTHER ELECTRONIC COMPONENTS.
2.
3.
WARNING
1. REPAIRS ON EPSON PRODUCT SHOULD BE PERFORMED ONLY BY AN EPSON CERTIFIED REPAIR TECHNICIAN. MAKE CERTAIN THAT THE SOURCE VOLTAGE IS THE SAME AS THE RATED VOLTAGE, LISTED ON THE SERIAL NUMBER/RATING PLATE. IF THE EPSON PRODUCT HAS A PRIMARY AC RATING DIFFERENT FROM AVAILABLE POWER SOURCE, DO NOT CONNECT IT TO THE POWER SOURCE. ALWAYS VERIFY THAT THE EPSON PRODUCT HAS BEEN DISCONNECTED FROM THE POWER SOURCE BEFORE REMOVING OR REPLACING PRINTED CIRCUIT BOARDS AND/OR INDIVIDUAL CHIPS. IN ORDER TO PROTECT SENSITIVE MICROPROCESSORS AND CIRCUITRY, USE STATIC DISCHARGE EQUIPMENT, SUCH AS ANTI-STATIC WRIST STRAPS, WHEN ACCESSING INTERNAL COMPONENTS. REPLACE MALFUNCTIONING COMPONENTS ONLY WITH THOSE COMPONENTS BY THE MANUFACTURE; INTRODUCTION OF SECOND-SOURCE ICs OR OTHER NONAPPROVED COMPONENTS MAY DAMAGE THE PRODUCT AND VOID ANY APPLICABLE EPSON WARRANTY.
2.
3.
4.
5.
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SAFETY INFORMATION
This printer is a page printer which operates by means of a laser. There is no possibility of danger from the laser, provided the printer is operated according to the instructions in this manual provided. Since radiation emitted by the laser is completely confined within protective housings, the laser beam cannot escape from the machine during any phase of user operation.
For United States Users;
[Laser Safety] This printer is certified as a Class 1 Laser product under the U.S. Department of Health and Human Services (DHHS) Radiation Performance Standard according to the Radiation Control for Health and Safety Act of 1968. This means that the printer does not produce hazardous laser radiation. [CDRH Regulations] The Center for Devices and Radiological Health (CDRH) of the U.S. Food and Drug Administration implemented regulations for laser products on August 2, 1976. Compliance is mandatory for products marketed in the United States. The label shown below indicates compliance with the CDRH regulations and must be attached to laser products marketed in the United States. WARNING : Use of controls, adjustments or performance of procedures other than those specified in this manual may result in hazardous radiation exposure. [Internal Laser Radiation] Maximum Radiation Power: Wave Length: 5.0 × 10-4 (W) 790 ± 20 nm
This is a Class IIIb Laser Diode Assay that has an invisible laser beam. The print head unit is NOT A FIELD SERVICE ITEM. Therefore, the print head unit should not be opened under any circumstances.
For Other Countries Users;
WARNING: Use of controls, adjustments or performance of procedures other than those specified in this manual may result in hazardous radiation exposure. This is a semiconductor laser. The maximum power of the laser diode is 5.0 × 10-4 W and the wavelength is 790 ± 20 nm.
For Denmark Users;
ADVARSEL Usynlig laserstråling ved åbning, når sikkerhedsafbrydere er ude af funktion. Undgå udsættelse for stråling. Klasse 1 laser produkt der opfylder IEC825 sikkerheds kravene.
For Finland, Sweden Users;
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VAROITUS Laitteen käyttäminen muulla kuin tässä käyttöohjeessa mainitulla tavalla saattaa altistaa käyttäjän turvallisuusluokan 1 ylittävälle näkymättömälle lasersäteiylle. VARNING Om apparaten används på annat sätt än i denna bruksanvisning specificerats, kan användaren utsättas för osynlig laserstrålning, som överskrider gränsen för laser klass 1.
For Finland, Sweden Service People
VAROITUS Avattaessa ja suojalukitus ohitettaessa olet alttiina näkymättömälle laser-säteilylle. Älä katso säteeseen. VARNING Osynlig laserstrålning när denna del är öppnad och spärren är urkopplad. Betrakta ej strålen.
For Norway Users;
ADVARSEL Dersom apparatet brukes på annen måte enn spesifisert i denne bruksanvisning, kan brukeren utsettes for unsynlig laserstråling som overskrider grensen for laser klasse 1. Dette er en halvleder laser. Maksimal effeckt til laserdiode er 5.0 × 10-4 W og bølgelengde er 790 ± 20 nm.
Laser Safety Labels
[Label on rear printer case] A laser safety labels is attached on the outside of the printer shown below.
For United State
For Europe
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[Label inside printer]
The following laser safety label will be attached inside the printer as shown below.
For Denmark, Finland, Sweden, and Norway
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PREFACE
This manual describes functions, theory of electrical and mechanical operations, maintenance, and repair of EPL-5500W. The instructions and procedures included herein are intended for the experience repair technician, and attention should be given to the precautions on the preceding page. The chapters are organized as follows:
CHAPTER 1. GENERAL DESCRIPTION
Provides a general product overview, lists specifications, and illustrates the main components of the printer.
CHAPTER 2. OPERATING PRINCIPLES
Describes the theory of printer operation.
CHAPTER 3. DISASSEMBLY AND ASSEMBLY
Includes a step-by-step guide for product disassembly and assembly.
CHAPTER 4. ADJUSTMENTS
Includes a step-by-step guide for adjustment.
CHAPTER 5. TROUBLESHOOTING
Provides Epson-approved techniques for adjustment.
CHAPTER 6. MAINTENANCE
Describes preventive maintenance techniques and lists lubricants and adhesives required to service the equipment.
APPENDIX
Describes connector pin assignments, circuit diagrams, circuit board component layout and exploded diagram.
The contents of this manual are subject to change without notice.
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REVISION SHEET
Revision Rev. A Issue Date November 24, 1995 Revision Page 1st issue
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TABLE OF CONTENTS
CHAPTER 1. CHAPTER 2. CHAPTER 3. CHAPTER 4. CHAPTER 5. CHAPTER 6. APPENDIX
GENERAL DESCRIPTION OPERATING PRINCIPLES DISASSEMBLY AND ASSEMBLY ADJUSTMENTS TROUBLESHOOTING MAINTENANCE
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Chapter 1
General Description
Table of Contents
1.1 FEATURES 1.2 SPECIFICATIONS 1.2.1 Basic Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2.2 Electrical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2.3 Reliability Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2.4 Environmental Conditions for Operating (Include Imaging Cartridge) . . . . 1.2.5 Environmental Conditions for Storage and Transportation . . . . . . . . . . . . 1.2.6 Applicable Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2.7 Specifications for Consumable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2.8 Physical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2.9 Software Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1-3 1-3 1-5 1-5 1-5 1-5 1-6 1-6 1-6 1-7
1.3 INTERFACE SPECIFICATIONS 1-9 1.3.1 Parallel Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 1.4 OPERATING INSTRUCTIONS 1-9 1.4.1 Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 1.4.2 Display of Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10 1.4.2.1 Status Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10 1.4.2.2 Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10 1.4.3 Printing Resolution Host PC Capability Dependency. . . . . . . . . . . . . . . . 1-11 1.5 MAIN COMPONENTS 1.5.1 C180 MAIN Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5.2 PWB-E Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5.3 PWB-F Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5.4 Optical Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5.5 FUSING UNIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5.6 Photoconductor Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5.7 Developing Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12 1-13 1-14 1-14 1-15 1-15 1-16 1-16
List of Figures
Figure 1-1. Exterior View of the EPL-5500W . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Figure 1-2. Printable Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Figure 1-3. Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 Figure 1-4. Component Layout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12 Figure 1-5. C180 MAIN Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13 Figure 1-6. PWB-E Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14 Figure 1-7. PWB-F Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14 Figure 1-8. Optical Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15 Figure 1-9. Fusing Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15 Figure 1-10. Photoconductor Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16 Figure 1-11. Developing Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
List of Tables
Table 1-1. Options for the EPL-5500W . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Table 1-2. Paper Feed Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Table 1-3. Paper Types. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Table 1-4. Usability of Special Papers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Table 1-5. Electrical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Table 1-6. Status Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10 Table 1-7. Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10 Table 1-8. Host PC Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
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General Description
1.1 FEATURES
The EPSON® EPL-5500W laser printer has a 300/600 dots per inch (dpi) resolution and 6 pages per minute (ppm) printing speed in a dedicated Microsoft® Windows® Printing System. It works under Microsoft Windows 3.1x and Windows 95, achieving very high performance due to the recent advances in PC technology. The main features are:
t
No ozone Printing speed -- 6 ppm Resolution -- 600/300 dpi Light weight -- about 5 kg (11 lb) Small footprint Low running cost: separation of the development/toner cartridge and photoconductor unit Ease of use with Microsoft Windows Printing System (WPS) PCL4 software emulation mode High throughput, especially with fine-pitch halftone image output Freedom from the memory overflow Freedom from document incompatibility, True WYSIWYG Bidirectional parallel interface (ECP and Microsoft Peppy modes) Achieves high throughput with a very high-speed parallel interface. Maximum transmission speed is approximately 2 MB/sec. (under ECP mode) or 600 KB/ sec. (under Peppy mode).
t t t t t t t t t t t t
Figure 1-1 shows an exterior view of the EPL-5500W.
Figure 1-1. Exterior View of the EPL-5500W
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General Description
Table 1-1 lists the optional units available for the EPL-5500W.
EPL-5500W Service Manual
Table 1-1. Options for the EPL-5500W
Cat. No. S050005 S051029 Description Developer cartridge Photoconductor unit Note Developer and toner cartridge --
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General Description
1.2 SPECIFICATIONS
This section provides statistical data for the EPL-5500W.
1.2.1 Basic Specifications
Printing method: Resolution: Printing speed: First printing time (A4/LT): Warm-up time: Paper supply: Laser beam scanning and dry electrophotography 600/300 dpi 6 ppm (letter/A4) Less than 20 seconds (face-up output) Less than 35 seconds (at rated current and 23° C (73° F) temperature) See Table 1-2.
Table 1-2. Paper Feed Methods
Capacity Using 20 lb. (75 g/m2) Paper 150 Standard built-in paper tray 5 to 10 Usage Thickness (Ream Weight) 16 to 24 lb. (60 to 90 g/m2) Envelopes made of 20 to 24 lb. (75 to 90 g/m2) paper 16 to 42 lb. (60 to 157 g/m2)
Paper Supply
Paper Sizes B5, A4, LT, EXEC, LGL Monarch, DL, C5, Env #10, 11, 12, 14 Any size feedable (Note 2)
Manual feed slot Notes: 1. 2.
1
The weight in pounds (lb) is determined by the weight of 500 sheets cut to 17 × 22 inches; 1 g/m2 = 0.2659763 lb. Paper size range: width length 3 to 8.5 inches (76 to 216 mm) 5 to 14.0 inches (127 to 356 mm) See Table 1-3.
Paper types:
Table 1-3. Paper Types
Standard paper Xerox® 4024 DP paper 20 lb (75 g/m2) Regular photocopier paper Bond paper Recycled paper 16 to 24 lb (60 to 90 g/m2) Card stock (90 to 157 g/m2) Envelopes Labels Letterhead Transparency (OHP) sheets Colored paper
Normal paper
Special papers
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General Description
Usability of special papers: See Table 1-4.
EPL-5500W Service Manual
Table 1-4. Usability of Special Papers
Input Standard built-in paper tray Manual feed slot OHP P P Envelopes P P Labels P P Card Stock P P Letterhead R R
R: Reliable feeding and good image quality. P: Possible, but better avoided. N: Not supported.
Paper feed alignment and direction: Paper ejection: Output tray capacity: Printable area (standard paper):
Center alignment for all sizes Face down 100 sheets (face down) See Figure 1-2.
4.0 mm
Printable Area
4.0 mm
4.0 mm
4.0 mm
Figure 1-2. Printable Area
Note: Noise: Ozone density: Toxicity: The actual printable area depends on the printer mode. Less than 35 dB(A), standby Less than 47 dB(A), operating Less than 0.01 ppm No toxicity exists in organic photoconductor (OPC), toner, or plastic materials
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1.2.2 Electrical Specifications Table 1-5. Electrical Requirements and Ranges
Description Rated voltage Input voltage range Rated frequency range Input frequency range Power consumption Power consumption while in standby mode 100 V Version 100 120 VAC 90 132 VAC 50 60 Hz 47 63 Hz Less than 500 W Less than 15 W (without option) Less than 600 W 200 V Version 220 240 VAC 198 264 VAC
1.2.3 Reliability Specifications
MPBF (Mean Prints Between Failures): Over 25,000 sheets Note: MPBF indicates the average number of pages printed before an occurrence of a problem requiring replacement or service. 3000 power on hours (POH) 1 out of 2,000 sheets or less (excluding multiple-sheet feeding) 1 out of 2,000 sheets or less (excluding multiple-sheet feeding) 1 out of 500 sheets or less 30 mm (1.2 inches) or less 1 out of 1,000 sheets 30 minutes or less 5 years or 1,800,000 sheets
MTBF (Mean Time Between Failures): Jam rate: Feed failure: Multiple paper feeds: Paper curl height: Leading edge bending (1 cm or more): MTTR (Mean Time To Repair): Durability:
1.2.4 Environmental Conditions for Operation (Including Imaging Cartridge)
Temperature: Humidity: Altitude: Levelness: Illuminance: Surrounding space: 10 to 35° C (50 to 95° F) 15 to 85% RH 2,500 m (8,200 feet) or lower 1° 3,000 lux or less (Must not be exposed to direct sunlight.) Printer should have at least 100 mm (4") of clearance on its sides and rear.
1.2.5 Environmental Conditions for Storage and Transportation
Temperature: Humidity: Drop test: Vibration: 0 to 35° C (32 to 95° F) 30 to 85% RH Clear to JIS Z0200-1987 Level 1 Vibration frequency 5 to 100 Hz and 100 to 5 Hz Acceleration 1G Acceleration direction 3 directions More than 61.3 KPa 18 months (following date of manufacture)
Resistance to atmospheric pressure: Storage life:
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1.2.6 Applicable Standards
Safety Standards
120 VAC model: 220/240 VAC model: UL 1950, CSA 22.2 No. 950 Deviation 3 EN 60950 (IEC950), NEMKO (IEC950), SETI (IEC950), SEMKO (IEC950), DEMKO (IEC950)
Safety Regulations (Laser Radiation)
120 VAC model: 220/240 VAC model: FDA (NCDRH) Class 1 VDE 0837 (Laser Class 1) (IEC825), SETI (IEC825), SEMKO (IEC825), DEMKO (IEC825)
EMI
120 VAC model: 220/240 VAC model: FCC Part 15 Subpart B Class B, DOC Class B Vfg 243 (VDE 0878 Part 3,30) EN55022 Class B (CISPR Pub. 22 Class B) CE marking, EMC
Others
Toner: OPC: Ozone: Materials: No effect on human health (OSHA-TSCA, EINECS) No effect on human health (OSHA) Less than 0.01 mmp other UL478 (5th edition) SWISS environmental law (must contain no CdS)
1.2.7 Specifications for Consumables
Life: Note: Developer and toner cartridge: 3,000 pages Photoconductor unit: 20,000 pages In continuous printing mode with A4/letter paper at a 5% image ratio (black/white ratio). The life varies, depending on the printing mode (continuous or intermittent) and/or the image ratio.
Environmental Conditions for Storage and Transportation
Temperature: Humidity: Drop test: Vibration: Resistance to atmospheric pressure: Storage term: 0 to 35° C (32 to 95° F) 30 to 85% RH Height 76 cm (30.4 inches) Same as printer More than 74 Kpa 18 months (following date of manufacture)
1.2.8 Physical Specifications
Dimensions (Width × Depth × Height): Printer: Weight: 352 × 264 × 299 mm (13.9 × 10.4 × 11.8 inches) Approx. 5 kg (11 lb), with consumables, excluding all options
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General Description
1.2.9 Software Specifications
Built-in modes: Microsoft Windows Printing System PCL4 (software emulation)
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General Description
EPL-5500W Service Manual
1.3 INTERFACE SPECIFICATIONS
The EPL-5500W is equipped with the following external interfaces: t Parallel interface
1.3.1 Parallel Interface
The parallel interface has the following two modes: t t ECP mode Microsoft Peppy mode
Pin assignments: Connector type: Applicable plug:
Fully IEEE-1284 compliant P90-25027-1 (Amphenol) receptacle 57-30360 (Amphenol or equivalent)
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General Description
1.4 OPERATING INSTRUCTIONS
This section describes printer functions, including control panel operation and messages.
1.4.1 Control Panel
The printer control panel gives you easy control over most common printer operations. The panel consists of the indicator lights described below.
GREEN Light
RED Light
Figure 1-3. Control Panel
Indicator Lights
t
GREEN light Printer is ready or idle. Printer is currently receiving data.
ON: Blinking:
t
RED light Printer has detected errors.
ON:
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1.4.2 Display of Messages
This printer indicates two types of messages with the status message window for the printer driver on the PC.
1.4.2.1 Status Messages
This section describes the status messages.
Table 1-6. Status Messages
Message Printer ready Printing Manual feed Paused Printing stopped Please wait Paused printer warming up Printer warming up Printer is ready. Printer is printing. Printer is loading paper from manual feed slot. Printer is in pause mode. Printer is stopping during printing of a job. Printer is in the wait condition. Printer is warming up. Printer is warming up. Status
1.4.2.2 Error Messages
This section describes error messages, what they indicate, and what measures to take to eliminate the error.
Table 1-7. Error Messages
Message Status The user is unable to redirect a port, or system software cannot find a file to complete a request. Memory in PC has run out. The printer is not connected to the local port when you are using PCL emulation. The printer does not return status information. The printer does not return status information. Printer is damaged. A paper jam occurred. Measures
Configuration error
Check the printer connection port, and reinstall the driver. Add the memory to the PC. PCL emulation does not support a network. Check the printer connection. Check the printer connection. Service required. Open the cover and remove the jammed paper. Then close the cover.
Low memory No local printer
Status not available Check printer/ cable Service error Clear paper jam
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Table 1-7. Error Messages (Continued)
Message Check Toner & Cover Status Printer is cover open or no toner cartridge is installed. Paper in the tray to be fed into the printer is different from the specified paper size. Paper settings are wrong. Measures Check the cover and toner cartridge. Check the paper size. Check the paper size settings.
Wrong paper loaded Change paper
1.4.3 Printing Resolution Host PC Capability Dependency
This printer driver calculates the host PC's capability every time Windows starts up, and the driver drops the printing resolution at the beginning of each job automatically if the value it detects will not allow complete printing at the resolution the user has set. This printer can print pages at the resolution if the HOST PC fulfill the following conditions.
Table 1-8. Host PC Conditions
Installed DRAM Quantity CPU Windows 3.1, WFW 3.11 < 8 MB 80386SX 16/20/25/33 MHz or compatibles 80386DX 16/20/25/33 MHz or compatibles 80486SX/DX 16/20 MHz or compatibles 80486SX/DX 25/33/50 MHz 80486DX2 50/66 MHz 80486DX4 75/100 MHz Pentium 60/66/75/90/100 120/133 MHz 300 DPI (Note 1) 300 DPI (Note 1) 300/600 DPI (Note 2) 8 MB 300 DPI (Note 1) 300 DPI (Note 1) 300/600 DPI (Note 2) Windows 95 < 8 MB 12 MB
--
--
300 DPI (Note 1) 300/600 DPI (Note 2)
300 DPI (Note 1) 300/600 DPI (Note 2)
300/600 DPI (Note 2)
300/600 DPI
300/600 DPI (Note 2)
300/600 DPI
Note 1: Note 2:
Some pages may be not be printed completely, depending on complexity of those pages. Some pages may not be printed at 600 DPI depending on complexity of those pages.
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1.5 MAIN COMPONENTS
To simplify maintenance and repair, the main components of the EPL-5500W have been designed for easy removal and replacement. The main components are: t t t t t t t t C180 MAIN Board PWB-E Board PWB-F Board Optical Unit Fusing Unit Photoconductor unit Developer cartridge Housing Main board Power supply circuit board High-voltage supply circuit board Printhead unit
C180 MAIN Board
Fusing Unit
PWB-E Board
Optical Unit
PWB-F Board
Figure 1-4. Main Components
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General Description
1.5.1 C180 MAIN Board
The C180 MAIN board contains a parallel interface controller and engine controller board. The primary functions of this board are receiving print data from the host and sending the print image to the engine controller via the video interface.
t Memory chips
4M-bit DRAM (U4)
t Custom ICs
ASIC E05B23 (U6) The engine controller consists of an M3807 x 8-bit CPU, including a MASK ROM. It controls laser scanning (the polygon mirror drive motor), image synchronization, laser beam pulse width, and power.
4M DRAM (U4) E05B23 (U6)
M3807 (IC201)
Figure 1-5. C180 MAIN Board
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General Description
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1.5.2 PWB-E Board
The PWB-E is the power supply board, which consists of a switching regulator circuit. It converts the AC line voltage into +24 V and +5 VDC voltages. There are two types of power supply board, the 100/120 V type and 220/240 V type. The difference between the two circuits is only in the input section.
CAUTION
Do not touch VR1 on PWB-E board. This volume is for factory setting only.
VR1
F1
Figure 1-6. PWB-E Board 1.5.3 PWB-F Board
The PWB-F is the high-voltage supply circuit board. It converts the development bias, OPC drum charge bias, and image transfer bias.
CAUTION
Do not touch VR3 on the PWB-F board. These volumes are for factory setting only.
VR3
Figure 1-7. PWB-F Board
1-14
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EPL-5500W Service Manual
General Description
1.5.4 Optical Unit
The optical unit consists of the laser diode (semi-conductor laser), the mirror motor (scanner motor) which drives the polygon mirror for laser scanning, and several mirrors and lenses. The laser beam generated by the laser diode is conducted to the OPC drum surface by way of the polygon mirror, as well as several mirrors and lenses, to create a latent electro-photographic image on the drum.
Figure 1-8. Optical Unit
1.5.5 Fusing Unit
The fusing unit fixes the toner to the paper using heat and pressure. This unit has a heater lamp, thermistor, and thermal fuse. There are two types of fusing units, the 120 V type and the 220/240 V type. The only difference between them is the heater lamp.
Figure 1-9. Fusing Unit
Rev. A
1-15
General Description
EPL-5500W Service Manual
1.5.6 Photoconductor Unit
Core mechanisms of the printing process, such as charging and imaging, are integrated into this unit.
Figure 1-10. Photoconductor Unit 1.5.7 Developing Cartridge
The developing mechanism for the printing process is integrated into this cartridge.
Figure 1-11. Developing Unit
1-16
Rev. A
Chapter 2
Operating Principles
Table of Contents
2.1 ENGINE OPERATION 2-1 2.1.1 Print Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 2.1.1.1 Paper Feeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 2.1.1.2 Drum Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 2.1.1.3 Laser Exposure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 2.1.1.4 Development . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 2.1.1.5 Image Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 2.1.1.6 Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 2.1.2 Engine Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 2.1.2.1 Main Motor Functions and Control . . . . . . . . . . . . . . . . . . . . . . . . 2-8 2.1.2.2 Paper Take-Up Sensor and Paper Exit Sensor. . . . . . . . . . . . . . . 2-9 2.1.2.3 Fuser Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 2.1.2.4 Scanner Mirror Motor Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 2.1.2.5 Laser Diode Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 2.1.2.6 Bias Voltages and Laser Drive Timing . . . . . . . . . . . . . . . . . . . . 2-13 2.1.2.7 Fan Motor Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 2.1.2.8 Power Supply Circuit Function and Safety Protection . . . . . . . . . 2-15 2.2 PARALLEL INTERFACE CONTROLLER OPERATION 2-16 2.2.1 C180 MAIN Board Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
List of Figures
Figure 2-1. Main Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Figure 2-2. Print Process Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Figure 2-3. Paper Feeding from the Paper Feed Tray . . . . . . . . . . . . . . . . . . . . 2-3 Figure 2-4. Drum Charge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Figure 2-5. Laser Exposure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Figure 2-6. Development . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Figure 2-7. Image Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Figure 2-8. Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Figure 2-9. Engine Controller Connecting Diagram . . . . . . . . . . . . . . . . . . . . . . 2-7 Figure 2-10. Gear and Roller Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Figure 2-11. Main Motor Drive Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Figure 2-12. Paper Take-Up Sensor and Paper Exit Sensor On/Off Timing . . . 2-9 Figure 2-13. Fuser Control Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Figure 2-14. Temperature for Fuser Control Procedure . . . . . . . . . . . . . . . . . . 2-10 Figure 2-15. Scanner Motor Control Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Figure 2-16. Laser Diode Drive Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Figure 2-17. LDATA Generation Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Figure 2-18. Laser Emission Power Adjustment Timing . . . . . . . . . . . . . . . . . . 2-12 Figure 2-19. High-Voltage Supply Block Diagram. . . . . . . . . . . . . . . . . . . . . . . 2-13 Figure 2-20. Print Process. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 Figure 2-21. Print Sequence (Start) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 Figure 2-22. Print Sequence (End) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 Figure 2-23. Power Supply Circuit Block Diagram . . . . . . . . . . . . . . . . . . . . . . 2-15 Figure 2-24. Parallel Interface Controller Section . . . . . . . . . . . . . . . . . . . . . . . 2-16 Figure 2-25. C180 MAIN Board Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . 2-16
List of Tables
Table 2-1. Functions of C180 MAIN Board Main Elements . . . . . . . . . . . . . . . 2-18
EPL-5500W Service Manual
Operating Principles
2.1 ENGINE OPERATION
This section describes the functions and operating principles of the EPL-5500W engine. Figure 2-1 shows the locations and names of the main engine components.
4
5 6
7
3 8
2 1
9
18
10 11
17 16
14 15
13
12
Figure 2-1. Main Components
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Fan Motor (M3) Lower Fusing Roller Paper Exit Sensor (PC3) Upper Fusing Roller Heater Lamp (H1) Paper Exit Roller Print Tray Optical Unit Toner Cartridge Manual Feed Guide 11. Paper Feeding Tray 12. Paper Lift-up Plate 13. Paper Take-up Roller 14. Paper Transport Roller 15. Paper Take-up Sensor (PC1) 16. Pre-image Transfer Roller 17. Electrode Comb 18. Drum Cartridge
Rev. A
2-1
Operating Principles
EPL-5500W Service Manual
2.1.1 Print Process
This section describes the print process from paper feeding to paper exit. Figure 2-2 shows a diagram of the print process.
Print Exit Optical Unit
Fusing
Drum Cartridge Drum Charge
Exposure
Image Transfer
Toner Hopper
Development Toner Cartridge
Paper Feeding Tray
Multi Feeding (150 sheets)
Manual Feed (1 sheet)
Figure 2-2. Print Process Diagram
2-2
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EPL-5500W Service Manual
Operating Principles
2.1.1.1 Paper Feeding
Paper can be fed into the printer from the paper feed tray (150 sheets) or from the manual feed slot (1 sheet at a time). Paper fed by the paper take-up roller is transported to the transport roller, pre-image transfer roller, and then exit roller. After this, the paper is fed out onto the print tray. The starting position of an image is decided by the paper take-up sensor (PC1). A photo sensor is used as the paper take-up sensor (PC1) and the paper exit sensor (PC3).
Paper Feeding Tray (Standard Tray)
When the paper take-up solenoid is energized, the main motor (M1) drive is transmitted to the paper take-up roller via the paper take-up clutch (a one-way clutch) to rotate the paper take-up roller one revolution. At the same time, the depression cam rotates and releases the paper lift-up plate to feed the top (first) paper. The fixed separating pad is used for the paper separation system. It prevents the second or later sheets from being fed together with the top paper.
Upper Fusing Roller Paper Exit Roller
Lower Fusing Roller
Paper Exit Sensor (PC3) Paper Take-Up Roller Depression Cam When SL1 is de-energized
PC Drum
Pre-Image Transfer Roller Paper Lift-Up Plate Fixed Separating Pad Transport Roller Paper Take-Up Sensor (PC1) When SL1 is energized
Paper TakeUp Clutch Paper Take-Up Solenoid (SL1) Paper Lift-Up Plate Paper
Figure 2-3. Paper Feeding from the Paper Feed Tray
Rev. A
2-3
Operating Principles
EPL-5500W Service Manual
2.1.1.2 Drum Charge
The PC drum is charged with static electricity before laser exposure. The rotating charge brush and pre-film are used as the charging method. Less ozone is generated by the corona charge of the rotating charge brush and the pre-film, and the PC drum can be charged with low voltage because the charge is directly applied to the PC drum. The charge brush is rotated by the drive of the M1 main motor via its gear.
Drum Cartridge Rotating Charge Brush PC Drum Protecting Shutter Drum Charging and Pre-film Bias PWB-F C180 MAIN IC201
PC Drum Protecting Shutter Charged Surface: (approx. -800 V) PC Drum
A
B A: Drum Charging Bias B: Drum Ground
Pre-film
Figure 2-4. Drum Charge
2-4
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EPL-5500W Service Manual
Operating Principles
2.1.1.3 Laser Exposure
The laser beam, emitted from the optical unit, makes an invisible static image. The SOS (start of scan) sensor, installed on the laser diode control board (PWB-D), unifies the laser emission timing for each scan line.
Charged Surface Reflector Mirror CN210 1 C180 MAIN IC201
5 Laser-Exposed Surface: (Approx. -50 V) PWB-D SOS Sensor Laser Diode 7 M2 CN205 1
Figure 2-5. Laser Exposure
2.1.1.4 Development
Toner is applied to the invisible static image on the PC drum and a toner image is created on the surface. When the PC drum starts to rotate (when the main motor is activated), the PC drum surface remains 0 V at the position between the rotating charge brush and sleeve roller. At this time, a specified positive voltage is applied to the sleeve roller to prevent toner from being attracted back onto the PC drum (reverse bias control).
2
4 3 Vs Terminal VBL Terminal VB (Developing Bias) VBL (Toner Blade Bias) PWB-F CN204 1 1 C180 MAIN IC201 VB Terminal
8 CN1F Vs (Lower Seal Bias)
8
Figure 2-6. Development
1. 2. 3. 4. 5. 6. 7. 8. Toner hopper: Contains toner. Toner agitating screw:Stirs the toner in the hopper and sends the toner to the toner transport roller. Toner transport roller: Transports the toner to the sleeve roller. Doctor blade: Spreads a thin, even coat of toner over the resin sleeve. The toner is negatively charged by passing between this blade and resin sleeve. Sleeve roller: Rotates the resin sleeve. Resin sleeve: Carries the toner to the PC drum surface for development. Bias seal: Collects the toner remaining on the resin sleeve. PC drum: Is exposed to the laser to create an invisible image and rotates to carry the developed image to the paper surface.
Rev. A
2-5
Operating Principles
EPL-5500W Service Manual
2.1.1.5 Image Transfer
The electrode comb is an image transfer system that transfers the toner image on the PC drum onto the paper.
Image Transfer Unit Housing Housing Electrode Comb Pre-Image Transfer Roller
C180 MAIN Electrode Comb PWB-F Housing 1 1 IC201 PWB-S 1 CN204 1
Pre-Image Transfer Roller Housing Ground Image Transfer Bias
8 CN1F
8
8
8
Figure 2-7. Image Transfer
2.1.1.6 Fusing
The toner image transferred onto the paper is fixed securely using a heat roller system as the fusing system. The upper fusing roller, which is heated by the heater lamp, fuses the toner image, which is securely fixed by the pressure between the upper and lower fusing rollers. Thermistor TH1 detects and controls the temperature of the upper fusing roller. Thermal fuse TF1 blows when the temperature exceeds 200° C (392° F), shutting down power to the heater lamp.
Thermal Fuse Thermistor Lower Fusing Roller Upper Fusing Roller Heater Lamp Paper
Figure 2-8. Fusing
2-6
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EPL-5500W Service Manual
Operating Principles
2.1.2 Engine Control
This section describes engine control, the power supply board, and the high-voltage supply board. The engine is controlled by the main board (C180 MAIN board). Figure 2-9 shows the engine controller connection diagram.
C180 MAIN Board Main Motor (M1) Polygon Motor (M2) Fan Motor (M2) Exit Sensor (PC3) Paper Take-up Sensor (PC1) Paper Take-up Solenoid (SL1) Fusing Roller Thermistor (TH1) Image Transfer Housing Image Transfer Charger PWB-F High Voltage Unit PWB-E Power Unit Heater Lamp Interlock Switch PWB-D Laser Diode Drive
PWB-S
Figure 2-9. Engine Controller Connection Diagram
Rev. A
2-7
Operating Principles
EPL-5500W Service Manual
2.1.2.1 Main Motor Functions and Control
The M1 main motor transmits the drive to the printer rollers and the optional second paper feed unit (lower cassette) via each gear, as shown below.
Toner Cartridge
Sleeve Roller Paper Exit Roller
A
Upper Fusing Roller Lower Fusing Roller
PC Drum
Pre-image Transfer Roller Main Motor (M1)
A
Optional Second Paper Feeding Unit Paper Take-Up Roller Paper Transport Roller
Figure 2-10. Gear and Roller Positions
2-8
Rev. A
EPL-5500W Service Manual
Operating Principles
Figure 2-11 shows the main motor drive circuit. The M1 main motor is a four-phase stepping motor, controlled by the CPU (IC201) on the main board (C180 MAIN). This board has a stepping motor driver IC that drives the M1 main motor with a constant current.
C1 80 MAIN Board M1 Main Motor
C N 206 A A B B 1 2 3 4
Figure 2-11. Main Motor Drive Circuit
2.1.2.2 Paper Take-Up Sensor and Paper Exit Sensor
The paper take-up sensor has three functions: 1. To detect the top edge of paper. The engine starts printing when the detection signal is received. 2. To detect paper size. The printer detects the time it takes for paper to pass the paper take-up sensor during paper feeding. If this time is long, longer paper is feeding; if the time is short, shorter paper is feeding. 3. To detect paper jams and feed jams. If the paper take-up sensor does not turn on for paper feeding, the printer detects a feed jam or no paper. A feed jam is a paper jam that occurs in the feed process. If any of the following conditions is detected, the printer detects a paper jam. A paper jam is a jam that occurs in the printing process area. The paper take-up sensor (PC1) or the paper exit sensor (PC3) is on at power on or when the upper case is closed. The paper take-up sensor (PC1) or the paper exit sensor (PC3) is not turned on or off within the specified time. (Refer to the following timing chart.)
Take Up Solenoid ON PC1 (CN203-3) PC3 (CN208-3) 2.0 11.0
[seconds]
3.5-4.5
3.4-4.7
Figure 2-12. Paper Take-Up Sensor and Paper Exit Sensor On/Off Timing
Rev. A
2-9
Operating Principles
EPL-5500W Service Manual
2.1.2.3 Fuser Control
The heater lamp, powered by AC voltage, heats the fuser. When the power supply board receives a FUSER signal from the main board (C180 MAIN), the power supply board (PWB-E) supplies the AC voltage to the heater lamp. This AC voltage is cut by an interlock switch when the case is open. Thermistor TH1 detects the surface temperature of the upper fusing roller and inputs that analog voltage to the 77-pin chip, IC201. Based on this temperature data, the heater lamp on/off signal (the FUSER signal) is output from the 54-pin chip, IC201, causing heater lamp H1 to turn on or off to control the fusing temperature. When the heater lamp is not turned off even if the thermistor detects a high temperature malfunction (which occurs if the surface temperature of the upper fusing roller exceeds 200º C), the signal from the 75-pin chip, IC201, changes from H to L to turn off the heater lamp forcibly.
C180 MAIN IC201 77
5 VDC
Analog Voltage Detected by the Thermistor (TH1)
CN202 1 2 TH1 Thermistor Heater Lamp H1 TF1 Thermal Fuse
54 75
H
L IC202B 4 L
2 H 3 5 6 H
IC202A 1 H
4
3 L
CN207 1 5 CN1E
1 5
PWB-E
CN3E 1 2 3
Heater Lamp ON/OFF Signal L H1:ON H H1:OFF
Figure 2-13. Fuser Control Circuit
The following figure shows the fuser temperature control procedure.
Temperature (Degrees C) 172 156 When a print is made immediately after warm up
112
Powe r On
Time
Warm up
Standby
Standby with Low Temperature
Figure 2-14. Temperature for Fuser Control Procedure
1. 2. After printer initialization, printer warm up starts, and the heater lamp turns on until the upper fusing roller's temperature reaches approximately 172º C (342º F). Standby: In standby mode, the upper fusing roller's temperature is controlled to maintain 156º C (313º F). When this condition continues for 3 minutes, the printer goes into standby mode at low temperature. Print cycle: When the printer receives the printing command from the controller, the upper fusing roller is controlled to maintain 172º C (342º F). Standby at low temperature: The upper fusing roller is controlled to maintain 112º C (234º F). Warm up:
3. 4.
2-10
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EPL-5500W Service Manual
If any of the following conditions are detected, the printer indicates a fuser error: 1.
Operating Principles
2. 3.
4.
If the thermistor detects the temperature has not risen by 20º C for 50 msec. within 12 to 30 sec. after warm up. (This error applies only when the thermistor detects a temperature of 90º C (194º F) or less.) If the thermistor detects that the temperature has not reached 172º C (342º F) within 60 sec. after warm up. Except in pause mode (see the note below), if the thermistor detects that the temperature in the idle state has fallen to 80º C (176º F) or lower for 50 msec., or the temperature during printing has fallen to 133º C (271º F) or lower. The thermistor detects that the temperature has exceeded 193º C (379º F) for 50 msec. during temperature control.
Note:
In Pause Mode, the control temperature is decreased to save power in the idle state, the heater lamp is turned OFF.
Thermo fuse TF1 cuts power if the temperature of the fusing section rises to an abnormally high level (over 200° C, 392° F).
2.1.2.4 Scanner Motor Control
Figure 2-16 is the scanner motor (M2) control circuit. The scanner motor is driven while it receives the POLYGON CTL signal. Motor rotation speed is 8622 rpm.
C180 MAIN Board M2 Scanner Motor CN210 NC +24V GND2 +5V P_CTL 1 2 3 4 5
Figure 2-15. Scanner Motor Control Circuit
If the any of following conditions are detected, the printer indicates a scanner motor error: 1. 2. 3. The SSCAN signal has not been given once within 1 sec. after the scanner motor is energized. The number of scanner motor rotations has not stabilized within ± 0.5 rpm by 4.2 sec. after the motor is energized. The number of scanner motor rotations has exceeded ± 3% for more than 0.5 sec. after the motor is energized, even if the rotation number stabilizes within ± 0.5 rpm.
Rev. A
2-11
Operating Principles
EPL-5500W Service Manual
2.1.2.5 Laser Diode Drive
Figure 2-16 shows the laser diode drive circuit. Laser diode emission is controlled by three signals (LDATA, LDAPC1, and LDAPC2) from the main board (C180 MAIN).
Laser Diode SSCAN LD_CTL LDAPC1 LDAPC2 L DATA SOS Sensor C180 MAIN B oard
LD SOS (PWB-D)
SOS Mirror
Figure 2-16. Laser Diode Drive Circuit
The LDATA signal is the laser on/off signal. When it is LOW, the laser emits, and when it is HIGH, the laser stops emitting. LDATA is the combination of the two signals in the figure below. If the VIDEO or the FORCED LASER DIODE ON signal is activated (LOW), the LDATA signal will be active. The VIDEO signal is an image signal sent from the video controller circuit. The FORCED LASER DIODE ON signal is a laser emission signal to apply the laser beam to the SOS sensor.
Forced Laser Diode ON
VIDEO from the Video Controller Circuit (C180 MAIN)
L DAT A
Figure 2-17. LDATA Generation Circuit
The laser diode is forcibly activated after scanner motor M2 turns on. At this time, laser emission power is adjusted. LDAPC1 and LDAPC2 are the laser emission power adjust signals; they are analog signals. LDAPC1 is a tuning, and LDAPC2 is a fine tuning signal.
Scanner Motor On LDATA
LDAPC1 LDAPC2
P_CTL
Figure 2-18. Laser Emission Power Adjustment Timing
If either of the following conditions is detected, the printer indicates a laser error: The LDAPC1 signal or LDAPC2 signal has been out of the specified range while laser power is adjusted.
2-12
Rev. A
EPL-5500W Service Manual
Operating Principles
2.1.2.6 Bias Voltages and Laser Drive Timing
Figure 2-19 is a diagram of the drum charge bias voltage, image transfer bias voltage, and the developing bias voltage control circuit. These bias voltages are generated from the +24 VDC from the high-voltage supply board (PWB-F). If the printer detects a case-open condition, the interlock switch is set to off, which cuts the +24 VDC, which, in turn, cuts the bias voltages. These bias voltages are controlled by the main board (C180 MAIN). The HV-T signal is the image transfer bias voltage control. While this signal is LOW, the image transfer electrode comb is charged to from +3 to +6K VDC by the high-voltage supply circuit. HV SEL1 and HV SEL2 are image transfer bias level control signals. The HVB signal is the digital signal for developing bias voltage control. This signal controls the bias on/off. The BIAS MON signal controls the bias voltage level (300 V to 375K VDC) using pulse data. The image density is controlled by the developing bias voltage level.
Power Supply Board (PWB-E) Main Board (C180 MAIN) PWB-S +24 VDC Interlock SW +24 VDC HV-C HV-T HV SEL1 HV SEL2 HV B BIAS MON High Voltage Supply Board (PWB-F) Drum Charge -2.0 K VDC Image Transfer Bias 3K to 6 K VDC
Developing Bias -270 to -370 VDC Toner Doctor Blade Bias -500 VDC Seal Bias -250 VDC
Figure 2-19. High-Voltage Supply Block Diagram
Rev. A
2-13
Operating Principles
Figure 2-20 shows the print process.
EPL-5500W Service Manual
Brush Roller Charging Laser Exposure
PC Drum
Development Image Transfer
Figure 2-20. Print Process
Figure 2-21 shows the start print sequence. The printer's engine starts printing when it receives the PRINT signal from the video controller circuit.
Normal M3 Rotation Print C o mm a n d Polygon Motor (M3) Paper Take-up Sensor (PC1) Paper Take-up Solenoid (SL1/2) Main Motor (M1) Drum Charge Laser Exposure Development Image Transfer 200 500 300 1st: 1510 2nd: 1680 2310 150 20 1st: 790 to 1300 2nd: 2670 to 3080 500 4000 [m sec.]
1st:770, 2nd:2820
260 480
Figure 2-21. Print Sequence (Start)
Figure 2-22 is the end of the print sequence.
[m sec.] Polygon Motor (M3) Paper Exit Sensor (PC3) Main Motor (M1) Drum Charge Laser Exposure Development Image Transfer 850
5160
480
Figure 2-22. Print Sequence (End)
2-14
Rev. A
EPL-5500W Service Manual
Operating Principles
2.1.2.7 Fan Motor Control
The fan motor (M3) rotates at engine initialization, and stops after 2 sec. The fan motor also rotates during printing. When printing ends, the fan motor stops after 3 min. If the following condition is detected, the printer indicates a laser error: The voltage equivalent to the motor current of the fan motor remains 160 mV or lower for 2 sec.
2.1.2.8 Power Supply Circuit Function and Safety Protection
The printer's power supply board (PWB-E) supplies the +5 VDC and +24 VDC. The +24 VDC is used as the bias voltage supply, main motor (M1) drive, scanner motor (M2) drive, fan motor (M3) drive, and solenoid drive. For safety protection, the +24 VDC line is cut when the interlock switch (case open switch) is off.
Interlock SW +24 VDC +5 VDC
AC IN
Power Supply Board (PWB-E)
SG FG
Figure 2-23. Power Supply Circuit Block Diagram
Rev. A
2-15
Operating Principles
EPL-5500W Service Manual
2.2 PARALLEL INTERFACE CONTROLLER OPERATION
The parallel interface controller section converts from a bidirectional parallel interface to a video interface. The parallel interface controller section is in the C180 MAIN board.
C180 MAIN Board Parallel Interface Controller Section
Engine Controller Section
Figure 2-24. Parallel Interface Controller Section 2.2.1 C180 MAIN Board Operation
Figure 2-25 shows a block diagram of parallel interface controller section of the C180 MAIN board.
Bidirectional Parallel I/F
E05B23 (U8)
Engine Controller Section
4M DRAM (U4)
Figure 2-25. C180 MAIN Board Block Diagram
2-16
Rev. A
EPL-5500W Service Manual
Operating Principles
Table 2-1 lists the functions of the main elements of the video controller section in the C180 MAIN board.
Table 2-1. Functions of C180 MAIN Board Main Elements
Element E05B23 ASIC DRAM Location U8 U4 Function This ASIC contains the following functions: Changing from parallel I/F to video I/F. DRAM management (refresh control, RAS/CAS control). These DRAMs are used as the working area of the E05B23.
Rev. A
2-17
Chapter 3
Disassembly and Assembly
Table of Contents
3.1 GENERAL INFORMATION 3.1.1 Precautions for Disassembly/Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1.2 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1.3 Small Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1.4 Service Checks after Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3-1 3-1 3-2 3-3
3.2 DISASSEMBLY AND ASSEMBLY 3-4 3.2.1 Housing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 3.2.1.1 Case Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 3.2.2 Removal of the Controller Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 3.2.2.1 Main Board (C180 MAIN Board) Removal . . . . . . . . . . . . . . . . . . 3-5 3.2.3 Disassembling the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 3.2.3.1 Optical Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 3.2.3.2 Image Transfer Roller Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 3.2.3.3 Upper Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 3.2.3.4 High-Voltage Supply Board (PWB-F) Removal . . . . . . . . . . . . . . 3-10 3.2.3.5 Power Supply Unit (PWB-E) Removal. . . . . . . . . . . . . . . . . . . . . 3-11 3.2.3.6 Fusing Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 3.2.3.7 Fusing Unit Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
List of Figures
Figure 3-1. Removing the Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Figure 3-2. Removing the Shield Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Figure 3-3. Removing the C169 MAIN-B Board . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Figure 3-4. Removing the Optical Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Figure 3-5. Removing the Image Transfer Unit -1. . . . . . . . . . . . . . . . . . . . . . . . 3-7 Figure 3-6. Removing the Image Transfer Unit -2. . . . . . . . . . . . . . . . . . . . . . . . 3-7 Figure 3-7. Moving the Image Transfer Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Figure 3-8. Reinstalling the Electrode Comb . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Figure 3-9. Removing the Harness Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Figure 3-10. Removing the Upper Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Figure 3-11. Removing the PWB-F Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Figure 3-12. Removing the PWB-F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Figure 3-13. Removing the PWB-E Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Figure 3-14. Removing the PWB-E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Figure 3-15. Gear and Spring Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Figure 3-16. Removing the Fusing Guide Plate . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Figure 3-17. Removing the Harness Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 Figure 3-18. Removing the Fusing Entrance Guide . . . . . . . . . . . . . . . . . . . . . 3-13 Figure 3-19. Removing the Fusing Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 Figure 3-20. Roller Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 Figure 3-21. Removing the Heater Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 Figure 3-22. Removing the Thermistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 Figure 3-23. Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 Figure 3-24. Removing the Paper Separator . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 Figure 3-25. Paper Exit Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 Figure 3-26. Removing the G-Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Figure 3-27. Removing the Upper Fusing Roller . . . . . . . . . . . . . . . . . . . . . . . 3-18 Figure 3-28. Removing the Lower Fusing Roller . . . . . . . . . . . . . . . . . . . . . . . 3-19 Figure 3-29. Removing the Thermal Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
List of Tables
Table 3-1. Table 3-2. Table 3-3. Table 3-4. Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Abbreviations Used for Screws. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Screw Types and Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checks after Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3-2 3-2 3-3
EPL-5500W Service Manual
Disassembly and Assembly
3.1 GENERAL INFORMATION
This chapter describes disassembly/assembly procedures to use to replace the main assemblies of the EPL-5500W.
3.1.1 Precautions for Disassembly/Assembly
Follow the precautions below when disassembling/assembling the printer.
WARNING
Ì Disconnect the power cord before disassembling/assembling the printer. Ì Be sure to handle the fusing unit carefully, because the unit remains hot for a while after the printer stops printing. Ì If it is necessary to plug in the power cord and operate the printer after disassembling it, please be careful of the following: 1.Keep your hands and clothing well away from operating or rotating parts (such as rollers, fan motors, etc.). 2.Never touch electric terminals or high-voltage components (such as the charger and the high-voltage unit).
CAUTION
Ì Do not disassemble the photoconductor unit and toner cartridge. Ì If the photoconductor unit is removed from the printer, do not place it in direct sunlight. Ì Do not disassemble the optical unit. Ì Never turn power on if the optical unit is not installed. Ì To prevent damage to ICs from static electricity, do not touch the ICs on the circuit board or the terminals of peripheral electrical components with your hands. Ì Use only the recommended tools to ensure safe and efficient maintenance work. Inappropriate tools may damage the machine. Ì Never open the upper unit until the main motor stops completely. Otherwise, the gears may be damaged. Ì When transporting the printer, remove the photoconductor unit and toner cartridge from the printer. Ì When transporting the printer a long distance, pack up the printer using the original packing material.
3.1.2 Tools
Use the tools listed in Table 3-1 for disassembling/assembling the printer and for troubleshooting.
Table 3-1. Tools
Name Philips screwdriver no. 2 Regular screwdriver Tweezers Soldering iron Round-nose pliers Commercially Available? Yes Yes Yes Yes Yes Part No. B743800200 B743000100 B641000100 B740200100 B740400100
Rev. A
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3.1.3 Small Parts
In the following sections, abbreviations are used for small parts, such as screws and washers. Tables 3-2 and 3-3 list these abbreviations.
Table 3-2. Abbreviations Used for Screws
Abbreviation CP CC CP(O) CP(S)(P1) CCB SCB SCB(S)(P1) Part Name Cross-recessed Pan head Cross-recessed Cup head Cross-recessed Pan head with Outside-toothed lock washer Cross-recessed Pan head with Spring lock washer and 1 Plain washer Cross-recessed Cup head Bind Slotted Cross-recessed B-tight Slotted Cross-recessed Bind with Spring washer and 1 Plain washer
Table 3-3. Screw Types and Abbreviations
Head Body Top 1.Cross-recessed head 1.Bind Side 1.Normal Washer (Assembled) 1.Plain washer 1
-----------
2.Slotted Crossrecessed head
2.Pan
2. B-tight
2.Outside-toothed lock washer
3.Cup
3.Spring washer
3-2
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Disassembly and Assembly
3.1.4 Service Checks after Repair
Check the repaired unit using the following list on completion of servicing.
Table 3-4. Checks after Repair
Item Location Control panel Heater lamp Test Page Data print Print position Checkpoint Do all LEDs and buttons function normally? Does the heater lamp turn on normally? Is the test page printed normally? Does data print in all modes? Is the gap between the top edge of the paper and the horizontal line in the adjustment printing sheet print exactly 4.2 mm (0.17 inch). Is toner and dust removed from the paper path? Is the paper take-up roller cleaned? Is the roller in the fusing unit cleaned? Is the outer surface of the printer clean? Are the consumables removed from the printer? Is the unit packed securely? Are accessories packed also? Check
Operation
Adjustments
Cleaning
Packing
Rev. A
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EPL-5500W Service Manual
3.2 DISASSEMBLY AND ASSEMBLY
This section describes and illustrates procedures for removing and disassembling components of the EPL-5500W. Cleaning is described in Chapter 6. The assembly procedures are not described, except for special notes where necessary, because assembly can be accomplished by performing disassembly in reverse.
3.2.1 Housing Removal
This section describes how to remove the cases and the rear frame.
3.2.1.1 Case Removal
1. 2. Push the upper unit lock release button, and open the upper unit. Remove each cover in the following order.
ASSEMBLY POINT
When reinstalling each cover, securely insert the protrusions for the cover into the cutouts in the printer frame.
4. Rear Cover
Upper unit Upper unit lock release button
3. Operation Cover
2. Front Cover
1. Left cover
Figure 3-1. Removing the Housing
3-4
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EPL-5500W Service Manual
Disassembly and Assembly
3.2.2 Removal of the Controller Section
The control section is comprised of the controller board (the C180 MAIN board).
3.2.1.1 Main Board (C180 MAIN Board) Removal
1. 2. 3. Turn the printer so that its right side faces you. Remove the right cover. Remove 2 screws, and then remove the shield case.
Figure 3-2. Removing the Shield Case
4. 5. 6. Disconnect all connectors on the C180 MAIN board. Remove the 5 screws for the C180 MAIN board. Remove the C180 MAIN board.
Figure 3-3. Removing the C180 MAIN Board
Rev. A
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EPL-5500W Service Manual
3.2.3 Disassembling the Engine
This section describes disassembling the engine, including the high-voltage unit (PWB-F) and power supply board (PWB-E).
3.2.3.1 Optical Unit Removal
CAUTION
Ì Do not touch the optical unit, except during replacement. Ì Do not open the unit under any conditions. Ì Do not remove the circuit board from the optical unit under any conditions. 1. 2. 3. 4. 4. 5. Open the top cover. Remove the right cover, left cover, and front cover. (Refer to Section 3.2.1.1.) Remove the cover shield plate. Disconnect connectors CN205 and CN210 from the C180 MAIN board. Remove the 6 screws from the optical unit. Remove the optical unit.
Figure 3-4. Removing the Optical Unit
3-6
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Disassembly and Assembly
3.2.3.2 Image Transfer Unit Removal
1. 2. 3. Open the top cover. Remove harness cover A. (Refer to Section 3.2.3.3.) Remove the 2 screws and holders at both ends of the image transfer unit.
Figure 3-5. Removing the Image Transfer Unit - 1
4. Disconnect the 2 connectors and remove the unit.
Figure 3-6. Removing the Image Transfer Unit - 2
Rev. A
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EPL-5500W Service Manual
ASSEMBLY POINT
After reinstalling the image transfer unit, check that the unit smoothly moves up and down.
Figure 3-7. Moving the Image Transfer Unit
5.
Remove the electrode comb.
ASSEMBLY POINT
When reinstalling the electrode comb, be careful of the direction of installation. Install the electrode comb so that the comb terminal faces the image transfer roller drive gear.
Figure 3-8. Reinstalling the Electrode Comb
3-8
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EPL-5500W Service Manual
Disassembly and Assembly
3.2.3.3 Upper Unit Removal
1. 2. 3. 4. 5. Open the upper unit. Remove the right cover and left cover. (Refer to Section 3.2.1.1.) Disconnect connectors CN202, CN208, and CN211 from the C180 MAIN. Remove harness covers A and B, and pull CN1 out from the PWB-E board. Remove the image transfer unit. (Refer to Section 3.2.3.2.)
A B
Figure 3-9. Removing the Harness Cover
6. Slide and remove the unit as shown in the illustration.
Figure 3-10. Removing the Upper Unit
Rev. A
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EPL-5500W Service Manual
3.2.3.4 High-Voltage Supply Board (PWB-F) Removal
1. 2. 3. Open the top cover. Remove 1 screw from the PWB-F cover. Remove the PWB-F cover.
Figure 3-11. Removing the PWB-F Cover
4. 5. 6. Remove the 4 screws from the PWB-F board. Disconnect 2 connectors. Remove the PWB-F board.
Figure 3-12. Removing the PWB-F
3-10
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Disassembly and Assembly
3.2.3.5 Power Supply Unit (PWB-E) Removal
1. 2. Remove the upper unit. (Refer to Section 3.2.3.3.) Remove 6 screws, and remove the PWB-E cover.
Figure 3-13. Removing the PWB-E Cover
3. 4. Disconnect connector CN207 from the C180 MAIN board. Remove 4 screws and 2 screws, and then remove the PWB-E.
Figure 3-14. Removing the PWB-E
Rev. A
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EPL-5500W Service Manual
3.2.3.6 Fusing Unit Removal
1. 2. 3. 4. 5. Open the top cover. (Refer to Section 3.2.3.3.) Remove the image transfer unit. (Refer to Section 3.2.3.2.) Remove 1 screw, and remove the drive tension section of the fusing unit. Remove the transport gear. Release the hook for the spring and remove the drive gear section of the fusing unit.
ASSEMBLY POINT
When rehooking the spring, be sure to hook it in the correct position.
drive gear section of the Fusing unit drive transport gear hook of the spring
drive tension section of the Fusing unit
Figure 3-15. Gear and Spring Position
6.
Remove 2 screws, and remove the fusing guide plate.
Figure 3-16. Removing the Fusing Guide Plate
3-12
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EPL-5500W Service Manual
7. Remove the harness cover.
Disassembly and Assembly
Figure 3-17. Removing the Harness Cover
8. Remove the fusing entrance guide.
Figure 3-18. Removing the Fusing Entrance Guide
Rev. A
3-13
Disassembly and Assembly
10. Remove 4 screws, and remove the fusing unit.
EPL-5500W Service Manual
Figure 3-19. Removing the Fusing Unit
ASSEMBLY POINT
After reinstalling the fusing unit, check the direction of the bushings on the paper exit roller and the connection between the rolle