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EPSON TERM NAL PRINTER
Myk. 800
SERVICE MANUAL
EPSON
)
4001968 Rev. A
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 © 1992 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.
WARN/NG Signals a precaution which, if ignored, could result in damage to equipment.
The precautionary measures itemized below should always be observed when performingrepair/ 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. 2. REPAIRS ON EPSON PRODUCT SHOULD BE PERFORMED ONLY BY AN EPSON CERTIFIED REPALR 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
3.
4.
5.
- ii -
PREFACE
This manual describes functions, theory of electrical and mechanical operations, maintenance, and repair of stylus 800. 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 amd exploded diagram.
The contents of this munual are subject to change without notice.
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Revision Rev. A
Issue Date December 18, 1992
Revision Page First issue Added information: Chapter 2 (Page 2-23) Chapter 3 (Page 3-5/6) Chapter 6 (Page 6-1/2) Corrected the figure: Chapter 2 (Page 2-8) Added information: Appendix (Page A-i, A-5', A-7', A-8', A-9', A-1 O')
Rev. B
May 7, 1993
Rev. C
June 11, 1993
Rev. D
March 10, 1994
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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
- vi -
Chapter 1
General Description
Table of Contents 1.1 FEATURES
1-1
1-2 1.2 SPECIFICATIONS 1.2.1 Printing Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2 1.2.2 Paper Handling Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. ...1-4 1.2.3 Paper Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............1-4 1.2.4 Ink Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ......1-6 1.2.5 Environmental Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. ....1-7 1.2.6 Electrical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ......1-7 1.2.7 Reliability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .........1-8 1.2.8 SafetyApproval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..............1-8 1.2.9 Physical Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..........1-8 1.3 INTERFACE SPECIFICATION 1-9
1-11 1.4 PRINTER OPERATIONS 1.4.1 control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . ~ . ................1-1 1 1.4.2 Panel Operation at PowerOn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..1-12 1.4.3 Default Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. ...1-12 1.4.3.1 Default Setting Item . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. ...1-12 1.4.4 Initial Ink Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. ..1-13 1.4.5 Error Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .....1-13 1-14 1.5 MAIN COMPONENTS 1.5.1 Main Control Board (C106 MAIN BOARD) . . . . . . . . . . . . . . . . . . . . . .. .1-14 1.5.2 Power Supply Unit (C106 PSB/PSE BOARD) . . . . . . . . . . . . . . . . . . . . .1-15 1.5.3 Printer Mechanism (M-481O) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .....1-15
List of Figures
Figure 1-1. View of the Stylus 800 . . . . . . . . . . . . . . . . . . . . . ...............1-1 Figure l-2. Nozzle Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ......1-2 Figure 1-3. Printable Area - Cut Sheet (Built-in Sheet Feeder) . .............1-5 Figure 1-4. Printable Area - Cut Sheet/ Envelope (Manual Insertion Slot) .. ...1-5 Figure 1-5. Adjust Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..........1-6 Figure 1-6. Temperature / Humidity Range . . . . . . . . . . . . . . . . . . . . . ........1-7 Figure 1-7. Data Transmission Timing . . . . . . . . . . . . . . . . . . . . . .........-..1-9 Figure 1-8. Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..1-11 Figure 1-9. C106 MAIN BOARD Component Layout . . . . . . . . . . . . . . . . . . . . .1-14 Figure l-10. C106 PSB/PSE BOARD Component Layout . . . . . . . . . . . . .....1-15 Figure 1-11. Printer Mechanism (M-481O) . . . . . . . . . . . . . . . . . . . . . . . . .....1-15
Rev. A
l-i
List of Tables
Table 1-1. Print Speed and Printable Columns . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Table 1-2. Character Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Table l-3. Adjust Lever Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ......1-6 Table l-4. Environmental Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...1-7 Table l-5. Electrical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. ...1-7 Table l-6. Signal and Connector Pin Assignments . . . . . ..................1-9 Table l-7. Default Setting Item . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .....1-12 Table l-8. Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .....1-13
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I-ii
Rev. A
STYLUS 800 Service Manual 1.1
General Description
FEATURES
The Stylus 800 is a serial inkjet printer that uses a newly developed inkjet technology to accomplish a superb quality output with high-speed printing. The major features of this printer are: Ll High print quality from a new inkjet technology. Cl Fast printing of LQcharacters at 150 cps. Cl Compact design saves precious work space. Ci Built-in auto sheet feeder with a capacity fora maximum of 100 cut sheets (either A4 or Letter). D Equipped with 4 scalable fonts and 15 bit-mapped fonts, standard. CI 8 character tables for the U.S. 6 character tables for Pacific countries. 16 character tables for European countries. The figure below shows a view of the printer.
printer cover
panel
paper separator
paper feeder cover
Figure 1-1. View of the Stylus 800
Rev. A
1-1
General Description
STYLUS 800 Service Manual
1.2 SPECIFICATIONS
This section provides detailed statistics for this printer.
{
1.2.1 Printing Specification
Print system:
Nozzle configuration:
On-demand ink jet system 48 nozzles (12 nozzles x 4 staggered columns)
Paper feed direction
0
I i I i
I .
I i I i
I.
II I,, I I I
i
# 4 Qi 5 .
i' . ., *
Figure 1-2. Nozzle Configuration
Printer direction: PMt speed: Printable columns: Bidirectional printing with logical seeking control See Table 1-1. See Table 1-1.
Table 1-1. Print Speed and Printable Columns
Character Pitch 10 cpi 12 cpi 15 cpi 17 cpi (l Ocpi/Condensed) Printable Columns Print Speed (LQ)
80
96 120 137 160
150 Cps
180
CPS
225 CPS 257 Cf)S 300 Cps
20 cpi (12 cpVCondensed)
f' -..
,,
1-2
Rev. A
STYLUS 800 Service Manual
Geneml Descri@ion
Character sets: Character tables:
Legal and 14 international character sets. See Table 1-2.
Table 1-2. Character Tables
Character Table ITALIC PC437 (U.S./Standard Europe) PC850 (Multilingual) PC860 (Portuguese) PC863 (Canadian-French) PC865 (Nodic) PC437 Greek PC851 (Greek) PC852 (East Europe) PC853 (Turkish) PC855 (Cyrillic) PC857 (Turkish) PC866 (Russian) ABICOMP BRASCII US Version European Version Pacific Version
I I
o o o o o o
x x x x x x x
I I
0 0 0 0 0 o o o o o o o o
x
x
I I
0 0 0 0 0 o
x x x x x x x
I
o o
I
I
x x
Fonts:
[Bit-mppedfonts] - EPSON Roman - EPSON %ns serif - EPSON Courier - EPSON Prestige - EPSON Script
(lOcpi/12cpi/15cpi/Proportional) (10/12/15/Proportional) (10/12/15) (10/12) (10/12)
IScaldlefmtsl - EPSON Roman
- EPSON %ns serif - EPSON Roman T - EPSON !%IIS %rif H Print mode:
[For Bit-mppedfontsl
8-32 8-32 8-32 8-32
points points points points
(Unit= (Unit= (Unit= (Unit=
2 2 2 2
points) points) points) points)
Selection ~-d &xture of the following mode are allowed. - Print quality (LQ) - Character pitch (10/12/15 cpi or proportional) - Condensed (not available with 15 cpi character pitch) - Double height - Double width - Emphasized - Double strike - Italic - Underline - Double underline - Overscore - Shadow / outline - Strike through IForscalablefonts] - Emphasized - Italic - Double underline - Strike through Control codes:
Rev. A
- Double stike - Underline - Overscore - Shadow / outline
EC,~//~~ 1-3
General Description
STYLUS 800 Sewice Manual
1.2.2 Paper Handling Specification
Feeding system: Friction feed from built-in sheet feeder or manual insertion slot.
Notes: The following operation are not al/owed. 1. Reverse feeding within 3 mm (O. 12 inches) from the top edge of the paper or 16 mm (0.63 inches) from the bottom edge of the paper. 2. Reverse feeding beyond 7.9 mm (0.3 inches).
.f"" :. .. .
Feeding pitch: Paper path: Feeding speed:
1/6, 1/8 inch feed or programmable with a 1/360 inch minimum increment. Built-in sheet feeder (front entry) Manual insertion slot (Top-rear entry) 87 msec. (at 1/6 inch feed pitch)
1.2.3 Paper Specification
Usable paper: Cut sheet ~ith Built-in sheet feeder] Size: For European/Pacific version: A4 (wX L :210mm (8.3")X 297mm (11.7")) For U.S. version: Letter (W x L: 216 mm (8.5") x 279 mm (11.0")) 0.065-0.14 nun (0.0026 - 0.0055") 64 - 90g/m2 (18 -24 lb./55 - 78 Kg) Bond Paper, Photocopier paper 182-216 mm (7.2 - 8.5") 257- 297mm (10.1 - 11.7") 0.065-0.11 mm (0.0026- 0.0043") 52- 90g/m2 (14 -24 lb / 45- 78 Kg) Bond Paper, Photocopier paper #6 (W X L : 166 mm (6%") X 92 mm (35/8")) #10 (Wx L: 240 mm (914") x 104 mm (4%")) 0.16-0.52 mm (0.0063 - 0.0197")
i.:,,-
Thickness: Wighk Quality: Width: Length: Thickness: Wight: Quality: Size: Thickness:
Note:
[With manual insertion]
The variation in paper thickness within the printable area must be 0.25 mm (0.0098~ or less.
Weight: Quality:
45-90 g/m2 (12 -24 lb.) Bond paper, Airmail, Photocopier paper
f'
Notes 1. Envelopes are usable only with manual insertion feed. 2. Printing with envelopes guaranteedonly under normal temperature and humidity condition. 3. Insert envelopes into the manual insertion slot sideways.
,. ,.
1-4
Rev. A
STYLUS 800 Service Manual
Geneml Description
Printable area:
Cut Sheet (with built-in sheet feeder)
-- c (Right marain]~ .
r
B (Left marain)>
4
r
Printable area
!
A (Top margin)
ID
I (Bottom margin)
1
Figure 1-3. Printable Area - Cut S~eet (Built-in Sheet Feeder)
Cut Sheet / Envelope (with the manual insertion slot)
B (Left marain) ~.*
c
Printable area
A (Top margin)
L &ottom margin)
Figure 1-4. Printable Area - Cut Sheet/ Envelope (Manual Insertion Slot)
Note: A: The minimum top margin= 3 mm (0.12") B: The minimum left margin= 3 mm (O. 12") A4 size= 3.8 mm (O. 15") C: The minimum right margin is: Letter size = 9.7mm (0.38') Manual insettion = 3 mm (O. 12'9 D: The minimum bottom margin= 13 mm (0.51')
Rev. A
1-5
General Description
SNLUS 800 Service Manual
Adjust lever settings:
The adjust lever, attached to the carnage unit, must be set to proper position for the paper thickness, as shown in Table 1-3.
Table 1-3. Adjust Lever Settings
Lever Position
LEFT RIGHT Paper Type Cut Sheets Envelopes Paper Thickness
~;%26--00~iO!$ 0 . 1 6 - 0.52 mm (0.0063- 0.020")
Plain paper,
(-..
I
I \
/1
Figure 1-5. Adjust Lever 1.2.4 Ink Cartridge
Type: Ink color: Print capacity: Exclusive cartridge (S020025) Black 0.7 million characters (LQ)
- . . . . . . . . . . . - . . . . . . . . .-
-. I
Note: This figure is equivalent to a 700page print volume when printing is performed at 1000 characters perpage on letter or A4-size paper.
Ink Capacity: Life:
29.0 +0.5/-1.0 CC
The effective
Temperature conditions:
life from the indicated production date is: -2 years (total period of time in package and after unpacking) -6 months (after unpacking) -30- 40"C (-22 -104 `F) [Storage]
(UDto1monthat40`C
(140 " F ) )
[Transport] ~36- 60"C (-22 -140 "F) "" (Up to 1 month at40"C (104 "F) or 120 hoursat60"C
(140 `F)) Note: The ink inside the ink cartridge freezes if it kept below -3'C (26.6"F). It requires several hours to unfreeze at room temperature (25 `C (77°~).
Dimension:
28.5 mm (1.12") Width 54.5 mm (2.15") Depth Height 38.5 mm(l.52")
STYLUS 800 Service Manual
Genera/ Descriptim
1.2.5 Environmental Conditions Table 1-4. Environmental Conditions
Description Temperature Humidity Resistance to shock Resistance to vibration Note: Operating 10-35 `c (50 - 95 `I=)(*1) 20- 80% RH (*1,*3) 1 G, within 1 msec. 0.15 G, 10-55 Hz Storage -20- 60 "C (-4 - 140 `F) (*2) 585~0
RH (*2,*3)
2 G, within 2 msec. (*2) 0.50 G, 10-55 Hz (*2)
q 1 = Operating conditions must be in this range.
*2= When the printer is in the shipping container. q3 = Without condensation. Humidity (%RH) 80Y0 ....... Print assured range ........ /
55~o
20?/0
10" C
(50" F)
27° C (80" F)
35°C (95" F)
`c ("F)
Figure 1-6. Temperature/ Humidity Range 1.2.6 Electrical Specifications Table 1-5. Electrical Specifications
Item Rated voltage Input voltage range Rated frequency range Input frequency range Rated current Power consumption 120V Version 120V AC 103.5- 132V 50- 60 Hz 49.5- 60.5 Hz 0.5 A 220- 240V Version 220- 240V AC 198- 264V 50- 60 Hz 49.5- 60.5 Hz 0.3 A
Approx. 13W Approx. 13W (self test with 10 cpi LQ characters) (self test with 10 cpi LQ characters) 10 MQ, minimum 10 MQ, minimum (applying 500VDC between AC line (applying 500VDC between AC line and chassis) and chassis) 10OOVAC rms -1 minute or 1200VAC rms -1 second (between AC line and chassis) 1500VAC rms -1 minute (between AC line and chassis)
Insulation resistance
Dielectric strength
Rev. A
1-7
General Description
STYLUS 800 Service Manual
1.2.7 Reliability
MTBF: MCBF: Printhead life: Total print volume: 4000 power on hours (POH) at a duty cycle of 10% 3 million lines (excluding the printhead) 1 billion dots per nozzle
75000 pages (with A4 or Letter size paper)
1.2.8 Safety Approval
Safety standards: US version: European version: Radio frequency interface (RFI): US version: European version:
CSA22.2 %220
UL1950 with D3
EN 60950 (~V) IEC 950 (SEMKO, DEMKO, NEMKO, SETI) FCC part 15, subpart B, Ck.S B Vfg. 243 (VDE 0878 part 3, part 30) EN 55022 (CISPR Pub.22) class B
1.2.9 Physical Specification
Size (W x D x H): Weight
435 X 264X
i~ (mm)
(17.1X 10.4X 6.1 (inch))
Approx. 5.0 Kg (excluding ink cartridge)
,(""
..
. . .
1-8
Rev. A
SNLUS 800 Service Manual
GenemlDescription
1.3 INTERFACE SPECIFICATION
The Stylus 800 is equipped with an 8 bit parallel interface, standard. Data format: Synchronization: Handshaking: Signal level: Adaptable connector: Data transmission timing: 8 bit parallel STROBE pulse swchronization By BUSY and ACKNLG signals TTL-compatible level 36-pin 57-30360 (Amphenol) or equivalent See Figure 1-7.
i'b-\ DATA
STROBE-- --
Figure 1-7. Data Transmission Timing
Table 1-6 shows the connector pin assignments and signal functions of the 8-bit parallel interface.
L!&
L- O. SuS(Min.)
O. SuS(Min.) O. SuS(Min.)
Table 1-6. Signal and Connector Pin Assignments
Pin No. Signal Name
1/0
I
Description The STROBE pulse is used to read data from the host computer. The pulse width must be 0.5@ or more. Normally, it is HIGH, and data is latched with rising edge of this signal. DATA 1-8 are parallel data bits. When one of these signals is HIGH, the data bit is 1; when LOW, the data bit is O. The most significant bit (MSB) is DATA 8. The signal state must be maintained for 0.5 pS on either side of STROBE signal's active edge. ACKNLG is an acknowledge pulse with a width of approximately 10 vS. This signal goes LOW upon the completion of data reception, to indicates that the printer is ready to receive further data. The BUSY signal informs the host computer of the printe~s status. When this signal is HIGH, the printer cannot accept further data. This signal indicates whether paper is available in the printer or not. A HIGH level indicates a no paper condition. Pulled up to +5V through a 1.0 KQ resistor in the printer. If this signal is set to LOW, the printer automatically performs one line feed upon receipt of a CR (carriage return) code. The status of this signal is checked only at power on and initialization.
1
STROBE
2-9
DATA 1-8
I
10
ACKNLG
o
11
BUSY
o
12 13
PE SLCT
o o
14
AFXT
I
15
Rev. A
NC
Not USed.
1-9
General Description
SNLUS 800 Service Manual
Table 1-6. Signal and Connector Pin Assignments (Continued)
Pin No. Signal Name
I/o
Signal ground. -
Description
16
17
GND
CHASSIS-GND
Chassis ground. (Both chassis ground and signal ground are connected in the ptinter.)
18 19-30
31
NC
GND INIT I
Not USed.
Twisted-pair return signal ground. If this signal goes LOW, the printer is initialized. The pulse width of this signal must be 50 pS or more. This signal goes LOW if the printer: - has a fatal error. - runs out of paper. Signal ground. Not USed. Pulled up to +5 Vthrough 1.0 KW resistor in the printer. Not used. (* Reserved.)
32
33 34
ERROR GND NC
o
. .
35
36 Note:
+5V
-
.
.
(-
The direction of the signal is as viewed from the printer.
1-1o
Rev. A
STYLUS 800 Service Manual
General DescriWion
1.4 PRINTER OPERATIONS
This section describes the basic operations of the printer.
1.4.1 Control Panel
The control panel of this printer contains five non-lock type push buttons and nine LED indicators for easy operation of the various printer functions. r \
O PAPER OUT O INK OUT [ jALT
II o
I
5
I
ECONOMY
/10
1'
I
h.
CONDENSED
[
,,
1
1
ju
I
I
r
000
,
r
J
I
FONT D
Q
Ii3
[Buttons]
Romm T PS) ~:a: ($ s)
Prestige script
Courier
Saris Sarif
LOAD / EJECT
5
R E SET
Figure 1-8. Control Panel
PAUSE ECONOMY/CONDENSED
Switches printer status between printing and no printing, if any print dataexists in the input buffer: - - - Selects ECONOMY printing mode or CONDENSED printing mode alternately. Also works as a reverse micro feed button, if the ALT button has been pressed. Selects one of the available fonts. Also works as a forward micro feed button, if the ALT button has been pressed. When you press this button, the printer either loads new paper into the printer or ejects paper currently in the printer paper path. Also works as a RESET button, if the ALT button has been pressed. This button alternates the function of certain buttons. When you hold down this button in PAUSE mode for 5 seconds, the printer moves the carriage to the ink cartridge installation/replacement position.
FONT LOAD/EJECT
ALT
[Indicators]
PAUSE DATA PAPER OUT INK OUT ECONOMY/CONDENSED FONT
Lights when the printer is in PAUSE mode. Lights when there is print data in the input buffer. Lights when the printer is out of paper. Blinks if a paper jam has occurred. Lights when the printer detects ink end in the ink cartridge. Blinks when the ink level becomes low. This LED shows the currently selected mode. lndicatw the currently selected font.
Rev. A
1-11
General Description
STYLUS 800 Service Manual
1.4.2 Panel Operation at Power On
The following functions can be activated at power on by holding down the specified button on the control panel. Self-test mode: Hex dump mode: Start the self-test printing mode by turning the printer on while holding down the FONT button. Start the built-in hexadecimal data dump print mode by returning the printer on while holding down the FONT and LOAD/EJECT buttons. Once this mode is selected, the printer prints all received print data in hexadecimal form. Start printing of a demonstration page by returning on the printer while holding down the ALT button.
Demonstration mode:
Other functions that can be activated with the control panel at power on, such as the default setting mode and the initial ink charge mode, are described in the sections that follow.
1.4.3 Default Setting
The printer can memorize certain number of printer setting parameters that defines its functions at the initialization. You can change these parameters with the default setting mode for your specific preference of the printer setting.
1.4.3.1 Default Setting Item
The settings listed in the table below can be made with the default setting mode. The default-setting mode can be activated by hold down the ECONOMY/CONDENSED button while turning on the printer. (Refer to the use~'s guide for the detail operation of the default-setting mode.)
Table 1-7. Default Setting Item
Menu Contents Character Table Auto Print Direction Description Select the character table ON: Print direction is automatically selected as to maintains optimal print quality (alignment). OFF: Depends on the command `ESC U'. ON: For network environment, such as LocalTalk. (Time-out printing is disabled.) ON: For normal environment. (llme-out printing is enabled.) ON: To ensure proper printing of the image containing graphics and scalable font, with certain applications, such as MS Word, WordPerfect V.5. I or earlier. q 1 OFF: For normal use. ON: Line feed operation is automatically performed by CR code input. OFF:NO line feed operation with single CR code. ON Facto~ Setting
Network l/F Mode
OFF f OFF
. . ..
Mixed Text/Graphics Mode
Auto Line Feed Note:
OFF
*1= If set to ON, the capacity of input buffer is limited to 8 Kbyte,
SWLUS 800 Service Manual
General Description
1.4.4 Initial ink Charge
When the printer is to be set up for primary use, whole ink supply path of the printer must be filled with a new ink, by performing the initial ink charge operation. [Step 1] Turn the printer on and press the PAUSE button to pause the printer. [Step 2] Open the printer cover and hold down the ALT button until the printhead moves to the ink cartridge replace position.
[Step 3]
Install the ink cartridge on the printhead, and press the ALT button again to move the printhead to capping position. Then, turn off the printer. charge operation.
[Step 4] Turn the printer on while holds down the ALT and the PAUSE buttons to start the initial
The PAUSE LED blinks while the initial ink charge operation is in progress, and when it completes, the printer automatically becomes ready state.
W The ink cartridge must be installed just after unpacking the package. H The initial ink charge operation should not be pe@ormed more than trm"ce on the same printer. It, otherwise, consumes too much ink in the ink carh"dge and shorten the waste ink tank life.
1.4.5 Error Conditions
he printer detects various errors and indicates them with the LED indicators and the buzzer.
Table 1-8. Error Codes
Error PAPER LED INK END LED PAUSE LED Buzzer Recovery Load the paper and press the buttons as follows: 1. PAUSE 2. LOAD/EJECT Same as above. Press PAUSE button and replace the ink cartridge with a new one. Then, press PAUSE button again to resume printing. q 2
Paper out
ON
OFF
OFF
V4 x 3 times
Paper jam
I
BLINKS
OFF
OFF [ V4 x 3 t i m e s
Ink low q 1
I
OFF
BLINKS
No beeps
Inkend I
OFF
ON ON OFF
Replace the ink cartridge and press PAUSE button. =t==
=-l--==
BLINKS V+ x 3 times 0.5 second beep 0.2 second interval
Install the ink cartridge and mess PAUSE button. Turn off the printer, and turn it on again.
Service maintenance
required. (Replace the waste ink absorbing material and reset the protect counters.)
Waste ink tank over-flow Notes: V : + :
OFF
ON
4 : 0.1 second beep 0 . 1 s e c o n d intetval + :
`1: This is not treated as an error. *2: It is not necessary to replace the ink cartridge until the printer detects the `Ink End' error.
Rev. A
1-13
General Description
STYLUS 800 Service Manual
1.5 MAIN COMPONENTS
The main components of this printer are: O Printer mechanism (M-481O) Q Main control board (C106 MAIN BOARD) ~ Power supply unit (C106PSB/PSEBOARD) Cl Control panel Cl Housing
,. . , (.
.!
1.5.1 Main Control Board (C106 MAIN BOARD)
The C106 MAIN BOARD is the main conboller of the Stylus 800. It takes charge of interfacing with the host computer and processing of received print data, as well as control of the whole printer mechanism. This board consists of the following components. CPU (IC1): Gate-array (IC3): 8-bit CPU (TMP96C141F-20) 19.6608 MHz operating clock Includes the following functions: - MMU (Memory Management Unit) - IFU (Interface Control Unit) - BMU (Bit Manipulation Unit) - PCU (1/0 Port Control Unit) - Head control unit (2 channel: HCU1, HCU2) 1 Mbit EPROM 4 Mbit Mask ROM (IC8 / for US, Pacific version) 8 Mbit Mask ROM (IC7 / for European version) 1 Mbit PSRAM 1 Kbit (64 x 16 Bit) EEPROM 3 lines serial bus Hybrid IC SMA7024MEL Constant current unipolar drive Hybrid IC SMA6501 Constant voltage unipolar drive
Program ROM (IC4): CG ROM (IC7/8): RAM (IC5): EEPROM (IC1O): CR Motor driver (IC13): PF Motor driver (QM1):
., c
n
I
Un
u u
Figure 1-9. C106 MAIN BOARD Component Layout
1-14 Rev. A
STYLUS 800 Service Manual
General Description
1.5.2 Power Supply Unit (C106 PSBIPSE BOARD)
The power supply unit converts input AC voltage and generates different DC voltages required by the printer mechanism and other electrical circuities. The C106 PSB BOARD is for 120VAC input, and the C106 PSE BOARD is for 220 to 240VAC input.
/-
--
o
Figure 1-10. C106 PSBIPSE BOARD Component Layout 1.5.3 Printer Mechanism (M-481O)
This printer mechanism M-481O is specifically designed for the Stylus 800, and it consists of the carriage assembly, which includes the printhead and the ink supply system, the carriage motor, the paper feed motor, the paper feeding mechanism, and the pump mechanism.
Figure 1-11. Printer Mechanism (M-481O)
.--. --.--. Rev. A
1-15
,. . . . .
f.:,'
.
Chapter 2
Operating Principles
Table of Contents
2.1 OVERVIEW 2-1
2-1 2.2 OPERATING PRINCIPLES OF THE PRINTER MECHANISM 2.2.1 Printer Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .2-2 2.2.2 Carriage Drive Mechanism . . . . . . . . . . . . . . . . . . . . . . ...............2-4 2.2.2.1 Platen Gap Adjust Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4 2.2.3 Paper Feed Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .......2-5 2.2.4 Ink System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..................2-6 2.2.5 Pump Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..........2-7 2.2.6 Cap Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........2-9 2-1o 2.3 OPERATING PRINCIPLES OF THE ELECTRICAL CIRCUITRIES 2.3.1 Operating Principles of the Power Supply Circuit . . . . . . . - . . . . . .....2-10 2.3.2 Operating Principles of the Main Control Circuit . . . . . . . . . . . . . . .....2-12 2.3.2.1 Reset Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .....2-13 2.3.2.2 Sensor Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .....2-13 2.3.2.3 Ink End Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .....2-14 2.3.2.4 Carriage Motor Drive Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-15 2.3.2.5 Paper Feed Motor Drive Circuit . . . . . . . . . . . . . . . . . . . . . .....2-16 2.3.2.6 Printhead Drive Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...2-17 2-18 2.4 INK SYSTEM MANAGEMENT 2.4.1 Ink Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .....2-19 2.4.1.1 PowerOn Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...2-19 2.4.1.2 Cleaning Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .....2-19 2.4.1.3 Standby Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .....2-20 2.4.1.4 Initial Charge Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . .....2-20 2.4.1.5 Refresh Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .....2-20 2.4.1.6 Cleaner Blade Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-21 2.4.1.7 l/C Replacefnent Operation . . . . . . . . . . . . . . . . . . . . . . . . .....2-21 2.4.1.8 Disengage On Operation . . . . . . . . . . . . . . . . . . . . . . . . . . .. ...2-22 2.4.1.9 Micro Absorbing Operation . . . . . . . . . . . . . . . . . . . . . . . . .. ...2-22 2.4.2 Counter and Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .....2-22 2.4.2.1 Refresh-l Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .....2-22 2.4.2.2 Flushing Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .....2-22 2.4.2.3 CLCounter K . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .....2-22 2.4.2.4 Protect Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .....2-23
Rev.A
2-i
List of Figures
~...,,
Figure 2-1. Functional Block Diagram of the Printer Mechanism . ...........2-1 Figure 2-2. Structure of Printhead . . . . . . . . . . . . . . . . . . . . . ...............2-2 Figure 2-3. Principles ofthe Printing Operation . . . . . . . . . . . . . . . . . . . . . ....2-3 Figure 2-4. Carriage Drive Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4 Figure 2-5. Platen Gap Adjust Lever . . . . . . . . . . . .......................2-4 Figure 2-6. Paper Feed Mechanism . . . . . . . . . . . . . . . . . . . . . .............2-5 Figure 2-7. Diagram ofthelnkSystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..2-6 Figure 2-8. Pump Mechanism Block . . . . . . . . . . . . . . . . . . . . . .............2-7 Figure 2-9. Pump Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .........2-8 Figure 2-10 Cap Mechanism . . . . . . . . . . . . . . . . . . . . . ..................2-9 Block Figure 2-11 ~D·OE Diagram of the Electrical Circuities . . . . . . . . . . . . . . .....2-10 Power Supply Circuit Block Diagram . . . . . . . . . . . . . . . . . .....2-11 Figure 2-12 Figure 2-13 Main Control Circuit Block Diagram . . . . . . . . . . . . . . . . . . .....2-12 Figure 2-14 ResetCircuit Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . .....2-13 Figure 2-15 Sensor Circuit Block Diagram . . . . . . . . . . . . . . . . . . . . . . . .....2-13 Figure 2-16. Ink End Detection Sequence . . . . . . . . . . . . . . . . . . . . . . . .....2-14 Figure 2-17. Carriage Motor Drive Circuit Block Diagram . . . . . . . . . . . . .....2-15 Figure 2-18. Paper Feed MotorDriveCircuit Block Diagram . . . . . . . . . .....2-16 Figure 2-19. Printhead Drive Circuit Block Diagram . . . . . . . . . . . . . . . . .....2-17 Figure 2-20. Relation oflnkSystem Operation and Carriage Position . . .....2-18
~:
(,: ,
List of Tables
Table Table Table Table Table Table Table 2-1. 2-2. 2-3. 2-4. 2-5. 2-6. 2-7. Carriage Drive Motor Specification . .........................2-4 P l a t e n Gap Adjust Lever Position . ..........................2-4 Paper Feed Drive Motor Specification . .......................2-5 Pump Mechanism Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8 DC Voltage Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. ..2-10 Carriage Motor Drive Modes . . . . . . . . . . . . . . . . . . . . . . . . . ....-2-15 Paper Feed Motor Drive Modes . . . . . . . . . . . . . . . . . . . . . . . .....2-16
., .,
2-ii
Rev.A
STYLUS 800 Service Manual
Operating Principles
2.1 OVERVIEW
This section describes the operating principles of the printer mechanism and the electrical circuits of the Stylus 800.
2.2 OPERATING PRINCIPLES OF THE PRINTER MECHANISM
The Stylus 800 printer mechanism is composed of the printhead unit, paper feed mechanism, carriage drive mechanism, pump mechanism, and various sensors. The figure below shows a functional block diagram of the printer mechanism. I I
w. "'einkdrain %
m n
MecK mism
]
D
CR Motor
Garr i age Un i t
Printhead/
Filter/ Driver circuit
1
m m
~. . . . . . . . . .
Figure 2-1. Functional Block Diagram of the Printer Mechanism
n
*
ASF
(Auto Sheet Feeder)
Rev. A
2-1
Operating Principles
STYLUS 800 Service Manual
2.2.1 Printer Mechanism
The printer mechanism of this printer uses a drop-on-demand ink jet system similar to the system used on all other Epson ink jet printers. However, the printhead in this system is completely redesigned to make it compact and highly reliable. The figure below shows the structure of the printhead and ink supply system.
s MLP
f-"
MLP is the abbreviation for Multi-Layer Piezoelectric element. When a drive pulse (voltage) is applied, this element pushes the vibration plate, compressing the cavity for ink injection from the nozzle. Ink supplied from the ink cartridge is stored in this space and is injected from the nozzles when the vibration plate compresses this area. These inject ink against the paper's surface in response to the application of the print signal. There are 48 individual nozzles making up this printhead.
s Cavity s Nozzles
Cartridge needle \
Printhead driver board I
Filter
Cavity (Nozzle)
set
(Multi-Layer Piezo)
Nozzle plat
A7'Nozz'e
,,, . . . f `
nk supply tank Viblation p
\
MLP (Multi-byer Piezo)
-. . .
Figure 2-2. Structure of Printhead
2-2
Rev. A
STYLUS 800 Service Manual
Operating Principles
Principles of the Printing Operation
The operation of the printhead to inject ink from each nozzle is: (1) Normal state No electrical charge is applied to the MLP (Multi-Layer Piezoelectric) element attached to the back of the cavity, and pressure inside the cavity is kept at constant level.
Nozzl
(2) Injecting state The head data signal is applied to the specific nozzle control line to select the active nozzle for printing, and the MLP element is gradually charged by the drive voltage. By charging the MLP element, the vibration plate is bent to compress the cavity. Then, ink is injected from the nozzle.
@
Figure 2-3. Principles of the Printing Operation
When the ink charge or printhead cleaning operation is performed, the ink in the cavity is vacuumed out with the pump mechanism. During printing, on the other hand, the ink is simultaneously supplied from the ink cartridge and injected from the nozzle, according to the change of volume in the cavity. A thermistor is attached to the printhead drive board to monitor the temperature, because the viscosity of the ink varies, depending on the temperature. The detected temperature level is fed back to the printhead drive voltage control circuit to regulate the drive voltage to a proper level.
Rev. A
2-3
Operating Principles
STYLUS 800 Service Manual
2.2.2 Carriage Drive Mechanism
The timing belt attached to the base of the carriage unit is driven by the carriage motor, causing the carriage unit to move along the carriage guide shaft left to right, or vice versa. The carriage drive motor on this printer is a 4-phase, 200-pole, hybrid-type stepping motor mechanism, allowing the printer to stop the carriage or change the carriage movement at any position. The position of the carriage is recognized by the home position sensor and position information is fed back to the carriage drive control circuit to determine the motor phase switching mode.
('
.
`-i.,
Table 2-1. Carriage Drive Motor Specifications
Item Motor Type Drive Voltage Coil Resistance Drive Frequency Excitation Mode
I
Description 4-phase / 200-pole hybrid-type stepping motor 35 V f 10Yo (31.5 -38.5 V) 10.0 Qt 7%/ pole (at 25° C, 77° F) 960 -5400 pps 1-2 phase excitation
I
Figure 2-4. Carriage Drive Mechanism 2.2.2.1 Platen Gap Adjust Lever
Set the platen gap adjust lever, attached to the carriage unit, to an appropriate position for the paper thickness used for printing.
Table 2-2. Platen Gap Adjust Lever Position
Paper Type Cut sheet Envelope Lever Position Horizontal (A) Vertical (B) Platen Gap -- +0.7 mm
Plain paper, Bond paper \ \
Envelope
(gn~
r
<.~j
P
)
::,. / -.
>
..
:,..,,.. .:. ...:.: , . . . ./
/
. . . . . . . . . .;:: ...
.'
:: :: :: `L :,
-. . . . . . . . . . . . . . . --
Figure 2-5. Platen Gap Adjust Lever
. .,
STYLUS 800 Service Manual 2.2.3 Paper Feed Mechanism
Operating Principles
This printer's paper feed mechanism can feed paper either from the built-in ASF (auto sheet feeder) or the manual feed slot. The paper feed drive motor is a 4-phase, 4t3-pole, PM-type stepping motor that directly drives the paper feed mechanism (paper advancing operation, paper pick-up operation). This motor also drives the pump mechanism, but only when the printer is in the cleaning state.
Table 2-3. Paper Feed Drive Motor Specification
Item Motor Type Drive Voltage Coil Resistance Drive Frequency Excitation Mode Description 4-phase / 48-pole PM-type stepping motor 35 V + 10% (31.5 - 38.5 V) 54 ~ 3 Q/ pole (at 25° C, 77° F) 650-800 ppS 2-2 phase excitation
)
Figure 2-6. Paper Feed Mechanism
Rev. A
2-5
Operating Principles
STYLUS 800 Sewice Manua)
2.2.4 Ink System
This printer's ink system is composed of the following mechanisms:
s Ink cartridge s Pump mechanism
(..
!-. .:,,
E Cap mechanism H Printhead cleaning mechanism s Waste ink drain tank The figure below shows a diagram of the ink system. Ink Cartridge
Head Driver
Boar
Filter
{-
)
!
Figure 2-7. Diagram of the Ink System
1 .. .
2-6
Rev. A
STYLUS 800 Service Manual
Operating Principles
2.2.5 Pump Mechanism
The paper feed motor drives the pump mechanism when the transmission gear is moved to the position where the paper feed motor engages the pump mechanism gear trains, when the carriage unit is at the ink system home position. The figure below shows a block of the pump mechanism. Pump system operation depends on the rotational direction of the paper feed drive motor, as shown in table below.
~-
L rl L.+ \ - - - - --1
- - - - ; L-- k--; ; LJ J
-----
cDrive: Paper feed mechanism>
I
5$7
I
I
1P
II
IJ
s)'
Figure 2-8. Pump Mechanism Block
Rev. A
2-7
Operating Principles
STYLUS 800 Service Manual
Table 2-4. Pump Mechanism Operation
f"'.,
PF Motor Rotational Direction CW (forward rotation)
Operation Pumping Pseudo-pumping (False absorbing) Gear backrush com~ensation Pump pulley reset Gear backrush compensation
1
(,
CCW (backward rotation)
The pump draws ink from the printhead nozzles and drains it into the waste ink drain tank. The printer performs this operation to eliminate dust or bubbles within the nozzles. Figure 2-9 illustrates the pump operation. When the paper feed drive motor rotates CW (forward), the pulley pumps in the wheel pump unit rotate in the direction of the arrow while squeezing the ink tube to push the ink inside the tube out to the waste ink drain tank. On the other hand, when the motor rotates CCW, the pulley pumps move inward along the grooves of the wheel pump so that pressure applied to the ink tube is released.
"L'
Pumping (Pump motor:
Uflfouch
Cw)
@+@
No pumping (Pump motor: CCW)
Wheel Pump /
,... ~..
Pulley Pump
Pumping (CW)
No pumping (CCW)
Figure 2-9. Pump Operation
STYLUS 800 Service Manual 2.2.6 Cap Mechanism
Operating Principles
The cap mechanism prevents the printhead nozzles from drying or bubbles from forming inside the nozzle while the printer is not in use. The printhead capping operation is performed automatically so that a cap closely contacts the printhead surface when the carriage unit is moved to the ink
system home position.
1
I
Carriage (Printhead)
I
[
. `d .
:--, :: :: :: :: :: :: ,, ::
c, :: :. ..:
w
I I* .. .. .. ..
\ Slider Valve
.I
F
Figure 2-10. Cap Mechanism
Rev. A
2-9
Operating Principles
STYLUS 800 Service Manual
2.3 OPERATING PRINCIPLES OF THE ELECTRICAL CIRCUITRIES
The Stylus 800 contains the following circuit board units: s C106 MAIN BOARD (Main control circuit board) s C106 PSB/PSE BOARD (Power supply circuit board) ,,, 1, f ...
In addition to the circuit boards above, part of the printhead drive circuit is built on a separate circuit board installed in the carriage unit, and the printhead is attached directly to this board. The figure below shows a block diagram of the electrical circuitries.
AC Input
M-481 O Printer mechanism
/Carriage
,------- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . / ,\
. . . . . . . . . . . . . . . . . . . . . . . . 1.....
Head driver Board
Head drive * voltage (+35VDC)
C106 PSB/PSE
+35VDC +5VDC L
I Printhead I
..................................
C106 MAIN
(',"
EEJ+
C106 PNL
L I
. . . . . . . . . . -. . . . . . . . . . . . . . . . . - . . . . . . . . . .- - -- - - . . . . . . . - - - -- .-'
Figure 2-11. Block Diagram of the Electrical Circuities
,. .,%
2.3.1 Operating Principles of the Power Supply Circuit
The power supply circuitry for this printer is provided either by the C106 PSB BOARD (120 VAC) or the C106 PSE BOARD (220-240 VAC). Both boards are identical in design and functionality, except for components in the primary circuit that accommodate the specified input voltage. l%e input voltage and the application of output voltages are summarized in table below.
{.
Table 2-5. DC Voltage Distribution I
Voltage +35 VDC ~ Application
~ Motor drive (carriage and paper feed) ~ Printhead (through the drive voltage generation circuit)
/ C106 MAIN BOARD +5 VDC I Sensors (home position and paperend) 1 Control panel ~ (PF motor holding voltage) .,
2-1o
Rev. A
STYLUS 800 Service Manual
Operating Principles
The figure below shows a block diagram of the power supply circuit (C106 PSB/PSE). This power supply circuit employs the RCC (ringing choke converter) switching control system. The input AC voltage supplied from the external AC source is first input to the filter circuit for higher harmonics absorption. The AC voltage is then input to the rectification and smoothing circuit, converting it into DC voltage. This DC voltage is input to the switching circuit for switching operation. Along with the switching operation on the primary side, +35 VDC is generated after passing through the smoothing circuit. The +35 VDC level is fed back to the primary switching circuit through the +35 V line voltage detection circuit and, thus, the +35 VDC output level is stabilized. This +35 VDC is also input to the +5 VDC generation circuit to generate a stable +5 VDC.
Primary-side
Secondary-side
lC51/Q51/L51 D5!YR53/C55
~~
Smoothing Circuit
C7
QI
T1 ,.--.
*"V"' .--, C51/C52 I
4
Main Switching I--Id ZD52
-44+
+35VDC
L 9
k
Full-wave Rectifier Circuit
w-J---C21C
L1/C6
1-
CIIR1
--
+ ZD511R70/R711R72/Q52 +35V -- Constant
u
+5V
Over-current Protection . .
Filter Circuit
Voltage Control . . Crcult ZD53
Pcl !
-
AC Input
Figure 2-12. Power Supply Circuit Block Diagram
This circuit contains the protection circuits described below. 1) +5 VDC line over voltage protection circuit The output voltage level of +5 V line is monitored with a Zener diode (ZD53) and if the voltage level exceeds predefined level (+7 V), the status is fed back to the primary switching circuit through a photocoupler (PC1) to stop the +35 V generation. +5 VDC line over current protection circuit The output current is monitored with a detection resistor (R53) and fed back to the +5 VDC generation switching control IC (IC51). If the current level exceeds the limit, the control IC shortens the ON time of the switching transistor (Q51) to decrease the output voltage level (constant current operation). +35 VDC line over voltage protection circuit The output level is monitored with a Zener diode (ZD36). If the voltage level exceeds the limit level (+36 V), it activates a photocoupler (PC1), and this stops the primary switching circuit operation. +35 VDC line constant voltage output control circuit The output level of +35 VDC line is monitored by a detection circuit that consists of a Zener diode (ZD51), a transistor (Q52), and resistors (R70, R71, R72). This circuit feeds back the output voltage level status through a photocoupler to the primary switching circuit to control the ON/OFF time of the switching transistor for constant output voltage control.
2)
3)
4)
Rev. A
2-11
Operating Principles
STYLUS 800 Service Manual
2.3.2 Operating Principles of the Main Control Circuit
The main control circuit of this printer is the C106 MAIN BOARD. This circuit is controlled by the 8-bit CPU TMP96C141F (ICI), running at 19.6608 MHz. This CPU has a unique architecture capable of handling data on the data bus at either an 8-bit bus width or a 16-bit bus width. Due to this, a 16-bit data bus width-type ROM is used on this board, increasing the internal processing speed. Gate array E05A85EB (IC3) manages pnnthead drive control, external I/F control (Centronics parallel I/F), and the control panel. The CPU directly controls both the carriage drive motor and the paper feed motor. This board is also equipped with EEPROM 93C46 (IC1O) to store certain parameters, such as the printer mechanism control parameter, default setting parameters, as well as a special counter value used for pririthead protection.
,. . :;c. . . ;
\ Common !
~'--";.
~'
. . r
Pwcl
PWD
I
* Drive Circuit ~
; (PWC/PWD) ~
.............................
Sl(Data)iLAT
Head driver (Printhead)
I ------------
IC3 E05A85EB
t
I
IC8 *1
Mask ROM
(-
IC4
PROM(1 M)
IC7 *2
Mask ROM
IC5
PS-RAM
I
(Prog ram) I I
CRO-3
(CG14M)
ADO-15
(CGI16M)
(1 M)
I
I
Icl (CPU) TMP96C141
P60x P61x
BzEl
1
IC13 ? CR Motor
--
QMI SMA6501 PF Motor
( ,'
,. .,.
V Control
Panel
(C106 Pt'd;)
Note:
q2:.
.
E41/Pacific only Europe only
Figure 2-13. Main Control Circuit Block Diagram
STYLUS 800 Service Manual 2.3.2.1 Reset Circuits
Operating Principles
The C106 MAIN BOARD contains two reset circuits: the +5 V monitor reset circuit and the +35 V monitor reset circuit. The +5 V monitor reset circuit monitors the voltage level of the +5 V line, using reset IC PST592 (IC12), and outputs a reset signal to both the CPU (ICI, TMP96C141) and the E05A85EB gate array (IC3), when the voltage level drops below +4.2 V. The +35 V monitor reset circuit, on the other hand, monitors the voltage level of the +35V line, using reset IC 51955BFP (IC1l), and outputs a reset signal to the CPU. The reset signal is generated when the voltage level drops below +28 V, and this causes a non-maskable interrupt (NMI).
+5VDC +3SVDC
&&
237
RESET
E05A85EB (IC3)
7 I_-EL.J
Figure 2-14. Reset Circuit Block Diagram 2.3.2.2 Sensor Circuits
The following sensor circuits enable the main board to monitor printer mechanism status: 1) HP sensor A photocoupler-type HP (home position) sensor is attached to the back of the carriage unit to detect the carriage home position as a print reference position. A HIGH level from the signal indicates that the carriage is in home position. A mechanical switch PE (paper end) sensor is built into the printer mechanism to determine whether there is paper in the printer or not. Two electrical contacts are attached to the ink cartridge holder in the carriage unit, and when the ink cartridge is installed, the metal pins built into the ink cartridge touch these contacts. The IE (ink end) sensor circuit applies a HIGH level signal when performin g the ink end status detection operation. The ink level is determined by the resistance between the two contacts by measuring the input signal level with analog port ANO (pin 73) of CPU. A thermistor is attached to the printhead unit to monitor its temperature. The CPU changes the printhead drive signal's pulse width (charge pulse width) based on the temperature level.
PE +5V
2) PE sensor 3) IE sensor
4) Thermistor
(CN4) P
x 9 slve 80 w
+5V 10 I
+5V
JJ r k) +5V m Ink
IC9
E05A85E9 (IC3)
INK ~
cartlt@l? "1 i ..~:~ i ,. . ,,, L.--. J `+" `
Cl=u (lCl)
+5V
I
Figure 2-15. Sensor Circuit Block Diagram
Rev. A
2-13
Operating Principles
STYLUS 800 Service Manual
2.3.2.3 Ink End Detection
The IE (Ink End) sensor attached to the carriage detects, not only the ink end, but also when ink is low and whether an ink cartridge is installed. The detected status is classified to five modes according to the output voltage level of the IE sensor.
u Mode A: u Mode B:
9 Mode C: s Mode D: s Mode E:
No I/C (Abnormal conduction) Ink is low Ink end (During pump operation) Ink end (During printing) No I/C (not installed)
(not printable) (printable) (not printable) (not printable) (not printable)
r=l
rIst check A < Vout c B ?
(
,.,
u'
a r--+
1) During printing: 2) During pump operation: 3) In stand-by state:
2-14
L*-,
.,> f,
b&K-.l
Figure 2-16. Ink End Detection Sequence
When the ink end detection operation has determined ink status, the printer indicates the status on the control panel, as described below: If Mode D (ink end) or Mode A or E (no I/C) is detected, the pnnthead is capped and the control panel indicates an "INK END" error. If Mode C is detected, the printer indicates an "INK END" error after the detection operation sequence completes and interrupts pump operation. If Mode A or E is detected, the printer indicates an "INK END" error after interrupting the pump operation. If Mode D or Mode A or E is detected, the printer indicates an "INK END" error on the control panel.
Rev. A
4,,,,,
STYLUS 800 Service Manual
Operating Principles
2.3.2.4 Carriage Motor Drive Circuit
I
Carriage motor drive IC SLA7024 (IC13) drives the carriage motor for the printer mechanism by a constant current, unipolar drive system. Gate array E05A85EB (IC3) selects the motor phase drive current level using the output signals from ports CRO to CR3 (pins 75 to 78). The phase switching operation is directly controlled by the phase control signals output from ports P600 to P603 (pins 1 to 4) of the CPU. The table below shows the carnage m-otor drive modes. -
Table 2-6. Carriage Motor Drive Modes
CR speed (CPS) 225
150 83 40 HOLD
Drive Frequency (PPS)
5400 3600 2000 960 --
Phase Excitation
1-2 phase 1-2 phase 1-2 phase 1-2 phase 2 phase
Acceleration Current (A/Phase)
0.80 0.60 0.80 0.45
Normal/Deceleration Current (A/Phase)
0.45/0.80 0.30/0.60 0.80 0.30/0.45 Approx. 0.15
SLA7024MEL (IC13)
CPU (ICI)
P600 ` P601 2
P603 P602
3 4
6 INA
INB IN-A 16 IN.B
5
`
7
+35V
CR Motor (CN6) ; CRCOM * CRA s CR-A b CRB CR-B
+5V
R59
A 1 -A WRM26 RM25 RFA RFB
8 18
--
B 11 -B
E05A85EB CRO 78
R33
R34 R35
(IC3)
CR1 77 CR2 76 75 CR3 -
R36
Figure 2-17. Carriage Motor Drive Circuit Block Diagram
Operating Principles 2.3.2.5 Paper Feed Motor Drive Circuit
STYLUS 800 Service Manual
The paper feed motor for this printer drives the following mechanisms: 9 Paper feed mechanism s Paper pickup mechanism s Pump mechanism Driver IC SMA6501 (QM1) drives the paper feed motor by a constant voltage, unipolar drive system. The CPU outputs phase control signals from ports P610 to P613 (pins 5 to 8) for the phase switching operation. The CPU also outputs the supply voltage switching control signal from port T03 (ph- 12) to switch tie supply volkge to +5 V-DC wh& the paper feed motor control is in HOLD mode. The drive modes are shown in table below.
; ~.,` c ..
Table 2-7. Paper Feed Motor Drive Modes
Mode
Continuousfeed Pump drive j I
Phase Excitation
2-2phase 2-2phase I I
Drive Frequency (PPS)
800 650 PF Motor
SMA6501
(QM1) CPU
(ICI)
(CN5) ~, 2
C2 C3 C4
4 7 9
(.e `
P610 ~
P611 6 P612 7 P613 8
` 01
3 62 6 63 8 64
` PFA
5. PF-A 2 PFB 6 PF-B
3 4
` 0 BP ~ CP "
12
PFCOM PFCOM
T03
12
D1 R4
QI
. . . . . . .. . .
+35V
+5V
777Figure 2-18. Paper Feed Motor Drive Circuit Block Diagram
f"'". .
2-16
Rev. A
STYLUS 800 Service Manual
Operating Principles
2.3.2.6 Printhead Drive Circuit
The printhead drive circuit for this printer is composed of the following two parts:
u Common drive circuit (trapezoidal drive pulse generation) s Head drive circuit (nozzle control built on the printhead)
The 64-bit thermal head driver SED5620D in the head drive circuit on the printhead is used as a nozzle selector to drive the printhead nozzles selectively. Print data is converted into serial data by gate array E05A85EB (IC3) and is output from port S1 (pin 63) to the head drive circuit on the printhead as data for each nozzle. Then, head driver SED5620D latches the head data when gate array E05A85BE outputs the LAT signal, and the latched data becomes 48-bit parallel data, with one bit corresponding to each nozzle of the printhead. When data transfer and nozzle selection is complete, gate array E05A85BE outputs the common drive pulse PWC (charge pulse) and PWD (discharge pulse) to the common drive circuit. The co mmon drive circuit then generates the trapezoidal pulse and applies it to the printhad as a common drive pulse. After this, the nozzle selected by the head data is activated to inject ink by energizing the MLP element drive with the applied trapezoidal drive pulse.
JAIL
GND .--------: ------- j----------------------- --'------------------------Pwc ;
(IC3) HCLK ` 5 LAT ` 4 ~1 63 HCLK ; LAT
2
SI
+5V4
I
L
`
2
TH
I I
CPU (lCl)
AN1 7
4
HEAD-2 (CN3)
Figure 2-19. Printhead Drive Circuit Block Diagram
Rev. A
2-17
Operating Principles
SNLUS 800 Service Manual
2.4 INK SYSTEM MANAGEMENT
#"' ,,,
This section explains how the ink system is controlled to protect the printhead and the ink supply system and to ensure highquality output. The ink system control is composed of the following operations:
s Power on s Cleaning s Standby s Refresh s False absorbing s Cleaner blade s Ink end process
t..
These ink system operations are controlled with the values indicated by the following counters and timers: H Refresh timer s Flashing counter s Protect counter The figure below shows how the carriage position determines which ink system operation is to be executed.
Ink system Home po~ition (HP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -------i---:
(. ""
%-'
; Printer mechanism
: (M-481O)
I
~ Cap/Pump
~ Mechanism
i~ . . . . . . . . .i.... : ~ / i ~:
Flashing # Position ` position
:. `--------i -------i.;.... . .+. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - . . . . . . - - - --- ------- -. ------, ------ i
I ASF Sheet loading position
False absorbing ~
i
`w
Cleaner end position ~"'''sta"a" `------ Rubbing ~ Cleaner reset position ~
I
I I
Ink catridge Replacement Position
I
I
Figure 2-20. Relation of Ink System Operation and Carriage Position
Rev. A
2-18
STYLUS 800 Service Manual
Opmeting Principles
2.4.1 Ink Operations
There are various ink operations that can be performed selectively by the printer. 2.4.1.1 Power on Operation Power on consists of the following operations, and only one of these operations is performed, depending on the position of the carnage when the printer is turned on.
s At ink system home position
1) Moves the carriage to the flushing position and performs the flushing operation. 2) Returns the carnage to the home position (standby for printing).
Note: The false absorbing operation ispetformedpreceding the above-mentioned sequence, depending on the protect counter R value.
N Notat ink system home position
1) Returns the carriage to home position. 2) Performs cleaner blade- I operation. 3) Performs ink absorbing operation. 4) Performs pressure release operation. 5) Performs micro absorbing operation. 6) Performs false absorbing operation. 7) Performs cleaner blade-II operation (including the flushing operation). 8) Moves the carriage to the standby position.
2.4.1.2 Cleaning Operation This operation is performed when cleaning is selected by pressing the ALT and PAUSE buttons simultaneously. There are three cleaning modes, each of which is selectively performed, depending on the cleaning counter K value and the number of printed lines from the previous cleaning operation.
s CL1 (Normal)
s CL2 (Intensive)
s CL3 (False)
1) If the carriage is out of home position, return it to the home position. 2) Cleaner blade - I operation. 3) Change the gear engagement. (pump drive ON) 4) Ink absorbing operation. 5) Performs pressure release operation and micro absorbing operation. 6) Cleaner blade -II operation. (including the flashing operation) 7) Move the carnage to the stand-by position, and change the printer state to the PAUSE state. 1) If the carriage is out of home position, return it to the home position, 2) Cleaner blade - I operation. 3) Change the gear engagement (pump drive ON) 4) Ink absorbing operation. 5) Pressure release operation. 6) False absorbing operation. 7) Rubbing operation. 8) Change the gear engagement. (pump drive ON) 9) Micro absorbing operation. 10) False absorbing operation. 11) Cleaner blade - II operation. (including the flashing operation) 12) Move the carriage to the stand-by position. The same operation as CL1, except that the carriage is moved to the false absorbing positionand the false absorbing operation is performed at step 4).
Rev. A
2-19
Operating Principles
STYLUS 800 Service Manual
2.4.1.3 Standby Operation The standby operation prevents an increase in the viscosity of the ink held inside the printhead nozzles. This operation is performed automatically if no data is received for more than three seconds from the last print data. 1) Counts the number of flushing operations from the last standby operation, using the combined print counter N. And performs the flushing based on the counter value. 2) Moves the carriage to the home position. 2.4.1.4 Initial Charge Operation `l%is operation, performed when initial charge mode is selected, charges the printhead with ink . The operation has two modes, depending on the value held by protect counters B and C.
s Initial Charge
1) If the carriage is not at home position, returns it to home position.
2) Performs cleaner blade - I operation.
3) Changes the gear engagement (pump drive on). 4) Performs ink absorbing operation (absorption= high). 5) Performs pressure release operation. 6) Performs ink absorbing operation (absorption= middle). 7) Performs pressure release operation. 8) Performs rubbing operation. 9) Performs micro absorbing operation. 10) Performs false absorbing operation. 11) Performs cleaner blade - II operation (including the flushing operation) 12) Moves the carriage to the standby position. 9 False Charge This operation is identical with the initial charge operation, except that the operations for steps 4) and 6) are changed as follows: . Moves the carriage to the false absorbing position, and performs the false absorbing operation. Then, moves the carriage to home position after step 8).
2.4.1.5 Refresh Operation This operation prevents an increase in the viscosity of the ink inside the printhead, as well as to eliminate any ink attached to the nozzle plate surface. Refresh consists of the following operations:
s Refresh - I operation
s Print start
This operation is activated by the REFRESH-I signal, which outputs every 20 seconds during continuous printing. 1) Returns the carriage to home position. 2) Moves the carnage to the flushing position. 3) Performs flushing operation. 4) Performs cleaner blade-III operation (including the flushing), based on the value of the combined print counter N. 5) Performs false absorbing operation, if the ink level counter R value exceeds 5600. 6) Returns to the previous state. This operation ejects high-viscosity ink inside the nozzles when the printing starts from the standby state. 1) Moves the carriage to the flushing position and performs flushing. 2) Starts printing operation. This operation absorbs ink inside the cap and eliminates ink attached to the nozzle plate surface. 1) Moves the carriage to the false absorbing position. 2) Performs false absorbing operation. 3) Resets the pump pulley. 4) Release a mechanical pressure of the pump drive mechanism. 5) Adjusts the phase with paper feeding mechanism gears. 6) Returns the carriage to the home position.
. . {.
s False absorbing
2-20
Rev. A
STYLUS 800 Service Manual
Operating Principles
2.4.1.6 Cleaner Blade Operation The cleaner blade operation eliminates any dust or ink attached to the nozzle plate surface. This operation consists of the following separate operational modes. This operation eliminates any dust attached to the nozzle plate surface before the ink absorbing operation is performed. 1) Sets the cleaner blade. 2) Moves the carriage to the cleaner start position. 3) Moves the carriage to the cleaner end position (head surface is wiped off with the cleaner blade). 4) Resets the cleaner blade. 5) Returns the carriage to the home position. s Cleaner blade -II This operation eliminates any dust or ink attached to the nozzle plate surface after the ink absorbing operation is performed. 1) Sets the cleaner blade. 2) Moves the carriage to the cleaner start position. 3) Moves the carnage to the cleaner end position (head surface is wiped off with the cleaner blade). 4) Resets the cleaner blade. 5) Moves the carnage to the flushing position and performs flushing. 6) Moves the carnage to the home position. s Cleaner blade - III This operation removes any dust or ink attached to the nozzle plate surface during printing. 1) Sets the cleaner blade. 2) Moves the carriage to the cleaner start position. 3) Moves the carriage to the cleaner end position (head surface is wiped off with the cleaner blade). 4) Resets the cleaner blade. 5) Moves the carnage to the flushing position and performs flushing. 6) Moves the carriage to home position. This operation removes dust or ink that adheres to the head surface. s Rubbing
s Cleaner blade - I
1) Sets the cleaner blade. 2) Moves the carriage to the cleaner start position. 3) Moves the carriage to the cleaner end position (wiping = rubber side) 4) Moves the carriage to the flashing position (wiping = felt side). 5) Moves the carriage to the home position. (This resets the cleaner blade.)
2.4.1.7 UC Replacement Operation
This operation is performed when the ink cartridge (1/C) is replaced. 1) 2) 3) 4) Moves the carriage to the I/C replacemen