Page 1 D F X - 8 0 0 0 SERVICE MANUAL EPSON...
Page 2 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 consequences thereof. Copyright 1990 by SEIKO EPSON CORPORATION...
Page 3 THE POWER SUPPLY CABLE MUST BE CONNECTED, USE EXTREME CAUTION IN WORKING ON POWER SUPPLY AND OTHER ELECTRONIC COMPONENTS. WARNING 1. REPAIRS ON EPSON PRODUCT SHOULD BE PERFORMED ONLY BY AN EPSON CERTIFIED REPAIR TECHNICIAN. 2. MAKE CERTAIN THAT THE SOURCE VOLTAGE IS THE SAME AS THE RATED VOLTAGE, LISTED ON THE SERIAL NUMBER/RATING PLATE.
Page 4 Includes a step-by-step guide for product disassembly and assembly. C h a p t e r 5 - Provides Epson-approved techniques for troubleshooting. C h a p t e r 6 - Describes preventive maintenance techniques and lists lubricants and adhesives required to service the equipment.
Page 5 REV.-A TABLE OF CONTENTS CHAPTER 1. GENERAL SPECIFICATIONS OPERATING PRINCIPLES CHAPTER 2. DISASSEMBLY AND ASSEMBLY CHAPTER 3. ADJUSTMENT CHAPTER 4. CHAPTER 5. TROUBLESHOOTING CHAPTER 6. MAINTENANCE APPENDIX – vi –...
Page 6 REVISION TABLE REVISION DATE ISSUED CHANGE DOCUMENT July 2, 1990 1st issue –v–...
Page 7: Table Of Contents
REV.-A CHAPTER 1 GENERAL SPECIFICATIONS FEATURES ....................SPECIFICATIONS ................
Page 8 REV.-A Loading Paper Format Information from 1.3.13.3 Memory ..............1-37 1.3.14 Paper Cutter .
Page 9 REV.-A 36-pin 57.3 0360 Connector ..........1-16 Figure 1-23.
Page 10 REV.-A Table 1-16. Page Length Set ............... 1-33 Table 1-17.
Page 11: Features
Copy mode can be selected by control panel Optional paper cutter Standard 8 bit parallel interface and RS-232C standard serial interface EPSON ESC/P-83 printer driver (Compatible with FX-850\l 050, DFX-5000) IBM Pro-printer emulation mode 3k byte input data buffer Compatible with EPSON optional interface board series #81 XX Figure 1-1.
Page 12: Specifications
REV.-A SPECIFICATIONS This chapter describes the specifications of the DFX-8000. 1.2.1 General Specifications This section describes general specifications with the exception of the interface specifications. 1.2.1.1 Printing Serial impact dot matrix Printing method: 18 wires (a double column of 9 wires, see Figure 1-2) Pin configuration: Pin diameter: 0.29 mm...
Page 13: Table 1-2. Character Size, Pitch
Paper feeding: Bi-directional variable width push tractor feed NOTE: Push or pull feed is also available, using the optional pull tractor unit. (See Chapter 3 for details.) 1/6” or 1/8” (DIP switch setting/programmable) Line spacing: n/2 16“ (programmable) Paper feed speed: 26 ms (6’’/sec) Line feed(l/6°...
Page 14: General Paper Specifications
REV.-A Printing speed: See Table 1-4 Table 1-4. Printing Speed Printing speed [CPS] Printing mode 1 0 6 6 High speed draft (pica) Draft (pica) 8 0 0 Draft (elite) 9 6 0 6 8 0 Condensed draft (pica) Emphasized draft (pica) 4 0 0 NLQ (pica) 1 6 0...
Page 15: Figure 1-3. Unsuitable Paper
REV.-A 3. Clean paper (with no folds, creases, or tears, (especially for the copying paper)) should be used. Figure 1-3 shows paper that is unsuitable. o--- “ Figure 1-3. Unsuitable Paper printing is available 20 lines after paper end. The paPer feeding pitch Forms-override 15mm from the bottom edge of paper.
Page 16 Figure 1-3. Unsuitable Paper 4. Forms-override printing is available 20 lines after paper end. The paper feeding pitch is not guaranteed. The end of printable area is 15mm from the bottom edge of paper. Figure 1-4. Forms Over Ride Area...
Page 17: Figure 1-6. Side Edge Of Perforation
REV.-A Weak horizontal and vertical perforations cause paper jams. must be less than 3: 1 The pitch of perforations (pitch of the cut part and uncut part) (ratio). . Perforations must have an uncut part on each side edge of the paper. Figure 1-6.
Page 18: Figure 1-10. Bad Folded Paper
REV.-A The raised portion at a perforation (fold) must be less than 1 mm from the flat part, with the bottom layer kept flat by force. Perforations Figure 1-8. Raised Portion at a Perforation 10. The sprocket hole must be circular. The hole may have teeth. 11.
Page 19: Single Part Form
REV.-A 1.2.1.3 Single Part Form Weight of paper is indicated in [Kg], [lb.], and [g/m2]. weight: 45 – 70 Kg 14 – 22 lb. 5 2 . 6 – 8 2 . 7 g / m 2 See Figure 1-1 I printable area: Figure 1-11.
Page 20: Multi-Part Forms
REV.-A 1.2.1.4 Multi-part Forms Same with “Single part form” (See Figure 1-3) Printable area: Copying paper: Max. 6 sheets (1 original + 5 copies) Front tractor Max. 4 sheets (1 original + 3 copies) Rear tractor Weight of paper is indicated in [Kg], [lb.], and [g/m2]. Weight: 35 –...
Page 21 REV.-A 5. The pasted parts must be pressed flat. There must be no creases in the paper. 6. Paper-stapling must be applied from the front. Paper must be flat. Figure 1-13 shows the stapling part cross section. Print able surf ace a : Les.
Page 22: Label Form
REV.-A 1.2.1.5 Label Form See Figure 1-17 and 18 Printable area: Figure 1-17. Label Form Printable Area -1 Figure 1-18. Label Form Printable Area -2 1-11...
Page 23: Figure 1-19. Label And Carrier
REV.-A W A R N I N G Do not perform the back feed. Do not perform the paper select. N O T E S : 1 . If label forms are used, the paper should be loaded from the front tractor. The paper select function must not be used.
Page 24: Overlapping Multi-Part Forms
REV.-A 1.2.1.6 Overlapping Multi-part Forms See Figure 1-20 Printable area: 13mm 13-31mm Figure 1-20. Printable Area of Multi-part Forms with Label W A R N I N G Do not perform the back feed. Do not perform the paper select. NOTES: 1.
Page 25: Ribbon Specification
REV.-A 1.2.1.7 Ribbon Specification Ribbon cartridge: # 8 7 6 6 Ribbon pack: # 8 7 6 7 (The ribbon pack is a handy pack containing an exchangeable endless ribbon.) Ribbon pack exchanges: Maximum 4 times for one cartridge. Color: Black Dimension: Cartridge...
Page 26: Physical
REV.-A 1.2.1.10 Physical 700(W) X 369(H) X 382(D) mm Dimensions: (See Figure in APPENDIX) Weight: 29Kg Without options 30Kg With the pull tractor 34Kg With the paper cutter 1.2.1.11 Reliability 24 million lines (except the printhead life) MCBF: 6000 POH (power on hour) MTBF: 400 million characters (14 dots/chr.) Life of printhead:...
Page 27: Interface Specif Ications
REV.-A 1.2.2 I n t e r f a c e S p e c i f i c a t i o n s The DFX-8000 employs an 8-bit standard parallel interface, and an RS-232C serial interface. 1.2.2.1 Parallel Interface Type: 8-bit standard parallel interface Data format:...
Page 28: Table 1-6. Parallel Interface Pin Assignment
REV.-A Table 1-6. Parallel Interface Pin Assignment Functional Description Pin No. Signal Name Return Pin No. Strobe pulse to read the input data. Pulse width STROBE must be more than 0.5 µs Input data is latched after falling edge of this signal. Parallel input data to the printer.
Page 29: Table 1-7. Dc1/Dc3 Control
REV.-A NOTES: 1. “DIR” indicates the input/output direction from the printer side. 2. The return side means the twisted pair return, which is connected to the signal ground. The interface signals must be sent through twisted pair lines, and the return lines must be connected. The cable should be shielded and the printer chassis ground should be connected to the chassis to reduce noise.
Page 30: Serial Lnterface
REV.-A 1.2.2.2 Serial Interface Type: RS-232C compatible serial interface Data format: RS-232C compatible serial Word length: Start bit Data bit 7 or 8 (Selectable by DIP switch) Parity bit Odd, Even or Non-parity (Selectable by DIP switch) 1 bit or more Stop bit Bit rate: 300, 1200, 9600, 19200 BPS...
Page 31: Figure 1-25. Xon/Off Control Handshake Timing
REV.-A Figure 1-25. XON/OFF Control Handshake Timing Figure 1-26. EIA Standard 25 Pin Connector Table 1-9. Serial Interface Pin Assignment Signal Function Dir. N a m e Frame ground — Transmit data. XON/XOFF code transmission. T X D o u t Receive data.
Page 32: Operator Control
REV.-A 1.3 OPERATOR CONTROL This section discusses the operating controls. 1 . 3 . 1 C o n t r o l P a n e l The control panel is equipped with 7 indicators, 8 switches and a buzzer. Here, we will discuss the functions of the control panel indicators and switches.
Page 33 REV.-A The adjusted value is stored in memory on the main board (backed up by battery) by pressing this switch, therefore the TOF position can be reset whenever power is applied. By pressing the ‘“ON LINE” switch, the printer exits from the TOF mode and the adjusted value isn’t stored in memory.
Page 34: Self-Test Function
REV.-A 1 . 3 . 2 S e l f - t e s t F u n c t i o n This system has a self-test (self-printing) function which checks the following: Control circuit Printer mechanism Print Quality The self-test for draft characters can be started by applying power while pressing the LF switch.
Page 35: Hexadecimal Dump Function
REV.-A 1.3.3 Hexadecimal Dump Function The hexadecimal dump function prints out the data received by the printer in hexadecimal. On each line, 16 bytes are printed in hexadecimal, and the ASCII character corresponding to each byte is printed on the right side. “.” is printed if there is no corresponding character (such as a control code). If less than 16 bytes remain, they can be printed by pressing the ON LINE switch.
Page 36: Table 1-10. Dip Switch Selections
REV.-A ..—. 1.3.4 S w i t c h J u m p e r S e t u P There are three DIP switches on the front covers at the front of the printer. These set the printer defaults. When power is applied or the printer is reset, the DIP switch selections are treated as the default setup.
Page 37 REV.-A Table 1-10. DIP Switch Selections (cent’d) Factory S w i t c h Function setup n u m b e r Input data buffer function Invalid Valid I 11 inches Page length setup I 12 inches Perforation skip function Valid Invalid Paper memory selection...
Page 38: Table 1-11. Character Set Selection
REV.-A Table 1-11. Character Set Selection Default CG Table Countries S w 1 - 7 SW 1-6 SW 1-8 (When SW 1-3 “ON”) (When SW 1-3 “OFF”) CG Table 1 U.S.A. France CG Table 2 Germany Denmark Sweden Italy Spain NOTE: In IBM mode the default CG table is selected by above switches.
Page 39: Buffer Full Printing
REV.-A 1.3.5 Buffer Full Printing The printer stores the received data in the input data buffer, and prints it when it receives a print command (CR). Printing is also performed when the buffer becomes full. 1 . 3 . 6 B u z z e r The control panel buzzer sounds at the following times: X 1 time When ESC command “BEL”...
Page 40: Paper End Detection Function
REV.-A During initialization, a READ/WRITE check is performed for RAM check abnormality: all RAM in the control circuit to check for errors. - CPU RAM — Lower address RAM - Upper address RAM A short circuit in a printhead drive transistor was detected. Printhead driver abnormality: The following states are also regarded as errors, and the interface signals...
Page 41: Automatic Paper Thickness Detection
REV.-A 1.3.10 Automatic Paper Thickness Detection This printer automatically detects the paper thickness, and adjusts the gap between the platen and printhead when the paper is loaded. Therefore, a platen gap lever adjustment is not required. 1 . 3 . 1 1 A u t o m a t i c P a p e r W i d t h D e t e c t i o n This printer detects the paper both edges and determines the left and right margin, which disables printing in areas where no paper exists.
Page 42: Figure 1-30. Multi-Part Forms With Labels
REV.-A 1 . 3 . 1 3 P a p e r M e m o r y F u n c t i o n This function makes it possible to print properly on forms which contain several areas having different thickness.
Page 43: Using The Paper Memory Feature
REV.-A 1.3.13.1 Using the Paper Memory Feature This printer can save the paper format and thickness information for up to two multi-part forms in the printer’s paper memory areas. This information for a certain form may be recalled and the printer automatically adjusts the gap between the printhead and the platen to provide maximum printing quality on that particular form.
Page 44: Table 1-17. Dip Sw 3-5 And. 3-6
REV.-A Step 4: Turn on DIP switch 3-5 and turn off DIP switch 3-6. This tells the printer you want to save information for multi-part forms that overlap slightly where they are joined together. Table 1-17. DIP SW 3-5 and 3-6 Multi-part forms Overlapping DIP SW 3-6...
Page 45: Figure 1-32. Horizontal Align-Top Edge
REV.-A Step 8: Use the MICRO FEED buttons to adjust the paper’s position so that the top edge of the label is aligned with the horizontal red line on the clear plastic ribbon mask. MICRO FEED Figure 1-32. Horizontal Align -Top Edge Step 9: Move the print head by hand to align the vertical red line on the ribbon mask with the left edge of the label.
Page 46: Figure 1-35. Vertical Align-Right Corner
REV.-A Step 12: Move the print head by hand to align the vertical red line on the ribbon mask with the right edge of the label. Now the intersection of the red lines on the ribbon mask should be in the lower right corner of the label.
Page 47: Loading Paper Format Information From
REV.-A Step 5: Turn on DIP switches 3-5 and 3-6. This tells the printer you want to save information for multi-part forms that overlap slightly and have labels on them. Table 1-19. DIP SW 3-5 and 3-6 Multi-part forms Overlapping DIP SW 3-5 DIP SW 3-6 multi-part forms...
Page 48: Printer Initialization
REV.-A 1 . 3 . 1 5 C o p y M o d e Hard-stuck characters can be printed on paper such as multi-part forms to get clear characters even on the bottom copy. This function is selectable from the control panel by pressing the FORM FEED switch in the on-line state. Switch is used to alternate “Copy mode”...
Page 49: Major Units
REV.-A 1.4 MAJOR UNITS The DFX-8000 consists of the following major units: Model-3C65 Printer mechanism BOPS board (AC 120V version) Power supply board BOPSE board (AC 220/240V version) c030MAIN board Main board C030DRV board Driver board Control panel Housing 1.4.1 Printer Mechanism Model-3C65 The Model-3C65 is a 9 pin 2 lows (Total 18 pin) serial dot matrix printer mechanism developed for the DFX-8000.
Page 50: Table 1-20. Major Components Of Model-3 C65
REV.-A Table 1-20. Major Components of Model-3C65 Component Name Description Printhead 9pins x 210ws/ Spring Charge Method dot impact head/ 36.5VDC Head Cooling Fan 2-phases/ 6-poles/ PM type Stepping motor/ 32.5VDC (built-in with printhead) External Fan DC Brushless motor/ 36.5VDC Carriage Motor DC Servo motor/ 36.5VDC/ CR motor...
Page 51: Table 1-21. Major Components Of The Bops/Bopse Board
REV.-A 1 . 4 . 2 P o w e r S u p p l y B o a r d U n i t The BOPS and BOPSE board is a power supply circuit which supplies the control circuit (Main board) and printer mechanism drive circuit (Driver board) with power.
Page 52 REV.-A 1 . 4 . 3 M a i n B o a r d The C030MAIN board is the main board in this system. The parallel and serial interfaces, control circuit and sensor circuit are located on the C0303MAIN board. Table 1-22 listed major components of the main board.
Page 53: Figure 1-40. C030Drv Board
REV.-A 1 . 4 . 4 D r i v e r B o a r d The C030DRV board is the driver board in this system. The Printhead, Head cooling-fan, Plunger, Paper feed motor, Carriage motor, PG motor and RF motor driver circuit are located on the C0303DRV board. Sensor signals from the printer mechanism are connected to the main board via this board.
Page 54: Control Panel
REV.-A 1 . 4 . 5 C o n t r o l P a n e l Figure 1-41 is the operator control panel containing switches, LEDs and buzzers. - POWER _ READY _ PAPER ON LINE FORM FEED LINE FEED /._.._.._..
Page 55: Operating Principles
REV.-A CHAPTER 2 OPERATING PRINCIPLES. 2.1 GENERAL PRINTER MECHANISM OPERATION ......2-1 2.1.1 Printhead Mechamism ............2 -1 2.1.2 Carriage Mechanism ............- 2-3 2.1.3 Platen Gap Adjustment Mechanism .
Page 56 REV.-A Figure 2-7. Front Tractor Operation ..........2-9 Rear Tractor Operation .
Page 57 REV.-A Pull Tractor Sensor Specfications......2-10 Table 2-7. Paper End Sensor Specifications ......2-10 Table 2-8.
Page 58: General Printer Mechanism Operation
REV.-A 2.1 General Printer Mechanism Operation This chapter will describe the functions and operating principles of printer mechanism ModeJ-3C65. 2.1.1 Printhead Mechanism The printhead mechanism is composed of a printhead, ink ribbon, and ribbon mask. The printhead is a spring-charge impact dot printhead. Figure 2-1 shows the operating principle of the printhead.
Page 59 REV.-A . Printhead f a n The printhead is cooled by two fans, the printhead fan and the external fan. printhead, and is turned on when the temperature sensor The printhead fan is integrated with the incorporated in the printhead coil detects a certain printhead temperature.
Page 60: Carriage Mechanism
REV.-A 2.1.2 Carriage Mechanism The carriage mechanism is composed of a carriage motor unit (carriage motor and encoder) and home position sensor. The interlock mechanism and external fan are also described here. Figure 2-2 shows the carriage mechanism. The carriage is supported by the two carriage guide shafts. The rotation of the carriage motor is transmitted to the carriage timing belt through the carriage belt pulleys on the right and left sides.
Page 61 REV.-A Table 2-2. Carriage Motor Specifications Encoder Specifications Carriage Motor Specifications Light emitting Type DC servo motor element Light receiving Photo diode Supply voltage 36.5 VDC + 1 V element Armature 5 VDC *5% 2.13 ohms (at 25”C) Supply voltage resistance 2-phase rectangular pulses Output waveform...
Page 62 REV.-A Interlock mechanism (’ Since the carriage moves at very high speed in the printer mechanism, it would be dangerous if a hand or finger was inserted into the mechanism during printing. When the top cover is opened, the interlock mechanism cuts the drive voltage to the carriage motor to stop the motor and prevent accidents.
Page 63: Platen Gap Adjustment Mechanism
REV.-A 2.1.3 Platen Gap Adjustment Mechanism The printer mechanism has an automatic platen gap adjustment function that ensures an optimum gap (between the platen and printhead) by measuring the thickness of the paper. Figure 2-4 shows the platen gap adjustment mechanism. The carriage guide shaft supporting the front of the carriage has an elliptical section.
Page 64: Ribbon Feed Mechanism
REV.-A 2.1.4 Ribbon Feed Mechanism The ink ribbon is an endless loop. The ribbon feed mechanism takes up the ribbon, and is driven by the ribbon motor. Figure 2-5 shows the ribbon feed mechanism operation. The ribbon is fed in one direction only. The rotation of the ribbon motor (counterclockwise) is transmitted to the ribbon feed gear (clockwise) through the ribbon feed select gear and ribbon feed transmission gear.
Page 65: Paper Feed Mechanism
REV.-A 2.1.5 Paper Feed Mechanism The paper feed mechanism is composed of a paper feed motor, tractor, paper-end sensor mechanism, pull tractor sensor, plunger mechanism, and paper selection mechanism. Figures 2-6 to 2-8 shows the paper feed mechanism. After the paper is loaded, it is fed by the tension roller, platen roller, and front/rear tractor. The rotation of the paper feed motor is always transmitted to the tension roller and platen roller (Figure 2-48), but it is transmitted alternately to the front and rear tractors.
Page 66 REV.-A Paper Paper Bail Tension Roller Tractor Select Gear ‘.’.- <.>’ Z+& ‘) ‘ \ ‘\& - Gear Front Tractor [0 - .. Front Paper End Sensor . . ~. . Paper Feed Motor Paper Feed Transmission Front Tractor Gear ,, ..
Page 67 REV.-A Table 2-6. Paper Feed Motor Specifications Type 4-phase 200-poie HB-type stepping motor I 3 6 . 5 +1 VDC Supply voltage 2.85 ~0.3 ohms Winding resistance Drive frequency 2610 pps (medium speed mode) 4274 pps (high speed mode) Excitation system I 1-2 phase excitation Table 2-7.
Page 68 REV.-A There are grooves at both ends of the platen, which are to prevent paper jams caused by paper chips from the sprocket holes in continuous paper or fringes produced when pressing copy paper so that it will not be separated. Since the continuous paper is fed at high speed, the paper chips or fringes could get caught between the ribbon mask and platen and cause a paper jam.
Page 69 REV.-A Plunger mechanism During printing, the paper is pushed against the platen by the paper bail so that the paper does not float away from the platen. However, when paper is loaded or ejected or when the tear off function is executed, the paper bail must be moved up to prevent a paper jam.
Page 70 REV.-A Tractor select mechanism The printer mechanism has two paper entrances: the front and rear tractors. The tractor select mechanism selects to which tractor the rotation of the paper feed motor is transmitted via the gear train, by controlling the ribbon feed motor. Figure 2-10 shows the tractor select mechanism operation.
Page 71: Paper Width Detection Mechanism
REV.-A 2.1.6 Paper Width Detection Mechanism The paper width detection mechanism is composed of a paper width sensor, ribbon mask, and carriage (Refer to Section 2.1.1 or 2). The paper width sensor is attached at the right of the ribbon mask. Since the sensor position must be precise, the ribbon mask and the paper width sensor are integrated into a unit.
Page 72: Power Supply Circuit
REV.-A 2.2 POWER SUPPLY CIRCUIT NOTE: From here on, the printer operation will be described in accordance with the corresponding circuit block diagram, operating principle figure, and circuit diagram in the APPENDIX. Therefore, read the description while referring to the corresponding circuit diagram. When part names or addresses which are not listed in the corresponding block diagram or operating principle figure are mentioned, they are listed in the circuit diagrams in the APPENDIX.
Page 73: Dc Voltages And Applications
REV.-A DC Voltages and Applications 2.2.1 Table 2-13 lists the applications of the DC voltages required by this printer. Table 2-13. DC Voltages Rated Current Application Voltage + 35V (vPI) 1.5A Printer mechanism voltage Printhead d r i v e +35V (VP2) 1.5A Printer mechanism voltage...
Page 74: Power Supply Circuit Operation
REV.-A Power Supply Circuit Operation 2.2.2 Figure 2-13 shows a block diagram of the power supply circuit. The basic constructions of the BOPS and BOPSE units are the same. The figures in parentheses are the current or voltage value, and the lower portions of the rectangles indicate the locations of major elements.
Page 75 REV.-A CL signal The constant voltage controller on the 35 V line not only monitors the voltage input to R34 and VR1 (for setting the 35 V line voltage) and feeds it back to201C 1 (EA1), but also controls output of the CL signal which informs the CPU on the main board that voltage limiting has occurred for the 35 V line.
Page 76 REV.-A *Fuil-wave (’ R e c t i f e r V o l t a g e S m o o t h i n g Double — CN 1 I n l e t R e c t i f i e r 5V Line c9/c 10 DB 1...
Page 77: Control Circuit
REV.-A 2.3 CONTROL CIRCUIT Figure 2-14 shows a block diagram of the control circuit, with the main board at20the center. The printer employs a uPD78322 internal 16-bit processing/external 8-bit bus one-chip CPU (5E) as the main CPU. This CPU is driven with a 14.7 MHz external clock (CR2). The control program is stored in the internal mask ROM (5E: mainly for mechanism 20control) and external PROM 27 (3B: mainly for ESC/P and IBM emulation, interfacing, and CG).
Page 78 REV.-A The E05A38NA is controlled by the CPU using MMIO ports. The ad dress timing is controlled by connecting the ASTB (Address Latch Strobe) pulse from the CPU to the ALE (Address Latch Enable) terminal. Although the data read/write timing is controlled by MMIO commands from the CPU, the gate array directly controls the printer mechanism and interface once the parameters are set.
Page 79: Reset Circuit
REV.-A ‘1) -------------1 r!-; RESET ; POWER SUPPLY~ ‘- CIRCUIT SO SIGNAL CIRCUI : BOARD CIRCUIT I –BOPS *Y ! -BOPSE L -------------A MAIN CPU COVER OPEN V25 70322 — — 9--- DIP SW Gate Array Gate Arrz CONTROL E05A38NA E05A16G/ PANEL ( 2 E )
Page 80 REV.-A 2.3.1 Interface Circuit Figure 2-15 shows a block diagram of the interface circuit. This section describes the data flow when data is input or output via each interface. Parallel interface When the E05A38NA gate array latches the data from the host computer (upon receiving the STRB signal), it automatically outputs the BUSY signal.
Page 81 REV.-A 2.3.2 Reset Circuit Figure 2-16 shows a block diagram of the reset circuit. The Vx circuit is the power-on reset circuit which generates the reset signal when the voltage becomes unstable due to the printer power being turned on or off. The reset signal is input to the E05A1 6GA gate array via the CPU, amplified, then supplied to the E05A38NA gate array and optional interface to reset each IC.
Page 82: Memory Backup Circuit
REV.-A 2.3.3 Memory Backup Circuit Figure 2-17 shows a block diagram of the reset circuit. When the printer power is turned off, the following data is backed up in the SRAM (5 C). Settings for paper handling, which are set using the operator panel, such as TOF, TEAR OFF, and PAPER MEMORY functions.
Page 83 REV.-A BACK UP VOLTAGE SRAM(5C) SUPPLY CIRCUIT Q3/Q4/zD3 - VDD = B A T 1 ~ CE SO SIGNAL POWER SUPPLY CONTROL CIRCUIT r=== Q l/ZD l/Q8 > LJMI Figure 2-17. Memory Backup Circuit Block Diagram 2-26...
Page 84: A-D Converter Detection Circuit
REV.-A 2.3.4 A-D Converter Detection Circuit Figure 2-18 shows a block diagram of the A-D converter detection circuit. The CPU includes an 8-channel 8-bit A-D converter. Each detection terminal is used to detect signals which continually change, making the best use of the A-D converter. Table 2-17.
Page 85: Control Panel
REV.-A The settings of DIP switches 1 to 3 are read by switching the time-sharing circuit. The CPU writes the data to the PB ports of the E05A 16GA gate array so that only the port connected to the DIP switch the CPU wants to read goes LOW. the PB ports of the E05A 16GA gate array are normally used to drive the lamps on the control panel (except when the printer is reset).
Page 86: Interrupt Port Detection Circuit
REV.-A 2.3.5 Interrupt Port Detection Circuit Figure 2-19 shows the interrupt detection signal assignment block diagram for the CPU. The CPU includes an interrupt controller, and executes forced interrupt operation in accordance with the priority of the interrupt. Table 2-18. Interrupt Port Detection Signal Functions Operation Port Signal...
Page 87: Detection Circuits Connected To
REV.-A 2.3.6 Detection Circuits Connected to the General-purpose Ports Figure 2-20 shows a block diagram of the general-purpose ports assigned to detect signals. As shown below, sensor signals from the various mechanisms are assigned to the general-purpose ports of the CPU and the E05A 16GA. The data latched at the general-purpose ports of the E05A 16GA is transferred to the CPU.
Page 88 REV.-A - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ~----_--------- f PA 1 -J CONTROL PANEL l----&- - - - - - - - - - - - - - - t DATA CUT.
Page 89: Ribbon Feed Motor/External Fan Control
REV.-A 2.3.7 Ribbon Feed Motor/External Fan Control/Drive Circuit Figure 2-21 shows a block diagram of the ribbon feed motor control/drive circuit. The ribbon feed motor is a PM type pulse motor driven with 2-2 phase excitation, which can be driven in either the forward or reverse direction and stopped at any position.
Page 90: Drive Circuit
REV.-A 2.3.8 Paper Feed Motor Control/Drive Circuit Figure 2-22 shows a block diagram of the paper feed motor control\ drive circuit. The paper feed motor is an HB type pulse motor driven with 1-2 phase excitation, and can be rotated in either the forward or reverse direction and stopped at any position.
Page 91: Platen Gap Motor Control/Drive Circuit
REV.-A 2 . 3 . 9 P l a t e n G a p M o t o r C o n t r o l / D r i v e C i r c u i t Figure 2-23 shows a block diagram of the PG motor control/drive circuit.
Page 92 REV.-A The platen gap is reset each time the paper is loaded. The platen gap setup sequence is shown in Figure 2-24. Hold the motor at the current posltlon Move the carriage to 196 th column Check the platen (PGHP) gap home posrhOn -(p’”’...
Page 93 REV.-A Figure 2-25 shows the platen gap setup conceptual diagram. Symbols used in the diagram are as follows: Gap between the printhead and platen (should be constant) Distance which varies in accordance with the difference in the printhead dimension Distance which varies in accordance with the difference in the dimension of a mechanism other than the printhead Amount of PG motor rotation equal to 70 steps (constant value) PGEND :...
Page 94: Carriage Motor Control/Drive Circuit
REV.-A 2.3.10 Carriage Motor Control/Drive Circuit Figure 2-26 shows a block diagram of the carriage motor control/drive circuit. The carriage motor is a DC servo motor driven using bipolar drive, and can operate in any of the following modes. Driven state. The carriage moves from left to right. a.
Page 95 REV.-A The carriage contains a thermistor. An A-D converter in the CPU detects the motor temperature (MTR TMP) each time printing for one line is completed. if the temperature rises above the limit, a motor problem is recognized, and the following lines will be printed at one-step lower speed. In the case of this printer, printing is possible during acceleration/deceleration of the motor to improve the throughput.
Page 96 REV.-A ~ --------------------------------- MTR TMP / / / ENCA ENCOOER 1 1// - - - - - - - - - - - - - , I INTERLOCK SW] <VP3> :’ - - - - - - - - - - - - - - - - - - - INTP 1 ENCAB D rive...
Page 97: Printhead Control/Drive Circuit
REV.-A 2.3.11 Printhead Control/Drive Circuit Figure 2-27 shows a block diagram of the printhead control/drive circuit. The number of head coils is 18 (9 X 2 rows). The drive circuit is a constant current coil drive circuit. Each coil is driven by two transistors (PNP and NPN). The PNP supplies common currents VP 1 and VP2 and the NPN connects and disconnects grounds GP 1 and GP2, and they drive the coil with different timing.
Page 98 REV.-A A thermistor is included in each internal coil of the printhead and in the printhead cooling fan, which converts the temperature into a voltage (HTMP or FTMP signal). The CPU executes sampling/holdin9 internal temperatures of the using an internal A-D converter (ports AN 1 and AN2) to monitor the printhead and printhead cooling fan.
Page 99 REV.-A Table 2-25. Printhead Control/Drive Circuit Specifications Printhead 3 6 . 5 & 1 VDC Supply voltage 7.36 A Current consumption (head total, average, printing 14 dots/character) 8.24 A (head total, maximum, printing 14 dots/character) 29.07 A (head total, average, 9-pin full driving mode) 33.85 A (head total, maximum, 9-pin full driving mode) 50.85 A...
Page 100: Housing
REV.-A CHAPTER 3 DISASSEMBLY AND ASSEMBLY GENERAL ....................
Page 101 REV.-A Platen Gap Sensor and Platen Gap Adjustment 3.2.8.1 Motor Removal ............3-38 Paper Feed Motor Removal .
Page 102 REV.-A Figure 3-29. Paper Guide Support Plate Removal ....... . 3-26 Figure 3-30.
Page 103: General
REV.-A 3.1 GENERAL This section describes the disassembly and assembly of the DFX-8000. 3 . 1 . 1 B e f o r e S t a r t i n g Read the following warnings before assembly or disassembly. DANGER Because this printer weighs 30 Kg and is much larger and heavier than existing models, careful attention should be paid when handling it.
Page 104 REV.-A W A R N I N G This printer must be properly packed in the correct container for ransportation as shown in Figure 3-2. The following four items must be used for transportation, as shown in Figure 3-3: a. Transport locking brackets b.
Page 105 Electric soldering iron B7651 11001 Lift handle #E656 — Electric screw driver (phillips head, adjustable torque) O: Commercially available tool E: EPSON exclusive tool A: Mandatory B: Recommended Table 3-2. Special Tools Part No N a m e Figure Description...
Page 106 REV.-A Screw designation All small parts, such as screws and washers, are indicated by abbreviated names. Table 3-3. Small Parts Abbreviations List Part Name Abbreviation Cup Screw Cross-Bind-head screw Cross-Bind-head with Outside-toothed washer Cross-Bind-head B-tight Cross-Bind-head S-tight Cross-Bind-head S-tight with Outside-toothed washer CBS (0) Cross-Pan-head with Spring washer Cross-Pan-head S-tight with Outside-toothed washer...
Page 107: Service Delivery Standard
REV.-A 3.1.3 Service Delivery Standard After repairing and testing are completed, be sure to perform additional confirmation, referring to Table 3-5. Copy Table 3-5, and use it as a check list. Table 3-5. Service Delivery Standard Check List Item Standard Check Are all necessary adjustments complet- Refer to Chapter 4.
Page 108: Disassembly And Assembly
REV.-A 3.2 DISASSEMBLY AND ASSEMBLY D A N G E R Carefully read the cautions in the preceding section “3. 1 BEFORE STARTING”, and follow the instructions. Here we will describe how to assemble and disassemble the printer, by referring to the disassembly sequence.
Page 109: Dfx-8000
REV.-A 3 . 2 . 1 Printhead E x c h a n g e The printhead can be changed without disassembling the unit. Use the exclusive head kit for printhead exchange on the DFX-8000. When you receive the kit, check that all of the following are included.
Page 110 REV.-A W A R N I N G Be careful not to break the tabs when taking off the connector cover. Be careful not to break the head cable holder latch when removing it. Use a slotted screwdriver if necessary. When replacing the printhead on the DFX-8000, be sure to follow the instructions in this manual.
Page 111 REV.-A Step 5: Unlock the two head cable cover latches by pressing them with your fingers, then remove protection sheet too. the cover ”by sliding it to the right. Remove the cable </ & ‘~~:lf”: ‘ < - Figure 3-8. Head Cable Cover Removal Step 6: Unlock the relay board assembly connector latch, disconnect the cable for the paper width sensor.
Page 112 REV.-A Step 10: Install the new printhead, ribbon mask, and cable protection sheet by following Steps 1 to 9 in the reverse order. Step 1 1: Replace the ribbon mask with a new one. Set the cable of the paper width sensor as shown in Figure 3-10.
Page 113: R O M E X C H A N G E
REV.-A 3 . 2 . 2 R O M E x c h a n g e The ROM can be changed without disassembling the unit W A R N I N G It is recommended that you remove the top cover prior to rotating the unit. Refer to section 3.2.3.1 for removing the top cover.
Page 114: Top Cover Removal
REV.-A 3 . 2 . 3 H o u s i n g R e m o v a l Here we will describe the procedure for removing the housing. 3.2.3.1 Top Cover Removal W A R N I N G Due to the weight of the top cover, it can overload and damage the rear cover hinge unless you support it while removing the screws.
Page 115: Side Cover Removal
REV.-A 3.2.3.2 Side Cover Removal D A N G E R When reconnecting the cable to the power switch (inlet side, power supply board side), be sure to connect the cables correctly. Otherwise, the AC input could short and burn. When installing the power switch, be sure to connect the wires as shown in Figure 3-15, and check them for proper connection.
Page 116 REV.-A Open the top cover Step 1: Remove the four CBB(M4 X 16) screws holding the left side cover, and remove it. Remove Step2: the right side cover in the same way. Step3: Disconnect the cables from the power switch at the CN 1 on the power supply board. Disconnect the cables (See Figure 3- 15) from the AC inlet at the power switch.
Page 117: Front Cover Removal
REV.-A 3.2.3.3 Front Cover Removal Step 1: Remove the side cover. (Refer to section 3.2.3.2.) Step 2: Remove two CBB(M4 X 16) screws fixing the left front cover hinge to the lower case. Remove the screws from the right hinge also. l—l CBB (M4 X ~\Fnm@ver...
Page 118 REV.-A 3.2.3.5 Bottom Panel Removal W A R N I N G It is recommended that you take off the top cover prior to tilting the unit as shown below. Refer to section 3.2.3.1 for top cover removal. When tilting the unit without removing the top cover, careful attention should be paid so as not to overload the top cover or other components.
Page 119: Upper Housing Removal
REV.-A 3.2.3.4 Upper Housing Removal Remove the side cover. (Refer to section 3.2.3.2.) Step 1: Step 2: Open the top cover. Disconnect connectors CN8 and CN9 from the left side of the main board. Remove the two CBB(M4 X 10) screws holding the upper panel and raise it. Withdraw the step 3: CN8 cable from the gap between the lower case and the upper case.
Page 120 REV.-A Remove the eight CTBB(M4 X 16) screws fixing the bottom panel to the lower housing. Draw Step 7: the bottom panel 5 inches toward you while keeping it erect. Step 8: Slowly turn the bottom panel down towards you. ~Bottom Panel Housing ‘Lower...
Page 121: Circuit Board Removal
REV.-A 3 . 2 . 4 C i r c u i t B o a r d R e m o v a l Here we will describe how to remove the circuit boards and the required disassembly. 3.2.4.1 Driver Board Removal Remove the bottom panel.
Page 122: Main Board Removal
REV.-A 3.2.4.2 Main Board Removal Step 1: Remove the driver board unit. (Refer to section 3.2.4. 1.) Step 2: Remove the cable running from connector CN4 at the main board. Step 3: Remove the two CBB (M3 X 12) screws and the two CBS (0) (M3 X 8) screws fixing the main board to the base plate, and remove the main board.
Page 123: Power Supply Board Removal
REV.-A 3.2.4.3 Power Supply Board Removal Remove the bottom panel. (Refer to section 3.2.3.5.) Step 1: Remove the cables running from connectors CN 1, CN2, CN3 and CN4 at the power supply Step 2: board. Remove the six CBB (M3 X 12) screws and the CBS (0) (M3 X 8) screw fixing the power supply Step 3: board to the base plate, and remove the power supply board.
Page 124: Control Panel
REV.-A 3.2.4.4 Control Panel Unit Removal Step 1: Remove the side cover. (Refer to section 3.2.3.2.) Step 2: Open the top cover. Disconnect connectors CN8 from the left side of the main board. Remove the two CBB(M4 X 10) screws holding the upper panel and raise it. Meanwhile, Step 3: withdraw the CN8 cable from the gap between the lower and upper housings.
Page 125: Interlock Switch Removal
REV.-A 3 . 2 . 5 I n t e r l o c k S w i t c h R e m o v a l Step 1: Remove the upper housing. (Refer to section 3.2.3.4.). Step 2: Disconnect the interlock connector from the driver board.
Page 126: Printer Mechanism
REV.-A 3 . 2 . 6 P r i n t e r M e c h a n i s m R e m o v a l Here we will describe how to remove the printer mechanism. W A R N I N G The printer mechanism of this unit is larger and heavier than that of previous models.
Page 127 REV.-A Step 5: Mount the lifting handle from inside, running it through the two holes on both side frames of the printer mechanism. Slowly raise the printer mechanism using the handle and take it out of the lower housing. Lifting Handle ndle Hole Figure 3-28.
Page 128: Paper Width Sensor Removal
REV.-A 3 . 2 . 7 P r i n t e r M e c h a n i s m Q u i c k C o m p o n e n t R e m o v a l This section describes removal of those printer mechanism components that can be removed without having to remove the printer mechanism unit.
Page 129: Carriage Home Position Sensor Removal
REV.-A 3.2.7.3 Carriage Home Position Sensor Removal Step 1: Remove the upper housing. (Refer to section 3.2.3.4.) Disconnect the carriage home position sensor cable from the connector on the head cable Step 2: board. Step 3: Remove the screw securing the carriage home position sensor, then remove the sensor. Figure 3-30.
Page 130: External Fan Unit Removal
REV.-A 3.2.7.4 External Fan Unit Removal Step 1: Remove the upper housing. (Refer to section 3.2.3.4.) Step 2: Disconnect the fan unit cable from the connector on the terminal board. (See APPENDIX, Figure A-2.) Step 3: Remove the three CS (M3 X 30) screws fixing the fan to the fan cover. Step 4: Remove the CB (SP) (M4 X 6) screw fixing the fan cover to the left frame of the printer mechanism.
Page 131: Loading Solenoid Removal
REV.-A 3.2.7.5 Loading Solenoid Removal Remove the upper housing. (Refer to section 3.2.3.4.) Step 1: Disconnect the loading solenoid cable (black) from the terminal board. (See APPENDIX, Figure Step 2: A-2.) Step 3: Remove the two CP (SP) (M3 X 6) screws securing the loading solenoid to the left frame, while holding the solenoid Remove the loading solenoid and iron core.
Page 132 REV.-A 3.2.7.6 Ribbon Feed Motor and Tractor Select Sensor Removal R/F Change Lever Unit Removal Remove the external fan unit. (Refer to section 3.2.7.4.) Step 1: Step 2: Disconnect the ribbon feed motor and the tractor select sensor cables from the connectors (white and yellow) on the terminal board.
Page 133 REV.-A R/F Change Lever Unit Disassembly Remove the two CP (PS) (M3 X 6) screws securing the ribbon feed motor to the R/F change Step 5: lever unit, then remove the ribbon feed motor. Disconnect the cable from the connector (black) on the ribbon feed motor. Remove the E ring (3) securing the tractor select lever, then remove the tractor change lever.
Page 134: Upper Paper End Sensor Removal
REV.-A 3.2.7.7 Upper Paper End Sensor Removal /’? ‘1 Step 1: Remove the loading solenoid. (Refer to section 3.2.7.5.) Remove the external fan unit. (Refer to section 3.2.7.4.) Step 2: Step 3: Unhook the upper paper end sensor cable from the wire saddle, then disconnect the cable from the terminal board.
Page 135 REV.-A Step 7: Remove the paper bail spring at the right frame side. Remove the E ring (6) securing the paper bail lever to the right side of the shaft, and remove Step 8: the paper bai’ lever, leaf spring, and shaft holder. er Bail Shaft w Bail Lever Bail Spring...
Page 136 REV.-A Remove the two CBS (0) (M4 X 6) screws securing the upper paper guide, then remove the Step 10: upper paper guide. CBS (0) (M4 X Figure 3-40. Upper Paper Guide Removal Remove the two CP (PS) (M3 X 6) screws securing the upper paper end sensor to the upper Step 1 1: paper guide, then remove the upper paper end sensor.
Page 137: Pull Tractor Sensor Removal
REV.-A 3.2.7.8 Pull Tractor Sensor Removal Step 1: Remove the upper paper guide. (Refer to section 3.2.7.7.) Remove the two CP (P) (M3 X 6) screws securing the terminal board to the printer mechanism, Step 2: the terminal board. then disconnect all the cables connecting be removed easily by removing it while pushing Remove the paper feed timing belt.
Page 138 REV.-A (“ and pull out the left pull out the tension roller shaft. When pulling it out, shift it rightward Step 7: side first, then pull out the right side. & -Q-n- - —. Figure 3-44. Tension Roller Shaft Removal-2 Remove the CPS (S) (M2 X 10) screw securing the pull tractor sensor to the left side frame, Step 8: and remove the sensor.
Page 139: Platen Removal
REV.-A 3.2.7.9 Platen Removal Remove the tension roller shaft. (Refer to section 3.2.7.8.) Step 1: Remove the four CPS (PS) (M4 X 8) screws securing the platen to the Platen holder and remove Step 2: the platen. CPS (PS) (M4 x g] p!aten-Holder Figure 3-46.
Page 140: Printer Mechanism Component Removal
REV.-A 3 . 2 . 8 P r i n t e r M e c h a n i s m C o m p o n e n t R e m o v a l This section describes printer mechanism unit disassembly. The description starts by assuming that the printer mechanism unit has been removed from the printer.
Page 141 REV.-A A S S E M B L Y P O I N T S : When connecting the cables which were disconnected in Step 1 above to the connector on the terminal board, refer to Figure A-2 “Terminal Board Cable Connections. ” When attaching the platen gap adjustment motor, adjust the backlash between it and the platen gap adjustment transmission gear to between 0.05 and 0.15 mm.
Page 142 REV.-A 3.2.8.2 Paper Feed Motor Removal Disconnect all the cables connecting the terminal board, then remove the two CP (P) (M3 X 6) Step 1: screws securing the terminal board to the printer mechanism (See Figure 3-42.) Step 2: Slowly turn the printer mechanism down towards you, then unhook the paper feed motor cable (red, 6 pin connector) from the two wire saddles and the wire holder.
Page 143 REV.-A A S S E M B L Y P O I N T S : When connecting the cables which were disconnected in Step 1 above to the connector on the terminal board, refer to Figure A-2 “Terminal Board Cable Connection s.” When removing the gears of the paper feed mechanism, refer to Figure 3-50.
Page 144 REV.-A 3.2.8.3 Front Tractor Unit Removal This section describes the front tractor unit removal. Remove the front tractor unit before removing the front paper end sensor. Step 1: Disconnect all the cables connecting the terminal board, then remove the two CP (P) (M3 X 6) screws securing the terminal board to the printer mechanism (See Figure 3-42.) Turn the printer mechanism and lay it on its back, then loosen the hexagonal nuts securing Step 2:...
Page 145 REV.-A 3.2.8.4 Rear Tractor Unit Removal unit removal. Remove the rear tractor unit before removing the This section describes the rear tractor rear paper end sensor. Disconnect all the cables connecting the terminal board, then remove the two CP (P) (M3 X 6) Step 1: screws securing the terminal board to the printer mechanism (See Figure 3-42.) Loosen the hexagonal nuts securing the shaft at the front side of the rear tractor unit to the...
Page 146 REV.-A 3.2.9.13 Carriage Motor Unit Removal This section describes the carriage motor unit removal, including ribbon mask holder removal Disconnect all the cables connecting the terminal board, then remove the two CP (P) (M3 X 6) Step screws securing the terminal board to the printer mechanism (See Figure 3-42.) Step 2: Rotate the printer mechanism and lay it on its back, then unhook all the cables going to the right frame from the two fasteners, two wire saddles, and the wire holder.
Page 147 REV.-A CHAPTER 4 ADJUSTMENT 4 . 1 A D J U S T M E N T O V E R V I E W ..............4-1 4.2 PRINTHEAD ADJUSTMENT VALUE WRITING .
Page 148: Adjustment Overview
REV.-A 4.1 ADJUSTMENT OVERVIEW This section describes the adjustment procedures required for reassembling the DFX-8000. When disassembly or replacement is performed during maintenance or repair of the parts described in this section, the following adjustments should be performed to ensure proper operation. Table 4-1.
Page 149 B 7 7 7 2 0 0 3 0 1 #F545 Tension gauge (200 g) B7651 14601 #E672 Dial gauge B7651 11401 #F541 Dial gauge base B7651 14501 O: Commercially available tool E: EPSON exclusive tool A: Mandatory B: Recommended Table 4-3. Special Tools...
Page 150 REV.-A 4.2 PRINTHEAD ADJUSTMENT VALUE WRITING The purpose of this adjustment is to set the PG offset value in accordance with the nose dimension of the printhead. (For details, refer to Chapter 2.) The offset for the nose dimension is represented by the adjustment value “ALPHA.” The “ALPHA” value is stored in the memory on the main board, so the PG adjustment mechanism can read the value as needed.
Page 151 REV.-A Load the paper by pressing either the LINE FEED or PAPER SELECT switch, then wait until Step 3: the PAPER OUT lamp goes off (approximately 15 seconds). Step 4: Press the ON LINE switch. Step 5: Press the MICRO FEED (A) switch the number of times indicated by the value written on the front of the printhead.
Page 152 REV.-A 4.3 BI-DIRECTIONAL PRINTING ADJUSTMENT The purpose of this adjustment is to correct the printer mechanism parameters which control bidirectional printing. Be sure to perform this adjustment when required. If this adjustment is not performed correctly, bidirectional printing may be misaligned, or, in the worst case, the carriage might operate incorrectly.
Page 153 REV.-A swithch. Press the ON LINE (The printing s w i t c h . pattern is print ed. ) Press the FORM FEED switch .( The BETA value is printed. ) Perform the Correct the BETA value. printing pattern ‘ printing alignment.
Page 154 REV.-A For the flying time, belt delay time (1 to 4), and Bi-D alignment values, select the combination which as shown below. minimizes the misalignment To shift the characters on the even-numbered lines to the right or Ieft,relative to those on the odd-numbered lines, press either of the following switches.
Page 155: Parallelism Adjustment
Figure 4-8 are within the specified range. Since the specified value (0.0 1 mm) is extremely small, adjustment is impossible using normal methods. Make sure to use the dial gauge and dial gauge base supplied by EPSON. Do not adjust the parallelism using any other method.
Page 156 REV.-A Remove the printhead and ribbon mask, and attach the dial gauge base in the same way as Step 2: attaching the printhead. Loosen the screw on the base and adjust the gauge mounting position so that the tip of the gauge (portion A in Figure 4-8) is securely attached to the platen and the needle registers on the scale.
Page 157: Timing Belt Tension Adjustment
REV.-A 4.5 TIMING BELT TENSION ADJUSTMENT The carriage motor timing belt tension must be adjusted when any part of the arriage mechanism, such as the carriage, carriage motor, belt pulley, or timing belt, is disassembled. Perform this adjustmen with the upper case (and the printer mechanism) removed. W A R N I N G Before starting this adjustment, carefully fix the printer mechanism, because a force of 6.5 kg will be applied to it when the tension lever is pulled in the horizontal direction.
Page 158 W A R N I N G This measurement is important because it determines the platen gap, so be sure to use the exclusive thickness gauge set and tension gauge supplied by EPSON. Thickness gauge set (0.57 mm) : #F518 (Part No. 6776702201) Tension gauge (200 gf) : #F545 (Part No.
Page 159 REV.-A Move the printhead manually so that the center of the printhead is aligned to the 15th column Step 1 1: on the printer scale. Measure the BETA value by following the flow chart shown in Figure 4-11. Step 12: Remove the printhead.
Page 160 REV.-A START Reset the BETA value by pressing the MICRO FEED (v) switch while pressing the TEAR OFF switch. Insert the exlusive thickness gauge (#5 18: 0.5 + 0.07, total 0.57 mm) between the printhead and platen. ‘4 Press the MICRO FEED (“) switch while pressing the TEAR OFF switch.
Page 161: Trouble Shooting
REV.-A CHAPTER 5 TROUBLE SHOOTING GENERAL ....................5.1.1 Error Message Function .
Page 162 REV.-A 5.1 GENERAL Because various types of problems can occur, troubleshooting is not easy to perform. Here is a simple procedure provided to perform troubleshooting. W A R N I N G When you replace the unit, the adjustment that corresponded with each unit replacement should be performed.
Page 163 REV.-A 5 . 1 . 1 E r r o r M e s s a g e F u n c t i o n The DFX-8000 indicates an error by ringing the buzzer. (Refer to Section 1.3.6.) Table 5-1. Error Message Error Indication S y m p t o m s Cause...
Page 164 REV.-A 5 . 1 . 2 B y p a s s o f T h e I n t e r l o c k S w i t c h a n d C o v e r - o p e n S e n s o r When you requires printing with the top cover open, the interlock switch and the cover open sensor must be bypassed.
Page 165: Unit Replacement
REV.-A 5.2 UNIT REPLACEMENT For troubleshooting, make repairs by unit replacement and adjustment, based on the problem symptoms. Follow the corresponding flow chart after finding the problem in Table 5-2. Table 5-2. Problem Identification and reference pages Reference Problem S y m p t o m s page Printer does not operate No LEDs are lit on the control panel.
Page 166 REV.-A The printer does not operate at all with power switch ON. Use the correct input voltage. Measure the output power supply board. Replace the fuse and pull out all the connectors on the output side of the power supply board. Replace the driver Does the boa rd.
Page 167 REV.-A An error is detected when power is switched ON. Identify the type of problem. Refer to Section 1 .3.6 and Table 5-1. ‘ i i f ;p:: 4’~”y Is the problem > corrected? Replace driver board. Is*e problem corrected? “%s Replace the main board.
Page 168 REV.-A Printing error occurs (in self-test) Execute the s e I f–t e st. Replace the resistance value pri nthead. +’ I-----dl-’!k’i> Is a specific dot missing? Replace the driver board. Perform carriage guide shaft parallelism adjustment. Is the problem corrected? ‘r’...
Page 169 REV.-A Abnormal paper feeding Set the paper c o r r e c t l y . Turn off the paper and turn the paper feed knob. Check whethere the paper feed knob turns smoothly or not. Turn on the power supply and feed the paper by pressing the return or change...
Page 170 REV.-A The control panel does not operate correctly. Check the output voltage from the power supply board. (Refer to power supply circuit diagram in APPENDIX.) Confirm that the Replace the control printer operates and panel. the corresponding LED lights correctly by pressing the switches.
Page 171 REV.-A Incorrect printing in ON-LINE mode. START Execute the self–test. Refer to other sections for troubleshooting. Check the interface kind of interface E parameters between printer and host computer. 8-bit Parallel Adjust the parameters. —-----l Figure 5-9. Unit Replacement -6 5-10...
Page 172 REV.-A D 1 6 Cl 6 C’1 B’1 2.93 ohms / wire (Refer to Table 2-1, Section 2.1. 1.) Figure 5-10. Printhead Cable Signal Assignmnet NOTE: Pin numbers (B 1 - 18, C 1 - 16, D1 - 16) in above are correspond with the pin assignments of Table A-1 8 in APPENDIX.
Page 173 REV.-A 5.3 POWER SUPPLY BOARD UNIT COMPONENT REPAIR This section describes the power supply circuit operation check and component repair of the BOPS/BOPSE board. Before starts the troubleshooting of the other units, you should be check the operation of power supply unit. Table 5-3 shows the troubleshooting procedures for the power supply board unit Table 5-3.
Page 174 REV.-A Table 5-3. Power Supply Board Unit Component Repair (cent’d) Checkpoint Solution Problem Symptom Cause +35V DC Replace the abnor- Voltage is The current Check if the outputs of any of mal IC(’S) or the sur- limiting cir- IC2A (pin 1), IC2B (pin 7) and IC3B not output not normal.
Page 175 REV.-A Table 5-3. Power Supply Board Unit Component Repair (cent’d) Solution Cause Checkpoint Problem Symptom Replace D9 or C41. The rectifier Verify that approximately – 12V is Voltage is – 12V DC is not output not normal. circuit is bad. output at the terminals of C4 1.
Page 176 REV.-A -tt+t -H+l- -t+tt -l-t++ +tH- +ttt iii+ -tttt ..,. Figure 5-11. Sample Waveform for the Power Supply Board -1 The waveform for the +35V switching transistor drive (IC 1 pins 8 and 1 1) .“ -tH-t +t++ -H-t+ .,1. .
Page 177: Driver Board
REV.-A DRIVER BOARD UNIT COMPONENT REPAIR check and component repair of the C030DRV board. This section describes the driver circuit operation Table 5-4 shows the troubleshooting procedures for the driver board unit. Table 5-4. Driver Board Unit Component Repair Solution Problem Symptom Cause...
Page 178 REV.-A ..+tt+- -+tH- -++++ -++++- -H++ -1-l-1+ +H+-++- Figure 5-14. Sample Waveform for the Driver Board -1 CR motor drive waveform (pins 30 and 31 of connector CN6) ..++++ ++tt -H++ i-t++ 4+++ ++++++++ Figure 5-15.
Page 179 REV.-A 5.5 MAIN BOARD UNIT COMPONENT REPAIR o f t h e C 0 3 0 M A I N b o a r d . This section describes the circuit operation check and component repair Table 5-5 shows the troubleshooting procedures for the main board unit. Table 5-5.
Page 180 REV.-A Table 5-5. Main Board Unit Component Repair (cent’d) Cause Checkpoint Solution Problem Symptom “Printhead An error is Check if an error signal has been Replace IC 5E. CPU is driver input at pin 32 (HP ERR) or pin 33 detected.
Page 181 REV.-A Iiiii; i i Figure 5-17. Sample Waveform for the Main Board -1 The CPU clock waveform (IC (5E) pins 22 and 23) ‘d - 2 Figure 5-18. Sample Waveform for the Main Boal The CR motor control signal waveform (IC (6A) pin Figure 5-19.
Page 182 REV.-A CHAPTER 6 MAINTENANCE 6.1 PREVENTIVE MAINTENANCE ............6-1 6.2 LUBRICATION AND ADHESIVE APPLICATION .
Page 183: Preventive Maintenance
6.2 LUBRICATION AND ADHESIVE APPLICATION EPSON recommends that the points illustrated in Figures 6-2, 6-3 and 6-4 be lubricated, with EPSON 02 and G26, which have been extensively tested and found to comply with needs of this printer. (Refer to Table 6-1 for details of 02 and G26.)
Page 184 Table 6-2. Lubrication Points R e f Reference Lubrication Points Lubricant Figure No. Oil pad ring of the carriage (in the both sides left and right sides of carriage) Oil pad of the carriage (under the head cable holder of carriage) Hooking points of the paper guide support plate spring (6 points) Holding hole edge of the rear carrige guide shaft (both left and right sides of frame)
Page 185 Table 6-3. Adhesive Application Points R e f Reference Lubricant Lubrication Points Figure No. Neji Lock Carriage motor fixing screw (2 screws) #2 (G) Timing belt holder fixing screw Parallelism adjustment lever fixing screw (2 screws) Lower paper guide Assembly fixing screw (3 screws) Terminal board fixing screw (2 screws) Platen gap motor fixing screw (2 screws) Platen gap motor fixing screw (2 screws)
Page 186 REV.-A (6’;6) (G26) Figure 6-2. DFX-8000 Lubrication and Adhesive Diagram 1...
Page 187 REV.-A Figure 6-3. DFX-8000 Lubrication and Adhesive Diagram 2...
Page 188 REV.-A “ 1---- ..–.—...- 4-”” ‘N ~–-.– , — . . ,,’ ,’ Figure 6-4. DFX-8000 Lubrication and Adhesive Diagram 3...
Page 189 REV.-A APPENDIX A.1 COMPONENT CONNECTIONS ............A-1 A.2 CIRCUIT DIAGRAMS AND SCHEMATICS .
Page 190 REV.-A Table A-7. C030MAIN CN8 Pin Assignments ........A-6 Table A-8.
Page 191 REV.-A A.1 COMPONENT CONNECTIONS This section describes the component connection and detailed pin assignments of each connectors of units. DFX-8000, and Table A-1 lists the connector s h o w s t h e c o m p o n e n t c o n n e c t i o n s of the Figure assignments and its reference tables.
Page 192 REV.-A T a b l e A - 1 . C o n n e c t o r A s s i g n m e n t s Component Connector Ref. Description N a m e Number N u m b e r s T a b l e C 0 3 0 M A I N CN 1...
Page 193 Table A-2. C030MAIN CN2 Pin Assignments Description Name ERROR Error signal Paper End signal Data input 7 BUSY BUSY pulse Data input 6 o u t ACKNOWLEDGE pulse Data input 5 INIT Initialize signal Data input 4 STRB STROBE pulse Data input 8 —...
Page 194 REV.-A Table A-4. C030MAIN CN5 Pin Assignments Name Description Ribbon motor A phase Ribbon motor B phase Ribbon motor C phase Ribbon motor D phase RFH/R Ribbon motor common voltage (Hold/Run) Paper feed motor A phase Paper feed motor B phase Paper feed motor C phase o u t Paper feed motor D phase...
Page 195 REV.-A Table A-4. C030MAIN CN5 Pin Assignments (Cent’d) Description Name HR7N Printhead right line NPN drive signal #7 o u t HR8N Printhead right line NPN drive signal #8 o u t HR9N Printhead right line NPN drive signal #9 ] HFANA I Head fan motor A phase o u t...
Page 196 Table A-5. C030MAIN CN6 Pin Assignments (Cent’d) Name Description — D V 3 5 + 35 VDC(VP3) monitor line — Ground NOTE: The pin assignments in above table are corresponded with the pins of connector CN4 on the “DIR” changes to opposite direction.) driver board.
Page 197 Table A-8. C030MAIN CN9 Pin Assignments Description Name + 5 VDC — COVER SW Cover open sensor signal — Ground Table A-9. C030MAIN CN1 O Pin Assignments Description Name CUTON Cutter signal CUTDIR Cutter direction signal o u t CUTTER Cutter install signal I Cutter home position sensor signal CUTHP...
Page 198 Table A-1 2. C030DRV CN5 Pin Assignments N a m e Description Printhead drive signal #6 (HR3P) Printhead drive signal #4 (HR2P) 3 I O u t I # 1 8 G N D I Printhead g r o u n d s i g n a l # 1 8 (HR9N) o u t...
Page 199 Table A-1 3. C030DRV CN6 Pin Assignments Name Description Tractor select sensor signal TRCTSEL — Ground RFCOM Ribbon motor common voltage (Hold/Run) Ground for VP3 — Ribbon motor D phase Ribbon motor C phase Ribbon motor B phase Ribbon motor A phase PGCOM Platen gap motor common voltage (Hold/Run) 9,10...
Page 200 REV.-A The terminal board is located at the left side frame of printer mechanism. The terminal board distribute the drive signals of mechanism from the driver board, and send back sensor signals to the main board through the driver board. F i g u r e A - 2 s h o w s t h e c o n n e c t o r a s s i g n m e n t s o f t h e t e r m i n a l b o a r d , a n d T a b l e A - 1 7 lists the Pin assignments of each connector.
Page 201 Table A-1 7. Terminal Board Connector Pin Assignments Connector Location N a m e Description (Fig. A-2) o u t PLGN Plunger NPN drive signal o u t PLGP Plunger PNP drive signal Ground — TRCT Pull tractor sensor signal —...
Page 202 REV.-A The head board is located on the right side of carriage base plate. The head board distribute the drive signals of printhead from the driver board, and send back sensor signals to the main board through the driver board. Figure A-3 shows the connector assignments of the head board, and Table A- 18 lists the pin assignments of each connector.
Page 203 REV.-A Table A-1 8. Head Board Connector Pin Assignments Connector Description Name Location (Fig. A-3) “ + 5 VDC CRHP Carriage home position signal — Ground Printhead drive signal #2 (HR 1 P) Printhead drive signal #1 (HL1 P) Printhead HFANB cooling fan motor p h a s e...
Page 204 REV.-A A.2 CIRCUIT DIAGRAMS AND SCHEMATICS N O T E S : 1 . F i g u r e t h a t i s w i t h a t t a c h e d t i t l e o f “ W i t h N o t e ” m e a n s , i t i n d i c a t e d b l o c k l i n e a n d l i n e .
Page 205 BOPSE B O A R D u .: ~-. — ‘ ’ ” iiiiirm:=:r ;(+) “’”1~” ”” -= !----l ‘“’–=– ‘m Figure A-5. BOPSE Board Component Layout A-1 5...
Page 206 — — — Board Component Layout Figure A-6. C030DRV A-1 6...
Page 207 “,! “H -,,, .- “,, ..!’l~- ..--.--.! ----- } ..------- ----- -: .+8.. ‘ - - - - - - - - . . . --.--,, 46 “ 4 , “ 7 , -A. ,4, - ..+.+ Emil...
Page 208 REV.-A ONLINE SW FF SW LF SW TEAR OFF SW TOF SW MICRO(F) SW MICRO(B) SW PAPER SEL SW (’ BUZZER “ 0.1 cl : READY LP L E D 1 ONLINE LP PAPER LP TEAR OFF LP T. O.F. LP FRONT1 LP FRONT2 LP REAR1 LP...
Page 209 EPSON...

Epson DFX-8000 Service Manual

Chapter 1 General Specifications

Chapter 2 Operating Principles.

Chapter 3 Disassembly and Assembly

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