EPSON IMPACT SERIAL DOT MATRIX PRINTER DFX-8500 SERVICE MANUAL SEIKO EPSON CORPORATION 4009310
NOTICE All rights reserved. Reproduction of any part of this manual in any form whatsoever without SEIKO EPSON’s express written permission is forbidden. The contents of this manual are subjects to change without notice. All efforts have been made to ensure the accuracy of the contents of this manual. However, should any errors be detected, SEIKO EPSON would greatly appreciate being informed of them.
PRECAUTIONS Precautionary notations throughout the text are categorized relative to 1) personal injury and 2) damage to equipment. WARNING Signals a precaution which, if ignored, could result in serious or fatal personal injury. Great caution should be exercised in performing procedures preceded by WARNING Headings. CAUTION Signals a precaution which, if ignored, could result in damage to equipment.
PREFACE This manual describes functions, theory of electrical and mechanical operations, maintenance, and repair of DFX-8500. The instructions and procedures included herein are intended for the experience repair technician, and attention should be given to die precautions on the preceding page. The Chapters are organized as follows: CHAPTER 1. GENERAL DESCRIPTION Provides a general product overview, lists specifications, and illustrates the main components of the printer. CHAPTER 2.
REVISION SHEET Revision Issued Data Contents Rev. A May 18, 1998/ First issue Rev. B June 25, 1998 Second issue due to minor correction on the manual contents.
TABLE OF CONTENTS CHAPTER 1. CHAPTER 2. CHAPTER 3. CHAPTER 4. CHAPTER 5. CHAPTER 6.
CHAPTER 1 GENERAL DESCRIPTION 1.1 FEATURES.............................................................................................................1-1 1.2 SPECIFICATIONS..................................................................................................1-3 1.2.1 Printing Specification............................................................................................................. 1-3 1.2.2 Paper Feeding ...........................................................................
1.5.4 C204 DRV-B Board................................................................................................................1-41 1.5.5 C204 SUB Board....................................................................................................................1-41 1.5.6 C204 PSB/PSE Board............................................................................................................1-42 1.5.7 Control Panel............................................................................
GENERAL DESCRIPTION 1.1 FEATURES The DFX-8500 is a 18-pin, serial, dot matrix printer with a maximum speed of 1120 characters per second (cps). It is designed for business use and provides high-speed, high-volume printing and continuous-sheet handling.
DFX-8500 The following table shows options. Code #8766 #8767 #8309 C81500X C81507X C82305* C82306* C82307* C82308* C82310* C82311* C82312* C82313* C82314* C82315* C82357* C82345* C82362 C82364 1-2 Table 1-1.
GENERAL DESCRIPTION 1.2 SPECIFICATIONS This section describes the specifications for DFX-8500. 1.2.1 Printing Specification Print method : Impact dot matrix Number of pins : 18-pin (Refer to Figure 1-2.) Print pin arrangement : 9 x 2 Print pin diameter : 0.0114 inches (0.29 mm) Color : Black Print direction : Bi-directional with logic seeking Print speed and printable columns: Refer to Table 1-2. 0.35 mm (1/72") 2.82 mm (8/72") 1.69 mm (1/15") Figure 1-2.
DFX-8500 Resolution: Print Mode High speed draft Draft Draft condensed Draft emphasized NLQ Bit image Refer to Table 1-3. Table 1-3.
GENERAL DESCRIPTION Character tables and type faces: Refer to Table 1-4. Table 1-4.
DFX-8500 1.2.2 Paper Feeding Feeding method: Push tractor feed (front / rear) Push and pull tractor feed (front / rear) Feeder: Front push tractor, rear push tractor, pull tractor (option) Paper insertion side alignment : Left Paper path: Tractor (front in, rear in, top out) Line spacing: 1 / 6 inches or programmable in increments of 1 / 216 inches. Feed speed: 1/ 6-inch feed: 26.5 ms Continuous feed: 0.251 mps (m/s). 9.
GENERAL DESCRIPTION 1.2.6 Safety Approvals 120 V version: Safety standards : EMI : 230 V version: Safety standards : EMI : UL1950 with D3 CSA C22.2 No.950 with D3 FCC part 15 subpart B class B CSA C108.8 class B EN60950 (VDE, NEMKO) EN55022 (CISPR pub.22) class B AS / NZS 3548 class B 1.2.7 CE Marking 230 V version: Low Voltage Directive 73/23/EEC : EN60950 EMC Directive 89/336/EEC : EN55022 class B EN61000-3-2 EN61000-3-3 EN50082-1 IEC801-2 IEC801-3 IEC801-4 1.
DFX-8500 1.2.11 Printable area Continuous paper : Refer to Figure 1-3. L M R M P W T M A B C D W X Y Z A B C D W X Y Z A B C D W X Y Z P L B M . PW (width) PL (length) LM (left margin) RM (right margin) TM (top margin) BM (bottom margin) Continuous Paper Refer to Section 1.2.12. Refer to Section 1.2.12. 13 mm to 31mm 13 mm or more 2.6 mm or more 4.2 mm or more Notes 1: In the top 75 mm area, the paper feeding pitch may be irregular.
GENERAL DESCRIPTION Labels : Refer to Figure 1-4. R M L M P W T M L a b e l L a b e l L a b e l L a b e l P L B M . PW (width) PL (length) LM (left margin) RM (right margin) TM (top margin) BM (bottom margin) Notes 1: Notes 2: Notes 3: Notes 4: Continuous Paper Refer to Section 1.2.12. Refer to Section 1.2.12. 13 mm to 31mm 13 mm or more 2.6 mm or more 4.2 mm or more Feeding backward or paper (PATH) selection are prohibited.
DFX-8500 Continuous forms with labels : Refer to Figure 1-5.
GENERAL DESCRIPTION Overlapping multi-part forms : L M Refer to Figure 1-6. P W R M P e r fo r a tio n s C a r r ie r P L B M N A O L T M PW (width) PL (length) LM (left margin) RM (right margin) TM (top margin) BM (bottom margin) OL (overlapping length) NA (non printable area) Notes 1: Notes 2: Notes 3: Notes 4: Continuous Paper Refer to Section 1.2.12. Refer to Section 1.2.12. 19 mm to 31mm 19 mm or more 21.2 mm or more 4.2 mm or more Less than 13.3 mm 25.
DFX-8500 1.2.12 Paper and Media 1.2.12.1 Continuous paper (Single sheet and multi-part) Width Length Copies Total Thickness Weight (not multi-part) Weight (one sheet of multi-part) Quality Multi-part binding Perforation Notes (inch) (mm) (inch) (mm) (inch) (mm) 2 (g/m ) (lb) 2 (g/m ) (lb) Table 1-5. Continuous Paper Front Entry Rear Entry Minimum Maximum Minimum Maximum 4.0 16.0 4.0 16.0 101 406 101 406 4.0 17.0 4.0 17.0 101 431 101 431 1 original + 6 copies 1 original + 5 copies 0.0025 0.021 0.0025 0.
GENERAL DESCRIPTION Figure 1-8. Paper-stapling Height Figure 1-9. Paper-stapling Method 1 Figure 1-10. Paper -stapling Method 2 Rev.
DFX-8500 1.2.12.2 Labels Label Size Backing Sheet Width Backing Sheet Length Label Thickness Total Thickness (inch) (mm) (inch) (mm) (inch) (mm) (inch) (mm) Quality Perforation Notes Table 1-6. Labels Front Entry Rear Entry Minimum Maximum Minimum Maximum Refer to Figure 1-11. 4.0 16.0 101 406 3.5 17.0 89 431 0.0 0.0047 0.0 0.12 0.0025 0.0075 0.065 0.19 AVERY CONTINUOUS FORM LABELS, AVERY MINI-LINE LABELS, or the same quality labels Refer to section 1.2.12.5.
GENERAL DESCRIPTION 1.2.12.3 Continuous Forms with Labels Label Size Width Length Weight (not multi-part) Weight (one sheet of multi-part) Label Thickness Total Thickness Quality (Multi-part forms) Quality (Label) Multi-part binding Perforation Notes Table 1-7. Continuous Forms with Labels Front Entry Rear Entry Minimum Maximum Minimum Maximum Refer to Section 1.2.12.2. (inch) 4.0 16.0 (mm) 101 406 (inch) 4.0 17.0 (mm) 101 431 2 (g/m ) 52.6 82.7 (lb) 14 22 2 (g/m ) 41.4 56.4 (lb) 11 15 (inch) 0.0 0.
DFX-8500 1.2.12.4 Overlapping Multi-part Form Width Length Weight (not multi-part) Weight (one sheet of multi-part) Copies Total Thickness (print area) Total Thickness (overlap area) Overlapping Length Quality (multi-part forms) Multi-part binding Perforation Notes Table 1-8. Overlapping Multi-part Form Front Entry Rear Entry Minimum Maximum Minimum Maximum (inch) 4.0 16.0 (mm) 101 406 (inch) 4.0 17.0 (mm) 101 431 2 (g/m ) 52.6 82.7 (lb) 14 22 2 (g/m ) 41.4 56.
GENERAL DESCRIPTION 1 9 o r m o re 1 9 - 3 1 1 3 + 3 2 1 .2 o r m o re 1 3 + 3 M u lti- p a r t c u t s h e e t B a s e s h e e t P a g e L e n g th S p o t- g lu e d p a r t 4 .2 o r m o re 2 1 .2 o r m o re P e r fo r a tio n o f b a s e s h e e t S p o t- g lu e d p s r t L o w e r e d g e P a g e W id th S p o t- g lu e d p a r t U n it : m m Figure 1-12. Paper Width Overlapping Area Figure 1-13. Perforations 1 Rev. B Figure 1-14.
DFX-8500 Figure 1-16. Raised Portion at a Perforation a) b) c) Figure 1-15. Perforations 3 Figure 1-18. Sprocket Hole 1 Figure 1-19. Sprocket Hole 2 Figure 1-17. Unsuitable Paper Figure 1-20. Bad Folded Paper 1-18 Rev.
GENERAL DESCRIPTION 1.3 INTERFACES The DFX-8500 is equipped with parallel interface, serial interface, and optional Type-B interface card. This section presents the specifications for each interface type. 1.3.
DFX-8500 Signal Level: TTL-level compatible, IEEE-1284 level 1 device Refer to Table 1-9. Table 1-9. Signal Level Parameter Minimum Maximum Condition VOH* 5.5 V VOL* -0.5 V IOH* 0.32 mA VOH = 2.4 V IOL* 12 mA VOL = 0.4 V CO 50 pF VIH 2.0 V VIL 0.8 V IIH 0.32 mA VIH = 2.4 V IIL 12 mA VIL = 0.8 V CI 50 pF Note: * A low logic level on the logical high signal is 2.0 V or less when the printer is powered off. And this signal is equal or exceeding 3. 0 V when the printer is powered on.
GENERAL DESCRIPTION 1.3.2 Parallel Interface (Reverse channel) Data transmission mode: Connector type: Synchronization: Handshaking: Data transmission timing: Signal Level: Extensibility request : Device ID : IEEE-1284 nibble mode 57-30360 (AMPHENOL) 36-pin plug or equivalent No Info. No info. No info.
DFX-8500 1.3.3 Serial Interface Synchronization : Asynchronous Signal level (ELA-232D) : MARK (logical 1) : -3Vto-25V SPACE (logical 0) : +3Vto+25V Word length : Start bit : 1 bit Data bit : 8 bit Parity bit : Odd, Even, Non, of Ignore Stop bit : 1 bit or more Baud rate : 2400, 4800, 9600 or 19200 bps Handshaking : DTR signal or X-ON / X-OFF DTR=MARK, X-OFF : Indicates that the printer cannot receive data.
GENERAL DESCRIPTION 1.3.5 Interface Selection The printer has three interfaces; the parallel interface, serial interface, and optional Type-B interface. These interfaces are selected manually by DIP SW or selected automatically. Manual selection: One of three interfaces can be selected by DIP SW setting. Automatic selection: The automatic interface selection is enabled by DIP SW setting.
DFX-8500 1.4 OPERATING INSTRUCTIONS This section describes the functions performed through the control panel, such as test print, hexadecimal dump, and paper memory function. 1.4.1 Control Panel The printer control panel gives you easy control over most common printer operations. The panel consists of indicator lights and buttons.
GENERAL DESCRIPTION 1.4.1.1 Switches The control panel contains eleven switches. Operation in normal mode: In normal mode, pressing panel switches executes following function. Refer to Table 1-13. Table 1-13. Switch Function in Normal Mode Switch Front / Rear Pause Micro Feed ↑ Micro Feed ↓ LF / FF Load TOF (top of form) Tear Off Copy Pitch Font Paper Select Function Change the front and rear paper path alternately. Alternates printing and no-printing status.
DFX-8500 1.4.1.2 Indicators The control panel contains fifteen LEDs. Rear (2) (Green / Red) : Green LED on when the rear paper path is selected with paper. Red LED on when the rear paper path is selected without paper. Off when the front paper path is selected. Front (2) (Green / Red) : Green LED on when the front paper path is selected with paper. Red LED on when the front paper path is selected without paper. Off when the rear paper path is selected.
GENERAL DESCRIPTION 1.4.2 Errors and Buzzers Errors fall into 2 types; normal error/warning and fatal error. See the tables below for detailed information. Table 1-15. Error/Warning Buzzer Information Error/Warning On Line Pause Head hot Head Fan hot Paper out error PAUSE LED Off On Blinking Blinking On Paper Out LED Off Off Off Off On Ribbon LED Off Off Off Off Off Beeper *1) ... Cover open error ON Off Off ... Incomplete changing paper On Off Off ...
DFX-8500 1.4.3 DIP Switch Settings There are five DIP switches that are located at the front paper entrance of the printer. These DIP switches can set the printer defaults. When power is applied or the printer is reset, the DIP switch selections are treated as the default setup. If the setup is changed, the power should be cycled or the printer should be reset. Table 1-16 shows the DIP switch selections for this printer. Table 1-16. DIP Switch Settings Switch No.
GENERAL DESCRIPTION Table 1-17.
DFX-8500 Table 1-19. Front Tractor Page Length SW2-1 Off Off Off Off Off Off Off Off On On On On On On SW2-2 Off Off Off Off On On On On Off Off Off Off On On SW2-3 Off Off On On Off Off On On Off Off On On Off Off SW2-4 Off On Off On Off On Off On Off On Off On Off On Others Page length for front tractor 11 inches 3 inches 3.5 inches 4 inches 5.5 inches 6 inches 7 inches 8 inches 8.5 inches 70 / 6 inches 12 inches 14 inches 17 inches Others 11 inches Table 1-20.
GENERAL DESCRIPTION 1.4.4 Functions 1.4.4.1 Usual operation Front / Rear: Changes the front and rear paper path alternately. Normal paper is set and the pull tractor is not used: The printer feeds the paper to the tear off position and cut the paper by the cutter, and feeds backward to paper park position. If the cutter is not used, it goes incomplete changing paper error. So cut the paper at the top of paper and push Pause switch or Front/Rear switch, and the printer feeds the paper backward.
DFX-8500 Paper Select: Pressing it selects one of the following paper Numbers. 1,2,3,4,5,6,7,8 : When the printer has the paper information. 0: Always a, b : When the printer has the paper memory data. Normal paper is set and the pull tractor is not used: The printer feeds the paper to the tear off position and cut the paper by the cutter, and feeds it backward to the paper park position. If the cutter is not used, it goes incomplete changing paper error.
GENERAL DESCRIPTION 1.4.4.2 Operation at Power On Self test: Prints the self test pattern. To cancel it, make printer pause and turn off the power. DIP switch setting print: Starts the setting printing mode. Data dump: Starts the data dump mode, in which all the input data are printed as hexadecimal numbers and corresponding characters. Clear EEPROM Area 1: Resets the printer to the standard factory setting, except mechanism data area. (i.e. This function is for emergency.
DFX-8500 1.4.4.3 Built-in Detection Cover open detection: When the cover is opened, the printer stops printing and enters the pause mode automatically after several beeps. The printer stays at the state until the cover is closed and the “Pause” switch is pressed. Several printer settings loaded at each power-on can be changed in this operation. Paper width detection: The printer detects the right paper edge and determines the right end of printable area.
GENERAL DESCRIPTION 1.4.5 Paper Memory Function You can get better printing quality when you print on overlapping multi-part forms or on continuous forms with labels by using the paper memory function. When you use this function, you have to write the information of paper thickness to the printer using DIP switches and the control panel in advance. This function is available only with the front paper path.
DFX-8500 1.4.6 Initializations 1.4.6.1 Power-on Initialization The initialization of this level is activated by power-on or /INIT signal (negative pulse) or cold-reset command (remote RS command). This initialization is: • to initialize the printer mechanism. • to clear the all buffers of data. • to cancel the download character definition. • to make the printer stand-by state, if no errors occur. • to execute software initialization. 1.4.6.
GENERAL DESCRIPTION 1.5 MAIN COMPONENT The main components of the DFX-8500 are as follows: Printer mechanism: Main control board: Mechanism driver board: ½ Printhead driver board: DIP SW.
DFX-8500 1.5.1 M-3I60 Printer Mechanism The M-3I60 printer mechanism is a 18-pin (9-pin two lows), serial impact dot matrix printer mechanism developed for the DFX-8500. It is designed to provide high-speed, high-volume printing, and is especially heavy and durable when compared with existing terminal printer mechanisms, Its paper feeding mechanism uses several kinds of fan-fold paper, and an automatic mechanism is included to provide enhanced paper handling.
GENERAL DESCRIPTION 1.5.2 Main Control Board (C204 MAIN Board) The C204 MAIN board is a main controller board. The board contains following ICs: 16-bit CPU: Gate array: PROM (including C.G.) : RAM ADM232L RESET IC EEPROM TMP95C051A; 24.57 MHz (IC2) E05B36 (IC1) 2M-bit (IC5) 4M-bit (IC14) RS-232C level converter (IC9) PST391D(IC13) 93C66 (IC11) There are two types of C204 MAIN board used as after service parts. The following Table shows differences between them. Figure 1-26.
DFX-8500 1.5.3 C204 DRV Board The C204 DRV board is the driver board specially for the printer mechanism. The ½ printhead, printhead fan, plunger, PF (paper feed) motor, CR (carriage) motor, CR fan, PG (platen gap) motor, and RF (ribbon feed) motor drive circuits are located on the driver boards. Sensor signals from the printer mechanism are connected to the main board via these boards. Major ICs on the DRV are as follows: .
GENERAL DESCRIPTION 1.5.4 C204 DRV-B Board The C204 DRV-B board is the ½ printhead driver board. The drive part is mainly consists of the discrete bipolar FETs. Figure 1-28. C204 DRV-B Board 1.5.5 C204 SUB Board The C204 SUB board consists of five DIP switch units. It is located behind the front paper cover. Figure 1-29. C204 SUB Board Unit Rev.
DFX-8500 1.5.6 C204 PSB/PSE Board C204 PSB/PSE board is a power supply circuit board which generates the power for the control circuit (main control board) and printer mechanism drive circuit (driver board). It contains cooling fan on the top. The PSB board is a 100-120 V AC version, and the PSE board is for 220-240 VAC. Figure 1-30. C204 PSB/PSE Board 1-42 Rev.
GENERAL DESCRIPTION 1.5.7 Control Panel The control panel for this printer consists of switches, LEDs, and buzzers (Refer to Figure 1-22 on page 1-23.). 1.5.8 Housing The housing used in the DFX-8500 consists of many more components than previous designs. The lower case is used as the main frame which holds the mechanism and circuits, and they are covered by the upper case, bottom plate and side cover, each of which has various covers.
CHAPTER 2 OPERATING PRINCIPLES 2.1 PRINTER MECHANISM OPERATION ..................................................................2-1 2.1.1 Printhead Mechanism ........................................................................................................... 2-4 2.1.2 Carriage Mechanism ............................................................................................................. 2-5 2.1.3 Platen Gap Adjustment Mechanism ................................................................
OPERATING PRINCIPLES 2.1 PRINTER MECHANISM OPERATION This section describes the Model 3I60 printer mechanism and explains how the printer works. The Model 3I60 printer mechanism features a 18-pin, impact dot printhead for serial printing. The printer mechanism is the main component of the printer and is supported by the other components (the power supply and control circuits). Figure 2-1 shows the Model 3I60 printer mechanism.
DFX-8500 Carriage mechanism : The carriage mechanism moves the printhead in the horizontal direction. The CR motor drives the carriage, with the printhead on it. The CR encoder sensor detects the CR motor speed and carriage position. The CR motor is closed-loop controlled. Because the CR motor is driven at a very high speed, it includes an isolation resistance sensor to detect abnormal resistance. The sensor detects an error if the resistance is less than 2.2 K ohms. (Refer to Section 2.3.
OPERATING PRINCIPLES Paper feed mechanism : The CR motor controls printing in the horizontal direction, and the paper feed mechanism controls movement in the vertical direction (line feeding and form feeding). The paper feed mechanism feeds paper vertically. The PF motor drives the paper feed mechanism. The front, rear, and top PE sensors detect whether paper is present in the paper path, and stop the printer from printing when there is no paper.
DFX-8500 2.1.1 Printhead Mechanism The printhead is a charge-type, impact dot printhead. Figure 2-4 shows its operation. The dot wire is attached to the actuating spring at point A. It is pulled back (left in the figure) by magnetic force when power is applied and during standby. The magnetic force holds back the actuating spring. When current flows through the coil, a counter-magnetic field is induced in the coil.
OPERATING PRINCIPLES 2.1.2 Carriage Mechanism Figure 2-5 shows the carriage mechanism. The front and rear carriage guide shafts support the carriage. The rotation of the CR motor is transmitted to the carriage timing belt through the carriage belt pulleys at the right and left sides. The printhead is mounted on the carriage, which is attached to the carriage timing belt and moves horizontally.
DFX-8500 2.1.3 Platen Gap Adjustment Mechanism Figure 2-6 shows the platen gap adjustment mechanism. The front and rear carriage guide shafts supporting the carriage have a vertical section. The rotation of the PG motor is transmitted to the rear carriage guide shaft through the gears. Counterclockwise rotation of the motor expands the platen gap and clockwise rotation reduces it. The encoder plate with equally pitched slits is attached coaxially to the motor axis.
OPERATING PRINCIPLES 2.1.4 Paper Feed Mechanism Figures 2-7, 2-8, and 2-9 show the paper feed mechanism. After the printer loads the paper, it is fed by the tension roller, platen roller, and front or rear tractor assembly. The PF motor rotates the tension roller and tractor select gear (Figures 2-8 and 2-9) and moves either the front or rear tractor assembly. The rotation of the paper feed transmission gear rotates the tractor select gear, which can engage either tractor train.
DFX-8500 Paper Paper Bail Tension Roller Tractor Select Gear Front PE Sensor PF Motor Pinion Gear Tractor Sprocket (Front) PF Transmission Gear Figure 2-8. Front Tractor Assembly Operation Paper Paper Bail Tension Roller Rear PE Sensor Tractor Select Gear PF Transmission Gear Tractor Sprocket (Rear) PF Motor Pinion Figure 2-9. Rear Tractor Assembly Operation 2-8 Rev.
OPERATING PRINCIPLES 2.1.4.1 Tractor Wire Operation The printer is equipped with a tractor wire (white line) to prevent paper jams when continuous paper is loaded from the front or rear entrance. The tractor tension spring on the right side frame pulls the wire and releases the stress on the continuous paper being fed. Figure 2-10 shows how the tractor wire operates.
DFX-8500 2.1.5 Ribbon Feed and Tractor Select Mechanisms The RF motor supplies power to both the ribbon feed and tractor select mechanisms. The rotation of the RF motor pinion swings the ribbon feed select gear like a pendulum, using the lever axis as a support point. The rotation of the RF motor is transmitted after the gears are engaged.
OPERATING PRINCIPLES Tractor select mechanism : Figure 2-12 shows the operation of the tractor select mechanism. Clockwise rotation of the RF motor is transmitted to the tractor select cam through the ribbon feed select gear and tractor select transmission gear, and rotates the tractor select cam clockwise. The tractor select lever contacts the inside curve of the cam due to the spring force; when the cam rotates, the tractor select lever moves horizontally along the curve.
DFX-8500 2.1.6 Plunger Mechanism Figure 2-13 shows the plunger mechanism. The paper bail assembly is attached to the end of the plunger's iron core. The paper bail assembly axis is connected to the frame. When the plunger coil is energized, the force of the paper bail spring returns the paper bail assembly to its original position. Paper Bail ASSY. Lever Plunger Iron Core Coil Tension Spring Figure 2-13. Plunger Mechanism 2-12 Rev.
OPERATING PRINCIPLES 2.2 POWER SUPPLY OPERATION The printer can be powered by either of two power supply boards: the 120 V C204 PSB board or the 220/240 V C204 PSE board. The only difference in the operation of these two boards is in the primary circuitry. They supply power to the printer in the same way. The power supply board outputs the DC current required to drive the control circuits and printer drive mechanism.
DFX-8500 2.2.1 Power Supply Overview Figure 2-14 shows a block diagram of the C204 PSB/PSE board. Surge Cut (at Power On) CN1 L Power SW.
OPERATING PRINCIPLES General : The power supply board converts the AC input voltage to the DC voltages required to operate the printer. The AC voltage is input to the AC inlet, and is supplied to the C204 PSB/PSE board via the power switch and a fuse. Two main switching regulator circuits consist of two blocks, +37 V Lines ½ and 2/2. The one convert the AC voltage to the +37 VDC specially for the print head coils drive requirement.
DFX-8500 Protection circuits : These +37VDC line blocks perform voltage control, and they have over-current limiting and over voltage protection circuits for each. Control and status signals : The PSB//PSE board receives two control signal from the C204 MAIN board and outputs two status signals to the MAIN board. Refer to Table 2-3 for the each signal and the printer status relationship. Fatal error recovery : When the printer detects the fatal error, the PSB/PSE board cannot recover for APPROX.
OPERATING PRINCIPLES 2.3 CONTROL CIRCUIT Figure 2-15 shows a block diagram of the control circuit with the C204 MAIN board at the center. 2.3.1 Control Circuit Operation Overview The core of the control circuit is the TMP95C061AF CPU (IC2). This CPU is driven using a 24.57 MHz external clock (CRU1). The CPU executes programs stored in the PROM (IC5). The CPU starts executing a program upon receiving the reset signal from an external device (IC13) via the gate array E05B36 (IC1).
DFX-8500 MAIN Board Mechanism CPU TMP95C061 (IC2) EEPROM (IC11) HTMP Printhead Temperature PWIDTH Paper Width Head Fan Temperature HFTMP Serial I/F 24.
OPERATING PRINCIPLES Table 2-5 describes the functions of the main components on the C204 MAIN and C204 DRV board. Board C204 MAIN IC Name TMP95C061 (CPU) E05B36 (Gate Array) PROM RAM C204 DRV Rev. B EEPROM ADM232 PST591D STK681-050 STK67138MK4 uPC393C Table 2-5. Main IC Functions Location Functions IC2 Receives data from the host computer via the gate array, loads the data to the input buffer in the RAM, and converts the image data to print data.
DFX-8500 Figure 2-16 shows the data flow for data input via the parallel interface. Although various circuits perform data processing, the control core is the CPU and all operations are executed via the CPU. In this circuit, the E05B36 IC (IC1) provides the interface between the external host computer and the CPU, and all data processing is performed by read/write operations to MMIO (Memory Mapped Input / Output). Data from the host computer is latched by repeating steps 1 through 3 below. 1.
OPERATING PRINCIPLES 2.3.2 Reset Circuit This section describes the hardware reset circuit. When the hardware reset signal is input, all ICs in the control circuit are reset, and the CPU executes the program from the starting address. Figure 2-17 shows the reset circuit block diagram. The circuit is equipped with a reset IC: PTS591(IC13) is used for resetting the + 5 VDC line. The reset operation is described below.
DFX-8500 2.3.3 Sensor Circuits Figure 2-18 shows the sensor circuits in block diagram form. The printer is equipped with the following sensors: 1. Front and rear PE sensors (use a photo interrupter) 2. Top PE sensor (to detect the TOF position, uses a photo interrupter) 3. Paper jam sensor (uses a magnetic transistor) 4. Tractor select sensor (uses a micro mechanical switch) 5. Pull tractor sensor (uses a micro mechanical switch) 6. CR encoder sensor (uses a photo interrupter) 7.
OPERATING PRINCIPLES Each sensor is described below. 1. Front and rear paper end sensors Detection form: Photo interrupter Output form: Open collector (pulled up to 10 K ohms resistor) Logical: Paper present: LOW Paper out: HIGH 2. Top paper end sensor (to detect the TOF position) Detection form: Photo reflector Output form: Open collector Logical: Paper present: LOW Paper out: HIGH 3.
DFX-8500 13. Paper width sensor Detection form: Photo reflector Output form : Emitter follower Judgemwnt : No paper present: Standard voltage level. Paper present: The voltage level is double the standard voltage level. 14. CR motor isolation resistance sensor (monitored by port AN2 of the CPU) To provide information about the CR motor life, the analog port (AN2) of the CPU checks the isolation resistance every time the printer is turned on. If the isolation resistance is equal or less than 2.
OPERATING PRINCIPLES 2.3.4 CR Motor Drive Circuit Figure 2-19 shows the internal circuit for the CR motor,Table 2-6 provides the CR motor specification, and Figure 2-20 shows a block diagram for the CR motor drive circuit. An STK681-050 (IC1) bipolar driver IC drives the CR motor. It has built-in bipolar switching transistors and a current limiter. A comparator IC uPC393C (IC3) monitors the current in the CR motor driver IC (IC1).
DFX-8500 Table 2-7 lists the CR motor drive modes. Table 2-7. CR Motor Drive Modes Drive Mode CR Motor Speed Acceleration / Constant (rpm) Deceleration Control Speed Curve Control Note1) Carriage moves Super Draft 2800 Acceleration and PI control with printing.
OPERATING PRINCIPLES PI Control : PI control keeps the CR motor speed constant using the encoder pulses ENCA and ENCB with the gate array E05B36. The E05B36 generates the PWM (pulse width modulation) signal according to the CR motor speed to the PWM port of the gate array and determines the duty of the carriage drive timing.CR ports I0, I1, and I2 output the drive signal for the CR motor.
DFX-8500 Deceleration control: Deceleration control provides smooth deceleration and prevents rapid vibration. The duty data for deceleration control is determined for each printing mode. Pulse width modulation (PWM) determines each printing mode. Current speed - SP3 1. The printer uses Deceleration driving mode 2, based on the duty data, and the rest of the time, it uses Deceleration driving mode 1. 2.
OPERATING PRINCIPLES 2.3.5 PF Motor Drive Circuit Stepping motor driver STK6713BMK4 (IC2) drives the PF motor. Figure 2-22 shows the PF motor drive circuit block diagram, and Table 2-9 provides the PF motor specifications. Table 2-9. PF Motor Specifications Description 4-phase, 200-pole, HB* pulse motor 37 VDC (applied to the drive circuit) o 2.8 ohms + 10 % per phase at 25 C 4274 pps** (normal mode,, constant driving): 9.9 ips*** 2610 pps (middle speed mode,, constant driving): 6 ips Driving: 1.75 A, + 0.
DFX-8500 2.3.6 RF Motor Drive Circuit Figure 2-24 shows a block diagram of the RF motor drive circuit, and Table 2-10 provides the RF motor specifications. The RF motor is a stepping motor. The control circuit performs open-loop phase switching control according to the timing data for acceleration, constant speed, and deceleration. CPU ports PG10 to PG13 output the motor phase switching signals. The control method is not equipped with a hold circuit for changing the motor phase.
OPERATING PRINCIPLES 2.3.7 PG Motor Drive Circuit Figure 2-25 shows a block diagram of the PG motor drive circuit, and Table 2-11 provides PG motor specifications. The PG motor is a stepping motor. The motor phase switching signals are output from the E05B36 ports PGA to PGD. The motor common voltage (PGCOM) alternates between drive mode (+37 VDC) and hold mode (+5 VDC) using the PG H/R signal of E05B36. The phase driver circuit is made by discrete transistors Q12 to Q15.
DFX-8500 2.3.8 Plunger Drive Circuit Figure 2-26 shows a block diagram of the plunger drive circuit, Table 2-12 provides the plunger specification, and Table 2-13 provides the plunger switching pattern. The plunger is driven using three switching patterns. Gate array E05B26 ports PLP and PLN output the plunger coil drive signals. When the PNP port of the gate array turns on switching transistors Q30 and Q31 are turned on and the supply voltage (VP3) flows into the plunger coil.
OPERATING PRINCIPLES 2.3.9 Printhead Drive Circuit Figure 2-27 shows a printhead drive circuit block diagram. General : The print data lines from IC1 are active when they are HIGH. When ports HDR1 (HDL1) to HDR9 (HDL9) of IC1 go HIGH, the FET gates are biased, and the FETs are turned on to apply the current to the printhead coil.
DFX-8500 Printhead high temperature feedback operation : The printer supports the printhead temperature detection sequence, which consists of the following steps: o 1. When the printhead temperature is less than 110 C, the printer performs normal printing. o 2. When the printhead temperature exceeds equal or more than 110 C, the printer performs interval printing (Carriage rest time at the sides is little bit longer than the normal.) o 3.
CHAPTER 3 DISASSEMBLY AND ASSEMBLY 3.1 OVERVIEW ............................................................................................................3-1 3.1.1 Precautions for Disassembly and Assembly ....................................................................... 3-1 3.1.2 Tools ........................................................................................................................................ 3-3 3.1.3 Specification for Screws..............................................
DISASSEMBLY AND ASSEMBLY 3.1 OVERVIEW This chapter describes the disassembly/assembly procedures to be used for replacing the main assemblies of the DFX-8500. 3.1.1 Precautions for Disassembly and Assembly Read this section before you disassemble, assemble, or transport the printer. WARNING ; Because the DFX-8500 weighs 29.0 kg (63.8 lb) and is much larger and heavier than most printers, you must be careful when handling it.
DFX-8500 Before transporting the printer, remove the paper and ribbon cartridge. Then attach the following packing materials, as shown in Figure 3-1: Transport locking bracket Carriage guide shaft support bar Printhead protector Foam packing for paper bail Figure 3-1. Packing Material Attaching After attaching the packing materials, pack the printer in its container as shown in Figure 3-2. Figure 3-2. DFX-8500 Packing 3-2 Rev.
DISASSEMBLY AND ASSEMBLY 3.1.2 Tools This section describes the tools required for assembling, disassembling, or adjusting the printer. Note : Refer to CHAPTER 4 for adjustment tools, CHAPTER 5 for troubleshooting tools, and CHAPTER 6 for tools for maintenance, lubrication, and adhesives. Table 3-1. Recommended Tools Tool (+) Driver No.2 (20 mm or more shaft length with magnetization is recommended.) (+) Driver No.1 Box screw driver (7 mm / 0.28 inches across) E-ring holder No. 3 E-ring holder No.
DFX-8500 P E A C O C K P E A C O C K Figure 3-3. Dial Gauges Figure 3-4. Dial Gauge Base Figure 3-5. Thickness Gauge Figure 3-6. Dial Gauge Master 3-4 Rev.
DISASSEMBLY AND ASSEMBLY 3.1.3 Specification for Screws In the following sections, abbreviations are used for small parts such as screws and washers. Table 3-2 lists these abbreviations. Table 3-3 lists screw and washer types. Table 3-2.
DFX-8500 3.1.4 Service Checks After Repair Before returning the printer after service, use the check list in Table 3-4, which provides a record to make servicing and shipping more efficient. Table 3-4. Inspection Check List for the Repaired Printer Category Item to check Maintenance Are all necessary adjustments completed? Are the results of the adjustments within the specified tolerances? (Refer to CHAPTER 4.
DISASSEMBLY AND ASSEMBLY 3.2 DISASSEMBLY AND ASSEMBLY WARNING ; Before you disassemble or assemble the printer, be sure to read and follow the instructions in Section 3.1, "OVERVIEW." ; Before you disassemble the printer, be sure to turn the printer power off and disconnect AC cable. This section describes how to disassemble the printer. See the APPENDIX for an exploded diagram of the printer. Use this diagram for simple disassembly procedures not described here.
DFX-8500 3.2.1 ROM Replacement CAUTION ; It is best to remove the top cover before you tilt back the printer as described in the steps below. Refer to Section 3.2.3.1 for instructions on removing the top cover. ; If you tilt back the printer with the top cover attached, be careful not to put too much weight on the top cover or any other printer components. ; Spread a thick, soft cloth under the printer before you follow the steps below. ; Remove the ROM carefully to avoid damaging the board.
DISASSEMBLY AND ASSEMBLY 3.2.2 Printhead and Ribbon Mask Assembly Removal The printhead can be changed without disassembling the entire unit. Use the exclusive printhead kit for printhead exchange on the DFX-8500. When you receive the kit, check that all of the following are included. P r in th e a d U n it O il ( O - 2 ) H e a d C a b le P r o te c tio n S h e e t R ib b o n M a s k A s s e m b ly Figure 3-8.
DFX-8500 CAUTION ; When you remove the connector cover, be careful not to break the tabs. ; When you remove the printhead cable holder, be careful not to break the printhead holder latch. Use a slotted screwdriver if necessary. Step 1: Open the top cover and remove the ribbon cartridge. Step 2: Remove the two CBS (M3x8) screws securing the FPC cover to the bottom plate of the printer mechanism. Step 3: Disconnect the three printhead cables and a ground cable from the FPC board on the bottom plate. Note 1.
DISASSEMBLY AND ASSEMBLY Step 5: Disconnect the narrow FPC cable from white connector (lock-type). th Step 6: Move the carriage to around 90 column, remove the two CP(S-P1)(M4X7) screws securing the printhead and remove the CP(S-P1)(M3X6) screw securing the ground FPC, then remove the printhead. C P (S -P 1 )(M 4 X 7 ) N a r r o w F P C C a b le C P (S -P 1 )(M 3 X 6 ) P r in th e a d C a r r ia g e Figure 3-12.
DFX-8500 ASSEMBLING POINT z Confirm that the cables are connected correctly. (Refer to Figures 3-12 and 5-3..) z Tighten the screws while pulling the printhead as shown below to secure the printhead firmly. Figure 3-14. Printhead Installation Step 12: Install the cable cover and the FPC cover. Step 13: Wipe off any stains from the carriage guide shaft, lubricate both ends of the carriage guide shaft with the included oil (0-2), and spread the oil over the shaft by moving the carriage manually.
DISASSEMBLY AND ASSEMBLY 3.2.3 Housing Removal This section describes how to remove the housing. 3.2.3.1 Top Cover Removal CAUTION ; Two people are required to remove the top cover; one person must hold the top cover while the other person removes the screws. If the top cover is not supported while the screws are removed, the weight of the top cover may damage the rear hinges. Step 1: Open the top cover.
DFX-8500 3.2.3.2 Left, Right, and Front Covers Removal and Fuse Replacement Step 1: Remove the four CBB (M4x16) screws securing the left side cover and remove the cover. Step 2: Remove the right side cover in the same way as you removed the left side cover. Also remove the four cables from the main switch on the right side cover. C B B (M 4 X 1 6 ) C B B (M 4 X 1 6 ) C B B (M 4 X 1 6 ) C B B (M 4 X 1 6 ) R ig h t a n d L e ft C o v e r s Figure 3-17.
DISASSEMBLY AND ASSEMBLY Step 3: After you remove the right side cover, you can replace the input fuse for the C204 power supply board unit. WARNING ; Make sure the new fuse meets the printer's AC power specifications. C a r r ia g e M o to r G r o u n d in g H a r n e s s F u s e C N 1 C 2 0 4 P S B /P S E B o a rd (R ig h t S id e ) Figure 3-19. Fuse Removal Step 4: Remove the three CBB (M4x16) screws securing the left side of the front cover to the lower cover.
DFX-8500 3.2.3.3 Front Panel Unit Removal Step 1: Remove the left and right side covers. (Refer to Section 3.2.3.2) Step 2: Open the top cover and disconnect connector CN5 (the panel unit connector). Step 3: Remove the two CBB (M4x16) screws from the front panel unit and remove the panel unit along with the panel connector cable. C B B (M 4 X 1 6 ) F r o n t P a n e l U n it Figure 3-21. Front Panel Removal 3-16 Rev.
DISASSEMBLY AND ASSEMBLY 3.2.3.4 Upper Case Removal Step 1: Remove the front panel unit. (Refer to Section 3.2.3.3) Step 2: Remove the six CBB (M4x16) screws, and two CBB (M3x10) screws from the upper case. Then remove the upper case. C B B (M 4 X 1 6 ) U p p e r C a s e C B B (M 3 X 1 0 ) Figure 3-22. Upper Case Removal Rev.
DFX-8500 3.2.4 Circuit Boards Removal This section describes how to remove the circuit boards. 3.2.4.1 Bottom Panel Assembly Removal CAUTION ; It is best to remove the top cover before you tilt back the printer as described in the steps below. Refer to Section 3.2.3.1 for instructions on removing the top cover. ; If you tilt back the printer with the top cover attached, be careful not to put too much weight on the top cover or any other printer components.
DISASSEMBLY AND ASSEMBLY Step 3: From the left side, remove the two CPB(O)(M4X8) screws securing the green and yellow earth cables between the bottom plate of the printer mechanism and the earth on the bottom panel assembly. Step 4: Disconnect the 6 connectors, (1) through (6) as shown in Figure 3-24.
DFX-8500 Step 7: While supporting the top cover to protect it from scratches, tilt back the printer and lay it on its back. Step 8: Remove the eight CBB (M4x16) screws securing the bottom panel assembly, and slowly remove the bottom panel unit assembly. C B B (M 4 X 1 6 ) Figure 3-26. Bottom Panel Assembly Removal 3-20 Rev.
DISASSEMBLY AND ASSEMBLY 3.2.4.2 Cooling Fan and C204 Power Supply Board Unit Removal Step 1: Remove the bottom panel assembly. (Refer to Section 3.2.4.1) Step 2: If you need to remove the cooling fan, disconnect connector CN5 and remove the four CCN (M3x30) screws securing it, and remove the fan. Step 3: Disconnect connectors CN2, CN3, and CN4. Step 4: Remove the six CBB (M3x12) screws and CPN (O) (M3x8) screw securing the C204 power supply board unit and remove the board.
DFX-8500 3.2.4.3 C204 SUB Board Unit Removal Step 1: Remove the bottom panel assembly. (Refer to Section 3.2.4.1) Step 2: Disconnect connectors CN15 and CN16 on the C204 MAIN board. Step 3: Remove the CBB (M3x8) screw and the CBB (M3x12) screw securing the C204 SUB board assembly and remove the board. C B B (M 3 X 8 ) C B B (M 3 X 1 2 ) C 2 0 4 S U B B o a r d U n it C N 1 6 C N 1 5 C N 1 5 C N 1 6 C 2 0 4 M A IN B o a rd Figure 3-28. C204 SUB Board Unit Removal 3-22 Rev.
DISASSEMBLY AND ASSEMBLY 3.2.4.4 C204 DRV-B and C204 DRV Board Units Removal Step 1: Remove the bottom panel assembly. (Refer to Section 3.2.4.1) Step 2: Disconnect connector CN3 and cable connector CN14 for the C204 DRV board. Step 3: Disconnect connectors CN1 and CN2 on the C204 DRV-B board. C 2 0 4 D R V B o a rd C 2 0 4 D R V -B B o a rd C N 3 C N 1 4 C N 1 C N 2 C 2 0 4 M A IN b o a rd C a b le ( fr o m C 2 0 4 M A IN b o a r d ) Figure 3-29.
DFX-8500 3.2.4.5 C204 MAIN Board Unit Removal Step 1: Remove the bottom panel assembly. (Refer to Section 3.2.4.1) Step 2: Remove the C204 SUB board unit (Refer to Section 3.2.4.3.) Step 3: Remove the C204 DRV-B board and C204 DRV board units (Refer to Section 3.2.4.4.) Step 4: Disconnect connectors CN6, CN7, CN8, and CN10. H a rn e s s to C N 7 ( 6 - p in ) to C N 6 ( 7 - p in ) C N 2 C N 3 C 2 0 4 M A IN B o a rd Figure 3-31.
DISASSEMBLY AND ASSEMBLY Step 5: Remove the four CBB (M3x12) screws and two CBS (O) (M3x8) screws securing the C204 MAIN board unit and remove the board. : C B S (O )(M 3 X 8 ) X 2 : C B B (M 3 X 1 2 ) X 4 C 2 0 4 M A IN B o a r d U n it H o o k s fo r C 2 0 4 M A IN B o a r d In s ta lla tio n Figure 3-34.
DFX-8500 3.2.4.6 AC Inlet Removal Step 1: Remove the C204 power supply board assembly. (Refer to Section 3.2.4.2) Step 2: Remove the C204 MAIN board assembly. (Refer to Section 3.2.4.5) Step 3: Remove the three CBB (M3x8) screws and one CB (O) (M4x6) screw securing the grounding plate to the bottom panel assembly and remove the grounding plate. C B B (M 3 X 8 ) B o tto m P a n e l A s s e m b ly G r o u n d in g P la te C B (O ) (M 4 X 6 ) A C In le t S e t Figure 3-35.
DISASSEMBLY AND ASSEMBLY 3.2.4.7 C204 PNL Board Removal Step 1: Remove the front panel unit. (Refer to Section 3.2.3.3) Step 2: Disconnect connectors CN1 and CN2 on the C204 PNL board. Step 3: Remove the CBB (M4x10) screw securing the C204 PNL board to the front panel unit and remove the board. C B B (M 4 X 1 0 ) F ro n t P a n e l C 2 0 4 P N L B o a rd C N 2 C N 1 Figure 3-37. C204 PNL Board Removal Rev.
DFX-8500 3.2.5 Interlock Switch and Cover Open Sensor Assembly Removal Step 1: Remove the upper case. (Refer to Section 3.2.3.4) Step 2: Disconnect the interlock switch cable and the cover open sensor cable from the junction board respectively. C o v e r O p e n S e n s o r C o v e r O p e n S e n s o r C o n n e c to r R e d : 3 - p in In te r lo c k S W . W h ite : 2 - p in C o n n e c to r J u n c tio n B o a r d C N 3 C 2 0 4 M A IN B o a rd Figure 3-38.
DISASSEMBLY AND ASSEMBLY 3.2.6 Printer Mechanism Removal This section describes how to remove and disassemble the printer mechanism. Before following the steps in this section, remove the printer mechanism from the printer as described in Section 3.2.6. WARNING Because the printer mechanism is large and heavy, you must be careful when you remove it. When you lift or lower the printer mechanism, follow these precautions: ; Two people are required to remove or install the printer mechanism.
DFX-8500 Step 5: Remove the four screws securing the printer mechanism to the lower case. S c re w s S c re w s Figure 3-43. Printer Mechanism Removal 1/2 Step 6: Install the lift handles from the inside of the printer mechanism. Insert each handle through the two holes in the side frames of the printer mechanism. Then slowly lift up the printer mechanism using the handles and remove it from the lower case.
DISASSEMBLY AND ASSEMBLY 3.2.6.1 Fan Removal Step 1: Step 2: Step 3: Step 4: Remove the upper case unit. (Refer to Section 3.2.3.4.) Remove the right cover. (Refer to Section 3.2.3.2.) Disconnect the connector for the fan from the relay connector. Remove the CP(O) screw securing the fan duct to the left frame and the CC screw securing the fan and the fan duct to the shaft on the left frame. Then remove the fan along with the fan duct. C P (O ) (4 x 5 ) L e ft F ra m e C C (3 x 3 0 ) Figure 3-45.
DFX-8500 3.2.6.2 Ribbon Feed Change Lever Unit Removal Step 1: Release the three hooks securing the ribbon feed gear cover to the ribbon feed motor frame and remove the cover and the ribbon feed gear. Step 2: Disconnect the three connectors for the ribbon feed motor, tractor select sensor, and the ribbon jam sensor from the connector junction board, as shown in Figure 3-47 and Figure 3-48. Step 3: Remove the head damper from the left side frame. Step 4: Remove the fan on the left frame.
DISASSEMBLY AND ASSEMBLY T o R F M o to r T o T r a c to r S e le c t S e n s o r T o R ib b o n J a m S e n s o r C o n n e c to r J u n c tio n B o a r d Figure 3-48. Removing Connectors ASSEMBLING POINT When you install the ribbon feed change lever unit, join the tip of the tractor select lever and the tractor select gear holder correctly. (Refer to Figure 2-12.) Rev.
DFX-8500 3.2.6.3 Tractor Select Lever (Upper and Lower) Assembly Disassembly This section describes how to disassemble the tractor select lever assembly, including how to remove the ribbon feed motor and tractor select sensor. Step 1: Remove the ribbon feed change lever unit. (Refer to Section 3.2.6.2.) Step 2: Remove the two CP(S-P1)(M3x6) screws, leaf springs, and washers securing the ribbon feed motor to the ribbon feed motor frame and remove the motor.
DISASSEMBLY AND ASSEMBLY 3.2.6.4 Ribbon Jam Sensor Removal Step 1: Remove the right cover. (Refer to Section 3.2.3.2) Step 2: Disconnect the connector for the sensor from the connector junction board. Step 3: Remove the CP(S-P1) (M3x6) screw securing the sensor to the bracket, and remove the sensor. C P (S -P 1 ) (M 3 x 6 ) F r o n t/R e a r T r a c to r S e le c t L e v e r A s s e m b ly Figure 3-51. Ribbon Jam Sensor Removal Rev.
DFX-8500 3.2.6.5 Connector Junction Board Assembly and FPC Board Assembly Removal This section describes how to remove the connector junction board assembly and FPC board assembly. Step 1: Remove the left side cover. (Refer to Section 3.2.3.2) Step 2: Disconnect all the cables from the connector junction board assembly. Remove the two CP (SP1) (M3x6) screws securing the connector junction board assembly to the printer mechanism and then remove the connector junction board assembly.
DISASSEMBLY AND ASSEMBLY 3.2.6.6 PG Sensor and PG Motor Removal CAUTION When you remove or install the PG sensor, be careful not to bend the PG motor encoder plate. Step 1: Remove the connector junction board assembly. (Refer to Section 3.2.6.5) Step 2: Remove the CBS screw (3X6) securing the PG sensor unit to the left frame. Then take out the unit to the front and remove it. Step 3: Remove the screw securing the PG sensor to the unit, and remove the sensor.
DFX-8500 3.2.6.7 Plunger and Paper Bail Assembly Removal This section describes how to remove the plunger (loading solenoid) and paper bail assembly. Step 1: Disconnect the black, 2-pin plunger connector from the connector junction board assembly, and remove the plunger cable from the connector junction board assembly. Step 2: Remove the two CP(S-P1) (M3x6) screws securing the plunger to the left side frame and remove the plunger. Step 3: Remove the iron core of the plunger from the paper bail shaft.
DISASSEMBLY AND ASSEMBLY Step 4: Remove the left tension roller lever spring. Step 5: Remove the E-ring (6) securing the paper bail shaft to the left frame and remove the platen roller shaft holder and paper bail lever. E - r in g s S h a ft H o ld e r P a p e r B a il S h a ft P a p e r B a il L e v e r E - r in g T e n s io n R o lle r L e v e r S p r in g Figure 3-55. Paper Bail Assembly Removal 1/2 Step 6: Disconnect 2 fan harnesses and remove 2 screws (CPS-P1) securing the CR fan duct.
DFX-8500 3.2.6.8 Upper Paper Guide and Top PE Sensor Removal Step 1: Remove the paper bail assembly. (Refer to Section 3.2.6.7) Step 2: Disconnect the red, 3-pin, top PE sensor connector from the connector junction board assembly. L e ft S id e F ra m e T o p P E S e n s o r C o n n e c to r C o n n e c to r J u n c tio n B o a rd Figure 3-57. Top PE Sensor Connector Removal Step 3: Remove the two CBS (M4x6) screws securing the upper paper guide to both frames and remove the paper guide.
DISASSEMBLY AND ASSEMBLY 3.2.6.9 Tension Roller Shaft Removal This section describes how to remove the tension roller shaft. It is better to remove the tension roller shaft with the paper bail assembly removed; however, removing it is not required. (Refer to Section 3.2.6.7.) for instructions on how to remove the paper bail assembly.) Step 1: Step 2: Step 3: Step 4: Step 5: Remove the connector junction board assembly. (Refer to Section 3.2.6.5.) Remove the paper bail assembly. (Refer to Section 3.2.6.7.
DFX-8500 Step 7: Remove the CR motor fan. (Refer to Section 3.2.6.19.) Step 8: Remove the E-ring (6) at the right end of the tension roller shaft and remove the tension roller shaft holder along with the leaf spring and the washer. Step 9: Remove the tension roller shaft by taking it out from the right frame. T e n s io n R o lle r S h a ft A s s e m b ly T e n s io n R o lle r S h a ft H o ld e r L e a f S p r in g W a s h e r E - r in g C a r r ia g e M o to r Figure 3-60.
DISASSEMBLY AND ASSEMBLY 3.2.6.10 Platen Removal Step 1: Remove the paper bail assembly. (Refer to Section 3.2.6.7.) Step 2: Remove the upper paper guide. (Refer to Section 3.2.6.8.) Step 3: Remove the four hexagon socket screws securing the platen to the platen holders. Then remove the platen with the lower paper guide composed of 3 parts in it. Step 4: Slide the 3 parts of the lower paper guide to release the notches and remove them one by one from the platen.
DFX-8500 3.2.6.11 Paper Jam Sensor Removal Step 1: Remove the platen along with the lower paper guide composed of 3 parts. (Refer to Section 3.2.6.10.) Step 2: Remove the CPN(SP)(M4x8) screw securing the left part of the lower paper guide to the platen. Step 3: Remove the part from the platen. P la te n R ig h t L e ft L o w e r P a p e r G u id e C P N (S P )(M 4 X 8 ) Figure 3-64. Lower Paper Guide Left Part Removal Step 4: Unhook the paper jam sensor (magnetic transistor) cover to remove it.
DISASSEMBLY AND ASSEMBLY 3.2.6.12 Pull Tractor Sensor Removal Step 1: Remove the upper paper guide. (Refer to Section 3.2.6.8) Step 2: Disconnect the red 2-pin pull tractor sensor connector from the connector junction board assembly. Step 3: Remove the CP(S) (M2x14) screw securing the pull tractor sensor (a micro-switch type sensor) to the left side frame and remove the sensor.
DFX-8500 3.2.6.13 Paper Width (PW) Sensor Removal Step 1: Disconnect the connector for the PW sensor. Step 2: Remove the CP(S-P1) (M2.5x6) screw securing the PW sensor to the ribbon mask holder. P a p e r W id th S e n s o r C P (S -P 1 )(M 2 .5 x 6 ) P a p e r W id th S e n s o r C o n n e c to r Figure 3-67. PW Sensor Removal 3-46 Rev.
DISASSEMBLY AND ASSEMBLY 3.2.6.14 PG Home Sensor Removal Step 1: Remove the front/rear tractor select lever assembly. (Refer to Section 3.2.6.2.) Step 2: Remove the E-ring securing the carriage guide shaft gear to the rear carriage guide shaft. C a r r ia g e G u id e S h a ft (R e a r) C a r r ia g e G u id e S h a ft G e a r E - r in g Figure 3-68. Carriage Guide Shaft Gear Removal Step 3: Disconnect the white, 2-pin, PG home sensor connector from the connector junction board assembly.
DFX-8500 ASSEMBLING POINT When you install the CR guide shaft gear, align the rib in the CR guide shaft gear with the PG adjustment transmission gear as shown in the figure below, then rotate the CR guide shaft gear 10 mm in CCW. F la t P a r t o f C R G u id e S h a ft ( R e a r ) F ra m e L e ft A d v a n c e 1 0 m m S to p p e r C R G u id e S h a ft G e a r P G T r a n s m is s io n G e a r Figure 3-70. CR Guide Shaft Gear Phase Alignment 3-48 Rev.
DISASSEMBLY AND ASSEMBLY 3.2.6.15 PF Motor Removal Step 1: Remove the connector junction board assembly. (Refer to Section 3.2.6.5.) Step 2: Remove the three CP (SP-1) (M4x8) screws securing the PF motor to the left side frame. Step 3: Remove the PF motor from the inside of the left side frame. C P (S -P 1 )(M 4 X 8 ) P a p e r F e e d M o to r Figure 3-71. PG Home Sensor Removal Rev.
DFX-8500 3.2.6.16 Left Side Frame Gear Removal Step 1: Step 2: Step 3: Step 4: Remove the front/rear tractor select lever assembly. (Refer to Section 3.2.6.2.) Remove the connector junction board assembly. (Refer to Section 3.2.6.5.) Remove the PG motor. (Refer to Section 3.2.6.6.) Remove the series of gears in the order indicated by the numbers in Figure 3-72. Figure 3-72. Left Side Frame Gear Removal 3-50 Rev.
DISASSEMBLY AND ASSEMBLY 3.2.6.17 Front Tractor Assembly Removal This section describes how to remove the front tractor assembly. Step 1: Step 2: Step 3: Step 4: Step 5: Disconnect the connector white 3-pin front PE sensor from the connector junction board. Remove the connector junction board assembly. (Refer to Section 3.2.6.5.) Lay the mechanism on its back. Remove the screw securing the tractor wire holder to the left side frame and remove the holder.
DFX-8500 3.2.6.18 Rear Tractor Assembly Removal This section describes how to remove the rear tractor assembly. Step 1: Disconnect the connector white 3-pin rear PE sensor from the connector junction board. Step 2: Remove the connector junction board assembly. (Refer to Section 3.2.6.5.) Step 3: Remove the flange nut securing the wire holder spring set to the right side frame, and remove the set. Step 4: Loosen the flange nut securing the rear tractor assembly to the left side frame.
DISASSEMBLY AND ASSEMBLY 3.2.6.19 CR Motor Fan Removal Step 1: Disconnect the cable for the motor from the relay connector. Step 2: Remove 2 fan fixing screws and remove the fan. F a n F ix in g S c r e w s C R M o to r F a n R ig h t F r a m e Figure 3-76. CR Motor Fan Removal Rev.
DFX-8500 3.2.6.20 CR Motor Removal Step 1: Remove the right cover. (Refer to Section 3.2.3.2.) Step 2: Disconnect the red and black cables from the terminals on the CR motor. (two cables for each terminal) Step 3: Remove the three CP(S) (M4x10) screws securing the CR motor to the right side frame and remove the motor. C P (S )(M 4 X 1 0 ) C R M o to r Figure 3-77.
DISASSEMBLY AND ASSEMBLY 3.2.6.21 CR (Carriage Encoder) Sensor Removal Step 1: Remove the printhead. (Refer to Section 3.2.2.) Step 2: Disconnect the red 4-pin CR sensor connector from the carriage connector junction board. Step 3: Remove the two CP(S-P1) (M2.6 x 5) screws securing the CR sensor to the carriage and remove the sensor. C a r r ia g e E n c o d e r S e n s o r C a r r ia g e 4 - p in C o n n e c to r C a r r ia g e C o n n e c to r J u n c tio n B o a r d Figure 3-78.
DFX-8500 3.2.6.22 Carriage Mechanism Disassembly This section describes how to disassemble the carriage mechanism, including removing the carriage, CR timing belt, and front and rear carriage guide shafts. Step 1: Remove the CR motor. (Refer to Section 3.2.6.20.) Step 2: Remove the belt pulley from the belt pulley holder. S id e F r a m e ( L ) B e lt P u lle y B e lt P u lle y H o ld e r Figure 3-80. Belt Pulley Removal Step 3: Unhook the spring securing the encoder belt to the right side frame.
DISASSEMBLY AND ASSEMBLY Step 5: Step 6: Step 7: Remove the front carriage guide shaft by pulling it through the hole in the right side frame. (When you remove the front carriage guide shaft, move the carriage to the left side.) On the left side frame, remove the E-ring (6) securing the carriage guide shaft gear to the rear carriage guide shaft, then remove the carriage guide shaft gear and paper thickness sensor holder.
DFX-8500 ASSEMBLING POINT When you install the front carriage guide shaft, tighten the screws while pushing the shaft toward the platen. ADJUSTMENT REQUIRED When you assemble the carriage mechanism, perform the following adjustments: • Carriage timing belt tension adjustment (described in Section 4.1.2) • Carriage guide shaft parallelism adjustment (described in Section 4.1.5 and Section 4.1.6) • Platen gap motor value (platen gap) adjustment (described in Section 4.1.
DISASSEMBLY AND ASSEMBLY 3.2.6.23 Paper Support Assembly Removal Step 1: Disassemble the carriage mechanism and remove all the parts related to the carriage. (Refer to Section 3.2.6.22.) Step 2: Referring to the exploded diagram in the Appendix, remove the paper support assembly. ADJUSTMENT REQUIRED When you install the paper support assembly, perform the following adjustments: • Carriage timing belt tension adjustment (described in Section 4.1.
DFX-8500 3.2.6.24 3.2.6.21 PF Drive Roller Removal Step 1: Step 2: Step 3: Step 4: Remove the platen. (Refer to 3.2.6.10) Remove the CR motor. (Refer to Section 3.2.6.20) Remove the left side frame gears. (Refer to Section 3.2.6.16) Referring to the exploded diagram in the Appendix, remove the PF driver roller. ADJUSTMENT REQUIRED When you install the PF drive roller, perform the following adjustments: • Carriage timing belt tension adjustment (described in Section 4.1.
CHAPTER 4 ADJUSTMENT 4.1 PRINTER MECHANISM ADJUSTMENTS ............................................................4-1 4.1.1 PG Motor Backlash Adjustment........................................................................................... 4-1 4.1.2 Carriage Timing Belt Tension Adjustment .......................................................................... 4-2 4.1.3 Tractor Wire Spring Tension Adjustment ........................................................................... 4-3 4.1.
ADJUSTMENT 4.1 PRINTER MECHANISM ADJUSTMENTS This section describes the printer mechanism adjustments for the DFX-8500. Whenever the printer is disassembled and the printer parts mentioned in this section are replaced or repaired, perform the appropriate adjustments to ensure proper printer operation. Perform adjustments before assembling the printer. 4.1.1 PG Motor Backlash Adjustment In the PG motor backlash adjustment, the PG motor pinion gear must mesh smoothly with the PG transmission gear cog.
DFX-8500 4.1.2 Carriage Timing Belt Tension Adjustment The carriage timing belt tension must be adjusted when any carriage mechanism part (such as the CR motor, belt pulley, or carriage timing belt) is disassembled. Remove the printer mechanism before performing this adjustment. (Refer to Section 3.2.6) CAUTION ; Before performing this adjustment, carefully secure the printer mechanism because a 7 kg (15.4 lb.) force is applied to it when the tension lever is pulled in the horizontal direction.
ADJUSTMENT 4.1.3 Tractor Wire Spring Tension Adjustment This section describes the tractor wire spring tension adjustment. If the spring is not adjusted properly, paper jams may occur, because the continuous paper tension (in the horizontal direction) is incorrect. When you remove the front or rear tractor assembly, perform this adjustment. Step 1: Step 2: Step 3: Step 4: Remove the printer mechanism. (Refer to Section 3.2.6) Release the release levers for the tractor sprockets on the front.
DFX-8500 4.1.4 Pull Tractor Sensor Position Adjustment This section describes the pull tractor sensor position adjustment. If the sensor position is incorrect, the sensor is always on. When you replace or disassemble the platen, rear paper guide, platen roller shaft, tension roller shaft, or pull tractor sensor, perform this adjustment. Figure 4-4 illustrates the pull tractor sensor position adjustment.
ADJUSTMENT 4.1.5 Carriage Guide Shaft Parallelism Adjustment The rear carriage guide shaft must be parallel to the platen. If it is not, printing may be abnormal because paper is not fed evenly at the left and right sides of the platen. A paper jam may occur. This adjustment is required when the rear carriage guide shaft is removed during carriage mechanism disassembly, the parallelism adjust lever is moved, or the platen is removed.
DFX-8500 Step 3: Attach the another needle to the master surface, APPROX. 2.00 mm depth, then correspond to the another gauge measure, and tighten the hexagonal screw. 3. Tighten the hexagonal screw. 2. Attach the gauge needle to the master surface, then correspond to the another gauge measure. Figure 4-7. Dial Gauge set Up 2 Step 5: Set the black marker to the "0" position. Figure 4-8. Black Marker to “0” Position Setting 4-6 Rev.
ADJUSTMENT Step 6: Remove a CP(PS)(M3X6) screw securing the timing belt holder to the timing belt, then remove the timing belt holder. C a r r ia g e G u id e S h a ft ( R e a r ) C P (P S )M 3 X 6 ) T im in g B e lt H o ld e r C a r r ia g e Figure 4-9. Carriage Plate Removal Step 7: Remove the paper bail assembly. (Refer to Section 3.2.6.5.) Step 8: Remove the tension roller shaft. (Refer to Section 3.2.6.7.) Step 9: Remove the printhead with the mask-less holder. (Refer to Section 3.2.1.
DFX-8500 Step 12: Measure the distance between the platen and the carriage guide shaft on the left side. Then measure the distance between the platen and the rear carriage guide shaft on the right side, and compare these values.(Figure4-11 shows the measurement position and the parallelism adjust lever operation.) Note: When you shift the carriage manually, do not touch the both dial gauges. Rotate the carriage motor pulley.
ADJUSTMENT 4.1.6 Platen Angle Adjustment This section describes the platen angle adjustment. The platen must be at a right angle to the carriage assembly. This adjustment is required when the platen is removed or replaced or when the two hexagonal screws securing the platen to both side frames are loosened. Do not remove the printer mechanism from the lower case.
DFX-8500 Step 4: Using the carriage guide shaft gear, attach the both dial gauge needles to the platen surface.(The needle doesn’t reach the end of the stroke). S id e F r a m e ( L ) A tta c h b o th n e e d le s . P la te n R e fe r to F ig u r e 4 - 1 0 a . C a r r ia g e G u id e S h a ft C a r r ia g e g u id e S h a ft G e a r Figure 4-14. Attaching Two Needles to Platen Surface Step 5: Measure the angle difference about three position such as figure below.
ADJUSTMENT U p B it A P la te n B it B D o w n ( A n g le A d ju s tm e n t M e th o d ) Figure 4-16. Measuring Angle Difference 2 Step 6: If the angle difference of two values are more than + 0.015 mm, loosen (but do not remove) the two hexagonal screws securing the platen stay to both side frames, then change the platen angle slowlly and manually.) Step 7: Tighten two hexagonal screws securing the platen stay to both side frames.
DFX-8500 4.1.7 Platen Gap Motor Value Adjustment This section describes how to measure the parameter (ALPHA and BETA values) for the PG mechanism unit. Since the ALPHA and BETA values are unique to each mechanism unit, it is written on the label as shown in Figures 4-17 and 4-18, so that it can be confirmed at glance. Be sure to perform this measurement and correct the value written on the label because the value is necessary when the other units (board, printhead) are changed.
Step 1: Step 2: ADJUSTMENT Remove the paper, ribbon cartridge, and ribbon mask holder from the printer. Then confirm the ALPHA value written on the print head nose. Close the top cover. ALPHA Value Write Mode : Step 3: Turn the printer on while pressing the Tear Off, Micro Feed (v), and Front/Rear switches. At this time the printer performs PG home position seek. and the carriage moves to the 15 column. Step 4: The panel indicates the current ALPHA adjustment value (Refer to Table 4-1.).
DFX-8500 P la te n T e n s io n G a u g e 1 3 5 - 1 6 5 g f T h ic k n e s s G a u g e (B E T A 3 ' = 0 .4 3 m m ) Figure 4-19. Thickness Gauge Setting Method Table 4-1. BETA Values Adjustment Beta No. Reference Thickness Gauge Allowed Value Default Value*1) BETA 3' 0.43 mm with 150gf pull BETA 2 0.00 mm 367 - 419 408 BETA 3 0.43 mm 405 - 437 435 BETA 4 0.80 mm 418 - 475 461 *1: When EEPROM is reset. 4-14 Rev.
ADJUSTMENT 4.1.8 Measurement Seeking and Bi-directional Printing Adjustment The purpose of this adjustment is to correct the printer mechanism parameters which control bi-directional printing. Be sure to perform this adjustment when required. If this adjustment is not performed correctly, bidirectional printing may be miss-aligned, or, in the worst case, the carriage might operate incorrectly. Before performing this adjustment, be sure to that the following adjustment are completed correctly. 4.1.
DFX-8500 S T A R T M o u n t th e r ib b o n c a r tr id g e . T u r n th e p o w e r S W o n w h ile p r e s s in g M ic r o F e e d ^ a n d M ic r o F e e d v S W s . T h e p r in te r p e r fo r m s c a r r ia g e m e a s u r e m e n t s e e k in g a u to m a tic a lly . ( It g o e s to O N L IN E s ta tu s a fte r th is o p e r a tio n .) T u r n th e p r in te r p o w e r o ff. E N D Figure 4-20. Carriage Measurement Seeking 4-16 Rev.
ADJUSTMENT S T A R T M o u n t th e r ib b o n c a r tr id g e . T u r n th e p o w e r S W o n w h ile p r e s s in g T e a r O ff, M ic r o F e e d ^ , a n d F r o n t/R e a r S W s . S e t th e 1 5 " fa n fo ld p a p e r a t F r o n t o r R e a r tr a c to r a n d lo a d th e p a p e r b y p r e s s in g L F /F F L o a d S W o r F ro n t/R e a r S W . "P G 1 . "P P 2 . P (R 3 .
DFX-8500 F lig h t T im e + X X X 4 0 C O L . 5 6 C O L . 4 0 C O L . Figure 4-22. Test Print Pattern Table 4-2. LED indication and Adjustment Value Comparison LED*1) Ribbon (Bi-d. adjustment) (PG adjustment) Pause Top of Form Tear Off Copy Pitch Font 7 Segment*3) *1) : off, : On nd *2) Indicates 2 column. st *3) Indicates 1 column. 4-18 Off On*2) + (positive) 300 (negative) 400 10 20 30 40 50 60 70 80 90 0 to 9 Rev.
ADJUSTMENT B i-D . A d ju s tm e n t M o d e A d ju s tm e n t S u p e r D r a ft P r in t M o d e : A d ju s tm e n t 1 . P a n e l d ip la y s th e c u r r e n t B i- D . a d ju s tm e n t v a lu e . 2 . P r in te r p r in ts " S p e e d = A A A B id a d ju s t = B B B " . B B B * 1 ) is th e c u r r e n t a d ju s tm e n t v a lu e . D r a ft P r in t M o d e : T h e p r in te r p r in ts th e te s t p r in t p a tte r n w ith th e c u r r e n t a d ju s tm e n t v a lu e .
CHAPTER 5 TROUBLESHOOTING 5.1 PROBLEM ISOLATION..........................................................................................5-1 5.2 SELF DIAGNOSTIC FUNCTION............................................................................5-2 5.3 TROUBLESHOOTING ...........................................................................................
TROUBLESHOOTING 5.1 TROUBLESHOOTING INFORMATION The information in this chapter makes troubleshooting easier to perform by listing various problems that can occur and providing possible solutions. Note: For this printer, no special tools are necessary for troubleshooting to the unit level, with the exception of a digital multi-meter. Some component-level troubleshooting may require an oscilloscope. 5.1.1 Error Messages The DFX-8500 indicates errors using beeps. Table 5-1 lists fatal errors. Table 5-1.
DFX-8500 5.1.2 Bypassing Interlock Switch and Cover Open Sensor To print with the top cover open or removed, you need to bypass the interlock switch and cover open sensor because these sensors automatically disable printing when the top cover is open. C o v e r O p e n S e n s o r R e d : 3 - p in In te r lo c k S W . W h ite : 2 - p in C o n n e c to r J u n c tio n B o a r d C N 3 C 2 0 4 M A IN B o a rd Figure 5-1.
TROUBLESHOOTING 5.1.3 Coil Resistance The following table provides the coil resistance for the motor, head fan, plunger, and printhead. Table 5-2. Motor, Fan, Plunger, and Printhead Coil Resistance Part Coil Resistance CR motor 1.66 ohms + 10 % o PF motor 2.80 ohms + 10 % at 25 C o RF motor 150 ohms + 10 % at 25 C o PG motor 250 ohms + 18 ohms at 25 C o Head fan 61 ohms + 4.3 ohms at 25 C o Plunger 9 ohms + 5 % at 25 C o Printhead 2.93 ohms + 0.
DFX-8500 FPC A FPC B FPC C Load Pattern : Head coil GND side : Head coil P/S side : Head thermistor PWD : Paper width sensor +5V : +5 VDC ENCA: Encoder A GND : GND HT : Head thermistor MA : Fan motor phase A MB : Fan motor phase B MC : Fan motor common MT : Fan motor thermistor P/S : Power supply (+37 VDC) ENCB: Encoder B Figure 5-4. Printhead Coil Resistance 5-4 Rev.
TROUBLESHOOTING 1. The printer does not operate when power is turned on. START Does the printer beep before it dies? No Check Table 5-1, Error Codes. Yes Is the AC input voltage normal? No Yes Has fuse F1 on the C204 power supply board blown? Yes No No Use the correct AC voltage. Replace the fuse F1 and disconnect CN2, CN3, and CN4 on the C204 power supply Board. Is the problem fixed? Reconnect CN2, CN3, and CN4 and turn on the printer.
DFX-8500 2. Carriage operation is abnormal. START Are the connectors listed in NOTE 1 inserted securely? No Reinsert the connectors. Yes No Is the fault corrected? Yes END Manually move the carriage to see if movement is smooth or not. Not smooth Smooth Check the CR motor and CR motor drivers using a multimeter. OK? No If the motor is bad, replace. If drivers are bad, replace at the same time. Yes Is the fault corrected? Refer to Section 5.3, Repair of the Printer Mechanism.
TROUBLESHOOTING 3. Carriage operation is normal, but the self-test is printed incorrectly (1/3). START Perform the self-test. Does the printer perform self-test ? No Yes Is there any dot missing or dragging ? Are the connectors listed in NOTE 1 inserted securely? Yes No Reinsert correctly. Yes No No Check printhead cable continuity. Visually check printhead pins. Replace any bad part. Yes Is the fault corrected? Yes END Is the fault corrected? No Perform the bidirectional printing adjustment.
DFX-8500 3. Carriage operation is normal, but the self-test is printed incorrectly (2/3). A Replace the C204 MAIN and./or C204 DRV-B board. Check the print head coil resistance. Is the printhead resistance correct? No Yes Check the printhead drivers. Check the printhead drivers. Are the drivers OK? No If the printhead drivers are OK, replace the printhead. Are the drivers OK? No If the printhead drivers are OK, replace the printhead. Yes Replace the C204 MAIN and./or C204 DRV-B board.
TROUBLESHOOTING 3. Carriage operation is normal, but the self-test is printed incorrectly (3/3). B Is the print correct? Yes No Perform bidirectional adjustment. Go back to Section 5.3 Repair of the Printer Mechanism, and check for other problems. END Perform bidirectional adjustment. END Rev.
DFX-8500 4. Printing is normal, but paper feeding is abnormal. START No Is the paper loaded correctly? Load the paper correctly. Yes When you move the PF motor manually, does it move smoothly? No Refer to Section 5.3 Repair of the Printer Mechanism. Yes Check the resistance of the PF motor coils and check the PF motor drivers. Is PF motor coil resistance correct? Yes Are the drivers shorted or open? No Is the motor resistance OK and are the drivers OK? No Refer to Section 5.
TROUBLESHOOTING 5. Panel unit operation is abnormal. START Is CN5 between the C204 MAIN and C204 PNL board connected correctly? No Reinsert connector CN5 correctly. Yes No Is the fault corrected? Yes Using a multimeter, check the switches on the C204 PNL board. Do the switches work correctly? END Yes Replace the C204 MAIN board. No Yes Replace the C 204 PNL board. Is the fault corrected? END Do the buttons work? No No Replace the C 204 PNL board. Yes END END Replace the C204 MAIN board.
DFX-8500 6. Data sent by the host computer is printed incorrectly. Note : The flowchart below assumes the host computer is operating normally. START Run the self-test. Is the self-test printed correctly? No Yes Troubleshoot printer using the previous flowcharts. Built-in Parallel Which I/F are you using? Serial or Optional Are the DIP switches set correctly? (See Tables 1-16,1-21, 1-22,and 1-23.) Check the cable connection from the host computer. No Set switches correctly.
TROUBLESHOOTING 5.2 CIRCUIT BOARD REPAIR This section provides detailed troubleshooting methods to isolate components in the power supply or on the main board. This information is for use by service personnel who repair to the component level. The table below provides causes, checkpoints, and solutions for different power supply circuit problems. The checkpoints include waveforms for normal operation. By referring to the checkpoints, determine the defective component. Then perform the proper repair.
DFX-8500 Table 5-5. C204 PSB/PSE Board Component Repair 2/3 Cause Checkpoint Solution The main switching FETs Observe the voltage Replace QF101. QF101 is defective. waveform between the drain side and GND. IC101 is defective. Pin 5 (FB) must be HIGH Replace IC101. then observe the voltage waveform between pin 2 (VOUT) and pin 12 (GND) of IC101. The +37 VDC (VP3) line The main switching FETs Observe the voltage Replace QF201. is dead. QF201 is defective. waveform between the drain side and GND.
TROUBLESHOOTING Symptom The 5 VDC line is defective. 37 VDC line (VP1/VP2) is abnormal. 37 VDC line (VP3) is abnormal. Rev. B Table 5-5. C204 PSB/PSE Board Component Repair 3/3 Cause Checkpoint IC204 is defective. Check the voltage level at pin 10 (V1) and pin5 (GP). Observe the drive waveform at pin 8 (VO) and pin 5 (GP). IC102 is defective. (If When the input voltage of the minus this IC is defective, it port (pin 6 for VP1 and pin2 for VP2) is cannot monitor the 37 less than 1.
DFX-8500 5.2.2 C204 MAIN/DRV/DRV-B Boards Repair Table 5-6 indicates major components which is used for the C204 MAIN/DRV/DRV-B boards and Table 5-7 shows the C204 MAIN/DRV/DRV-B boards component level troubleshooting. Table 5-6. C204 MAIN/DRV/DRV-B boards Component Repair 1/7 Cause Checkpoint Solution The DRERR signal Check the logic level of the DRERR Replace the head was sent to the C204 signal at CN10 or check the VP1 and driver on the C204 power supply board VP2 voltage.
Symptom The printer does not operate at all. Rev. B TROUBLESHOOTING Table 5-6. C204 MAIN/DRV/DRV-B boards Component Repair 2/7 Cause Checkpoint Solution The control ROM is Confirm that the PROM is inserted the Replace IC5. defective. socket correctly. The gate array (IC1) Check pin 86 (D0)of IC1 for a change Replace IC1. is defective. in the signal (HIGH or LOW). The CPU (IC2) is Look at the oscillator at either pin 27 Replace CRU1 or defective (x1) or pin 28 of the CPU.
DFX-8500 Symptom The carriage operates abnormally. 5-18 Table 5-6. C204 MAIN/DRV/DRV-B boards Component Repair 3/7 Cause Checkpoint Solution IC1 on the C204 Check the signals for the carriage Replace IC1. MAIN board is motor phases at pins 204 (CRA), 205 defective. (CRB), 206 (CRC), and 5 (CRD) of IC1 Q16, Q17, Q18, or Check the signals for the carriage Replace Q16, Q17, Q19 on the C204 motor phases at collectors Q16 (CRA), Q18, or Q19. MAIN board is Q17 (CRB), Q18 (CRC), and Q19 defective. (CRD).
Symptom The carriage operates abnormally. Rev. B TROUBLESHOOTING Table 5-6. C204 MAIN/DRV/DRV-B boards Component Repair 4/7 Cause Checkpoint Solution The carriage encoder Observe the carriage encoder sensor Replace the sensor is defective. output signal at pins 4 (ENCA) and 3 carriage encoder (ENCB) of CN4 on the C204 MAIN sensor. board. Carriage operation is Check the switching waveform for Q5, Replace the unstable (due to a Q6, and Q7. abnormal transistor. lack of motor torque).
DFX-8500 Symptom Paper feeding is abnormal. Ribbon feeding is abnormal. 5-20 Table 5-6. C204 MAIN/DRV/DRV-B boards Component Repair 5/7 Cause Checkpoint Solution The CPU IC2) on the Check the PF motor phase drive Replace IC2. C204 MAIN board is signals at pins 2 - 5 of IC2. defective. IC2 on the C204 DRV At IC2, check the output signals for Replace IC2. board is defective. pins 2 (OUT_A), 3 (OUTXA), 6 (OUT_B), and 7 (OUTXB). The CPU IC2) on the Check the RF motor phase drive Replace IC2.
TROUBLESHOOTING Symptom The head fan operation is abnormal. The PG motor operates abnormally. The plunger is defective. Table 5-6. C204 MAIN/DRV/DRV-B boards Component Repair 6/7 Cause Checkpoint Solution IC1 on the C204 Observe the PG motor phase signal at Replace IC1. MAIN board is pins 163 (FANA) and 164 (FANAX) of defective. IC1. Q10 or Q11 on the Observe the head fan phase drive Replace Q10 or C204 MAIN board is voltage level for pins 25 (HFANA) and Q11. defective. 17 (HFANB) of CN1.
DFX-8500 Symptom The self-test is printed incorrectly 5-22 Table 5-6. C204 MAIN/DRV/DRV-B boards Component Repair 7/7 Cause Checkpoint Solution IC1 on the C204 Observe the output signal at pins 136Replace IC1. MAIN board is 181 of IC1. defective. The head driver FETs Observe the voltage waveform at the Replace the on the C204 MAIN each FET drain side. abnormal FET. and/or C204 DRV-B boards are defective. The CPU (IC2) on the Observe the signals at pins 38 (PTS1) Replace the IC2.
TROUBLESHOOTING 5.2.3 Printer Mechanism Repair The table below describes how to isolate problems with the printer mechanism. To replace or adjust printer mechanism parts, refer to Chapter 3, Disassembly and Assembly, and Chapter 4, Adjustments. If a symptom recurs following a repair attempt, look for other possible causes and solutions in the table below. Symptom The CR motor does not operate. The carriage moves, but no printing is performed. Rev. B Table 5-7.
DFX-8500 Symptom A particular dot does not print. The print is too light or print density is not uniform. Printing is performed, but the printer does not feed paper or does not feed it correctly. The ribbon feed (RF) motor does not operate. Table 5-7. Printer Mechanism Repair 2/4 Cause Checkpoint The printhead is Measure the printhead coil resistance. defective. (Refer to Figure 5-4 for details.) Check whether a dot wire is worn. The printhead is defective. Check if the tip of a dot wire is worn.
TROUBLESHOOTING Symptom The RF motor does not operate. Table 5-7. Printer Mechanism Repair 3/4 Cause Checkpoint The parallelism value Check whether the carriage moves is incorrect. smoothly when moved manually. (Check that foreign objects are not lodged in the printer mechanism.) The RF motor does not operate. The RF motor is defective. The PG motor does not operate. The backlash value is incorrect. The PG encoder sensor is defective The encoder plate is defective.
DFX-8500 Symptom Printing occurs outside the paper width. The paper bail assembly does not work. Continuous paper becomes crumpled at the front or rear tractor assembly. The tractor select (front or rear) function is not working. 5-26 Table 5-7. Printer Mechanism Repair 4/4 Cause Checkpoint The PW sensor is Check the PW sensor. defective. Solution Replace the PW sensor. The plunger is defective. Check the coil resistance of the plunger. (It should be about 9 ohms.) Replace the plunger.
CHAPTER 6 MAINTENENCE 6.1 PREVENTIVE MAINTENENCE..............................................................................6-1 6.2 LUBRICATION AND ADHESIVE APPLICATION...................................................
MAINTENANCE 6.1 PREVENTIVE MAINTENANCE To keep the printer in good condition, regularly clean the case exterior (using denatured alcohol) and vacuum the mechanism's interior to remove dust and paper debris. After cleaning the printer, check that it is adequately lubricated, as described in Section 6.2, below. Before returning the printer to the customer, inspect the springs and paper feed rollers and check that the printer operates properly.
DFX-8500 Table 6-2. Lubrication Points Ref. No. (1) (2) (3) Ref.
MAINTENANCE Figure 6-2. Lubrication and Adhesive Diagram 1 Rev.
DFX-8500 Figure 6-3. Lubrication and Adhesive Diagram 2 6-4 Rev.
MAINTENANCE Figure 6-4. Lubrication and Adhesive Diagram 3 Rev.
APPENDIX A.1 CONNECTOR PIN ASSIGNMENTS ..................................................................... A-1 A.2 CIRCUIT DIAGRAMS ........................................................................................... A-9 A.3 COMPONENT LAYOUT...................................................................................... A-21 A.4 CONNECTOR JUNCTION BOARD CONNECTORS.......................................... A-27 A.5 PART LIST .....................................................................
APPENDIX A.1 CONNECTOR PIN ASSIGNMENTS Figure A-1 illustrates the interconnection of the primary components. Table A-1 summarize the description and sizes of the connectors.
DFX-8500 Table A-1.
APPENDIX Pin 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 25 29 30 23, 24,, 26, 27, 28 Pin 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 167 18 19 20 Pin 1 2 Rev. B Table A-2.
DFX-8500 A-4 Pin 1 2 3 4 Table A-5. C204 MAIN Board Connector CN4 Signal Name I/O Function GND +5V ENCB I CR encoder B phase pulse ENCA I CR encoder A phase pulse Pin 1 2 3 5 6 7 9 9 11 13 4, 10, 912, 14 Table A-6.
APPENDIX Pin 1, 2, 3, 4, 5, 6 7 8 9 10 11 12 13 14 15 16 17 18 19, 20, 21, 22, 23, 24 25 26 27 28 29 30 31 32 33 34 35 36 Rev. B Table A-12.
DFX-8500 Pin 1 2, 3, 4 5, 6, 7, 8 9, 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26, 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 Pin 1 2 3 4 5 6 A-6 Table A-13.
APPENDIX Rev. B Pin 1 2 3 4 5 6 7 Table A-15. C204 MAIN Board Connector CN16 Signal Name I/O Function DIPCNT2 O DIP SW select port 2 DIPCNT3 O DIP SW select port 3 DIPCNT4 O DIP SW select port 4 DIPCNT5 O DIP SW select port 5 DIPCNT6 O DIP SW select port 6 DIPCNT7 O DIP SW select port 7 DIPCNT8 O DIP SW select port 8 Pin 1, 3, 5, 8 2 4 6 7 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48, 49, 50 Table A-16.
DFX-8500 Pin 1, 2, 3 4, 5, 6 Pin 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19, 20 A-8 Table A-17. C204 DRV Board Connector CN3 Signal Name4 I/O VP3 GP3 I Function +37 VDC GND for VP3 Table A-18.
APPENDIX A.2 CIRCUIT DIAGRAMS See the following pages for the figures below: Figure A-2. C204 MAIN Board Exploded Diagram C204 MAIN Figure A-3. C204 DRV Board Exploded Diagram C204 DRV Figure A-4. C204 DRV-B Board Exploded Diagram C204 DRV-B Figure A-5. C204 PSB Board Exploded Diagram C204 PSB Figure A-6. C204 PSE Board Exploded Diagram C204 PSE Rev.
APPENDIX A.3 Component Layout Figure A- 7. C204 MAIN Board Component Layout (1) Rev.
DFX-8500 Figure A- 8. C204 MAIN Board Component Layout (2) A-22 Rev.
APPENDIX Figure A- 9. C204 DRV Board Component Layout (1) Figure A- 10. C204 DRV Board Component Layout (2) Rev.
DFX-8500 Figure A- 11. C204 DRV-B Board Component Layout (1) Figure A- 12. C204 DRV-B Board Component Layout (2) A-24 Rev.
APPENDIX Figure A- 13. C204 PSB Board Component Layout Rev.
DFX-8500 Figure A- 14. C204 PSE Board Component Layout A-26 Rev.
APPENDIX A.
DFX-8500 A.5 Part List Table A-20. Part List (1/3) No. 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 152 153 159 160 161 162 A-28 Part Names HOUSING ASSY.,LOWER FRAME ASSY.,BOTTOM COVER ASSY.,FRONT HOUSING ASSY.,UPPER HOUSING ASSY.,TOP LOGO PLATE COVER,PAPER SUPPORT CAP,LOWER COVER,REAR CAP,MAGNET HOUSING SUB ASSY.,TOP COVER,I/F MAGNET SUB ASSY.
APPENDIX Table A-20. Part List (2/3) NO. 529 Part Names BOARD ASSY.,INTERMIT,HEAD NO. 587 530 531 532 533 534 535 536 537 538 539 540 541 543 544 545 546 547 548 549 550 551 552 553 554 555 556 557 558 559 561 562 563 564 565 BOARD ASSY.,INTERMIT,CARRIAGE BOARD ASSY.,DETECTOR,PTS PAPER ASSY.,SUPPORT ROLLER ASSY.,LOAD BLUSH,ELIMINATION ELECTLIC DETECTOR ASSY.,PE,UPPER DETECTOR ASSY.
DFX-8500 Table A-20. Part List (3/3) NO. 647 648 649 650 651 652 653 654 655 Part Names SPUR,GEAR,40 EXTENSION SPRING,320 MOUNT PLATE WIRE,RIGHT MOUNT PLATE,WIRE,LEFT EXTENSION SPRING,40 SPUR GEAR,32 C.P.S SCREW,2X14,F/ZN HEXAGON NUT A HEXAGON NUT,B NO. 669 671 672 673 674 675 676 801 901 656 LEVER,TENSION,CANCEL 1001 657 658 660 661 662 663 664 665 666 667 668 BUSH,8 BUSH,12 RESISTOR 0OHM, C.B.S.
APPENDIX A.6 EXPLODED DIAGRAMS See the following pages for the exploded diagrams below. Note that the last page shows the packing material for DFX-8500. Figure A-16. EXPLODED DIAGRAMS FOR DFX-8500 (1) EXPLODED DIAGRAM (1) Figure A-17. EXPLODED DIAGRAMS FOR DFX-8500 (2) EXPLODED DIAGRAM (2) Figure A-18. EXPLODED DIAGRAMS FOR DFX-8500 (3) EXPLODED DIAGRAM (3) Figure A-19. EXPLODED DIAGRAMS FOR DFX-8500 (4) EXPLODED DIAGRAM (4) Figure A-20. EXPLODED DIAGRAMS FOR DFX-8500 (5) EXPLODED DIAGRAM (5) Figure A-21.
DFX-8500 A-32 Figure A-16. Exploded Diagrams (1) Rev.
Rev. B Figure A-17.
DFX-8500 A-34 Figure A-18. Exploded Diagrams (3) Rev.
Rev. B Figure A-19.
DFX-8500 A-36 Figure A-20. Exploded Diagrams (5) Rev.
Rev. B Figure A-21.
DFX-8500 A-38 Figure A-22. Exploded Diagrams (7) Rev.
Rev. B Figure A-23.
EPSON OVERSEAS MARKETING LOCATIONS EPSON AMERICA, Inc. EPSON DEUTCHLAND GmBH 20770 Madrona Avenue, P.O. Box 2842 Torrance, CA 90509-2842 Phone: (800)922-8911 Fax: (310)782-5220 EPSON UK LTD. Zülpicher Straße 6, 4549 Düsseldorf Germany Campus 100, Maylands Avenue, Hemel Hempstead, Herts, HP2 7TJ U.K. Phone: (+44)01442-61144 Fax: (+44)01442-227227 EPSON IBERICA, S.A. 68 bis, rue Marjolin 92300, Levallois-Perret France Phone: (1)4087-3737 Telex: 610657 EPSON ITALIA S.P.A. Avda.
EPSON SEIKO EPSON CORPORATION
