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EPSON COLOR INKJET PRINTER
Stylus Pro XL+
SERVICE MANUAL
EPSON
4006101
PREFACE
This document provides supplementary information to describe the Stylus Pro XL+, which is a follow-on version of the Stylus Pro XL. Therefore, you must refer to this information in conjunction with the Stylus Pro XL Service Manual for details on any subjects common to both printers.
REVISION SHEET
Revision A Issue Date March 15, 1996 Revision Page 1st issue
-ii-
Stylus Pro XL+
Product Description
1.1 FEATURES
The Stylus Pro XL+ is a high-quality, high-performance color ink jet printer. This printer is provided with a standard bidirectional parallel interface suitable for the Microsoft® WindowsTM 95 environment and a serial interface for the Macintosh. The main components and case of this printer are similar to the Stylus Pro XL. The main features are: Ì High-quality color printing 720 dpi printing using EPSON Micro Dot mode 720 dpi printing on: plain paper EPSON premium paper transparencies 720 dpi printing of raster graphics at 200 cps Bidirectional parallel interface (IEEE-1284 nibble mode) Mac serial interface Type-B interface (optional) Black and color ink out / ink low indicator LEDs
Ì Ì
High print speed Built-in-3 I/F
Ì
Ink out / low indicators
Rev.A
1-1
Product Description
Stylus Pro XL+
1.2 SPECIFICATIONS
This section provides statistical facts and other detailed information for the printer.
1.2.1 Printing Specifications
The table below shows print speeds and printable columns.
Table 1-1. Print Speed and Printable Columns
Character Pitch 10 cpi (pica) 12 cpi (elite) 15 cpi 17 cpi (pica condensed) 20 cpi (elite condensed) Graphics Density 180 dpi × 180 dpi 360 dpi × 360 dpi H -- 720 dpi × V -- 360 dpi 720 dpi × 720 dpi Printable Columns 127 152 190 218 254 Printable Dots 2289 4578 200 cps 9156 9156 Print Speeds (LQ) 200 cps 240 cps 300 cps 343 cps 400 cps Print Speed (10 cpi)
Control codes: Input data buffer:
ESC/P 2 and expanded raster graphics codes 128K bytes
1-2
Rev.A
Stylus Pro XL+
Product Description
1.2.2 Ink Cartridge Specifications
Black
Type: Color: Print capacity: Life: Storage temperature: Exclusive cartridge Black 1170 pages (ECMA132 letter) The effective life from the indicated production date is 2 years. 30 40° C (-22 104° F) Storage under a month at 40° C (104° F) -30 60° C (-22 140° F) Transit under a month at 40° C (104° F) -30 60° C (-22 140° F) Transit under 120 hours at 60° C (140° F) 26.9 × 67.4 × 41.8 mm (1.06 × 2.65 × 1.65 in.)
Dimensions (W × D × H):
Color
Type: Colors: Print capacity: Life: Storage Temperature: Exclusive cartridge Cyan, magenta, yellow 620 pages (5% duty for each color, A4, 360 dpi) The effective life from the indicated production date is 2 years. 30 40° C (-22 104° F) Storage under a month at 40° C (104° F) -30 60° C (-22 140° F) Transit under a month at 40° C (104° F) -30 60° C (-22 140° F) Transit under 120 hours at 60° C (140° F) 54.0 × 67.4 × 41.8 mm (2.13 × 2.65 × 1.65 in.)
Dimensions (W × D × H):
Notes:
Ì The ink cartridge cannot be refilled; it is the only consumable item in the printer. Ì Do not use an ink cartridge that has exceeded the ink life. Ì Ink freezes below -3° C; however, it can be used after it returns to room temperature.
Rev.A
1-3
Product Description
Stylus Pro XL+
1.3 INTERFACE SPECIFICATIONS
The Stylus Pro XL+ comes standard-equipped with two interfaces: an 8-bit bidirectional parallel and an RS-422 mini-DIN serial interface for the Macintosh. This printer is also equipped with a slot for an optional Type B interface.
1.3.1 Parallel Interface Specifications
1.3.1.1 Forward Channel
Transmission mode: Synchronization: Handshaking: Signal level: Adaptable connector: Data transmission timing: 8-bit parallel, IEEE-1284 compatibility mode By STROBE pulse synchronization By BUSY and ACKNLG signals TTL compatible level 36-pin 57-30360 (Amphenol or equivalent) See Figure 1-7 of the Stylus Pro XL Service Manual.
Note:
Transition time (rise time and fall time) of every input signal must be less than 0.2 µs. Transition time (rise time and fall time) of every output signal must be less than 0.12 µs.
The printer sets the BUSY signal HIGH before setting either the ERROR signal LOW or the PE signal HIGH. BUSY is held HIGH until all these signals return to their inactive state. The BUSY signal is active (HIGH) under the following conditions: Ì During data reception (See Figure 1-7 of the Stylus Pro XL Service Manual..) Ì When the input buffer is full Ì When the INIT input signal is active Ì During initialization Ì When the ERROR is active Ì During self-test Ì During default setting Ì When the parallel interface is not selected The ERROR signal is active (LOW) under the following conditions: Ì When a paper-out error occurs Ì When a release lever operation error occurs Ì When a hardware error (a fatal error) occurs The PE signal is active (HIGH) under the following conditions: Ì When a paper-out error occurs
1-4
Rev.A
Stylus Pro XL+
Product Description
Table 1-2 shows connector pin assignments and signal functions of the 8-bit parallel interface forward channel.
Table 1-2. Signal and Connector Pin Assignments for the Parallel Interface (Forward Channel)
Pin No. Signal Name Return I/O* GND Pin Description The STROBE pulse is used to read data from the host computer. Pulse width must be 0.5 µs or more. Normally, it is HIGH, and data is latched with the rising edge of this signal. DATA 0-7 are parallel data bits. When one of these signals is HIGH, the data bit is 1; when LOW, the data bit is 0. The most significant bit (MSB) is DATA 8. The signal state must be maintained for 0.5 µs on either side of the STROBE signal's active edge. ACKNLG is a negative pulse indicating that the printer can accept data again. The BUSY signal informs the host computer of the printer's status. When this signal is HIGH, the printer cannot accept any more data. This signal indicates whether paper is available in the printer or not. A HIGH level indicates no paper. This signal is always at HIGH while printer power is on. Not used. If this signal goes LOW, the printer is initialized. The pulse width of this signal must be 50 µs or more. This signal goes LOW if the printer has detected an error. Pulled up to +5 V through 3.9K resistor in the printer. Pulled up to +5 V through 3.3K resistor in the printer. Not used. Chassis ground. Signal ground. Not connected
1
STROBE
19
I
2-9
DATA 0-7
20 - 27
I
10
ACKNLG
28
O
11
BUSY
29
O
12 13 14 31 32 18 35 36 17 16, 33, 19-30 15, 34
PE SLCT AFXT INIT ERROR Logic H +5 V SLIN Chassis GND GND NC
28 28 30 30 29 -- -- 30 -- -- --
O O I I O O -- I -- -- --
*
The I/O column indicates the direction of the signal as viewed from the printer.
Rev.A
1-5
Product Description
Stylus Pro XL+
1.3.1.2 Reverse Channel
Transmission mode: Synchronization: Handshaking: Signal level: Adaptable connector: Data transmission timing: 8-bit parallel, IEEE-1284 nibble mode. Refer to the IEEE-1284 specification. Refer to the IEEE-1284 specification. IEEE-1284 level 1 device (See the forward channel.) The same as for the forward channel. Refer to the IEEE-1284 specification.
Table 1-3 shows connector pin assignments and signal functions of the 8-bit parallel interface for reverse channel.
Table 1-3. Signal and Connector Pin Assignments for the Parallel Interface (Reverse Channel)
Pin No. 1 Signal Name Host Clk Return I/O* GND Pin 19 I Host clock signal. DATA 0-7 signals represent data bits 0 - 7, respectively. Each signal is at a HIGH level when data is logical 1 and LOW level when data is logical 0. These signals are used to transfer the 1284 extensibility request values to the printer. Printer clock signal. Printer busy signal and reverse channel transfer data bits 3, 7. Acknowledge data request signal and reverse channel transfer data bits 2, 6. X-flag signal and reverse channel transfer data bits 1, 5. Host busy signal. Not used. Data available signal and reverse channel transfer data bits 0, 4. 1284 active signal. A HIGH signal indicates that all other signals sourced by the peripheral are in valid status. Pulled up to +5 V via 3.3K resistor. Chassis GND. Signal GND. Not connected. Description
2-9
DATA 0 - 7
20 - 27
I
10 11 12 13 14 31 32 36 18 35 17 16, 33, 19 - 30 15, 34
Ptr Clk Ptr Busy / Data Bit 3, 7 Ack Data Req / Data Bit 2, 6 Xflag / Data Bit 1, 5 Host Busy INIT Data Avail / Data Bit 0, 4 1284-Active Logic-H +5V Chassis GND GND NC
28 29 28 28 30 30 29 30 -- -- -- -- --
O O O O I I O I O O -- -- --
*:
The I/O column indicates the direction of the signal as viewed from the printer.
1-6
Rev.A
Stylus Pro XL+
Extensibility Request:
Product Description
The printer responds affirmatively when the extensibility request values are 00H or 04H, values that mean -- 00H: Request Nibble Mode Reverse Channel Transfer 04H: Request Device ID Return data using nibble mode reverse channel transfer. The printer sends following device ID string when it is requested. [00H][39H] MFG:EPSON; CMD:ESCPL2-00; MDL:Stylus Pro XL+; CLS : PRINTER;
Device ID:
Note:
[00H] denotes a hexadecimal value of zero.
1.3.2 Optional Interface Specifications
Type-B interface Level-2 (300 mA type) is supported.
Note :
With the simplified serial interface card C82305*, "Disregard a parity bit" setup is not supported.
ESC/P 2 is selected MTP48p,PW127cl10cpi,PRG(VCxxxx)rev,AP300ma Stylus Pro XL+ ESCP-00 EPSONLQ2
Reply message Main-Type: Product-Name: Emulation-Type: Entity-Type:
Rev.A
1-7
Product Description
Stylus Pro XL+
1.4 OPERATIONS
This section describes the basic operations of the printer.
1.4.1 Control Panel
The control panel for this printer has 1 lock-type and 5 non-lock-type pushbuttons, and 15 LED indicators for easy operation of the various printer functions.
: Button : LED
Figure 1-1. Control Panel Appearance
Buttons
Operate Turns the printer on or off. This button is in the secondary circuit of the power supply. This lets the printer execute the head-capping function after it receives the signal to turn off and before actual printer power down. Modifies the functions of other buttons. Holding down this button for 3 seconds causes the printer to move the carriage to the ink cartridge installation position. Pressing Alt again causes the carriage to return to the home position. Cycles through the font choices. Pressing the Font button while holding down the Alt button causes the carriage to move to the gap-adjustment position. Pressing the Alt button again causes the carriage to return to the home position. Selects either economy or condensed printing mode. Pressing the Economy/Condensed button while holding down the Alt button starts the black printhead cleaning cycle. Either loads a new sheet into the printer or ejects paper currently in the paper path. Pressing the Load/Eject button while holding down the Alt button starts the color printhead cleaning cycle. Stops printing temporarily or resumes printing if it has been stopped temporarily. Pressing Pause while holding down the Alt button resets the printer.
Alt
Font
Economy/Condensed
Load/Eject
Pause
1-8
Rev.A
Stylus Pro XL+
Product Description
Indicators
Operate Paper Out Ink Out (Black) Ink Out (Color) Economy Condensed Font Pause Data On when the printer is on. Blinks while the printer is powered on or off. On when the printer is out of paper. Blinks when a paper jam occurs. On when the black ink cartridge is out of ink or not installed. Blinks when black ink is low. On when the color ink cartridge is out of ink or not installed. Blinks when color ink is low. On when economy printing mode is selected. On when condensed printing mode is selected. These LEDs indicate the selected font. On when printing is paused. On when print data is in the input buffer. Data and Pause lights blink if an error occurs.
1.4.2 Panel Operation at Power On
The list below contains printer modes and the procedures you can use to activate them: Self-test mode Hex dump mode Turn on the printer while holding down the Load/Eject button. Turn on the printer while holding down the Font and Load/Eject buttons. Once this mode is selected, the printer prints all received data in hexadecimal format. Turn on the printer while holding down the Economy/Condensed button. The printer enters the default setting mode. Turn on the printer while holding down the Alt, Font, Load/Eject, and Pause buttons.
Default setting mode Initialize EEPROM
Note:
You can exit self-test, hex dump, or default setting by turning off the printer.
Rev.A
1-9
Product Description
Stylus Pro XL+
1.4.3 Error Conditions
The printer can detect the various errors and indicate them with LEDs.
Table 1-4. Error Indications
Paper Out On -- -- -- -- Blinks Blinks -- Ink Out (Black) -- On Blink -- -- -- Blinks -- Ink Out (Color) -- -- -- On Blink -- Blinks --
Error Paper out Black ink end Black ink low Color ink end Color ink is low Paper jam Maintenance request Carriage error
Operate -- -- -- -- -- -- -- --
Economy Condensed Pause -- -- -- -- -- -- Blinks -- -- -- -- -- -- -- Blinks -- -- -- -- -- -- --
Data -- -- -- -- -- --
Blinks Blinks Blinks Blinks
-- Not used to indicate the specified error.
1-10
Rev.A
Stylus Pro XL+ Service Manual
Operating Principles
2.1 OPERATING PRINCPLES - OVERVIEW
This section describes the operating principles of the printer mechanism and the electrical circuits of the Stylus Pro.
2.2 OPERATING PRINCIPLES OF THE PRINTER MECHANISM
2.2.1 Principles of the Printing Operation
The printing mechanism for the Stylus Pro XL+ has a drop-on-demand ink jet system, similar to the system in all other EPSON ink jet printers. The Stylus Pro XL+ printer uses the Micro Dot printing function both with black ink and super 720 dpi color printing. The type of Micro Dot printing the Stylus Pro XL+ performs is the same as is available in the Stylus COLOR II and Stylus COLOR IIs/820. However, with those printers, Micro Dot printing is available for printing with black ink only. The Micro Dot printing mode can be selected automatically with 720 dpi printing quality using the printer driver settings described in the following table.
Table 2-1. Special Printing Mode
Paper Type Print Density (DPI) 360 Normal Paper H -- 720 × V -- 360 360 EPSON Premium Paper for 360 dpi H-- 720 × V -- 360 720 720 720 720 360 Print Mode Normal Dot Printing EPSON Micro Dot Printing Normal Dot Printing EPSON Micro Dot Printing
EPSON Premium Paper for 720 dpi Labels for 720 dpi High Quality Glossy Card Stock High Quality Glossy Paper Transparency film
EPSON Micro Dot Printing EPSON Micro Dot Printing EPSON Micro Dot Printing EPSON Micro Dot Printing Normal Dot Printing
Micro Dot printing mode can improve output quality, because it eliminates banding that can sometimes occur in normal mode. The dot size in EPSON Micro Dot Printing mode is smaller than the dot size in normal printing. Normal print mode is mainly used in resolutions of 360 dpi or less.
Rev.A
2-1
Operating Principles
Stylus Pro XL+ Service Manual
2.3 OPERATING PRINCIPLES OF THE ELECTRICAL CIRCUITS
The Stylus Color Pro XL+ contains the following circuit board units: Ì Ì Ì C184 MAIN board (main control circuit board). C137 PSB/PSE board (power supply circuit board). This board is the same as Stylus Color's C137 PNL (control panel board). This board is similar to Stylus Color's.
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; the printhead is attached directly to this board. The figure below shows a block diagram of the electrical circuits.
2.3.1 Operating Principles of the Main Control Circuit
The main control circuit for this printer is the C184 MAIN board. This circuit is controlled by a 16-bit H8/3003 CPU (IC1), running at 14.7456 MHz. The CPU has a unique architecture, capable of handling data on the data bus at either an 8-bit or 16-bit bus width. Because of this, both a 16-bit and an 8-bit data bus width-type ROM can be used on the board, increasing the internal processing speed. Also, the CPU's unique architecture is capable of refresh control. In addition, the CPU controls the serial interface (RS-422 for Mac) and optional interface (Type B interface). Gate array E05B21 (IC2) manages the printhead driver, the external Centronics® parallel interface, the extension CG board, and the control panel. The gate array also oversees the controls that create the 4-bit signals for the carriage or the paper feed motor. (The carriage and paper feed motor are controlled by current duty data.) This board also is equipped with a 93C46 EEPROM (IC11) to store certain parameters, such as the black/color head data, printer mechanism control parameters, default setting parameters, as well as a special counter value used for printhead (ink management) protection. Timer IC NJU6355E (IC10) counts each time the printer goes through its cleaning cycle and keeps track of how much time has elapsed since the printer has been used, thereby allowing the printer to be cleaned only when necessary. The timer value is backed up by the lithium battery.
P- R OM (4M ) (IC3)
P-R O M (1 -4M) (IC4)
D - R A M (4 M ) (IC5)
D - R A M (4 M ) (IC6) D a ta Bus
MROM (4-32M) (IC7)
Ad dr es s Bu s
Typ e-B I/F
R ef r es h
Re se t ( Log i c )
CP U
R e se t (P ow e r)
(IC9)
(IC8) M51955B
H8/3003 (IC1) D MAREQ SD I / O C LK Vx
(IC10 )
E 05B21
(IC2)
P ST 5 92D
Panel
EEPROM
To B To A
(IC11) 93 C 4 6
SN 75LBC775 R S-4 22 Seri al I/F
(IC13 )
Par alle l I/F
( T ime r C ou nte r )
C 184 MAIN B oa rd H 8 D 2 7 7 8 A ( I C 1 6, 1 7) From A Black/C ol or H ead C ommon D ri ver Ci rcui t (U 1, U2)
S E D 6 1 1 0 DOA
B l a c k 6 4 No z zl e s
C ol or 48 Nozzl es
SL A7 04 3 M ( I C 1 4 , 1 5 ) From B C ar ria ge / Pa pe r Fe ed Mot or D ri ver
M
Figure 2-1. Main Control Circuit Block Diagram
2-2
M oto r D riv er S ignal
B lack / C olor H ead
NJ U6355E
Ca rriage / Paper Feed
S electo r Dr ive Signal
C om m on and N ozz le
Rev.A
Stylus Pro XL+ Service Manual
Operating Principles
2.3.2.1 Reset Circuits
The C184 MAIN board contains 2 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 (logic line), using reset IC PST592D (IC9), and outputs a reset signal to the CPU (IC1) and the E05E21 gate array (IC2) when the voltage level drops below +4.2 V. The +35 V monitor reset circuit monitors the voltage level of the +35 V line, using reset IC M51955B (IC8), 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).
+35 V
+5 V CPU (IC1) M 5 19 55 B (IC8) 68 6 72 NMI RES E05B21 ( IC2) PST592D (IC X) 1 80 RESET
TBRST
P6 2
+5 V
71
55
RST Type B
Figure 2-2. Reset Circuit Block Diagram
Rev.A
2-3
Operating Principles
Stylus Pro XL+ Service Manual
2.3.2.2 Sensor Circuits
The following sensor circuits enable the C184 MAIN board to monitor printer mechanism status: HP sensor A photocoupler-type HP (home position) sensor is attached to the surface of the printer mechanism to detect the carriage home 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. A LOW level from the signal indicates that no paper is loaded. Micro switches (BCO sensor for the black ink cartridge, CCO sensor for the color ink cartridge) are attached to the bottom of ink cartridge holder in the carriage unit. When the ink cartridge is installed, these switches are pressed and a LOW level from the signal indicates that the ink cartridge is installed into the ink cartridge holder. These sensing timing is only in the cartridge installation mode and one minute after the carriage holed to prevent from miss censoring owing from switch actuators shock in printing condition. A thermistor is attached to the color printhead driver board to monitor its temperature using the thermistor's resistance value (at 25° C (77° F), the normal value is approximately 10K ). The CPU changes the printhead drive signal's pulse width (charge pulse width) based on the temperature level.
PE sensor
BCO sensor, CCO sensor
Thermistor
GA (IC2)
3 (CN8) PE SWC0 181 180 SWC2 BCO (CN11)
SWC1 4 (CN9) HP SWA0
CCO (CN12)
CPU (IC1)
5 PB3 86 TH AN0
(CN12)
Figure 2-3. Sensor Circuit Block Diagram
2-4
Rev.A
Stylus Pro XL+ Service Manual
Operating Principles
2.3.2.3 Carriage Motor Driver Circuit
Carriage motor driver IC SLA7043 (IC15) outputs a constant current to drive the carriage motor in the printer mechanism. Gate array E05B21 (IC2) decides the motor phase and speed, and then it sends a signal to the carriage motor driver IC (SLA7043), using the 4-bit serial transmission line. The first bit indicates the direction of motor rotation. The other three bits (a, b, c) are current duty data for the motor speed for each printing sequence. (Refer to Table 2-2, below.) SLA7043 can select the reference voltage itself based on these three bits of current duty data. Also, the driver IC receives these signals via two serial transmission lines for the two motor phases (phase A and phase B). As a result, the carriage motor can be driven in micro step sequence (1/720 inches, minimum). The SLA7043 motor driver reads four-bit serial data using four clock counts from the E05B21 (IC2) clock. Each bit is read at the falling edge of the clock pulses. Then, received serial data is written into the shift register and then shifted the latch register. When the strobe pulse becomes active from the E05B21 (IC2), serial data is moved into the reference voltage selection circuit and the voltage is changed. Therefore, when the printer is in the constant speed mode, this strobe pulse becomes inactive. The following table indicates the current duty of each carriage motor speed mode.
Table 2-2. Serial Data Contents
Mode 0 1 2 3 4 5 6 7 c b a* 0 0 0 0 0 1 0 1 0 0 1 1 1 0 0 1 0 1 1 1 0 1 1 1 Vref × 1/3 (Vref = +5 V) Vref (Typical) × 0% × 20% × 40 % × 55.5% × 71.4% × 83% × 91% × 100%
*
"a" indicates the 2nd bit, "b" indicates the 3rd bit, and "c" indicates the 4th bit.
The following figure shows 4-bit serial data and how this data is transferred by the SLA7043 driver. The step time for the reference voltage is determined by the interval time of the strobe pulse.
E05B21 (IC2)
CRCLK CRSTB CRASO CRBSO CRV0-5 CRHOLD 205 197 198 199 196 5-10 5 16 2 13 6 17 3 14 9 10 C B Q5 E
SLA7043 (IC15)
CLKA CLKB STBA STBB DATA A DATA B REF A REF B RSA RSB GND
A A B B
1 8 11 18
1 2 3 4 5 (CN6)
Figure 2-4. Carriage Motor Circuit Block Diagram
Rev.A
+35 V
2-5
Operating Principles
Stylus Pro XL+ Service Manual
2.3.2.4 Paper Feed Motor Driver Circuit
The paper feed motor for this printer drives the following mechanisms: Ì Ì Ì Paper feed mechanism Paper pickup mechanism Pump mechanism
Driver IC SLA7043 (IC14) drives the paper feed motor by a constant current. The principle of operation is same as for the carriage motor driver circuit. However, the paper feed motor drives not only the paper feed mechanism but also the pump unit. (Refer to Section 2.3.2.4.)
Table 2-3. Paper Feed Motor Drive Modes
Mode Paper feed Pump drive
E05B21 (IC2)
202 PFCLK 198 PFSTB 204 PFASO PFBSO PFV0-2 PFHOLD 201 11-13 205 5 16 2 13 6 17 DATA B 3 REF A 14 REF B 9 RSA 10 RSB GND B Q4 E B B
Phase Excitation 2-2 phase or 2W1-2 phase 2-2 phase
SLA7043 (IC14)
CLKA CLKB STBA STBB DATA A A A
Drive Frequency 391 or 1600 pps 300 or 1800 pps
1 8 11 18
1 2 3 4 5 (CN7)
Figure 2-5. Paper Feed Motor Driver Circuit Block Diagram
2-6
+35 V
Rev.A
Stylus Pro XL+ Service Manual
Operating Principles
2.3.2.5 Printhead Driver Circuit
The printhead driver circuit for this printer is composed of the following two parts: Ì Ì Common driver circuit (common drive pulse generation) Head driver circuit (nozzle control built on the printhead)
The common driver circuit is hybrid IC H8D2778A on the C184 MAIN board. The head driver circuit is IC SED61110D0A on the printhead unit itself. The printhead drive signals are output from gate array E05B21. They consist of the common driver control signals (SBDT/SCDAT, SCLK, SSTB, SCLR, BH1C0/CH1C0, BH1C1/CH1C1, BH1D/CH1D, BHDIS/CHDIS) and the nozzle select signals (BHDAT/CHDAT, BHCLK/CHCLK, BHLAT/CHLAT, BHNCHG/CHNCHG). The common driver control signals from gate array E05B21 are translated to common drive voltage pulses by IC H8D2778A and input to each printhead nozzle PZT. The nozzle select signals are also output from gate array E05B21 to SED6110D0A on the head unit to select the print nozzles. Then the ink dots are ejected from the selected nozzles.
C184 MAIN E05B21 (IC2)
SBDAT SCLK SSTB SCLR BH1C0/1 BH1D BHDIS BHCLK BHLAT BHDAT BHNCHG Common Driver
On Carriage (Head Driver Board)
Black Head Nozzles
H8D2778A
COM SED6110DOA (U1)
CN11
CN 1
CLK LAT SI
Common Driver SCDAT H8D2778A COM SED6110DOA (U2) Color Head Nozzles
CH1C0/1 CH1D CHDIS CHCLK CHLAT CHDAT CHNCHG
Figure 2-6. Printhead Driver Circuit Block Diagram
C N12
CN 1
CLK LAT SI
Rev.A
2-7
Operating Principles
Stylus Pro XL+ Service Manual
Common Driver Signals
The common driver control signals consist of the common voltage control signals (SBDAT/SCDAT, SSTB, SCLR, SCLK) and the common drive pulse generation signals (BH1C0/CH1C0, BH1C1/CH1C1, BH1D/CH1D, BHDIS/CHDIS). The common voltages (VH), ranging between the maximum voltage and 0 (V), are split into 256 levels, which are then translated into 8-bit serial data for the common voltage control signal (BHDAT/CHDAT), which is output from gate array E05B21 to the common driver H8D2778A to fit with each printhead specifically. The signals are received by SSTB, SCLR and SCLK to the common driver.
SCLT
H L H L H L H L
SDAT
SCLR
SSTB
Figure 2-7. Common Driver Signal Timing Chart
After the common voltage (VH) is stabilized, common drive pulse generation signals are translated to generate the common drive pulses from gate array E05B21 to the H8D2778A common driver.
COM
VH
BH 1C 0/C H 1C 0
BH 1C 1/C H 1C 1
BH1D/CH1D
Figure 2-8. Common Drive Pulses
2-8
Rev.A
Stylus Pro XL+ Service Manual
Operating Principles
Nozzle Select Signals
The nozzle select signals are output from gate array E05B21 to SED6110D0A on the head unit to select the printhead nozzles. Nozzle select data (BHDAT/CHDAT) is HIGH for selected nozzles and LOW for unselected nozzles. Nozzle select data translation timing is controlled by 64 clock signals (BHCLK/CHCLK), one for each nozzle. After the print nozzles are selected, the common drive pulses are input to each PZT on the selected nozzles via SED6110D0A. Then the ink dots are ejected from each selected nozzle's PZT.
BHDAT/CHDAT #1 BHCLK/CHCLK # 64
BHLAT/CHLAT
BHNCHG/CHNCHG
BH1C0/CH1C0
BH1C1/CH1C1
BH1D/CH1D
COM
VH
Figure 2-9. Common Drive / Nozzle Select Signal Timing (Normal Dot Printing)
Rev.A
2-9
Operating Principles
Stylus Pro XL+ Service Manual
Normal Dot Versus EPSON Micro Dot Printing Mode
The Stylus Color Pro XL+ can eject ink in two different modes (normal print mode and EPSON Micro Dot Mode). These modes are the same as the modes used in the Stylus Color II/Stylus Color IIs. (Refer to Section 2.2.1.) However, EPSON Micro Dot Printing in the Stylus Color II and Stylus Color IIs can be used only for printing with black ink. EPSON Micro Dot Printing in the Stylus Pro XL+ can be used with both black and color printing. In normal dot printing, a pair of common drive pulses are translated to the printhead to produce one dot. On the other hand, one print dot consists of single dot in the EPSON Micro Dot Printing. A single common drive pulse is translated to the printhead, as shown in the following figure.
COM
VH
BH1C0/CH1C0
BH1C1/CH1C1
BH1D/CH1D
Figure 2-10. Common Drive Pulse for EPSON Micro Dot
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Operating Principles
2.4 INK SYSTEM MANAGEMENT
This section explains how the ink system is managed to protect the printhead and the ink supply system and to ensure high-quality output. Ink system operations are controlled by the following counters: Ì Ì Protect counter Ink consumption counter
2.4.1 Counters
EEPROM 93C46 (IC11) on the main board stores the counter values used for controlling ink system operation.
2.4.2.1 Protect Counters
The values of protect counters A and B, C are stored in the EEPROM on the main board, and while the printer is on, this data is also stored in the RAM on the main board. Ì Protect counter A This counter manages the total amount of drained ink. If the counter value is equal to or exceeds 51,000, the printer indicates an error on the control panel indicating that maintenance is required.
Notes for Service
Protect counter A is reset: 1. Upon shipment from the factory. 2. After maintenance is performed (whenever you replace the ink drain tank). Ì Protect counter B, C These counters set limits to prevent the user from frequent initial ink charging. The counters values are stored in the EEPROM as flags and are reset by the EEPROM reset function.
2.4.2.2 Ink Consumption Counter
This counter manages black and color ink consumption. The counter is counted up during printing, automatically. It also counts compulsory head cleaning and the interval times between usage of the ink cartridge. This counter is only reset by the installation of a new ink cartridge.
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Disassembly and Assembly
3.1 DISASSEMBLY AND ASSEMBLEY - OVERVIEW
This section describes procedures for disassembling the main components of the printer. Unless otherwise specified, disassembled units or components can be reassembled by reversing the disassembly procedure. Therefore no assembly procedures are included. Precautions for any disassembly or assembly procedure are described under the heading "Disassembly/Assembly Points." Adjustments required after assembling the unit are described under the heading "Required Adjustments."
3.1.1 Precautions for Disassembling the Printer
See the precautions below when disassembling the printer.
WARNING
Ì Disconnect the power cable before disassembling or assembling the printer. Ì Wear protective goggles to protect your eyes from ink. If ink gets in your eye, flush it with fresh water and see a doctor immediately. If ink comes into contact with your skin, wash it off with soap and water. If irritation occurs, contact a physician. Ì A lithium battery is installed on the C184 MAIN Board of this printer. Be sure to observe the following instructions when servicing the battery: 1. Keep the battery away from any metal or other batteries so that electrodes of opposite polarity do not come in contact with each other. 2. Do not heat the battery or put it near fire. 3. Do not solder on any part of the battery. (Doing so may result in leakage of electrolyte from the battery, burning, or explosion. The leakage may affect other devices close to the battery.) 4. Do not charge the battery. (An explosive gas may be generated inside the battery, and cause burning or explosion.) 5. Do not dismantle the battery. (The gas inside the battery may hurt your throat. Leakage, burning, or explosion may also result.) 6. Do not install the battery in the wrong direction. (This may cause burning or explosion.)
CAUTI O N
There is danger of explosion if the battery is incorrectly replaced. Replace only with the same or equivalent type recommended by the manufacturer. Dispose of used batteries according to government's laws and regulations.
ATTENTION
Risque d'explosion si la pile est remplacée incorrectement. Ne remplacer que par une pile du même type ou d'un type équivalent recommandé par le fabricant. Elminer les piles déchargées selon les lois et les règles de sécurité en vigueur.
CAUTI O N
Ì Never remove the ink cartridge from the carriage unless specified to do so. Ì When transporting the printer after the ink cartridge has been installed, be sure not to remove the ink cartridge when you pack the printer for shipping. Ì Use only recommended tools for disassembling, assembling, or adjusting the printer. Ì Apply lubricants and adhesives as specified. (See Stylus Pro XL Service Manual Chapter 6.) Ì Make specified adjustments when you disassemble the printer. (See Chapter 4.)
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Disassembly and Assembly
3.2 DISASSEMBLY AND ASSEMBLY
CAUTION
Ì When you remove the ink cartridge, always install a new cartridge immediately after taking out the old one. Ì When you replace the ink cartridge, the printer performs the ink cartridge replacement operation automatically. The exclusive service cartridges have the following part numbers: Monochrome: 1020626 YMC: 1027990 Ì Never keep ink cartridges longer than 6 months.
3.2.1 Printer Mechanism Disassembly
The procedures described in this section explain how to remove components in the printer mechanism.
3.2.1.1 Carriage Unit Removal
1. 2. 3. 4. 5. 6. 7. 8. Remove the printer mechanism. (See Stylus Pro XL Service Manual, Section 3.2.4.) Move the carriage to the left side of the printer while pressing the hook that fixes the carriage to the home position. Remove the 2 CBS (O) (M3× 6) screws securing the front frame to both side frames. Remove the cartridge holder with from the carriage unit. (See the Stylus Pro XL Service Manual, Section 3.2.5.1.) Release the carriage timing belt from the belt pulley while pressing the pulley lever. Remove the both sides flange nuts and plain washers. Remove 2 parallelism adjustment bushings and carriage shaft spacers from both side frames. Take off carriage shaft spacer L and carriage shaft spacers B, C, or D (if they have been installed).
Carriage Shaft Spacer Plain Washer
Left Side Frame
Carriage Shaft Spacer L;B Carriage Shaft Spacer L;C Carriage Shaft Spacer L;D
Carriage Shaft Spacer L
Carriage Guide Shaft
Flange Nut (M4) Parllelism Adjust Bushing
Carriage Shaft Spacer R Right Side Frame Parllelism Adjust Bushing Carriage Shaft Spacer Plain Washer
Carriage Guide Shaft
Flange Nut (M4)
Figure 3-1. Fixing the Carriage Guide Shaft
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9.
Disassembly and Assembly
Lift the carriage unit with the carriage guide shaft out of the printer mechanism.
CAUTION
Ì Take appropriate measures to protect the printhead unit from static electricity, because the driver IC is directly attached to the printhead unit. Ì Never touch the metallic nozzle surface of the printhead cover. Handle it only by holding the edges of the printhead. Ì After you have replaced the printhead or the printer mechanism, you must perform the head data writing operation before any other adjustments. (See Section 4.1.1.) Ì Put the carriage shaft spacers L, B, C and D between the left frame and the carriage guide shaft to minimize the gap between them. The adjustable range is from 0.8 mm to 1.8 mm. The thickness of carriage shaft spacers are as follows: Carriage Shaft Spacer L 0.6 mm Carriage Shaft Spacer L and B 0.8 mm Carriage Shaft Spacer L and C 1.0 mm Carriage Shaft Spacer L and D 1.2 mm
ADJUSTMENT REQUIRED
Ì Platen gap adjustment (See Chapter 4.)
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Adjustment
4.1 ADJUSTMENT - OVERVIEW
This section describes adjustments required when the printer is disassembled and assembled after repair. Since this printer has both a black and color head, it needs new adjustments not required for previous printers. Refer to the following table to perform the appropriate adjustments.
CAUTI O N
t Always perform adjustments in the order indicated. t After performing steps 1-5, do the cleaning operation for the black and color printheads. The cleaning operation is necessary, because printing sample patterns for the head angle, Bi-D alignment, and the head gap increases the viscosity of the ink, and the printer will not print the correct value. For instance if you replace the black head, you must do the following adjustments in the order shown: (1) Black head angle, (2) black-color head vertical, (3) head gap, (4) Bi-D alignment. t After removing an ink cartridge, always install a new cartridge immediately. During adjustments and testing, use cartridges designed exclusively for service (Monochrome: 1020626, CMY: 1027990 )
Table 4-1. Required Adjustments
Service Performed When replacing the printer mechanism When replacing or disassembling the main board or printer mechanism When replacing or disassembling the black head (board) Adjustment Needed 1. Writing head data (see Section 4.1.1) 2. Bi-D alignment adjustment (see Section 4.1.2). 3. Head gap adjustment (see Section 4.1.3). 1. Writing head data (see Section 4.1.1) 2. Bi-D alignment adjustment (see Section 4.1.2). 3. Head gap adjustment (see Section 4.1.3). 1. Writing head data (see Section 4.1.1) 2. Black head angle adjustment (see Section 4.1.4). 3. Black - color head vertical adjustment (see Section 4.1.5). 4. Head gap adjustment (see Section 4.1.3). 5. Bi-D alignment adjustment (see Section 4.1.2). 1. Writing head data (see Section 4.1.1) 2. Color head angle adjustment (see Section 4.1.6). 3. Black - color head vertical adjustment (see Section 4.1.5). 4. Head gap adjustment (see Section 4.1.3). 5. Bi-D alignment adjustment (see Section 4.1.2). 1. Writing head data (see Section 4.1.1) 2. Color head angle adjustment (see Section 4.1.6). 3. Black head angle adjustment (see Section 4.1.4). 4. Black - color head vertical adjustment (see Section 4.1.5). 5. Head gap adjustment (see Section 4.1.3). 6. Bi-D alignment adjustment (see Section 4.1.2). 1. Platen gap adjustment (see Section 4.1.7). 2. Writing head data (see Section 4.1.1) 3. Bi-D alignment adjustment (see Section 4.1.2). 4. Head gap adjustment (see Section 4.1.3).
When replacing or disassembling the color head (board)
When replacing or disassembling both the color and black head
When replacing or disassembling the carriage unit
NOTE:
The destination data writing operation (see Section 4.1.2) is performed automatically when you quit the program from the adjustment main menu and turn off the printer. When you need to replace the printer mechanism, you will find the head data information written on the outside of carton containing the printer mechanism.
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4.1.1 Head Data Writing Operation
Data unique to the specific black and color printhead used in the printer is stored in the EEPROM on the C184 MAIN board. These values must be written to the EEPROM first when the printhead unit, the printer mechanism, main board, or EEPROM chip is replaced. However, it is not necessary to write them to EEPROM again, even if the EEPROM is reset from the control panel.
CAUTION
Before running this program, be sure the interface setting is set to parallel or auto select. 1. 2. Connect the PC to the target printer using a parallel interface cable, and turn the printer on. Load BASIC on the PC, and run the adjustments program. You see the following destination select menu: ***** Customer ***** 1. EAI, EAI (Latin America), EAL, ESP 2. EDG, EUL, EFS, EIS, EIB, EUL (Northern Europe), EUL (Middle East), EHK 3. 4. JAPAN 5. 6. 7. END Select Menu ? 3. Input the number for the destination. Then the main menu appears, as shown in the menu that follows.
CAUTION
If you enter an incorrect number as the destination selection, printer functions are not guaranteed.
STYLUS Pro XL+ Program : Rev. X customer : 1. Head VH input 2. Ink consumption counter reset 3. Head angular & linear adjustment 4. Head position check 5. BK. YMC head gap adjustment (head gap center ) 6. Bi-D adjustment (Bi-d center ) 7. Head VH indication 10. Change customer & data / END 0. Cleaning Select Menu ? s 4. Select "1, Head VH input" typing 1 and pressing Enter to perform the head data writing operation. Then the menu for setting the black head data appears, as shown below: input head VH BK VH = ? s
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5. 6. Input the black head VH values. Then the menu for setting color head VH values appears. Input the color head VH values. Then the program returns to the main menu.
Adjustment
CAUTION
t The head VH data is written on the each head unit as shown in the following figure. t The setting values are not stored permanently in the EEPROM until you turn the printer off. Turn off the printer immediately after the adjustments.
Nozzle Select Circuit Board Head VH Value
Figure 4-1. Printhead VH Value
7. 8. When the main menu appears, choose "10. Change customer & data / END" by typing 10 and Enter. Choose "END" by typing 7 to exit the adjustment program.
CAUTION
Specific destination parameters, including the destination, interface mode, TOF value, and economy/condensed, are not written to the EEPROM yet. Turn off the printer immediately after the adjustments. 9. Turn off the printer.
4.1.1.1 Head VH Indication
This function prints out the VH values for the installed black and color heads stored in the EEPROM. The values are in HEX, so convert them into the head VH values using a conversion table and input in the printer. 1. Select "7, Head VH indication" by typing 7 and pressing Enter to print out the head VH settings. The printer prints the head values in four columns, as shown below: Head VH : X1 X2 X3 X4
CAUTION
X1 and X2 show the VH for the black head; X3 and X4 show the VH for the color head.
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4.1.2 Destination Data Writing Operation
The setup value that specifies the printer destination is stored in EEPROM on the C184 MAIN board. Therefore, this setup value must be written to the EEPROM when the main board or EEPROM chip is replaced. This function is always selected to finish the program using END operation.
CAUTION
Before writing the destination data writing, set the interface to parallel or auto select. 1. 2. Connect the PC to the target printer using a parallel interface cable and turn the printer on. Load BASIC on the PC, and run the program. You see the following destination select menu. ***** Customer ***** 1. EAI, EAI (Latin America), EAL, ESP 2. EDG, EUL, EFS, EIS, EIB, EUL (Northern Europe), EUL (Middle East), EHK 3. 4. JAPAN 5. 6. 7. END Select Menu ? 3. Input the number for the destination. Then the main menu appears, as shown shown below.
CAUTION
If you enter an incorrect number as the destination selection, printer functions are not guaranteed.
STYLUS Pro XL+ Program : Rev. X customer : 1. Head VH input 2. Ink consumption counter reset 3. Head angular & linear adjustment 4. Head position check 10. Change customer & data / END 0. Cleaning Select Menu ? s 4. 5. 6. When the main menu appears, choose "10, Change customer & data / END" by typing 10 and pressing Enter. The main menu immediately disappears briefly and then the destination select menu appears. Choose "END" by typing 7 to exit the adjustment program.
CAUTION
Settings have not yet been written to the EEPROM. Turn off the printer immediately after the adjustments. 7. Turn off the printer.
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4.1.3 Black Head Angle Adjustment
The black head angle adjustment is required when the black head is replaced or disassembled. If this adjustment is not correct, a white banding problem may occur, or color head timing may not match black head timing. The following figure illustrates the black head angle adjustment. The black head angle is adjusted with linear and angular spacers. A linear spacer is attached to both sides of the head base, and an angular spacer is attached only to the right side of the head base. Spacers for the black head come in different shapes for the thickness needed. The following figure shows the relationship between the shape and thickness.
Black Head
Head Base Head Carriage Angular Spacer
Linear Spacer (Angle Adjustment)
Figure 4-2. Black Head Angle Adjustment
Angular Spacers (for Black Head)
Linear Spacers (Only for Black Head)
Spacer Name
angular spacer BK
angular spacer BK-B
Thickness
0.05
0 .10
Sha pe
Spacer Name
linear spacer K
linear s pac er J
Thickness
0.05
0.12
Sha pe
angular spacer BK-C
0.15
linear spacer I
0.19
angular spacer BK-D angular spacer BK-E
0.20 0.25
linear spacer linear spacer B
0.26 0.33
linear spacer C linear spacer D
linear s pac er E
0.4 0 0.4 7
0.54
linear spacer F
0.61
linear spacer G
linear s pacer H
0.68
0.75
Figure 4-3. Types of Spacers and Relationship between Shape and Thickness
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Stylus Pro XL+ Service Manual
Connect the PC to the target printer using a parallel interface cable and turn the printer on. Load BASIC on the PC, and run the program. You see the following destination select menu. ***** Customer ***** 1. EAI, EAI (Latin America), EAL, ESP 2. EDG, EUL, EFS, EIS, EIB, EUL (Northern Europe), EUL (Middle East), EHK 3. 4. JAPAN 5. 6. 7. END Select Menu ?
3.
Input the number for the destination. Then the main menu appears, as shown below.
CAUTION
If you enter an incorrect number as the destination selection, printer functions are not guaranteed.
STYLUS Pro XL+ Program : Rev. X customer : 1. Head VH input 2. Ink consumption counter reset 3. Head angular & linear adjustment 4. Head position check 5. BK. YMC head gap adjustment (head gap center ) 6. Bi-D adjustment (Bi-d center ) 7. Head VH indication 10. Change customer & data / END 0. Cleaning Select Menu ? s 4. Choose "3, Head angular & linear adjustment" by typing 3 and pressing ENTER. (The printer prints the check pattern, along with the sample name. )
CAUTION
t When you replace both the black and color heads, always adjust the color head angle first. The black head angle is based on the color head angle. t After you replace the black head and print the black head angle pattern, you only have to insert an angular spacer if the pattern is incorrect.
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3-2. BLACK HEAD ANGLE ADJUSTMENT
B
A
Figure 4-4. Black Head Angle Adjustment Sample
The printer prints a pattern like one in the following sample. Only the nozzles in rows A and D are fired (making it is easy to see the angle of the black head). 6. In the figure above, pay attention to position A. (Do not look at position B.)
Look at position A Position A Position A
Replace the right angular spacer with a thinner one
Replace the right angular spacer with a thicker one
Figure 4-5. Spacer Selection Flowchart
7. 8. 9. Using the following flowchart, replace the angular spacer for the black head, which is under the right linear spacer. The procedure for this replacement is explained beginning with step 7. Turn the printer power off now. Manually move the carriage to the center while pressing the carriage lock lever, and remove the two ink cartridges.
10. Remove the rubber cap covering the head screw at the side of color ink cartridge. Then loosen (but do not remove) 3 screws. (Refer to Figure 4-6.)
CAUTION
After replacing the spacer, always install new ink cartridges before returning the printer to the user. During this adjustment, use ink cartridges exclusively for service: (Monochrome: 1020626, CMY: 1027990 ).
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Stylus Pro XL+ Service Manual
Rubber Cap
CBB(M3 x11)
CBB(M3x11)
CBB(M 3x11)
Figure 4-6. Removing the Rubber Cap
11. Replace the angular spacer for the black head with a new one. (Refer to Figure 4-7.) (To replace the angular spacer, use tweezers to push the head base toward the rear.) 12. After replacing the angular spacer, reassemble the ink cartridge holder and reinstall the ink cartridges. Use the BASIC program to verify the angle of the black head. Confirm the angle by performing the steps 1 to 6 again, and if the angle is wrong, perform the adjustment again until the head angle is correct.
CAUTION
t The angular spacers come in five thicknesses. Continue performing this adjustment by changing the black head spacers until the angle is correct. t When inserting an angular spacer, always place the angular spacer on the linear spacer.
Carriage Unit
Black Head 1. Push
Head Ba se
Angular Spacer
Line ar Spa cers
2. Replace
Platen Gap Adjust Lever
Figure 4-7. Angular Spacer Replacement Method
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4.1.4 Color Head Angle Adjustment
The color head angle adjustment is required when the color head is replaced or disassembled. If this adjustment is not correct, a white banding problem may occur, or the black head timing may not match the color head timing. The following figure illustrates the color head angle adjustment. The color head angle is adjusted with the angular spacer. The angular spacer is attached only to the left side of the head base.
Color He ad
Color Head (Reverse Side)
Head Ba se Carriage
An gu lar Spa cer
(Angle Adjustment Concept)
(Spacer Setting Location)
Figure 4-8. Color Head Angle and Angular Spacer Position
1. 2. Connect the PC to the target printer using a parallel interface cable and turn the printer on. Load BASIC on the PC, and run the program. You see the following destination select menu. ***** Customer ***** 1. EAI, EAI (Latin America), EAL, ESP 2. EDG, EUL, EFS, EIS, EIB, EUL (Northern Europe), EUL (Middle East), EHK 3. 4. JAPAN 5. 6. 7. END Select Menu ? 3. Input the number for the destination. Then the main menu appears, as shown below.
CAUTION
If you enter an incorrect number as the destination selection, printer functions are not guaranteed.
STYLUS Pro XL+ Program : Rev. X customer : 1. Head VH input 2. Ink consumption counter reset 3. Head angular & linear adjustment 4. Head position check 5. BK. YMC head gap adjustment (head gap center ) 6. Bi-D adjustment (Bi-d center ) 7. Head VH indication 10. Change customer & data / END 0. Cleaning Select Menu ? s
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3-1 YMC HEAD ANGULAR A
Stylus Pro XL+ Service Manual
B
Ma g en ta Mage nta
Cyan Cyan
Figure 4-9. Color Head Angle Confirmation Sample
When the main menu appears, choose "3, Head Angle Confirmation Pattern Printing" by typing 3 and pressing ENTER. (The printer prints a check pattern with the sample name.)
CAUTION
When replacing both the black and color heads, always adjust the color head angle first. The black head angle and the black - color head vertical position adjustments are based on the color head angle adjustment.
Angular Spacers (For Color Head)
Spacer Name
angular spacer YMC
angula r sp ac er YMC-B
Thickness
0.30
0.35
Shape
angular spacer YMC-C angular spacer YMC-D
0.40 0.45
angular spacer YMC-E
0.50
Figure 4-10. Relationship between the Shape and Thickness
Angular spacers for the color head come in five thicknesses, each having its own shape. The following figure shows the relationship between the shape and thickness. Since the color head is not equipped with a linear spacer, the angle adjustment is decided only by the angular spacer (specifically designed for the color head), which is placed under the left side of the head base. 5. 6. In Figure 4-9, pay attention to the position of A and B while you reset the left angular spacer. The replacement procedure is explained beginning in step 6. Turn off the printer now.
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Adjustment
Move the carriage to the center manually, and loosen (but do not remove) the screw securing the color head to the carriage.
Look at positions A, B Position A, B Position A, B
(A)
(B)
(A)
(B)
Replace the right angular spacer with a thicker one
Replace the right angular spacer with a thinner one
Figure 4-11. Spacer Selection
8. 9. Remove the rubber cap covering the head screw at one side of color ink cartridge. Then loosen (but do not remove) 3 screws. (Refer to the Figure 4-9.) Replace the angular spacer on the left side with a new one, referring to the figure below. (Replace the angular spacer using tweezers to push the head base toward the rear.)
10. Rerun the BASIC program and choose "3, Head Angle Confirmation Pattern Printing" again by typing 3 and pressing ENTER. Then verify that the confirmation sample is correct.
Carriage Unit
Color Head
1
P u sh
Base Head
Paper Gap Adjust Lever
Spacer Angular (one side only)
Replace 2
Figure 4-12. YMC Angular Spacer Replacement
11. If the sample is incorrect, repeat steps 6-10 until the upper lines in the sample are aligned with one another and the lower lines in the sample are exactly equidistant to one another (as shown at B in Figure 4-11). 12. When you complete this adjustment, turn off the printer.
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4.1.5 Black - Color Head Vertical Adjustment
This adjustment calibrates the vertical position between the black head and the color head. Align the top nozzles (both nozzle # 1 on the black head and nozzle # 1 on the color head). You can make this adjustment by using only the linear spacers for the black head. This adjustment is required when the black head or the color head is replaced or disassembled. The following figure illustrates this adjustment.
Adjust
Carriage Unit Color Head #2 #1 #2 #3 #7 #4 #6 #8 Black Head #1 #5 #9 Vertical Position
#16
M agenta Cyan Y ellow
#64 #63 #62
#61 Vertical Position
Figure 4-13. Black - Color Head Vertical Adjustment
1. 2. Connect the PC to the target printer using a parallel interface cable and turn the printer on. Load BASIC on the PC, and run the program. You see the following destination select menu. ***** Customer ***** 1. EAI, EAI (Latin America), EAL, ESP 2. EDG, EUL, EFS, EIS, EIB, EUL (Northern Europe), EUL (Middle East), EHK 3. 4. JAPAN 5. 6. 7. END Select Menu ? 3. Input the number for the destination. Then the main menu appears, as shown below.
CAUTION
If you enter an incorrect number as the destination selection, printer functions are not guaranteed.
STYLUS Pro XL+ Program : Rev. X customer : 1. Head VH input 2. Ink consumption counter reset 3. Head angular & linear adjustment 4. Head position check 5. BK. YMC head gap adjustment (head gap center ) 6. Bi-D adjustment (Bi-d center ) 7. Head VH indication
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10. Change customer & data / END 0. Cleaning Select Menu ? s 4. When the main menu appears, choose "3, Head angular & linear adjustment" by typing 3 and pressing ENTER. (The printer prints the check pattern, along with the sample name.)
CAUTION
When replacing the black head, always adjust the black head angle first, because the black - color head vertical adjustment is based upon the black head angle.
3 -3 . BL A CK HE AD SP ACE R S EL E CT IO N
Magenta
-5
-4
-3
-2
-1
OK(0)
B la ck +1 +2 +3 +4 +5
Figure 4-14. Linear Spacer Selection Sample
5. In Figure 4-14, the vertical position is correct when both the magenta line and the black line are aligned (as shown in position OK (0)). If the vertical position is correct, turn off the printer. If the black and magenta lines are not aligned, perform the vertical adjustment as described in steps 6-10.
CAUTION
t The number shown in the sample indicates the thickness level compared to the current linear spacer. (See * .) There are 11 linear spacers with 11 different thicknesses. t The linear spacer is attached by two pieces, one on each side of the head base. Therefore, when you need to replace one linear spacer, always replace both linear spacers at the same time. t When replacing the linear spacer, place it under the angular spacer. * If necessary, replace the linear spacer. For instance, if your pattern is similar to the pattern shown under 2, replace the linear spacer with a thinner linear spacer. If your pattern is similar to the pattern shown under 2, replace the linear spacer with a thicker spacer. Turn the printer off. Move the carriage to the center while pressing the carriage lock lever, and remove the two ink cartridges. Remove the rubber cap that covers a head screw at the side of color ink cartridge, and then loosen (but do not remove) 3 screws. (Refer to the figure on the next page.)
6. 7. 8.
CAUTION
After replacing the spacer, always install new ink cartridges before returning the printer to the user. During adjustment, use the ink cartridges exclusively for service (Monochrome: 1020626, CMY: 1027990 ).
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Stylus Pro XL+ Service Manual
Change the linear spacers (2 spacers for the monochrome head only) with new ones, referring to the figure below. (Replace linear spacers by using tweezers to push the head base toward the rear.)
Carriage Unit
1
Push
Head Base
Angular Spacer 2 Replace
Platen Gap Adjust Lever
Linear Spacers x 2
(Linear Spacer Replacement Position)
Figure 4-15. Linear Spacer Replacement Method
10. Rerun the BASIC program, and choose the "Head Vertical Position Confirmation" by typing 3 and pressing ENTER; then confirm that the sample print is correct. If the sample is incorrect, change the thickness of the linear spacer and perform this adjustment again until the two black and magenta lines are aligned at the position "OK (0)."" 11. When you complete this adjustment, exit the BASIC program and turn off the printer.
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4.1.6 Head Gap Adjustment (Black and Color Head)
The head gap adjustment is required when the printer mechanism, main board, or printhead (board) is replaced or disassembled. This adjustment calibrates the head drive timing between the black and color head. If this adjustment is not made, the vertical alignment will not be completed. 1. 2. Connect the PC to the target printer using a parallel interface cable and turn the printer on. Load BASIC on the PC, and run the program. You see the following destination select menu. ***** Customer ***** 1. EAI, EAI (Latin America), EAL, ESP 2. EDG, EUL, EFS, EIS, EIB, EUL (Northern Europe), EUL (Middle East), EHK 3. 4. JAPAN 5. 6. 7. END Select Menu ? 3. Input the number for the destination. Then the main menu appears, as shown below.
CAUTION
If you enter an incorrect number as the destination selection, printer functions are not guaranteed.
STYLUS Pro XL+ Program : Rev. X customer : 1. Head VH input 2. Ink consumption counter reset 3. Head angular & linear adjustment 4. Head position check 5. BK. YMC head gap adjustment (head gap center ) 6. Bi-D adjustment (Bi-d center ) 7. Head VH indication 10. Change customer & data / END 0. Cleaning Select Menu ? s 4. When the main menu appears, choose "5, BK. YMC head gap adjustment" by typing 5 and pressing ENTER. (The printer prints a check pattern sample with a sample compensation value. The printer prints a sample like the one shown in the following figure.)
Black Line HEAD GAP ADJUST NO. X
Color (Magenta) Line
Figure 4-16. Head Gap Adjustment Sample
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Adjustment
The adjustment value input menu appears as shown: INPUT ADJUST No. (IF OK INPUT Y)? s adjust range (from 32 to 32) 5.
Stylus Pro XL+ Service Manual
If the sample print is not vertically aligned for both odd-numbered lines (black lines) and even-numbered lines (magenta lines), enter a compensation value in the range from -32 to +32. t Positive compensation value: Shifts the 2nd line to the left t Negative compensation value: Shifts the 2nd line to the right When both the black and magenta lines are vertically aligned, input Y or y, and press ENTER. This returns you to the main menu. When the main menu appears, choose "10, Change customer & data / END" by typing 10 and Enter. (This returns you the destination setting menu.) Choose "7, END" by typing 7 and pressing ENTER to quit the adjustment program.
6. 7.
CAUTION
Settings have not yet been written to the EEPROM. Turn off the printer immediately after the adjustments. 8. Turn off the printer.
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4.1.7 Bi-D (Bidirectional Printing) Alignment Adjustment
The bidirectional alignment is required when the printer mechanism, main board, or printhead (board) is replaced. Performing this adjustment determines a compensation value to rectify any deviation in the print position. This deviation could be caused by different print speeds, which are due to tolerances in the mechanical components, or to differences in print timing between odd-numbered lines and even-numbered lines in bidirectional printing. The printer stores the compensation data in the EEPROM on the C184 MAIN board and refers to this data when performing bidirectional printing. 1. 2. Connect the PC to the target printer using a parallel interface cable and turn the printer on. Load BASIC on the PC, and run the program. You see the following destination select menu. ***** Customer ***** 1. EAI, EAI (Latin America), EAL, ESP 2. EDG, EUL, EFS, EIS, EIB, EUL (Northern Europe), EUL (Middle East), EHK 3. 4. JAPAN 5. 6. 7. END Select Menu ? 3. Input the number for the destination. Then the main menu appears, as shown below.
CAUTION
If you enter an incorrect number as the destination selection, printer functions are not guaranteed.
STYLUS Pro XL+ Program : Rev. X customer : 1. Head VH input 2. Ink consumption counter reset 3. Head angular & linear adjustment 4. Head position check 5. BK. YMC head gap adjustment (head gap center ) 6. Bi-D adjustment (Bi-d center ) 7. Head VH indication 10. Change customer & data / END 0. Cleaning Select Menu ? s 4. When the main menu appears, choose "6, Bi-D Adjustment" by typing 6 and pressing ENTER. (The printer prints a check pattern with a sample compensation value. The next menu appears on the display.) INPUT ADJUST No. (If OK INPUT Y)? s 720 DPI adjust range ( from 30 to 30)
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Adjustment
5.
Stylus Pro XL+ Service Manual
If the sample print is not vertically aligned for both the odd-numbered and even-numbered lines, enter a compensation value in the range from 30 to +30. t Positive compensation value: Shifts the 2nd line to the left t Negative compensation value: Shifts the 2nd line to the right When the sample print becomes vertically aligned for both lines, press Y and ENTER; then the printer prints out the current Bi- D setting pattern, and this returns you to the 360 DPI Bi-d adjustment mode. Adjust the 360 DPI Bi-d setting mode in the same way as 720 dpi Bi-D adjustment. If you have finished the 360 dpi Bi-d adjustment, choose "10, END" by typing 10 and pressing ENTER. (The destination setting menu appears on the display again.) Choose "7, END" by typing 7 and pressing ENTER to quit the adjustment program.
6. 7. 8.
CAUTION
Settings have not been written to the EEPROM yet. Turn off the printer immediately after the adjustments. 9. Turn off the printer.
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4.1.8 Platen Gap Adjustment
This adjustment is required when the carriage unit is replaced or removed from the printer mechanism. Adjust the distance between the printhead nose and the paper surface to 1.1 mm. 1. 2. Attach a thickness gauge (commercially available) to the left side adjustment position on the paper guide plate, as shown in the figure below, so that one side hooks the paper feed pinch roller unit. Move the carriage unit manually onto the thickness gauge.
Table 4-2. Gap and Adjustment Direction
Gap between Head Nose and Gauge Surface Narrow Spread 3. 4. 5. Left Bushing CW CCW Right Bushing CCW CW
Rotate the parallelism adjustment bushing, attached to the left and right ends of the carriage guide shaft, when the black and color printheads contact the thickness gauge. After attaching the printheads to the gauge surface, verify that the gap between the carriage roller and the front frame is less than 0.04 mm. (See Figure 4-18.) Attach the 1.1 mm thickness gauge to the right side adjustment position on the paper guide plate, as shown below, so that one side hooks the paper feed pinch roller unit.
Attach the thickness gauge under the PF pinch roller unit.
Paper Guide Plate Right Adjustment Position
Left Adjustment Position
Platen
B u sh i n g
Pu mp Un it
Front Frame
Thickn ess Gau ge
Fron t Frame
Thickn ess Gau ge
PF Pinch Roller Unit
Attachment Point
F RO NT Tension Roller
Thickness Gauge
Pa pe r Gu id e Platen
Figure 4-17. Adjusting the Paper Gap
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Adjustment Note:
Stylus Pro XL+ Service Manual
When checking the gap between the carriage roller and the front frame, use the thickness gauge or the paper guide plate. If the gap is correct the gauge cannot be installed into the gap. If the gap is incorrect, the gauge can be inserted in the gap.
Carriage Roller
G AP
0.04 mm Thickness Gauge Eject Frame
Figure 4-18. Confirming the Gap
6. Move the carriage manually to the right adjustment position and repeat steps 3, 4 and 5 referring to Figures 4-17 and 4-18.
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4.1.9 Ink Consumption Counter Reset Operation
This operation is required when the ink cartridge is replaced. Usually, this operation is performed by the panel operation. But if you perform this operation, you can reset the ink consumption counter value at any time. 1. 2. Connect the PC to the target printer using a parallel interface cable and turn the printer on. Load BASIC on the PC, and run the program. You see the following destination select menu. ***** Custom