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Epson Stylus Pro XL Service Manual

Color inkjet printer
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EPSON COLOR INKJET PRINTER
Stylus Pro XL+

SERVICE MANUAL

EPSON
4006101

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Summary of Contents for Epson Stylus Pro XL

  • Page 1: Service Manual

    EPSON COLOR INKJET PRINTER Stylus Pro XL+ SERVICE MANUAL EPSON 4006101...
  • Page 2 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.

  • Page 3: Revision Sheet

    REVISION SHEET Revision Issue Date Revision Page March 15, 1996 1st issue -ii-...
  • Page 4 Macintosh. The main components and case of this printer are similar to the Stylus Pro XL. The main features are: High-quality color printing 720 dpi printing using EPSON Micro Dot mode 720 dpi printing on: plain paper...

  • Page 5: Printing Specifications

    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 Printable Columns Print Speeds (LQ) 10 cpi (pica)

  • Page 6: Ink Cartridge Specifications

    Stylus Pro XL+ Product Description 1.2.2 Ink Cartridge Specifications Black Type: Exclusive cartridge Color: Black Print capacity: 1170 pages (ECMA132 letter) Life: The effective life from the indicated production date is 2 years. Storage temperature: –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)

  • Page 7: Interface Specifications

    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.
  • Page 8 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) Signal Return Pin No. I/O* Description Name GND Pin The STROBE pulse is used to read data from the host...

  • Page 9: Reverse Channel

    Product Description Stylus Pro XL+ 1.3.1.2 Reverse Channel Transmission mode: 8-bit parallel, IEEE-1284 nibble mode. Synchronization: Refer to the IEEE-1284 specification. Handshaking: Refer to the IEEE-1284 specification. Signal level: IEEE-1284 level 1 device (See the forward channel.) Adaptable connector: The same as for the forward channel. Data transmission timing: Refer to the IEEE-1284 specification.

  • Page 10: Optional Interface Specifications

    04H: Request Device ID Return data using nibble mode reverse channel transfer. Device ID: The printer sends following device ID string when it is requested. [00H][39H] MFG:EPSON; CMD:ESCPL2-00; MDL:Stylus Pro XL+; CLS : PRINTER; Note: [00H] denotes a hexadecimal value of zero.

  • Page 11: Control Panel

    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.

  • Page 12: Panel Operation At Power On

    Stylus Pro XL+ Product Description Indicators Operate On when the printer is on. Blinks while the printer is powered on or off. Paper Out On when the printer is out of paper. Blinks when a paper jam occurs. Ink Out (Black) On when the black ink cartridge is out of ink or not installed.

  • Page 13: Error Conditions

    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 Error Operate Economy Condensed Pause Data (Black) (Color) Paper out — — — — — —...

  • Page 14: Operating Principles Of The Printer Mechanism

    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.

  • Page 15: Operating Principles Of The Electrical Circuits

    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: 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).

  • Page 16: Reset Circuits

    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.

  • Page 17: Sensor Circuits

    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.

  • Page 18: Carriage Motor Driver Circuit

    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.

  • Page 19: Paper Feed Motor Driver Circuit

    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: 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.

  • Page 20: Printhead Driver Circuit

    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: 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.
  • Page 21 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...
  • Page 22 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.
  • Page 23 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.

  • Page 24: Ink System Management

    Stylus Pro XL+ Service Manual 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:...

  • Page 25: Precautions For Disassembling The Printer

    Stylus Pro XL+ Service Manual 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.

  • Page 26: Disassembly And Assembly

    Stylus Pro XL+ Service Manual Disassembly and Assembly 3.2 DISASSEMBLY AND ASSEMBLY When you remove the ink cartridge, always install a new cartridge immediately after taking out the old one. When you replace the ink cartridge, the printer performs the ink cartridge replacement operation automatically.
  • Page 27 Stylus Pro XL+ Service Manual Disassembly and Assembly Lift the carriage unit with the carriage guide shaft out of the printer mechanism. Take appropriate measures to protect the printhead unit from static electricity, because the driver IC is directly attached to the printhead unit.

  • Page 28: Adjustment - Overview

    Stylus Pro XL+ Service Manual 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.

  • Page 29: Head Data Writing Operation

    Adjustment Stylus Pro XL+ Service Manual 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.
  • Page 30 Stylus Pro XL+ Service Manual Adjustment 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. The head VH data is written on the each head unit as shown in the following figure.

  • Page 31: Destination Data Writing Operation

    Adjustment Stylus Pro XL+ Service Manual 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.

  • Page 32: Black Head Angle Adjustment

    Stylus Pro XL+ Service Manual Adjustment 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.
  • Page 33 Adjustment 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.
  • Page 34 Stylus Pro XL+ Service Manual Adjustment 3-2. BLACK HEAD ANGLE ADJUSTMENT 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).
  • Page 35 Adjustment Stylus Pro XL+ Service Manual Rubber Cap Color Ink Cartridge Holder 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.)

  • Page 36: Color Head Angle Adjustment

    Stylus Pro XL+ Service Manual Adjustment 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.
  • Page 37 Adjustment Stylus Pro XL+ Service Manual 3-1 YMC HEAD ANGULAR Ma g en ta C y a n Mage nta 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.
  • Page 38 Stylus Pro XL+ Service Manual 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 Replace the right...

  • Page 39: Black - Color Head Vertical Adjustment

    Adjustment Stylus Pro XL+ Service Manual 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.
  • Page 40 Stylus Pro XL+ Service Manual Adjustment 10. Change customer & data / END 0. Cleaning Select Menu ? 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.) 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.
  • Page 41 Adjustment 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...

  • Page 42: Head Gap Adjustment (Black And Color Head)

    Stylus Pro XL+ Service Manual Adjustment 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.
  • Page 43 Adjustment Stylus Pro XL+ Service Manual The adjustment value input menu appears as shown: INPUT ADJUST No. (IF OK INPUT Y)? adjust range (from –32 to 32) 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.

  • Page 44: Bi-D (Bidirectional Printing) Alignment Adjustment

    Stylus Pro XL+ Service Manual Adjustment 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.
  • Page 45 Adjustment 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. Positive compensation value: Shifts the 2nd line to the left Negative compensation value: Shifts the 2nd line to the right When the sample print becomes vertically aligned for both lines, press Y and ENTER;...

  • Page 46: Platen Gap Adjustment

    Stylus Pro XL+ Service Manual Adjustment 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.
  • Page 47 Adjustment Stylus Pro XL+ Service Manual Note: 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.
  • Page 48 Stylus Pro XL+ Service Manual Adjustment 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.

  • Page 49: Head Cleaning Function

    Adjustment Stylus Pro XL+ Service Manual 4.1.10 Head Cleaning Function This function performs the compulsory ink charging to the printer head in order to check using the service tool for ink charging. Connect the PC to the target printer using a parallel interface cable and turn the printer on.

  • Page 50: Connector Summary

    STYLUS PRO XL+ Service Manual Appendix A.1 CONNECTOR SUMMARY The figure below shows the interconnection of major components of the Stylus Color Pro XL+. C1 37 PSB/PSE AC Inlet CN 2 Printer Mechanism CN 5 ASF Plunger C 184 M AI N...
  • Page 51 Appendix STYLUS PRO XL+ Service Manual Table A-1. Connector Summary Board Location Pins Description C164 MAIN Centronics parallel I/F Type B parallel I/F RS-422 serial I/F Power supply from PS board Carriage motor phase output PF/PM motor phase output Paper end sensor...
  • Page 52 STYLUS PRO XL+ Service Manual Appendix Table A-2. Connector Pin Assignments — CN1 Name Description STB / Host Clk STROBE signal / Clock signal (Host) DATA1-8 Data strobe signal ACK / Ptr Clk ACK signal / Clock signal (Printer) BUSY / Ptr Busy (Data...
  • Page 55 STYLUS PRO XL+ Service Manual Appendix Figure A-4. C137 PSB Board Circuit Diagram Rev.A...
  • Page 56 Appendix STYLUS PRO XL+ Service Manual Figure A-5. C137 PSE Board Circuit Diagram A-10 Rev.A...
  • Page 57 STYLUS PRO XL+ Service Manual Appendix Figure A-6. C137 PSE (Korea) Board Circuit Diagram Rev.A A-11...
  • Page 59 EPSON...

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