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Epson DFX-8500 Service manual www.s

1. DB1 D15XB60 40 PC1 2747 4 NJM431L T lt DFX 8500 C204PSB BOARD OT LDR35C C125 0 du T
2. NJMAS1L T3 _ CN4 OUT 5 3 GND NC M5 19558 O Gl 30 5 500 EX B C204P d cou ui APPENDIX A 3 Component Layout CNS 2 203 1 E 018 eea Li y di a B Tto sa 4 4 C T3 m ei a 5 0 25 2 bur L a E Je Lm at wa eps P su 00 gt gt 8 z an n Ls STIL i UL ates 1 10 cst cor 83I TJI 5 1 IT TTWH su L CIT m s T ZINJ 6 TY ev 28 9 E era 55 8 St 25 Bl NIVHH2OCO 2 3d L S 2 38 Q AZZ 230 NOSd3 Beli oannim r amp 1 3 tno Figure A 7 C204 MAIN Board Component Layout 1 Rev B A 21 DFX 8500 C311 Coc ene cie 7 C307 C306 caes C213 ca R220 C216 R139 C217
3. 5 1 5 2 SELF DIAGNOSTIC 5 2 5 9 Ev E Rb ua eai 5 3 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 Forthis 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 Fatal Error Information 7 2 Description Note 3 LED 1 e The isolation resistance in the CR Auto power off motor is too low after 12 seconds e Optional cutter cable is not connected Auto power off after 12 seconds e Optional cutter is defective The PG home sensor is broken Auto power off The PG motor is broken after 12 seconds The parallelism adjustment is incorrect PG adjustment values are incorrect PG backlash is too tight e The carriage is locked Auto power off e The interlock switch doesn t close after 12 seconds exactly The parallelism adjustment
4. eene 4 4 4 1 5 Carriage Guide Shaft Parallelism Adjustment esee 4 5 4 1 6 Platen Angle Adjustment urere ieeIeuiess 4 9 4 1 7 Platen Gap Motor Value Adjustment eese nenne nnnm nnn 4 12 4 1 8 Measurement Seeking and Bi directional Printing Adjustment 4 15 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 If the pinion gear is poorly aligned or the pinion gear and cog are too tight printer operation is noisy or the character density is incorrect 47 If the PG motor backlash is too tight PG motor doesnt rotate smoothly and the panel indicates ES Step 1 Loosen the two screws securing the PG motor to the left side frame Refer to Section 3 2 6 4 Step 2 Make sure the PG motor pinion gear is properly aligned with the PG transmission gear cog Move the PG motor until there is 0 05 to 0 15 mm 0 002 t
5. 3 27 3 2 5 Interlock Switch and Cover Open Sensor Assembly Remowval 3 28 3 2 6 Printer Mechanism Remowvoal eese sesenta nennen nnne nnne nan 3 29 3 2 61 Fan Removal inei ed epe 3 31 3 2 6 2 Ribbon Feed Change Lever Unit 3 32 3 2 6 3 Tractor Select Lever Upper and Lower Assembly Disassembly 3 34 3 2 6 4 Ribbon Jam Sensor Removal sse 3 35 3 2 6 5 Connector Junction Board Assembly and FPC Board Assembly Removal 3 36 3 2 6 6 PG Sensor and PG Motor Removal sse 3 37 3 2 6 7 Plunger and Paper Bail Assembly 3 38 3 2 6 8 Upper Paper Guide and Top PE Sensor 3 40 3 2 6 9 Tension Roller Shaft Removal sse nnne 3 41 3 2 6 10 Platen Removal toten mittere len ive es 3 43 3 2 6 11 Paper Jam Sensor sse nennen nnne enn 3 44 3 2 6 12 Pull Tractor Sensor Removal sse 3 45 3 2 6 13 Paper Width PW Sensor 3 46 3 2 6 14 PG Home Sensor 3 47 3 2 6 15 PF Motor Removal eese essen
6. 1 2 2 4 3 55 5 Lx i ENS 2 2 E 3 55s 4 EE E ER 5 2 Oe 2 3 15 is 18 25 Sseutatoo x 030 DESSEN 4 ey 017 aoo 0555 034 DESSEN 44 0010 45 Te tov a 11 as 19 121 13 ta 15 18 1 8 4M BITS 2 3 2M BITS 00006006060 00000060600 ce11 cato 3800 330p CUTT NT CE IQ 741507 741507 1547 741574 4 E GND GND IC3 uPcC 3930 GND GP3 RFCOM RFB CRA PFCOM PFCOM O PFCOM
7. 3 6 3 2 DISASSEMBLY AND ASSEMBLY cc ccceccce ccce ecce ecce ecc 3 7 3 2 1 ROM Replacement 2 5 rere erit ceni eee euet tese rentes eroe ren 3 8 3 2 2 Printhead and Ribbon Mask Assembly 3 9 3 23 Housing RemowVal 5 3 13 3 2 9 1 Top Cover RemovVval oie re dee en geret E EU aue de 3 13 3 2 3 2 Left Right and Front Covers Removal and Fuse 3 14 3 2 3 3 Front Panel Unit 44244 3 16 3 2 3 4 Upper Case 3 17 3 2 4 Circuit Boards nasa natn 3 18 3 2 4 1 Bottom Panel Assembly enne 3 18 3 2 4 2 Cooling Fan and C204 Power Supply Board Unit 3 21 3 2 4 3 C204 SUB Board Unit 3 22 3 2 4 4 C204 DRV B and C204 DRV Board Units 3 23 3 2 4 5 C204 MAIN Board Unit Removal sese ener 3 24 3 2 4 6 AC Inlet 3 26 3 2 4 7 C204 PNL Board Remowval eene
8. Table 1 22 Serial Parity Setting Hes None of On o Table 1 23 Serial I F Baud Rate Setting SW4 7 SW 8 19200 9600 4800 2400 1 30 Rev GENERAL DESCRIPTION 1 4 4 Functions 1 4 4 1 Usual operation Front Rear Changes the front and rear paper path alternately B 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 After the paper is out the printer loads the paper from another path s tractor Overlapping multi part forms or continuous forms with labels is set or pull tractor is used Incomplete changing paper error is occurred immediately Cut the bottom of paper at current page and push Pause switch or Front Rear switch and the printer feeds the paper forward After the paper is out the printer loads the paper from another path s tractor Pause This switch alternates printer activity between printing and non printing Hold this switch down over 3 seconds and the printer resets all data Push this switch when incomplete changing paper is occurred
9. 1 16 roa er 1 16 1d INDE eise 1 19 1 3 1 Parallel Interface Forward 1 19 1 3 2 Parallel Interface Reverse 111 1 3 31111 eee ennt 1 21 1 3 3 Serial Interface 5 c1 uio hc eee acc ws ct seep ati wd coed an 1 22 1 3 4 Optional Interface eerie ce 1 22 1 3 5 Interface Selection ihe te ee ee a eat 1 23 1 3 6 Prevention Hosts from Data Transfer 4 1 23 1 4 OPERATING 8 22 2 2 1 24 1 41 Control Pahelp ead ieee 1 24 124 SWIICIOS ca tee ee 1 25 1 4 4 2 INGICALONS i et een 1 26 1 4 2 Errors and BUZZers cereo reete innu 1 27 1 4 3 DIP Switch Settings I 1 28 MAA FUNCTIONS ERR EET E E T ETE 1 31 1 4 4 1 Usual operation uena e a a a a aaa 1 31 1 4 4 2 Operation at Power ennt nn nennen nes 1 33 1 4 4 3 Bu llt iricDetectlon
10. c203 A n weisse FL LM st 51996 C105 E z is iis s rn SS a Nis C106 2 pon B d 7 B 2 21 e HERTE res av CM 8 di RISO 2 Se 2 pe 5 a pe e 0203 S RSS 3 2 8 W apio 201 dh m 3 3 104 9104 201 2 2 3 2 ur 26102 18 qu vw TLP 721F a 2 am x 20 e 84 12202 a Qa 236 21 5 ul R220 z021 8 y i 1 4h TIT2G Figure A 13 C204 PSB Board Component Layout APPENDIX 8647022 Rev B 25 DFX 8500 vu 3 WD 108 20Z ASSY 00 A 26 Figure A 14 C204 PSE Board Component Layout T CNI 1 3 Ar 2 9 cT T6 34H 250V 00 2 m x c6 z 0 L 3 T z PE eer PES poe MS n xs N z U 7 44 ts 2 1 400 8 153 M R201 9 AN 2 35 o 8151 2 R106 RI 10101 2 5 e pira 4
11. Figure A 17 Exploded Diagrams 2 APPENDIX EXPLODED DIAGRAM FOR DFX 8500 2 A 33 v V 8H 81 5 616 EXPLODED DIAGRAM FOR DFX 8500 3 00 lt 8 4 8H SE V y swesbeig 61 EXPLODED DIAGRAM FOR DFX 8500 4 XIaN3ddV 9 V pepojdx3 02 EXPLODED DIAGRAM FOR DFX 8500 5 00 lt 8 4 8H 28 7 9 pepojdx3 12 e1nDi4 639 2 4 amp 614 psx I ict 515 a SS RN 518 psn sm i4 516 545 E EN p d 2 P Lee ff ee 625 N did Sy Vos A ul e 3 M 626 5 EXPLODED DIAGRAM FOR DFX 8500 6 XIaN3ddV DFX 8500 650 8 N MM Paper 5 s UNS UN N NN M p ad ROUEN 2 DD ES XE N N 24 CUN X um ia gt o a EXPLODED DIAGRAM FOR DFX 8500 7 Figure A 22 Exploded Diagrams 7 A 38 Rev 8H 6 V Durjoeg 22 4 PACKING MATERIAL FOR DFX 8500 XIaN3ddV EPSON OVERSEAS MARKETING LOCATIONS EPSON AMERICA Inc 20770 Madrona Avenue P O Box 2842 Torrance CA 90509 2842 Phone 800 922 891 1 Fax 310 782 5220 EPSON UK LTD Campus 100 Maylands Avenue Hemel Hempstead Herts HP2 7TJ U K P
12. Load the paper correctly When you move the PF Refer to Section 5 3 Repair of the Printer Mechanism otor manually does i move smoothly Check the resistance of the PF motor coils and check the PF motor drivers Is the motor resistance OK and are the drivers Refer to Section 5 5 Repair of the Printer Mechanism Is PF motor coil resistance correct Yes Are the drivers shorted o open No Are the drivers shorted o Yes Replace the C204 MAIN board and or C204 DRV board Replace the C204 DRV board and the PF motor Perform final printing of self test No D Refer to Chapter 4 and perform the PG motor backlash 4 Refer to Section 5 3 Repair of the Printer Mechanism adjustment 5 10 No D Refer to Chapter 4 and perform the PG motor backlash adjustment Rev B TROUBLESHOOTING 5 Panel unit operation is abnormal 15 CN5 between the C204 MAIN and C204 PNL board connected correctly Reinsert connector CN5 correctly Is the fault corrected Yes Using a multimeter check the switches on the C204 PNL board Do the switches work correctly Yes Replace the C204 MAIN b
13. Lower Paper Guide CPN SP M4X8 Figure 3 64 Lower Paper Guide Left Part Removal Step 4 Unhook the paper jam sensor magnetic transistor cover to remove it Step 5 Remove the paper jam sensor Paper Jam Sensor Paper Jam Sensor Cover Lower Paper Guide Left Figure 3 65 Paper Jam Sensor Removal ASSEMBLING POINT When you attach the paper jam sensor make sure it is oriented correctly front to back 3 44 Rev B 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 CP S M2X14 Pull Tractor Sensor Platen Holder Right Hexagon Nut Figure 3 66 Pull Tractor Sensor removal Rev B 3 45 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 Paper Width Sensor Connector Figure 3 67 PW Sensor Removal 3 46 Rev B 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 carria
14. 3 49 3 2 6 16 Left Side Frame Gear Removal sss eene 3 50 3 2 6 17 Front Tractor Assembly 3 51 3 2 6 18 Rear Tractor Assembly 3 52 3 2 6 19 CR Motor Fan Removal tete repete een Ud extra die 3 53 3 2 6 20 CR Motor entnehmen netten nnne sinis nnne 3 54 3 2 6 21 CR Carriage Encoder Sensor Removal sse 3 55 3 2 6 22 Carriage Mechanism 2 40 00000 enne 3 56 3 2 6 23 Paper Support Assembly 2 3 59 3 2 6 24 PF Drive Roller 0 00 nnne nnn 3 60 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 amp 7 Because the DFX 8500 weighs 29 0 kg 63 8 Ib and is much larger and heavier than most printers you must be careful when handling it Whenever it needs to be moved two or more persons must carry it supporting it from the bottom Never lift the printer by holding the front cover because it may come off Disconnect the power cord before disassembling or assembling the printer Disconnect
15. 6 0 2220 11 12190 0042 00 A 1 A 2 CIRCUIT DIAGRAMS anen MAUS PED ena A 9 COMPONENT LAY QU T A 21 A 4 CONNECTOR JUNCTION BOARD A 27 BAD VEINS E CT A 28 A 6 EXPLODED DIAGRAMS A 31 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 C204 DRV B CN2 8 C204 PSB PSE EIA 232D AC Input IEEE1284 s m z CN2 20 CN13 7 amp Cover Open Sensor 2 e o TYPE B Printer Mechanism CN11 36 CR Encoder 2 lal s Printhead o C204 MAIN 5 CN15 6 CN1 6 Paper Cutter 5 C204 SUB Unit CN6 6 CN7 12 EN1460x2 CN16 7 CN2 7 C204 8 5 N e a z o o ICN1 50x2 CN 7 CN2 7 C204 PNL Figure A 1 Cable Connection Rev B A 1 DFX 8500 Table A 1 Board Connector Summary Co
16. Board CRINS CR Motor lt Insulation Motor L Jp RF Motor POFF Drive Circuit PF e p PF Motor 2 Drive Circuit IC2 Motor IC14 HPSENS HNSENS DRV B Board Printhead i P prive Circuit 1 2 p Frinthead 12 P ROM EsRRRRARRRRHRRSRRERERERERRARERRARR IC5 Printhead js Drive Circuit 2 2 Printhead 2 2 Optional gt DTRICTS T B I F Current Monitoring CR Motor ES CRCLM Control amp Drive amp Interlock SW Card gt Circuit IC1 IC3 ____ CR Motor EM cospae NC IC1 PG p PG Motor ___ gt PG Motor Drive Circuit lt j PG Home PG Encoder AB lt PE Signals DB Front Rear Top Control Paper Jam m Ribbon Jam ontro PSB PSE 36 gt Monitoring PD Pull Tractor i Board NR PREGR Tractor Select 222 pee PLG J Plunger Drive 3 Plunger Circuit Option p 4 Cutter Tr FAN p Fan Drive gt F CRU2 Circuit an LED PER Panel Unit 4 sw livin Reset IC RESET gt Head Fan p Head Fan 13 RSTOUT Drive Circuit ERRCRPFX Hi gt PDATA1 8 O m STB SWCNT IACK BUSY SWITCH gt SUB Boara lt DIP SWs Figure 2 15 Control Circuit Block Diagram 2 18 Rev B OPERATING PRINCIPLES Table 2
17. 1 SigalName JO Function 02 22 252 uo _ 234A _ O og ___ ss 22 35 PTO 1 5 VDC switched by reset status 1 _ Hoontolsinal __ 12 PLN 1 ____ 13 RFHR 0 RHFmotrcommon RFmotorC phase pulse 1 RFmotorAphasepulse 6 O PGmotorDphasepule _____17 PAB O PGmotoBphasepulse monitoring 19 CRmotorcurrentlimitsignal 1 CRCGLM CR motor current limit signal CRD O CR motorbridge D signal CRB O motorbridgeB signal PFmotorcommon PFmotorCphasepule O PFmotoAphasepule uu a X TRSE l Tractorselectsigna P Pultractor mount dismount PJAM Paper jam detection 31 F PE Front paper end 1 Rearpaprend 933 Toppaprend 34 X PGENCBB 1 PGencoderBsigna 35 PGENCA PG encoder signal 36 PGHOME PGhomeposiio 1 398 59 RED 0 RFmotorbridgeD signal 40 O __ ___ motor bridge signal PGHR 0 X PGmotrcommon ____ 42 PGmotorC phase pulse 43 0 PGmotorAphasepule 44 CR motor current limit sign
18. HB mq Shaft V Leaf Bec Paper Bail Lever Figure 3 56 Paper Bail Assembly Removal 2 2 3 39 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 Left Side Frame PE Sensor Connector Connector Junction Board Figure 3 57 Top PE Sensor Connector Removal Step 3 Remove the two CBS 4 6 screws securing the upper paper guide to both frames and remove the paper guide Step 4 Remove the two CPS SP M3x8 screws securing the top PE sensor to the upper paper guide and remove the sensor Top PE Sensor Upper Paper Guide Figure 3 58 Top PE Sensor Removal 3 40 Rev B 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 Step 6 Rev B 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 While pushing t
19. Indicates 274 column 3 Indicates 1 column 4 18 Rev B Bi D Adjustment Y Super Draft Print Mode Y ADJUSTMENT Adjustment Adjustment Y 1 Panel diplays the current Bi D adjustment value 2 Printer prints Speed AAA Bid adjust 1 is the current adjustment value Draft Print Mode Y Adjustment The printer prints the test print pattern with the current adjustment value Y NLQ Print Mode Yes Y Adjustment Does the 1st and 3rd and even 2nd 4th lines vertical alignment is OK No Yes Change the Bi D adjustment value Declement 10 steps Top of Form SW once Declement 1 step Push MicroFeed SW once Inclement 10 steps Tear Off SW once Inclement 1step Push MicroFeed v SW once Panel diplays the current Bi D adjustment value Turn the printer power off Press the Copy SW y Press the Pause SW The current adjustment value is stored in the EEPROM Return 1 Speed BBB Super Draft SdrSpd Draft DrfSpd NLQ NLQSpd Figure 4 23 Bi d Adjustment Rev B 4 19 CHAPTER 5 TROUBLESHOOTING 5 1 PROBLEM 1
20. OUTB prc o 9 OUTXB __ gt PFD GP3 Figure 2 23 PF Motor Drive Circuit Block Diagram Rev B 2 29 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 The RF motor rotates when the carriage moves Table 2 10 RF Motor Specifications Internal Coil Resistance 150 ohms 10 96 per phase at 25 720 pps Current Consumption Driving 0 10 A average Driving Method Constant voltage driving 2 2 phase drive 3 MAIN Board 1 E05B36 IC1 RFCOM PG10 TMP95C061A PG11 RF Motor IC2 PG12 PG13 PNP Transistor x4 m Figure 2 24 RF Motor Drive Circuit Block Diagram 2 30 Rev B OPERATING PRINCIPLES 2 3 7 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
21. Platen Referto Carriage Guide Shaft Figure 4 10a Carriage guide Shaft Gear Figure 4 14 Attaching Two Needles to Platen Surface Step 5 Measure the angle difference about three position such as figure below Using the CR motor pulley to move the carriage with the dial gauge toward the right side See Figure 4 11 70 mm Center Position f e ce 4 he E EA C N Ug Wg 9 0 0 9 9 E loz 0z VA 474 010206 0 04 Figure 4 15 Measuring Angle Difference 1 4 10 Rev B ADJUSTMENT Platen es Angle Adjustment Method 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 Rev B 4 11 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 perf
22. 37 VDC 456 GPS GND for VP3 Table A 18 C204 DRV B Board Connector CN1 Pin SignalNam4 VO Function 9SPrntheadpin CNRC 0 GND p ome GND gt t Prig __ ___ 14 6 PH 0 ___ ____ po 468 O _ ____ 18 Rz ec lu 1 ae UD 2 O Prnteadpinfl __ 340 tps T Prntheadpinfi3 grege GND 2 a vi PaO fe GND Printhead pin 8 Printhead Table A 20 C204 PSB PSE Board Connector CN5 Pin 4 JO Function lt lt FANDR O Fanmotodrve A 8 Rev B 2 CIRCUIT DIAGRAMS See the following pages for the figures below Figure A 2 C204 MAIN Board Exploded Diagram ZZ Figure A 3 C204 DRV Board Exploded Diagram gt Figure A 4 C204 DRV B Board Exploded Diagram Figure A 5 C204 PSB Board Exploded Diagram Figure 6 C204 PSE Board Exploded Diagram Rev B APPENDIX A 9 8419 FANCOM Q 115711671 1u fo 1u 6 PSZ BUSAK pes REFOUT 1270 2609 7172601 P72 PG02 79 2605 677610 75 614 76 12 P77 P615
23. Speed 0 takes effect SP3 Speed 0 1 When the carriage speed reaches SP3 Deceleration driving mode 3 takes effect This control method is the inverse continuity break method 2 During this time the control circuit measures time periods using the encoder signal When the rising edge of next pulse is not detected after 1 5 seconds Deceleration driving mode 1 takes effect and the control circuit controls short break SPref 2 5 o T 5 8 5 0 1 2 3 alpa pa pa 43 4 gt Deceleration 2 __ 5 Deceleration 1 5 L gt lt gt 6 Deceleration 3 PWM Perodic Time 1 2 3 indicate the PWM control section number Figure 2 22 CR Motor Drive Circuit Block Diagram 2 28 Rev B 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 2 8 ohms 10 96 per phase at 25 4274 normal constant driving 9 9 ips 2610 pps middle speed mode constant driving 6 ips Driving 1 75 A 0 20 A per phase average 0 26 0 2 HB Hybrid pulses per second ips inches per second The motor pulse switching signals are transmitted from CPU p
24. esee ES 4 R206 lp 9 a201 Maie 2 fun 956195 00 0192 M mu 5 dh ds fU 8 5 a M 248 A k R d qup We ani 02 BNE 2 2 020 jit s o Sai alg n 18 E 155 o p 4r 2 3 d 5 ci B 2 d 2 m tE z R21 3 6 02 PCt01 nied gt TLP TLP TLP NONAS 4 721F 721F 721 a 8227 3 ii 8132 Ar 8 m ga 29 _ J27 m 9111 234 129 z 21 1 82 R294 ye RSO gus 430 aB o m at 18 7N 6103 8102 Aigo 9 10209 5 S E 84 em Je 7x omn 3 2 8 12 ES 8 2 a Ta Wwe 3 3 5 8 8 o Sen gt mms 16202 3 3 ms 5 5212 ak a 4909 azn is 8 5 E gt a R220 wm 8 alte m o g ou L201 8137 ae Os E cai H5 5 Sh c 0113 C120 J36 1222 e T m 8 g 9210 5 32 5 8 JE Le S 28 lt 31 TS 8 8 8 8 dk X 1225 4 x 9213 5 B a 2224450 4 0233 fn V nem HE o 8 8 58 g 218 8 3 5 R122 C226 939 4r 321 7 1 8 J43 ESL 1L C234 R243 1 6 C232 9212 C CN2 CN3 APPENDIX A 4 Connectors on
25. 1 1 78 R193 S Less R216 N 4 C26 8 R223 77 LJ csa R201 Raus c27 C Q CJ R219 5 58 2828 Sor 33 3 Cse caa R222 R171 R176 52 ca RR Ha Rise 625 Les me R194 Lt amp us B is Com 5 8161 eat SE R245 R159 R148 R149 Cora a 815 5 ciseL_ ES 22 L k72 Riso RE Lis R153 ad __ 2 R156 R157 Ce 27 15 Ed EE 52 88 2 122 HA 3 can c2 167 Fa een eats C1 ao Wo ae ent d as Oo GU ci28 Ha LL Coes Raa TE Cts c2 Caus CIS alec C3 81886051 iem 118 6 cu cus GA cus C121 R15 127 R27 5 des EN R R6 ree en Cre Lj Bs Les Cras Cris Cori 125 Co LR Cris ar LR Ens Cra Lea 8197 Cries C198 Cris Cor C22 C123 R23 R97 73 Cone Ciii Mis ma cam c71 E Pio een ES 22 9121 15 Roel Ga LC mos RIZ Figure A 8 C204 MAIN Board Component Layout 2 A 22 Rev B APPENDIX 4 _____ 2 0000 015 539 C2OHDRV 5192 88 UE gee eee se
26. 5 VDC using the PG H R signal of E05B36 The phase driver circuit is made by discrete transistors Q12 to Q15 The phase output pulse from the platen gap encoder ENCA is input to port ENCA of E05B36 and the phase B output pulse from the platen gap encoder ENCB is input to port ENCB of E05B36 The E05B36 counts these pulses using the internal counter and determines the amount and direction of motor rotation Table 2 11 PG Motor Specifications 250 18 ohms per phase at 25 Driving 0 20 A average Holding 0 02 5 mA Constant voltage driving 2 2 phase drive MAIN Board i DRV Board VP 3 5V 010 E05B36 IC1 Q10 HR an gt 012 2 d PGB i gt 013 D g PGC p 014 9 8 mals UU UU 7 0 gt _____ PG Motor Figure 2 25 PG Motor Drive Circuit Block Diagram Rev B 2 31 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
27. 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 Factory Setting Print direction nied Autolinefeed st Inactive Active 0 Buzzer Acive __ Auto CR 2381 Plus Inacive Active Off Refer to Table 1 23 5 2 Continuous forms with labels Inactive Active Off 5 3 Skip over binding 5 4 Paper memory Memory a Memory b Off 551058 __ y Of 1 28 Rev B GENERAL DESCRIPTION Table 1 17 Character Table Setting Standard SW1 1 SWi 2 sw1 3 SWi 4 SWi 5 SWi 6 _ Charactertable 04 of PC850 Multilingual X of On Of _ PC860 Portuguese On 0 04 On PC861 Icelandic PC863 Canadian French PC865 Nordic On Off Abicomp 22 On BRASCII Jof On On On On On On On On Off Off On Off Off On j lSOLatin Italic USA Off On of On On italic France Off On On Off On italic UK
28. ON Decelraion2 J Decelraion3 ON ON J Acceleration ON ON J Right gt Left Decelraioni ON Deceeration2 J J Decelraion3 ON ON 2 26 Rev B 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 10 11 and 12 output the drive signal for the CR motor Acceleration control Until the carriage speed reaches the constant speed set by PI control acceleration control determines the speed of the carriage The printer can print while the carriage is accelerating The carriage speed moves to constant control speed smoothly to prevent the CR motor from exceeding the constant control speed The E05B36 gate array controls the motor driver STK681 050 which performs the current chopping Figure 2 21 shows the acceleration control curve Speed 0 SP1 1 It causes the carriage to accelerate 2 Because the control circuit measures time periods with the encoder signal when the carriage speed reaches SP1 it changes to the next sequence SP1 SP2 SP1 SP2 1 When the carriage speed reaches SP1 the printer uses the acceleration driving mode based on the duty data and t
29. The data flow from the Type B I F card is the same as the data flow from the parallel interface described above except the signal names and data access method differ E05B36 IC1 CPU IC2 123 STROBE Input Data Buffer STBINTI CR command 2 Buffer full Yes BUSY ACK Yes G a E ft CPU IC2 Command Analyzer l Line Buffer 5 Attribute Character Gnerator gt Controls printer mechanism E05B36 7 Figure 2 16 Parallel Interface Data Flow 2 20 Rev B 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 Power On Off Reset Reset IC PTS591 IC13 monitors the 5 line on the C204 MAIN board If it drops to 4 2 or smaller the reset IC outputs a LOW signal to the CPU 1 2 and E05B36 IC1 gate array Forced Reset The gate array outputs the RSTOUTX or ERRCRPFX signals to the XRESET
30. the top 75 mm area the paper feeding pitch be irregular Notes 3 If the optional pull tractor is used the top 120 mm area should not be printed Notes 4 Forms override printing is available 20 lines after the paper end Paper feeding pitch is not guaranteed The end of the printable area is 9 to 15 mm apart from the bottom edge of the paper Figure 1 6 Overlapping Multi part Form Printable Area Rev B DFX 8500 1 2 12 Paper and Media 1 2 12 1 Continuous paper Single sheet and multi part Table 1 5 Continuous Paper Minimum Maximum Minimum Maximum 101 406 101 406 101 431 101 431 Copes 7 e 0 065 0 53 0 065 0 46 not multi part P 14 22 14 22 one sheet of multi part 11 15 11 15 Quality Multi part binding Rough bindings of multi part paper cause paper jam The each sheet of multi part paper should normally be put together by spot gluing paper stapling tape stitching Spot gluing is recommended for the better printing quality Spot gluing must be applied on both sides of paper Refer to Figure 1 7 The spot glued parts must be pressed flat There must be no creases in the paper The paper stapling must be applied from the front of paper and the paper must be flat Refer to Figure 1 8 Paper stapling must be applied for both feeding directions Refer to Figure 1 9 The paper stapling should be flat Refer to Figure 1 10 Never use metal staples The position of bindi
31. Gonnected directly to the DTR _____________ RTS Out Request to send always SPACE level when the printer is powered on Pulled up to 12 V via 4 7K ohm resistor 3 RXD 1 0 0 0 0 0 O Signal GND Signal GND 1 Chassis Chassis GND GND Other NC Notused Not connected Note In Out refers to the direction of signal flow from the printer s point of view 1 3 4 Optional Interface Type B and Type B level 2 optional interfaces are available Refer to Table 1 1 1 22 Rev B 1 3 5 GENERAL DESCRIPTION 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 1 3 6 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 In this automatic interface selection mode the printer is initialized to the idle state scanning which interface receives data when it is powered on Then the interface that receives data first is selected When the host stops data transfer and the printer is in stand by state for the seconds specified by DIP SW setting the printer is returned to the idle state As long as the host sends data or the printer interface is busy state the selected interface is let as it is Interface state and i
32. Observe the drive waveform at pin 8 Replace 204 or VO and pin 5 GP ZD211 37 VDC line 10102 is defective If When the input voltage of the minus Replace IC203 VP1 VP2 is this IC is defective it port pin 6 for VP1 and pin2 for VP2 is abnormal cannot monitor the 37 less than 1 3 VDC the comparator VDC lines and outputs a HIGH signal printing operation becomes abnormal 37 VDC line 12203 is defective When the input voltage of the plus Replace IC203 is abnormal this IC is defective it is bigger than 1 3 VDC the comparator cannot monitor the 37 outputs a HIGH signal VDC lines and motor operations become abnormal Rev B 5 15 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 Symptom Cause Checkpont The printer does The DRERR signal Check the logic level of the DRERR Replace the head not operate at all was sentto the C204 signal at CN10 or check the VP1 and driver on the C204 power supply board VP2 voltage MAIN board VP1 HIGH level turns off or C204 DRV B the power supply board VP2 The PD signal was Check the logic level of the PD signal Replace the head sent to the C204 during power on and verify the voltage drive
33. Paper feeding is The oS 2 on the Check the PF motor de drive Replace defective board is defective pins 2 OUT A 3 OUTXA 6 OUT and 7 OUTXB Ribbon feeding is The CPU IC2 onthe Check the RF motor phase drive Replace IC2 defective The common Check the collector voltage of Q21 Replace Q20 or switching transistor on 021 the C204 DRV board is defective The phase switching For transistors Q22 Q25 observe the if there is no output transistor on the C204 input signal from the CPU base and signal replace the DRV board is the output signal collector abnormal transistor defective Fuse F1 on the C204 Check if fuse F1 is defective Replace F1 DRV board is defective 5 20 Rev B TROUBLESHOOTING Table 5 6 C204 MAIN DRV DRV B boards Component Repair 6 7 Checkpoint Solution The head fan on the C204 Observe the PG motor phase signal at Replace operation is MAIN board is pins 163 FANA and 164 FANAX of abnormal 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 The normal voltage is approximately 37 VDC The PG motor on the C204 Observe the PG motor phase signal at Replace operates MAIN board is pins 10 PGA 12 14 PGAX abnormally defective and 13 PGBX of IC1 The common Check the collector vol
34. 04h Request device ID in nibble mode of reverse channel transfer Device ID OOh 3Ah MPG EPSON CMD ESCP9 PRPII9 BDC MDL DFX 8500 CLS PRINTER Connector pin assignments Refer to Table 1 11 Table 1 11 and Connector Pin Assignment Reverse channel Pin No Signal Name eee iN HostCIk This signal is a strobe pulse used to read extension request values from the host computer during negotiation DEN Uc 8 The signals are data bits of extension request Values during negotiation This printer supports following values 0000 0100 Request Device ID by nibble mode sending 0000 0000 Request nibble mode PtrCIk Printer data sending clock the host comp puter T to host computer host computer AUTO FEED HostBusy This signal informs the printer of the host computer arora state When the signal is HIGH the host computer cannot accept data 15 X yjNetued 0 0 0 16 GND ____ JLlogcgroundlevel o yY Oe rie mone signal GND are connected to each other 18 jNetcomeced 19 30 GND Ground level for the twisted pair return signal INIT High level fixed 32 ERROR OUT nDataAvail Printer sending data bits 0 and 4 during data transfer to the host computer 3 GND ____ Sameasforinst9to30 INO 35 __ 5 X Pulled upto 5V through 1 0K ohm resistor 36 SLCT IN IN 1284Active If this
35. 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 Figure 3 15 Lubricating to Carriage Guide Shafts ADJUSTMENT REQUIRED 3 12 Rev B DISASSEMBLY AND ASSEMBLY 3 2 3 Housing Removal This section describes how to remove the housing 3 2 3 1 Top Cover Removal amp 7 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 Step 2 While someone supports the top cover remove the four screws two on the right and two on the left securing the top cover to the hinges and remove the cover Top Cover Figure 3 16 Top Cover Removal Rev B 3 13 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 CBB M4X16 Y 4 16 ms 4 16 CBB M4X16 Right and Left Covers Fi
36. 2 Carriage guide shaft parallelism adjustment described in Section 4 1 5 and Section 4 1 6 e Platen gap motor value platen gap adjustment described in Section 4 1 7 e Bidirectional printing adjustment described in Section 4 1 8 Rev B 3 59 DFX 8500 3 2 6 24 3 2 6 21 PF Drive Roller Removal Step 1 Remove the platen Refer to 3 2 6 10 Step 2 Remove the CR motor Refer to Section 3 2 6 20 Step 3 Remove the left side frame gears Refer to Section 3 2 6 16 Step 4 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 2 Carriage guide shaft parallelism adjustment described in Section 4 1 5 and Section 4 1 6 e Platen gap motor value platen gap adjustment described in Section 4 1 7 e Bidirectional printing adjustment described in Section 4 1 8 3 60 Rev B CHAPTER 4 ADJUSTMENT 4 1 PRINTER MECHANISM ADJUSTMENTS 4 4 00000022 4 1 4 1 1 PG Motor Backlash 4 1 4 1 2 Carriage Timing Belt Tension 4 2 4 1 3 Tractor Wire Spring Tension Adjustment eese nennen 4 3 4 1 4 Pull Tractor Sensor Position
37. 2 14 CONTROL 2 13 2 3 1 Control Circuit Operation Overview enne nenne nnn nennt nn 2 17 2 3 2 Reset desee ice eo 2 21 2 3 3 Sens r mec P M 2 22 2 3 4 CR Motor Drive ce aane a Don 2 25 23 5 Motor Drive Circuit enciende 2 29 2 3 6 RF Motor Drive Circuit eina ie 2 30 2 3 7 PG Motor Drive einn enne nsnm nani nnn 2 31 2 3 8 Plunger Drive 2 32 2 3 9 Printhead Drive nnn aa nnmnnn sa amas a R44 nan 2 33 OPERATING PRINCIPLES 2 1 PRINTER MECHANISM OPERATION This section describes the Model 3160 printer mechanism and explains how the printer works The Model 3160 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
38. 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 Step 5 Remove the CBS M4x8 screw securing the tractor wire holder and remove the holder Step 6 Remove the rear tractor gear Step 7 Remove the E ring and release the shaft holder from the left side frame Step 8 To remove the rear tractor assembly first move it to the left to release the right end of the shaft from the right side frame Then release the left end of the shaft and remove the assembly Flange Nut Shaft Holder V Leaf Spring m m E ring 6 Tractor Assembly Rear E ring 6 Shaft Holder Figure 3 75 Rear Tractor Assembly Removal ADJUSTMENT REQUIRED 3 52 Rev B 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 Fan Fixing Screws Right Frame Figure 3 76 CR Motor Fan Removal Rev B 3 53 DFX 8500 3 2 6 20 CR Motor Removal Step 1 Remove the right cover Refer to Section 3 2
39. 3 DFX 8500 4 Table 5 C204 MAIN Board Connector CN4 Pin SignalNam 410 Function dq y ef 2 45V 3 2 CR encoder B phase pulse 4 1 ChRencoderAphasepulse Table A 6 C204 MAIN Board Connector CN5 Function 437 VDC GND for VP1 Funcio 37 VDC GND for VP2 37 VDC GND for VP1 5 VDC switched by reset status 0 Head driver error signal Power down signal Current limit signal Power shutdown signal Rev B APPENDIX Table A 12 C204 MAIN Board Connector CN11 SignalNam O gd a loas 7 8 9 X L 310 S y ef 1 Resetsgnd 12 NH Inhibitsignal output _ 1 Commandrequestsignal da XWRRDY I Wriereadysigna __ Readrequestsigna de Write signal 2 _____17 Readsignd 2 E O Chip select signal 19 20 21 22 23 24 GND y O 28 Addressbus 26 Addesbu 2 27 Addessbsi 28 Addessbu0 30 O Databs6 2 Data bus 4 SC DO O X DatabsO0 Rev B A 5 DFX 8500 Table A 13 C204 MAIN Board Connector CN14
40. 5 describes the functions of the main components on the C204 MAIN and C204 DRV board Table 2 5 Main IC Functions C204 MAIN 2 Receives data from the host computer via the gate array loads CPU the data to the input buffer in the RAM and converts the image data to print data 205836 The main features Gate Array e CS Chip Select signal creation Address decoding Address latching Clock pulse creation Printhead driver control CR motor driver control CR and PG motor pulse encoder I O input output Encoder pulse Phase signal creation for the motors port control Interface control Abnormal CR and PF motor detection RESET signal creation PROM the program that runs the CPU RAM ar Holds the CPU working area and buffers input line and image buffers EEPROM IC11 Memorizes the printer unique parameter during the power is off ADM232 EIA to Logic level voltage level converter PST591D IC13 System reset IC C204 DRV STK681 050 Drives the CR motor Rev 5 67138 4 Drives the PF motor uPC393C IC3 Detects the current in the CR motor driver and feeds it back to the gate array on the C204 MAIN board 2 19 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 inte
41. 863 Abicomp BRASCII Roman 8 ISO Latin 1 Hebrew 7 Hebrew 8 862 1 These tables can not be selected by DIP switches Note ESC command is effective on all the character tables Input data buffer OK byte or 128 K bytes depend on DIP switch settings Rev B 1 5 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 L 1 6 feed 26 5 ms L Continuous feed 0 251 m s 9 9 ips inch sec Note The feeding speed will be reduced to 0 152 mps 6 0 ips when the pull tractor is mounted 1 2 3 Electrical Specification 120 V version Rated voltage 120 V AC Input voltage range 99 to 132 V AC Rated frequency range 50 to 60 Hz Input frequency range 49 5 to 60 5 Hz m Rated current 3 5 A max 7 5 m Power consumption Approx 160 W ISO IEC10561 Letter pattern Energy Star compliant Insulation resistance 10 M ohms min between AC line and chassis 500 V DC Dielectric strength 1000 AC Vrms 1 min or 1200 AC Vrms 1 sec between AC line and chassis 220 240 V version Rated voltage 220 to 240 V AC Input voltage
42. D3 IC2 AN2 ressure Figure 2 20 CR Motor Drive Circuit Block Diagram Rev B 2 25 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 Deceleration Control Speed Curve Control Carriage moves i PI control with printing Note 2 2100 Bit image 3 NLQ HD Super Draft X 1 3 Bit image 4 Draft X 1 3 660 Bit image 1 X 1 3 Bit image 2 X 1 3 Bit image 3 X 1 3 NLQ X 1 3 Draft X 1 6 Bit image 4 X 1 3 Bit image 3 X 1 6 Carriage moves Home position without printing seek Note 3 Paper width detection seek Measurementseek Notes 1 Refer to Table 2 8 Notes2 This division applies to all printing modes control oversees the constant speed Refer to page 2 27 for more information on PI control For increased throughput the division Super Draft to Draft HD allows printing during acceleration and deceleration Notes 3 This division increases throughput when the carriage is moving and the printer is not printing J UJ 210 The printer has three deceleration control modes The degree of deceleration is determined by how the CR motor transistors are driven Table 2 8 describes how the transistors are driven for each mode Table 2 8 CR Motor Drive Sequence Carriage Transfer Direction Driving Mode Driver Refer to Figure 2 19 Acceleration ON ON Left gt Right Decelraioni
43. EN60950 i EMC Directive 89 336 EEC EN55022 class B EN61000 3 2 EN61000 3 3 50082 1 801 2 IEC801 3 IEC801 4 1 2 8 Acoustic Noise Level 58 dB A ISO 7779 pattern 1 2 9 Ribbon Cartridge Type Fabric Color Black Ribbon life 15 million characters draft 10 cpi 14 dots character Dimensions 506 0 mm W x 123 5 mm D x 23 0 mm H 1 2 10 Physical Specifications Dimensions 700 mm W x 382 mm D x 369 mm H Weight APPROX 29 Kg Rev B 1 7 DFX 8500 1 2 11 Printable area Continuous paper Refer to Figure 1 3 RM right margin BM bottom margin Notes 1 In the top 75 mm area the paper feeding pitch may be irregular Notes 2 If the optional pull tractor is used the top 120 mm area should not be printed Notes 3 Forms override printing is available 20 lines after the paper end Paper feeding pitch is not guaranteed The end of the printable area is 9 to 15 mm apart from the bottom edge of the paper Figure 1 3 Continuous Paper Printable Area 1 8 Rev B GENERAL DESCRIPTION Labels Refer to Figure 1 4 Continuous Paper PW width Refer to Section 1 2 12 Notes 1 Feeding backward or paper PATH selection are prohibited Notes 2 the top 75 mm area the paper feeding pitch may be irregular Notes 3 If the optional pull tractor is used the top 120 mm area should not be printed Notes 4 Forms override printin
44. Guide Shaft Gear Positioning Rev B 4 7 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 7Omm lt q lt Right Side Frame Carriage Parallelism Adjust Lever Step 13 Notes 1 Notes 2 Step 14 Step 15 Step 16 Step 17 4 8 Carriage Motor Motor Pulley Figure 4 11 Carriage Guide Shaft Parallelism Adjustment If the distance measured at the left side is greater than that measured at the right side move the parallelism adjust lever in the direction shown by the white arrow in Figure 4 9 If the distance measured at the left side is less than that measured at the right side move the lever in the direction shown by the black arrow The carriage guide shaft moves as shown in Figure 4 8 For example when the parallelism adjust lever is moved in the direction of the black arrow the distance between the right side of the platen and printhead nose narrows a little bit The carriage guide shaft moves as shown in Figure 4 8 When the parallelism adjust lever is moved in the direction of the black arrow
45. INTERMIT HEAD 587 ROLLER TRANSMISSION GEAR 541 1 1 600 PLAIN WASHER 3X0 2X9 548 TRACTOR RIGHLFRONT 606 5 SCREW M2 6X5F ZN 549 PAPER SUPPORT 607 MINI CLAMPYMC 05 H 0 PAPER GAP ADJUSTMENT MIDDLE 623 WIRE HOLDER GEAR C P S P S SCREW 3X10 F ZN Rev B A 29 DFX 8500 Table A 20 Part List 3 3 647 SPUR GEAR 40 1 669 FANCR 655 HEXAGON 901 INDIVIDUAL CARTON BOX FOR EUROPE 656 LEVER TENSION CANCEL 1001 INDIVIDUAL CARTON PACIFIC 660 RESISTOROOHM 1304 ____ 666 BOARD ASSY INTERMIT MECHANISM 1910 CARRIAGE FIXING PLATE 0 668 COMPOSITION SCREW FAN 2118 PLASTIC BAG50X70X A 30 Rev B 6 EXPLODED DIAGRAMS APPENDIX 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 Figure A 17 EXPLODED DIAGRAMS FOR DFX 8500 2 Figure A 18 EXPLODED DIAGRAMS FOR DFX 8500 3 Figure A 19 EXPLODED DIAGRAMS FOR DFX 8500 4 Figure A 20 EXPLODED DIAGRAMS FOR DFX 8500 5 Figure A 21 EXPLODED DIAGRAMS FOR DFX 8500 6 Figure A 22 EXPLODED DIAGRAMS FOR DFX 8500 7 Figure A 23 PACKING MATERIAL FOR DFX 8500 Rev B A 31 DFX 8500 EXPLODED DIAGRAM FOR DFX 8500 1 Figure A 16 Exploded Diagrams 1 A 32 Rev Rev B
46. Neji Lock 2 G 10000 730200200 Note E EPSON exclusive product not commercially available NCAUTION amp 7 Do not apply too much lubricant because it may create stains or cause the mechanism to malfunction Rev B 6 1 DFX 8500 Table 6 2 Lubrication Points Rer No Ref Figure Lubrication Point Carriage oil pad ring on both left and right sides of carriage O2 2 6 3 Carriage oil pad under the carriage head cable holder 3 6 3 Hole holding the tip of the rear carriage guide shaft in both left G26 and right side frames 4 6 3 Both edges of the rear carriage guide shaft guide shaft Rear carriage shaft holding lever contact point with the rear carriage guide shaft 8 164 7 Platen roller shaft holder contact point with the platen roller 17 Tractor select cam G26 Table 6 3 Adhesive Application Points Ref No Ref Figure Adhesive Application Point 25 Neji Lock 2 Figure 6 1 Correct Adhesive Application 6 2 Rev B MAINTENANCE 12 Figure 6 2 Lubrication and Adhesive Diagram 1 6 3 Rev B DFX 8500 X _ QUNM 1527 T wee 3 649 62 2 RE ky 6 Figure 6 3 Lubrication and Adhesive Diagram 2 Rev B Rev B Figure 6 4 Lubrication and Adhesive Diagram 3 MAINTENANCE 6 5 APPENDIX CONNECTOR PIN 55
47. Remove the belt pulley from the belt pulley holder Side Frame L Figure 3 80 Belt Pulley Removal Step 3 Unhook the spring securing the encoder belt to the right side frame Refer to Figure 2 5 Step 4 Loosen the two flange nuts securing the front carriage guide shaft to the left and right side frames Figure 3 81 Front Carriage Guide Shaft Removal 3 56 Rev B DISASSEMBLY AND ASSEMBLY Step 5 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 Step 6 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 Step 7 Unhook the spring securing the paper thickness sensor assembly and remove the sensor assembly Rear Carriage Guide Shaft Paper Thickness op Sensor 1 Carriage Guide Shaft Gear E ring 6 2 d 9 oe PG Motor Figure 3 82 Rear Carriage Guide Shaft Removal Step 8 Remove the PG motor Refer to Section 3 2 6 6 Step 9 Remove the carriage damper solid rubber from the inner side of the right side frame and remove the three CBS M4x8 screws securing the carriage motor holder to the right side frame Step 10 Remove the guide shaft holding spring and the E ring then remove the right guide shaft holder lever Step
48. Section 3 2 6 1 Ribbon Feed Gear Cover Head Dumper Ribbon Feed Gear Ribbon Feed Change Lever Unit Ribbon Feed 2 Motor A Ribbon Feed Frame Figure 3 46 Ribbon Feed Change Lever Unit Removal 1 2 Step 5 Remove the two CBS M3x6 screw securing the ribbon feed change lever unit to the left side frame then remove the ribbon feed change lever unit Connector Junction Board 3 PN gt KRU Connector for Ribbon Jam Sensor R Connector for Ribbon Feed motor W Connector for Tractor Select Sensor Y Ribbon Feed Change Lever Unit CBS M3X6 Figure 3 47 Ribbon Feed Change Lever Unit Removal 2 2 3 32 Rev B DISASSEMBLY AND ASSEMBLY To RF Motor To Tractor Select Sensor 22 To Ribbon Jam Sensor 2 Connector Junction Board 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 Hefer to Figure 2 12 Rev B 3 33 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 ribbo
49. abnormal sensor circuit monitoring reset signal creation control of the PSB PSE board control of the panel unit and reading the DIP switch settings on the C204 SUB board Signals such as DRERR driver error and PD power down are connected to the C204 PSB PSE board to provide back up control of the EEPROM when the printer is turned off and control of the power supply voltage When the POFF signal informs the CPU that the power has been turned off or CL that the power supply voltage has dropped the CPU turns off the power supply voltage of the C204 PSB PSE board by outputting the PD signal The reset circuit outputs the reset signal when the printer is turned on or off the voltage level drops or a reset signal is input from an external device It resets the control circuit for a certain period directly or via the E05B36 Rev B 2 17 DFX 8500 MAIN Board Mechanism CPU 95 061 4 Cover Open 2 Sensor HTMP Printhead EERON Temperature IC11 PWIDTH K Paper Width Head Fan 24 57MHz amp Temperature CRU1 D 4 p AS 4 e gt TXD RXD
50. beam is absorbed not reflected The Pull tractor sensor monitors whether the pull tractor is installed Top PE Sensor TIMING BELT PF Tension Roller Platen Gear Tension Pulley Tractor Select Gear Paper Feed Transmission Gear PF Motor Pinion Gear Figure 2 7 Tension Roller and PF Roller Operation Rev B 2 7 DFX 8500 Paper Paper Bail Tension Roller Tractor Select Gear Front PE Sensor PF Motor Pinion ed Tractor Sprocket Front PF Transmission Gear Figure 2 8 Front Tractor Assembly Operation Paper Paper Bail Tension Roller Tractor Select Gear Rear PE Sensor PF Transmission Gear Pinion Figure 2 9 Rear Tractor Assembly Operation 2 8 Rev B 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 The front left tractor sprocket or rear right tractor sprocket is fixed in position by the shape of the bottom frame of the printer mechanism while the other sprocket the front right sprocket or rear left sprocket can move along the tractor shafts When the tractor release lever is released the sprocket can move smoothly side to side along the tractor shafts Wh
51. driven by the 37 VDC The fan lowers the temperature of the PSB PSE board circuit components and it also lowers the CR motor temperature because the motor locates on the way of an air exhaust channel of the fan Table 2 3 PSB PSE Board Output DC Voltages 37 V VP3 GP3 C204 DRV CR motor drive PF motor drive PG motor drive e RF motor drive e HF drive e CR fan drive e Plunger drive Optional Cutter s motor drive 5 V GL C204 MAIN e All logic systems operating voltage C204 DRV e PF motor hold voltage C204 DRV B e Plunger hold voltage C204 PNL PG motor hold voltage Power for all the sensors VX GL C204 MAIN e Voltage for power system pull up It is switched C204 DRV by VXCNT signal of the CPU 122 C204 DRV B Rev B 2 15 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 10 minutes by the DRERR signal of the C204 MAIN board after the power is turned off Therefore you must wait more than 10 minutes turn the power on again E 2 4 PSB PSE Board Co
52. from the front panel unit and remove the panel unit along 3 16 with the panel connector cable PRIM 4 16 Front Panel Unit Figure 3 21 Front Panel Removal Rev B DISASSEMBLY AND ASSEMBLY 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 3 2 3 4 Upper Case Removal Step 1 Upper Case lica I TES AME m m CBB M3X10 3 17 Figure 3 22 Upper Case Removal Rev B 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 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 When you attach the bottom panel make sure the parallel interface cable latch is not caught between the lower case and bottom panel Step 1 Remove the left and right side covers Refer to Section 3 2 3 2 Step 2 On the right side of the printer mechanism remove the CBS O screw securing the green and yel
53. gears The tractor select sensor detects the selected tractor and signals that information to the control circuit Paper Bail Assembly Pull Tractor Sensor Plunger Top PE Sensor Paper Jam Sensor ractor Select Sensor Rear PE Sensor Printhead Front PE Sensor 4 p Rear Tractor Sprocket Front Tractor Sprocket Figure 2 3 Printer Mechanism Operation 2 Rev B 2 3 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 Then the actuating spring ejects the dot wire forward against the ink ribbon printing a dot on the paper 35 VDC Actuating Spring GND Mask Holder Cutting Platen Assembly Dot Wire Iron Core Ribbon Printhead Drive Coil Figure 2 4 Printhead Mechanism 2 4 Rev B 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 a
54. if the tip of a dot wire is worn Print density differs at the right and left sides of the page darker on one side than the other Print density is too light even the new ribbon cartridge is mounted Visually check the paper path Check whether the PF motor pinion gear rotates smoothly when rotated manually Measure coil resistance for the PF motor The correct resistance is approximately 2 8 ohms 1096 Also check the PF motor drivers Remove the ribbon cartridge rotate it and check whether it feeds the ribbon normally Check whether the ribbon driving gear rotates when the cartridge is moved manually Replace the printhead Replace the printhead Replace the printhead Perform the parallelism adjustment as described in Section 4 1 5 Perform the parallelism adjustment as described in Section 4 1 5 Remove any foreign substances Check backlash between PF motor pinion gear and paper feed reduction Replace the PF motor and if drivers are bad replace main board at the same time Replace the ribbon cartridge Remove any foreign objects or replace damaged ribbon feed mechanism part the ribbon feed select gear ribbon feed transmission gear or ribbon feed Rev B TROUBLESHOOTING Table 5 7 Printer Mechanism Repair 3 4 Checkpoint The RF motor The parallelism value Check whether the carriage moves Perform the does not operate is incorrect smoothly when moved man
55. ior eoe ord per n dto it 1 34 1 4 5 Paper Memory 1 35 2 ans 1 36 1 4 6 1 Power on Initialization 1 36 1 4 6 2 Software nnn 1 36 1 4 6 3 Panel 1 36 1 5 MAIN COMPONENT pem 1 37 1 5 1 M 3160 Printer Mechanism 1 1 1 1 1 nenne nnmnnn 1 38 1 5 2 Main Control Board C204 MAIN 12111 1 39 1 5 3 6204 1 40 1 5 4 C204 DRV B Board 1 41 1 5 5 0204 5 1 41 1 5 6 0204 PSB PSE Boar dh saxa CONCERN Ed 1 42 1 5 7 Gontrol Pari l 1 43 1 5 8 eee cR 1 43 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 The main fe
56. is Check the ribbon jam sensor Replace the ribbon occurs even the defective jam sensor ribbon is fed correctly Rev B 5 25 DFX 8500 Table 5 7 Printer Mechanism Repair 4 4 Checkpoint Solution Printing occurs The PW sensor is Check the PW sensor Replace the PW outside the paper defective sensor width The paper bail Check the coil resistance of the assembly does defective plunger It should be about 9 ohms not work Continuous paper The tension value of The distance between the frame and Perform the tractor becomes the tractor wire spring the seal securing the white line should wire spring tension crumpled at the is incorrect be about 3 mm 0 12 inches adjustment as front or rear described in Section tractor assembly 4 1 3 The tractor select The tractor select Check the continuity of the tractor Replace the tractor front or rear sensor is defective select sensor select sensor function is not working The tractor select Visually check the tractor select gear Join the tip of the gear is disconnected holder tractor select lever to from the tractor select the tractor select cam gear holder 5 26 Rev B CHAPTER 6 MAINTENENCE 6 1 PREVENTIVE 6 2 LUBRICATION AND ADHESIVE MAINTENANCE 6 1 PREVENTIVE MAINTENANCE To keep the printer in good condition regularly clea
57. jam error Measurement On Blinking Blinking When carriage breaking length seeking error is abnormal it goes Measurement seeking error e ____ _________ operation Note 1 The descriptions show how the beeper sounds Beeper sounds 100 ms and interval is 100 ms Beeper sounds 500 ms and interval is 100 ms Table 1 15a Fatal Error Information DO TUR UT indicant CR motor circuit shortage error 1 Auto power off after 12 seconds Cutter error ___2 __ Auto power off after 12 seconds 4 Carriage load measurement Auto power off after 12 seconds error Auto power off after 12 seconds 7 Head power off mediately Head power off immediately Auto power off after 12 seconds DRETETENVTN MEN p Auto power off after 12 seconds Watch dog error Auto power off after 12 seconds Note 1 The 7 segment LED indicates error No and E alternately Note 2 The descriptions show how the beeper sounds Beeper sounds 100 ms and interval is 100 ms Beeper sounds 500 ms and interval is 100 ms Note 3 Turn the printer power off while the 7 segment LED are on or the printer shuts power down automatically You can t turn the printer back on for 5 minutes after the printer shuts power down automatically ___7 ____ Head circuit shortage error iE a 1 27
58. one third speed of High duty mode Notes 3 When the print head temperature rises to the upper limit the printer stops printing And when the print head temperature falls to the normal level then the printer starts printing again Rev B 1 3 DFX 8500 Draft Resolution Refer to Table 1 3 Table 1 3 Resolution Print Mode Horizontal Density Vertical Density Adjacent Dot Print High speed draft 90 dpi 7 at 72 Draft 120 dpi Draft condensed 240 dpi 72 dpi Draft emphasized 120 dpi NLQ 240 dpi 144 dpi Bit image Control code ESC P and IBM 2381 Plus emulation Character tables Standard version 11 character tables Italic table PC437 US Standard Europe PC850 Multilingual PC860 Portuguese PC861 Icelandic PC863 Canadian French PC865 Nordic Abicomp BRASCII Roman 8 ISO Latin 1 NLSP version 35 character tables Italic table PC437 US Standard Europe PC850 Multilingual PC437 Greek PC852 East Europe PC853 Turkish PC855 Cyrillic PC857 Turkish PC866 Russian PC869 Greek MAZOIWA Poland Code MJK CSFR 150 8859 7 Latin Greek ISO Latin 1T Turkish Bulgaria Bulgarian Estonia Estonia PC 774 LST 1283 1993 ISO 8859 2 ISO Latin 2 PC 866 LAT Latvian PC866 UKR PC 860 PC 861 PC 865 PC APTEC PC 708 PC 720 AR864 PC 863 Canadian French Abicomp BRASCII Roman 8 ISO Latin 1 Hebrew 7 Hebrew 8 PC862 Note These tab
59. or pull tractor sensor perform this adjustment Figure 4 4 illustrates the pull tractor sensor position adjustment When you assemble the pull tractor sensor or rear paper guide check the following items e Verify that the pull tractor sensor lever is touching the rear paper guide frame but the sensor is off Make sure the distance between the sensor lever and sensor switch is approximately 2 mm 08 inches Sensor Switch Left Side Frame Sensor Lever Pull Tractor sensor Figure 4 4 Pull Tractor Sensor Position Adjustment 4 4 Rev B 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 Do not remove the printer mechanism If remove the printer mechanism from the lower case the adjust value will be out of order when you reassemble the printer mechanism to the lower case Also it is necessary to remove the tension roller shaft before performing this adjustment Refer to Section 3 2 6 7 The parallelism is adjusted so that the difference between the distances from the rear carriage guide shaft to the platen measured at the tw
60. printer is turn off 2 Select the memory you want to write the information See DIP SW setting 3 Select the page length See DIP SW setting 4 Select the paper type See DIP SW setting 5 Turn the printer on while both sides of Paper Select switch are depressed 6 Point the label position when you use the paper with a label 8 Open the printer cover b Move the pointer Refer to Figure 1 23 to one of the label s corner up down Feed the paper by Micro Feed switches right left Move the printing head by manually C Press Top of Form switch d Move the pointer to the diagonal corner of the label Press Top of Form switch f Close the printer cover 7 Confirm the writing sequence was done correctly by beep sounds Once or twice The information are written to the memory a or b correctly 3 times The sequence was not correct and it was ignored Pointer Red Cross Ribbon Mask Figure 1 23 Pointer Rev B 1 35 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 2 Software Ini
61. range 198 to 264 V AC 2 Rated frequency range 50 60 Hz Input frequency range 49 5 to 60 5 Hz L Rated current 1 4 A max 3 5 A Power consumption Approx 160 W ISO IEC10561 Letter pattern Energy Star compliant Insulation resistance 10 M ohms min between AC line and chassis 500 V DC u Dielectric strength 1500 AC Vrms 1 min between AC line and chassis 1 2 4 Environmental Condition Temperature 5 to 35 C operating 30 to 60 non operating Humidity 10 to 80 RH operating 1 5 to 85 RH non operating 1 Resistance to shock 1 G within 1 ms operating 2 G within 2 ms non operating 2 Resistance to vibration 0 25 G 10 to 55 Hz operating 0 50 10 to 55 Hz non operating 2 1 Without condensation 2 With shipment container 1 2 5 Reliability Total print volume 26 million lines except print head MTBF 10 000 25 duty Print head life 400 million characters at 14 dots character Ribbon life 15 characters at 14 dots character 1 6 GENERAL DESCRIPTION 1 2 6 Safety Approvals 120 V version L Safety standards UL1950 with D3 CSA C22 2 No 950 with D3 EMI FCC part 15 subpart B class B CSA C108 8 class B 230 V version L Safety standards EN60950 VDE NEMKO B EMI 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
62. remove it from the lower case Lift Handle 656 Printer Mechanism Lower Housing Assembly Figure 3 44 Printer Mechanism Removal 2 2 ASSEMBLING POINT ADJUSTMENT REQUIRED When you install the printer mechanism perform the following adjustments e Platen gap motor value platen gap adjustment described in Section 4 1 7 e Bidirectional printing adjustment described in Section 4 1 8 3 30 Rev B DISASSEMBLY AND ASSEMBLY 3 2 6 1 Fan Removal Step 1 Step 2 Step 3 Step 4 Rev B 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 CP O 4x5 Left Frame Figure 3 45 Fan Removal 3 31 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 Refer to
63. signal is set to HIGH this printer active P1284 reverse mode Note In Out refers to the direction of signal flow from the printer s point of view Rev B 1 21 DFX 8500 1 3 3 Serial Interface Synchronization Asynchronous Signal level ELA 232D E MARK logical 1 3Vto 25V SPACE logical 0 3Vt0 25V Word length m Start bit 1 bit E Data bit 8 bit B Parity bit Odd Even Non of Ignore Stop bit 1 bit or more 2400 4800 9600 or 19200 bps Handshaking DTR signal or X ON X OFF m DTR MARK X OFF Indicates that the printer cannot receive data DTR SPACE X ON Indicates that the printer is ready to receive data Note The DTR signal is MARK and X OFF code 13h is transmitted when the rest of the input buffer becomes 256 byte The DTR signal is SPACE and X ON code 11h is transmitted when the rest of the input buffer is regained 256 byte Error handling When parity error is detected the received byte is changed to the character code Overrun error and framing error are ignored Connector 25 pin sub miniature D shell connector female Connector pin assignment and signals Refer to Table 1 12 Table 1 12 Signal and Connector Pin Assignment EIA 232D Pin Signal Name In Out FunctionalDescripion 20 DTR jOut Indicates that the printer is ready to receive data or not A1 REV ____ Qut_
64. supply voltage VP3 flows into the plunger coil When switching transistor Q30 is turned off Q31 is turned off and the hold voltage 5 V flows into the plunger coil via Q32 using the port PLN of the E05B36 Table 2 12 Plunger Specifications Specification E DC solenoid upply Voltage 37 VDC applied to the drive circuit Internal Coil Resistance 9 ohms 5 at 25 Current Consumption Driving 3 7 A MAX Holding 0 4 A Table 2 13 Plunger Switching Pattern Suspension Roller Status _ Q30andQ31 0200 Closed On Closed gt Opened Closed with holding voltage Of 0071 VP 3 F3 NPN E05B36 PLP IC1 0 v 2 GP3 Figure 2 26 Plunger Drive Circuit Block Diagram 2 32 Rev B 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 At the same time ports HDRS1 HDLS1 to HDRS9 HDLS9 of IC1 go HIGH the FET gates are biased and the FETs are turned on because the each printhead coil is driven by bipolar drive method When the HD port of IC1 goes LOW the FET is turned off and the printhead coil current is cut Two 37 VDC lines VP1 GP1 on the C204 DRV B board and VP2 GP2
65. then go to the next step Micro feed Adjusts the paper position including Top of Form and Tear off positions The switch advances the paper forward by 1 216 inch step and switch advances the paper backwards by 1 216 inch step LF FF Load Pressing it loads continuous paper when the printer is out of paper Pressing it shortly executes line feed Holding it down for a few seconds executes form feed Top of Form Advances the paper so that the characters base line can be adjusted at the mark of ribbon mask holder and enters the Top of form adjustment mode The Top of Form LED turns on and the TOF position is adjustable with the Micro Feed switches in this mode When the Top of Form switch is pressed again this mode is terminated The adjustment position 15 stored as TOF and the paper is fed back to the position before this mode When TOF adjustment is executed just after loading the adjusted position will be treated as the loading position This switch is only available when the cover opens Tear Advances the paper until its perforation comes to the paper cutting part of the printer cover and enters the tear off mode The Tear off LED turns on and the Tear off position is adjustable with the Micro Feed switches in this mode When the Tear switch is pressed again this mode is terminated The adjustment position is stored as the tear off position and the paper is feed back to the posit
66. to provide enhanced paper handling The structural differences between the DFX 8500 and the DFX 8000 are DFX 8500 includes a CR motor isolation resistance sensor DFX 8500 includes a paper jam sensor DFX 8500 includes a ribbon jam sensor To prevent paper jams the DFX 8500 includes a tractor wire at the front and rear tractors The detection method of the carriage encoder sensor has been changed In the DFX 8000 the encoder plate was attached to the rotor of the CR motor while the DFX 8500 uses a belt type encoder DFX 8500 does not include a carriage home position sensor 0000 Figure 1 25 M 3160 Printer Mechanism 1 38 Rev B 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 TMP95C051A 24 57 MHz 122 Gate array E05B36 IC1 PROM including C G 2M bit 105 4M bit 1014 ADM232L RS 232C level converter IC9 RESET IC PST391D IC13 EEPROM 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 C204 MAIN Board Table 1 24 Color Attribute 1 For USA Pacific Serial I F Hexagonal head screw type Rev B 1 39 DFX 8500 1 5 3 C204 DRV Board The C204 DRV board is the driver board specially for the printer mechanism 7 printhead printhead fan p
67. 11 Remove the two CP S P1 M4x6 screws securing the parallelism adjust lever and remove the lever Step 12 Remove the rear carriage guide shaft with the carriage base from the right side frame Rear Carriage Guide Shaft Parallelism Adjustment Lever CP S P1 M4X6 Guide Shaft Holder Lever Right CP S P1 XM4X6 CBS M4X8 Carriage Motor Holder Figure 3 83 Right Side Frame Removal Rev B 3 57 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 e Platen gap motor value platen gap adjustment described in Section 4 1 7 e Bidirectional printing adjustment described in Section 4 1 8 3 58 Rev B 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
68. 204 MAIN board to head junction board CN2 of C204 MAIN board to C204 DRV B board CN1 of C204 DRV B board to printer mechanism Rev B 5 7 DFX 8500 3 Carriage operation is normal but the self test is printed incorrectly 2 3 Replace the C204 MAIN and or C204 DRV B board Check the print head coil resistance Is the No printhead resistance correct Y Check the printhead drivers Yes Check the printhead drivers No If the printhead drivers are OK replace the printhead Are the drivers OK If the printhead drivers are OK replace the Replace the C204 MAIN and or C204 DRV B board printhead Replace the C204 MAIN and or C204 DRV B board y Refer to Section 5 3 Repair of the Printer Mechanism Refer to Section 5 3 Repair of the Printer Mechanism 5 6 Rev B TROUBLESHOOTING 3 Carriage operation is normal but the self test is printed incorrectly 3 3 Rev B Is the print correct Perform bidirectional adjustment Go back to Section 5 3 Repair of the Printer Mechanism and check for other problems Perform bidirectional adjustment END END DFX 8500 4 Printing is normal but paper feeding is abnormal START Is the No paper loaded correctly Y
69. 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 CP S M4X10 CR Motor Figure 3 77 CR Motor Removal ADJUSTMENT REQUIRED When you install the CR motor perform the carriage timing belt tension adjustment as described in Section 4 1 2 When you install the printhead perform the platen gap motor value platen gap adjustment as described in Section 4 1 7 3 54 Rev B DISASSEMBLY AND ASSEMBLY 3 2 6 24 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 Carriage Encoder Sensor Carriage 4 pin Connector Carriage Connector Junction Board Figure 3 78 CR Sensor Removal 1 2 CP S P1 M2 6X5 YS Carriage Encoder Sensor 0 o Carriage Figure 3 79 CR Sensor Removal 2 2 Rev B 3 55 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
70. 3 2 6 17 Front Tractor Assembly Removal This section describes how to remove the front tractor assembly Step 1 Disconnect the connector white 3 pin front PE sensor from the connector junction board Step 2 Remove the connector junction board assembly Refer to Section 3 2 6 5 Step 3 Lay the mechanism on its back Step 4 Remove the screw securing the tractor wire holder to the left side frame and remove the holder Step 5 Loosen the flange nut securing the front tractor assembly to the left side frame by the left end and remove the tractor transmission gear Step 6 Remove the flange nut on the right side and remove the right tractor wire spring holder set Step 7 Remove the E ring 6 securing the rear shaft of the front tractor assembly to the left side frame and remove the shaft holder Step 8 Move the assembly to left to release the right end of the shaft then release the left side of the shaft from the left side frame and remove the assembly Carriage Motor 5 4 8 de A 5 E 1 MB Tractor Wire Holder L 1 Wire Spring Left Right Figure 3 73 Tractor Wire Removal Tractor Transmission Flange Nut Gear _ 2 5 E ring 6 Flange Nur N Shaft Holder a3 Leaf Spring Shaft Holder 22 Washer E ring 6 Tractor Assembly Front Figure 3 74 Front Tractor Assembly Removal ADJUSTMENT REQUIRED Rev B 3 51 DFX 8500 3
71. 4 1 2 Perform the carriage guide shaft parallelism adjustment as described in Section 4 1 5 encoder sensor Replace or clean the carriage encoder belt Replace the FPC Measure the coil resistance of the CR motor It should be approximately 1 66 ohms 10 96 Manually check the carriage timing belt tension Check whether the carriage moves smoothly when moved manually Check that foreign objects are not lodged in the printer mechanism Check the waveform for the carriage encoder signal Refer to Table 5 6 Check the encoder belt below the carriage timing belt Check the continuity of the common wires for the printhead FPC 5 23 DFX 8500 Table 5 7 Printer Mechanism Repair 2 4 Checkpoint 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 5 24 The printhead is defective The printhead is defective The parallelism value is incorrect The platen gap value is incorrect Foreign objects are lodged in the paper path The PF motor is not driving the gear properly The PF motor is defective The ribbon cartridge is defective Foreign objects are caught in the gears Measure the printhead coil resistance Refer to Figure 5 4 for details Check whether a dot wire is worn Check
72. B Encoder B 5 VDC ENCA Encoder A GND GND HT Head thermistor 4 Printhead Coil Resistance Figure 5 Rev B 5 4 TROUBLESHOOTING 1 The printer does not operate when power is turned on Does the printer beep before it dies Is the AC input voltage normal Has fuse F1 on C204 power supply board blow Measure the output voltage from the c 294 power supply board Is the Check Table 5 1 Error Codes Use the correct AC voltage Replace the fuse F1 and disconnect CN2 CN3 and CNA on the C204 power supply Board Reconnect CN2 CN3 and 4 and turn on the printer When you turn on power again does the ew fuse also output voltage Check all motors solenoid printhead and drivers using a multimeter Are they Replace the C204 power supply d board Replace bad motor solenoid or within normal range printhead If driver also is bad replace at the same time Replace the C204 MAIN board C204 DRV board and or C204 DRV B board Is the fault corrected Yes Yes See Section 5 3 to repair the printer mechanism Rev B DFX 8500 2 Carriage operation is abnormal Are the connectors listed in Reinsert the con
73. BLESHOOTING MAINTENANCE vi CHAPTER 1 GENERAL DESCRIPTION e 1 1 122 SPECIFIGAFIONG c 1 3 1 2 1 Printing Specification ias auradan 1 3 1 2 2 ara E ENE E A 1 6 1 2 3 Electrical Specification iaeei 1 6 1 2 4 Environmental Condition uelle eese eee nnmnnn 1 6 1 25 CIEL 1 6 1 26 Safety Approvals erae 1 7 1 2 7 CE Marking ned ii 1 7 1 2 8 Acoustic nei tes e Seek coms ete 1 7 1 2 9 ME 1 7 1 2 10 1 7 1 211 Printable area nii ae eee ue coto ec Resa 1 8 1 2 12 Paper and 1 12 1 2 12 1 Continuous paper Single sheet and 1 12 1 2 12 2 Labels e e edi tase ote sea epe 1 14 1 2 12 3 Continuous Forms with 1 14 1 2 12 4 Overlapping Multi part Form sess 1 16 1 2 12 5 nien ee
74. 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 any form whatsoever without SEIKO EPSON s express written permission is forbidden The contents of this manual are subjects to change without notice All efforts have been made to ensure the accuracy of the contents of this manual However should any errors be detected SEIKO EPSON would greatly appreciate being informed of them The above notwithstanding SEIKO EPSON can assume no responsibility for any errors in this manual or the consequences thereof EPSON is a registered trademark of SEIKO EPSON CORPORATION General Notice Other product names used herein are for identification purposes only and may be trademarks or registered trademarks of their respective companies Copyright 1998 by SEIKO EPSON CORPORATION Nagano Japan 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 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 The precautionary measures itemized below should always be observed when performing repair maintenance procedu
75. Italic Denmark off Of On On On On iticSwden Table 1 18 Character Table Setting NLSP SW 1 1 SW1 2 SW1 3 Sw1 4 SW1 5 SW1 6 Character table PC437 US standard Europe Of On 04 _ 437 Off Of Off On jPC852EastEuop PCB58 0 0 0000000 y 853 On On Of 857 Turkish __ 1 1 1 On On PC866 Russian On Off On On __ 150 8859 7 Latin Greek Off On On n n On Off ISO Latin 1T Turkish On n n n n n n n n Of of Off On Of 6 of Off _ PCAPTEO 2 Off ian On On Off _ Bulgaria Bulgarian On On On On PC774 LST 1283 1993 Off ian Off PC861 lelandic On On n n On On On On Off Off Off SO8859 2 On On n n n n n n Off PC865 Nordic Italic USA Off talic German On On On On Italic Sweden On On On On Off On On _ Italic France On Off On On On On On On On On On On Rev B 1 29 DFX 8500 Table 1 19 Front Tractor Page Length SW2 1 SW2 2 SW2 3 SW2 4 Page length for front tractor Table 1 20 Rear Tractor Page Length SW2 1 SW2 2 SW2 3 SW2 4 Page length for rear tractor Table 1 21 I F Selection SW 3
76. N board is motor phases at pins 204 CRA 205 defective CRB 206 CRC and 5 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 018 CRC 019 defective is doesn t work Check the voltage level between Anode Replace ZD2 Q34 and Kathode of ZD2 is APPROX 6 2 V or Q35 on the C204 DRV Check the signals for the carriage Replace IC1 board is defective motor phases at pins 14 IN A and 10 OUT1 of IC1 Measure the voltage level at pins 10 Replace IC1 OUT1 and 5 GP of IC1 when the carriage is operating The normal voltage level is approximately 37 VDC IC3 on the C204 DRV Observe the waveform at pin 1 of IC3 Replace IC3 board is defective Rev B TROUBLESHOOTING Table 5 6 C204 MAIN DRV DRV B boards Component Repair 4 7 Symptom Cause Checkpont The carriage The carriage encoder Observe the carriage encoder sensor Replace the operates sensor is defective output signal at pins 4 ENCA and 3 carriage encoder abnormally ENCB of CN4 on the C204 MAIN sensor board Carriage operation is Check the switching waveform for Q5 Replace the unstable due to a and Q7 abnormal transistor lack of motor torque Rev B 5 19 DFX 8500 Table 5 6 C204 MAIN DRV DRV B boards Repair aes Symptom Cause Checkpoint
77. OBE 19 In The strobe pulse Read in of data is performed at the falling edge of this pulse DATA 0 7 20 27 The DATAO through signals represent data bits O to 7 respectively Each signal is at high level when data is logical 1 and low level when data is logical 0 the printer can again accept data BEAR ARMAMA receive data 13 SLCT 28 vas at high level when the printer i powered on Not used INIT In The falling edge of a negative pulse or a low signal on this line causes the printer to initialize Minimum 50 us pulse is necessary 18 Pulled upto 5V 3 9K ohm resistor 35 __ Pulled upto 5Vvia3 SKohmresisto m I 16331930 1534 NC Notconnected Note In Out refers to the direction of signal flow from the printer s point of view 1 20 Rev B GENERAL DESCRIPTION 1 3 2 Parallel Interface Reverse channel Data transmission mode IEEE 1284 nibble mode Connector type 57 30360 AMPHENOL 36 pin plug or equivalent Synchronization No Info Handshaking No info Data transmission timing No info Signal Level TTL level compatible IEEE 1284 level 1 device Extensibility request The printer responds to the extensibility request in the affirmative when the request is 00h or 04h which mean 00h Request nibble mode of reverse channel transfer
78. Open Sensor Fi Cover Open Loc Sensor Connector Y i Red Interlock SW White 2 pin Connector Junction Board Figure 3 38 Interlock Switch Assembly Removal Step 3 Remove the CBB M4x10 screw securing the interlock switch assembly to the lower case and remove it Step 4 Remove the CBB M3x10 screw securing the cover open sensor to the upper case and remove it Mf Interlock SW mu A bl E ssembly Lower Case Figure 3 39 Interlock Switch Assembly Removal CBB M3X10 Cover Open Sensor Upper Case Figure 3 40 Interlock Switch and Cover Open Sensor Removal 3 28 Rev B 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 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 amp 7 Two people are required to remove or install the printer mechanism amp 7 Use the lift handles 656 part number B765111001 designed for lifting or lowering the printer mechanism when you remove or install it 47 To avoid straining your waist hands or feet place the printer on a low table before following
79. ad HIGH of the DRERR signal at driver on the C204 MAIN CNA board and or C204 DRV B board CL signal is HIGH Measure the signal level Wait until the printer of the CL signal at CN4 prints again Replace the E05B36 on the C204 MAIN board Fuse F1 blows The line filter circuit is Check if any of pins Replace the abnormal immediately after defective C1 C5 or R1 is shorting element replacement the AC line Rev B 5 13 DFX 8500 Table 5 5 C204 PSB PSE Board Component Repair 2 8 Symptom Checkpont Solution 37 VP1 The main switching FETs Observe the voltage Replace QF101 VP2 line is dead QF101 is defective waveform between the drain side and GND C101 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 VP3 line The main switching FETs Observe the voltage Replace QF201 is dead QF201 is defective waveform between the drain side and GND Q201 is defective Observe the voltage Replace Q201 waveform between the collector side and GND Q202 is defective Observe the voltage Replace Q202 waveform between the collector side and GND 5 14 TROUBLESHOOTING Table 5 5 C204 PSB PSE Board Component Repair 3 3 Checkpoint The 5 line is IC204 is defective Check the voltage level at pin 10 V1 Replace 204 defective and pin5 GP
80. al 2 Po RO CRmotorcurrentlimitsignal O 46 O Clock pulse for CR motor driver 0 ChRmotobridgeCsignal Po OCR motor bridge A signal P PF motor bridge D signal PO PB PFmotorbridgeBsignal Table A 14 C204 MAIN Board Connector CN15 Pin SignlNam 10 Function et Pt status I 2 A1l DIP2 DIPSWestaus DP3 DIPSW3staus DIP4 _______ DIP SW4 status DIP5 a DIP SW5 status DIPCNT1 O DIP SW select port 1 A 6 Rev B APPENDIX Table A 15 C204 MAIN Board Connector CN16 Pin SignlNam JO Function BDIPCN DIPSWseletpot2 DIPCNT3 O DIPSWselectpot3 DIPCNT4 DIPSWselectpot4 4 0 DIPSWselectpotb5 5 6 DIPSWseletpoto 6 DPCN7 DIPSWseletpot7 7 DIPSWseletpot8 Table 16 C204 DRV Board Connector 2 Pin SignlNam 10 Function 1858 7 2 T oe 222 ___ d ____ ___ __ 6 Ribbnjam NC pr c ru INTLOC GND for VP3 E RFmotorphaseA E a 0 ghRmotrphaseA 48 49 50 QeFmotorcommon Rev B A 7 DFX 8500 Table A 17 C204 DRV Board Connector CN3 Fin Signal Name4 Function e e
81. alue Refer to Table 4 1 Step 5 Write the ALPHA value written on the print head into the memory Press the Micro Feed v switch to increment value by 1 Press the Micro Feed switch to decrement the value by 1 Step 6 1 When you finish the adjustment such as you have replaced the print head press the LF FF Load SW then the ALPHA value is written to the EEPROM and finish the adjustment mode Then turn the power off and install the ribbon mask holder and the ribbon cartridge 2 When you continue the BETA values write operation press the Pause SW then the ALPHA value is written to the EEPROM and enter to the BETA values write mode BETA Values Write Mode Step 7 Open the top cover and inset the 0 43 mm thickness gauge into the space between the platen and the print head nose At this time never shift the print head If done it return to Step 3 Step 8 Contact the tension gauge to the hole of the thickness gauge and pull it straight to the right Step 9 Hold the thickness gauge gradually with the print head nose by pressing the below switch Press the Micro Feed v switch to increment value by 1 Press the Micro Feed switch to decrement the value by 1 The panel indicates the current BETA3 adjustment value Refer to Table 4 1 Step 10 Set the value when the tension gauge indicates the 150 135 165 gf the tension gauge can move to right in a degree Step 11 After complete BETA3 a
82. atures of the printer are OOO OOO Maximum printing speeds 1120 cps high speed draft mode 840 cps draft mode 210 cps NLQ mode at 10 cpi Advanced paper handling 10 inches per second ips paper feeding Paper jam detection Paper width detection Front and rear two way push tractors Optional pull tractor Automatic paper back out and loading from another paper path and paper park Automatic platen gap adjustment for paper thickness Automatic tear off Paper memory function Automatic paper path changing Auto cut mode enables the optional perforation cutter to cut the paper at the perforation Bi directional parallel interface IEEE 1284 nibble and RS 232C serial interface standard EPSON ESC P upper compatible with DFX 8000 and IBM LEXMARK 2381Plus emulation 35 character tables in the NLSP National Language Support version and 11 character tables in the standard version 2 NLQ and 1 draft bit map type faces and 8 barcode fonts are supported Optional paper cutter and perforation cutter Upgraded data handling 128 KB input buffer Automatic interface selection Type B optional I F cards The figure below shows the DFX 8500 Rev B Figure 1 1 DFX 8500 Exterior View 1 1 DFX 8500 The following table shows options Table 1 1 Option Code 8766 8767 Ribbon pack Pull tractor unit Paper cutter Perforation cutter Serial interface card inch screw Serial interface card mm screw 32 KB int
83. board Step 3 Disconnect connectors CN1 and CN2 on the C204 DRV B board C204 DRV Board C204 DRV B Board C204 MAIN board Cable from C204 MAIN board Figure 3 29 C204 DRV DRV B Boards Removal 1 Step 4 Remove the eight CBS M3x8 screws securing the C204 DRV B board and C204 DRV board via shielding plate respectively CBS M3X8 X 8 Shielding Plate Shielding Plate C204 DRV Board Figure 3 30 C204 DRV DRV B Boards Removal 2 2 Rev B 3 23 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 10 Harness to CN7 6 pin to CN6 7 pin C204 MAIN Board Figure 3 31 C204 MAIN Board Removal 1 4 Figure 3 33 C204 MAIN Board Removal 3 4 3 24 Rev B DISASSEMBLY AND ASSEMBLY Step 5 Remove the four CBB M3x12 screws and two CBS M3x8 screws securing the C204 MAIN board unit and remove the board J CBS O M3X8 X 2 JL CBB M3X12 X 4 C204 MAIN Board Unit Figure 3 34 C204 MAIN Board Removal 4 4 ADJUSTMENT REQUIRED When you install the C204 MAIN board assembly perform the following adjustments e Platen gap motor value platen gap adjustment described in Section 4 1 7 e Bidirectional printing adj
84. ck the two head cable cover latches by pressing them with your fingers then remove the cover by sliding it to the right Remove the cable protection sheet too Figure 3 11 Head Cable Cover Removal 3 10 Rev B DISASSEMBLY AND ASSEMBLY Step 5 Disconnect the narrow FPC cable from white connector lock type 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 CP S P1 M4X7 Narrow FPC Cable 1 CP S P1 M3X6 Printhead Carriage Figure 3 12 Printhead Removal Step 7 Disconnect the white connector for the paper width PW sensor on the ribbon mask Step 8 Remove the two shafts securing the ribbon mask to the carriage using a hexagon head screw wrench then remove the ribbon mask Shafts PW Sensor Connector Figure 3 13 Ribbon Mask Removal Step 9 Install the new printhead ribbon mask and cable protection sheet by following Steps1 to 9 in the reverse order Step 10 Replace the ribbon mask with a new one Set the cable of the paper width sensor as shown in Figure 3 13 After installation check that the ribbon mask is a little loose Step 11 Install the new printhead torque the screws to 12 1 kg cm Replace the head cable protection sheet with a new one then connect the head cables to the connector Rev B 3 11 DFX 8500 ASSEMBLING POINT Figure 3
85. 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 Iron Core CP S P1 M3X6 Figure 3 54 Plunger Removal 3 38 Rev B Step 4 Step 5 Step 6 Step 7 Step 8 Step 9 Step 10 Rev B DISASSEMBLY AND ASSEMBLY Remove the left tension roller lever spring 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 rings Shaft Holder gt Tension Roller Lever Spring Figure 3 55 Paper Bail Assembly Removal 1 2 Disconnect 2 fan harnesses and remove 2 screws CPS P1 securing the CR fan duct Then remove the CR fan duct along with the CR fan Refer to Section 3 2 6 1 Remove the right tension roller lever spring Remove 2 E rings to release the release tension lever at the inner side of the left frame Remove the E ring 6 at the right end of the paper bail shaft Then remove the paper bail lever leaf spring and shaft holder Slide the shaft left to release the right end of the shaft from the right frame Then lift up the shaft by the right end and remove it along with the release tension lever E ring 6 227 Paper Bail Assembly mE
86. cpi LB LI 12 cpi COMM 15 MOO 17 BOM 20 cpi 5 2 LED off LED on Font Green W The status of Font selection is displayed by two Font LEDs 00 Super draft LIN Draft Roman Sans Serif 0 LED off LED on Power Green The LED is on when the printer is powered and it is off when the printer is powered off Paper Out Red The LED is on when the printer is in the paper out status and it is off when the printer is out of this status B The LED blinks when the printer is in the paper jam status Ribbon Red The LED blinks when the printer is in the ribbon jam status Paper Select Seven segment Green TheLED indicates selected paper No 1 26 Rev B 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 LED LED LED OnLine 04 8 Jot Pauses ot 1084 Headhot Blinking Off 8 HeadFanhot Blinking Of 2 sheet it goes paper out error open it goes cover open error changing paper the paper it goes incomplete changing paper path error Eu feed paper Paper size error ON Off Off When paper width of the setting different it goes Paper size error sheet it goes paper jam error Viola EM al status it goes ribbon
87. d SW or Front Rear SW v PG is printed v 1 PG Beta1 BBB PG Beta2 CCC PG Beta3 DDD PG Beta4 EEE is printed 2 Panel diplays the current flight time adjustment value Refer to Table 4 2 3 Flight Time FFF is printed The printer prints the test print pattern with the current flight time setting value Refer to Figure 4 22 Does the odd 1st and 3rd and even 2nd and 4th lines vertical alignment is OK Yes v Press the Pause SW Change the flight time adjustment value v Declement 10 steps Top of Form SW once 2 Declement 1 step Push MicroFeed SW once The current flight time adjust value Inclement 10 steps Tear Off SW once is stored in the EEPROM Inclement 1step Push MicroFeed v SW once Panel diplays the current flight time adjustment value v Press the Copy SW Go to Bi D Adjustment Mode Turn the printer power off Rev B 4 17 Figure 4 21 Flight Time Adjustment DFX 8500 Flight Time XXX TTTTTTTTTTTTTTTTTTTTT TTTTTTTTTTTTTTTTTTTTT TTTTTTTTTTTTTTTTTTTTT TTTTTTTTTTTTTTTTTTTTT 40 COL 56 COL 40 COL Figure 4 22 Test Print Pattern Table 4 2 LED indication and Adjustment Value Comparison LED 1 Bi d adjustment positive negative PG adjustment 300 400 1 L1
88. d number of pins Refer to APPENDIX Figure A 15 3 36 Rev B DISASSEMBLY AND ASSEMBLY 3 2 6 6 PG Sensor and PG Motor Removal 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 Step 4 Remove two CP S P1 M3x6 screws securing the PG motor and remove the motor Encoder Plate PG Motor PG Motor Pinion Gear CP S P1 M3x6 Platen Gap Sensor CPS P M3X6 Figure 3 53 PG Sensor and PG Motor Removal ASSEMBLING POINT When you install the PG motor make sure the backlash between the PG motor and PG motor transmission gear is between 0 05 and 0 15 mm almost no backlash When you install the PG sensor unit align the C cut portion of the unit with the lower shaft securing the PG to the frame ADJUSTMENT REQUIRED When you install the PG sensor or PG motor perform the platen gap motor value platen gap adjustment as described in Section 4 1 7 Rev B 3 37 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
89. djustment press Pause SW to enter next step Step 12 Close the print head nose to the platen by pressing the below switch Press the Micro Feed v switch to increment value by 1 Press the Micro Feed switch to decrement the value by 1 The panel indicates the current BETA2 adjustment value Refer to Table 4 1 Step 13 After complete BETA2 adjustment press Pause SW to enter next step Step 14 Inset the 0 43 mm thickness gauge into the space between the platen and the print head nose Step 15 Hold the thickness gauge gradually with the print head nose by pressing the below switch Press the Micro Feed v switch to increment value by 1 Press the Micro Feed switch to decrement the value by 1 The panel indicates the current adjustment value Refer to Table 4 1 Step 16 After complete adjustment press Pause SW to enter next step Step 17 Inset the 0 80 mm thickness gauge into the space between the platen and the print head nose Step 18 Hold the thickness gauge gradually with the print head nose by pressing the below switch Press the Micro Feed v switch to increment value by 1 Press the Micro Feed switch to decrement the value by 1 The panel indicates the current BETA4 adjustment value Refer to Table 4 1 Step 19 After complete 4 adjustment press Pause SW then all of measured BETA values written to the EEPROM and turn the printer power off Note When eithe
90. e carrier Each comer of those labels must be rounded e Each label and backing sheet should not have any folds or creases Between each label there should be the same sheet as those labels The backing sheet must be continuous paper Continuous forms with labels should be inserted from front entrance Refer to Section 1 2 12 6 Rev B 1 15 DFX 8500 1 2 12 4 Overlapping Multi part Form Table 1 8 Overlapping Multi part Form Commu T E uc 101 406 101 431 not multi part 14 22 one sheet of multi part i5 11 15 Copies 1 original 5 copies 1 backing 25 sheet print area 0 065 0 53 overlap area m 0 13 0 70 2 1 mm more than 0 10 carbonless multi part forms Multi part binding Multi part paper must be bound at the top side by spot gluing Figure 1 12 The bindings must not be too hard And there should not be any spilt glue The position of binding must be outside of printable area Multi part paper should be bound firmly to each other and the binding must not be too large Refer to Section 1 2 12 5 Notes Overlapping multi part form should be inserted from front entrance Refer to Section 1 2 12 6 1 2 12 5 Perforation Weak horizontal and vertical perforations cause paper jams D The length ratio of the cut part and uncut part of perforations must be more than 3 to 1 and less than 5 to 1 Refer to Figure 1 13 e Horizontal perforation
91. ed White i2 pin Connector Junction Board D PO Figure 5 1 Interlock Switch Assembly Location The interlock switch and cover open sensor consists of an assembly To bypass the interlock switch and the cover open sensor 1 remove the left side cover 2 make the short circuit connectors for the interlock switch and cover open sensor connectors 3 insert the short circuit connectors for the interlock switch and cover open sensor connectors Short Circuit Connector White i2 pin Connector Junction Board C204 MAIN Board Figure 5 2 Bypassing Interlock Switch and Cover Open Sensor 5 2 Rev B 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 CR motor 2 80 ohms 10 at 25 150 ohms 10 at 25 C 9 ohms 5 at 25 C Shield Cable Double sided Adhesive Tape Head Cable Protection Sheet Head Cable Board Figure 5 3 Disconnect Printhead FPC Rev B 5 3 DFX 8500 10 12 1700090 1740 62609 168 3 Load Pattern MA Fan motor phase A MB Fan motor phase B MC Fan motor common ead coil GND side 18 Head coil P S side Head thermistor MT Fan motor thermistor 1 HT PWD Paper width sensor 5 P S Power supply 37 VDC ENC
92. een print head and the platen is automatically adjusted for proper printing according to the paper thickness Skip over binding This function is used to print on a multi part form with the binding which scratches the print head during paper feeding If this function is used the print head parks apart from those bindings during paper feeding to avoid paper jam This function can be selected by DIP switch and the through put will be reduced at that time Auto cut mode The printer cuts the paper at the perforation position automatically while data is printing This function is valid when the perforation cutter is used selected by DIP SW 3 7 and the paper length is more than 4 inch The setting of the printer driver has priority over DIP SW 3 7 Do not use this mode for labels continuous forms with labels and overlapping multi part forms Automatic TOF position setting When TOF position is different from loading position with the printer power on the printer feeds the paper to the next TOF position automatically 1 34 Rev B 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 pa
93. elected paper and push Pause switch Current paper is aorb The printer feeds the paper forward If the printer can t aware out of paper status it goes incomplete changing paper path error If incomplete changing paper path error is occurred please cut at the bottom of paper and push Pause Switch then the printer ejects the paper forward Current paper No is nota orb The printer feeds the paper to the tear off position and cut the paper by cutter and feeds backward to paper park position If cutter is not used or the printer fails to feed the paper to paper park position it goes incomplete changing paper path error If incomplete changing paper path error is occurred at the tear off position please cut at the top of paper and push Pause switch then the printer feeds the paper backward 1 32 Rev B 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 Clear EEPROM Area 2 Resets the printer to the standard factory setting only mechanism data area i e This function is for e
94. elligent serial I F card inch screw 32 KB intelligent serial card mm screw 32 KB intelligent parallel I F card inch screw 32 KB intelligent parallel I F card mm screw Local Talk I F card 32KB IEEE 488 card Coax I F card Twinax I F card Ethernet I F card IEEE 1284 parallel I F card Ethernet I F card Ethernet I F card 1 2 Rev 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 Refer to Figure 1 2 Print pin arrangement 9 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 1 69 mm 1 15 Figure 1 2 Printhead Pin Configuration Table 1 2 Print Speed and Printable Columns Print Mode Character Pitch Printable Columns Print Speed cps High Duty High speed draft 10 cpi 136 1120 1066 Draft 10 cpi 136 12 cpi 163 1008 0 15 cpi 204 Draft condensed 17 cpi 233 20 cpi 272 Draft emphasized 136 NLQ 10 cpi 136 12 cpi 163 15 cpi 204 NLQ condensed 17 cpi 233 20 cpi 272 Notes 1 The line including graphic FFh or download characters or bit image data will be printed by High duty mode Notes 2 The line including special high duty download characters or bit image data will be printed by
95. emove them one by one from the platen Hexagon Socket Screw Platen Rh N 8E 4 x b n 3 4 Ge J Platen Holder Left Platen Holder Right Lower Paper Guide Figure 3 62 Platen Removal No through Rear Platen 0 03mm Front Thickness Gauge Platen Holder Positionning Tab Figure 3 63 Platen Positioning ASSEMBLING POINT When you attach the 3 parts of the lower paper guide to the platen start with the one at the right end and work toward the left When you mount the platen to the platen holders space between the platen and positioning tab on the both sides must be less than 0 03mm Refer to Figure 3 63 ADJUSTMENT REQUIRED When you install the platen perform the following adjustments Carriage guide shaft parallelism adjustment described in Section 4 1 5 and Section 4 1 6 e Platen angle right angle adjustment described in Section 4 1 6 e Platen gap motor value platen gap adjustment described in Section 4 1 7 Rev B 3 43 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
96. en the tractor release lever is engaged the sprocket can move along the tractor shafts but it cannot move smoothly because the tractor wire tension is valid In the Figure 2 10 point A shows the movement range of the left tractor sprocket when the tractor release lever is released Point B shows the movement range of the right tractor sprocket when the release lever is engaged or released If the paper in the printer becomes bubbled you can pull the tractor wire to the right to stabilize the paper tension between the left and right tractor sprockets C A i d uu cum 7 j P oth Tension Tractor Wire Tractor Wire B Tension Spring in case of front enterance Figure 2 10 Tractor Wire Operation Rev B 2 9 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 When the RF motor pinion gear rotates counterclockwise the motor rotates the ribbon feed mechanism when it rotates clockwise the motor rotates the tractor select mechanism Ribbon feed mechanism Figure 2 11 shows the ribbon feed mechanism The ribbon i
97. executes the function shown in Table 1 14 Table 1 14 Switch Function at Power On Swtch Function NLQ self test Measurement seeking Refer to Chapter 4 Notes1 All of mechanism adjustment values are cleared Then it requires the printer mechanism adjustment Notes2 All of user setting value is replaced with the factory setting value Rev B 1 25 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 Pause Orange The LED on when the printer is paused and it is off when the printer is not paused The LED blinks when the printer is in the print head hot status Top of Form Green The LED on when the top of form position is adjustable and tear off position is adjustable Tear Off Green TheLED on when the paper is in Tear off position and it is off when the paper is out of the Tear off position Copy Green The LED is on at copy mode and it is off at normal mode Pitch Green The status of Pitch selection is displayed by three Pitch LEDs 10
98. g is available 20 lines after the paper end Paper feeding pitch is not guaranteed The end of the printable area is 9 to 15 mm apart from the bottom edge of the paper Figure 1 4 Label Printable Area Rev B 1 9 DFX 8500 Continuous forms with labels Refer to Figure 1 5 o fi Non Printable Area 0 6 oo 4i O OJO LOL Label ROL 1 Continuous Paper PW width PL length LM left margin TM top margin LFL left margin from label TFL top margin from label LOL left margin on label TOL top margin on label Notes 1 Feeding backward or paper PATH selection are prohibited Notes 2 the top 75 mm area the paper feeding pitch may be irregular Notes 3 If the optional pull tractor is used the top 120 mm area should not be printed Notes 4 Forms override printing is available 20 lines after the paper end Paper feeding pitch is not guaranteed The end of the printable area is 9 to 15 mm apart from the bottom edge of the paper Figure 1 5 Continuous Forms with Labels Printable Area 1 10 GENERAL DESCRIPTION Overlapping multi part forms Refer to Figure 1 6 LM RM PW lt _ emm Carrier OL TM PW width PL length LM left margin RM right margin TM top margin BM bottom margin OL overlapping length Notes 1 Feeding backward or paper PATH selection are prohibited Notes 2
99. ge guide shaft gear to the rear carriage guide shaft Carriage Guide Shaft Rear C bas 6 LOON ES d lt o 52 GS ED FS a SAM 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 Step 4 Detach the hook securing the PG home sensor and remove the sensor PG Home Sensor Platen Gap PG Motor Figure 3 69 PG Home Sensor Removal Rev B 3 47 DFX 8500 ASSEMBLING POINT Shaft Gear PG Transmission Gear Figure 3 70 CR Guide Shaft Gear Phase Alignment 3 48 Rev B 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 Figure 3 71 PG Home Sensor Removal Rev B 3 49 DFX 8500 3 2 6 16 Left Side Frame Gear Removal Step 1 Remove the front rear tractor select lever assembly Refer to Section 3 2 6 2 Step 2 Remove the connector junction board assembly Refer to Section 3 2 6 5 Step 3 Remove the PG motor Refer to Section 3 2 6 6 Step 4 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 B DISASSEMBLY AND ASSEMBLY
100. gure 3 17 Left and Right Side Covers Removal ASSEMBLING POINT e When you attach the right side cover connect the cable from connector CN1 on the C204 power supply board unit and the cable from the AC inlet to the main switch on the right side cover as shown below H Reverse side of _ the side cover R Magnification Main Switch AC Inlet Set Brown cable Brown cable C204 Power Supply Board Blue cable Blue cable Figure 3 18 Cabling for the Main Switch 3 14 Rev B 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 NWARNING amp 7 Make sure the new fuse meets the printer s AC power specifications Carriage Motor x Grounding Harness C204 PSB PSE Board Right Side 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 Then remove the front cover along the left hinge 4 16 Front Cover Figure 3 20 Front Cover Removal Rev B 3 15 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
101. he rest of the time it uses Deceleration driving mode 2 2 During this time the control circuit measures time periods using the encoder signal and controls the following e When duty data becomes Dutymin before the carriage speed reaches SP2 Then when the carriage speed reaches SP2 the next sequence SP2 takes effect e When the carriage speed reaches SP2 before duty data becomes the next sequence SP2 takes effect SP2 When the carriage speed reaches SP2 PI control oversees the carriage speed SPref 2 T 5 1 i E 0 i l 9 Acceleration Constant Speed Control 5 Deceleration 2 SS Figure 2 21 CR Motor Drive Circuit Block Diagram Rev B 2 27 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 During this time the control circuit measures time periods using the encoder signal and controls the following e When duty data becomes before the carriage speed reaches SP3 e When the carriage speed reaches SP3 before duty data becomes Dutymini the next sequence SP3
102. he ribbon so that the portion hit by the pins is constantly changing The RF motor drives the ribbon feed mechanism SHAF CR GUIDE REAR Interlock Switch CR Motor PG Motor Printhead G BELT CR Carriage Encoder Belt RF Motor PG Home DETECTOR CR Position Sensor Figure 2 2 Printer Mechanism Operation 1 2 2 Rev B 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 The printer is equipped with three PE sensors the front PE sensor at the front tractor the rear PE sensor at the rear tractor and the top PE sensor at the paper bail The pull tractor sensor detects whether the optional pull tractor unit is installed The printer is also equipped with a paper jam sensor The control circuit reads the signals from the sensors and indicates when an error occurs Tractor select mechanism The printer mechanism has two paper entrances one at the front tractor and one at the rear tractor By controlling the RF motor the tractor select mechanism chooses which tractor to use and power from the PF motor is conveyed via a series of
103. he tension pulley to the front remove the CR timing belt Remove the upper paper guide Refer to Section 3 2 6 8 Using tweezers unlock the locking tab of the tension roller gear at the left end of the tension roller shaft and remove the gear Remove the E ring 6 on the left end of the tension roller shaft and remove the shaft holder Tension Roller Gear Tension Roller Shaft Assembly Tension Roller Shaft Holder Figure 3 59 Tension Roller Gear Removal 3 41 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 Tension Roller Shaft Assembly Tension Roller Shaft Holder NR Leaf Spring Carriage Motor Figure 3 60 Shaft Holder Removal Tension Roller Shaft Assembly Figure 3 61 Tension Roller Shaft Removal 3 42 Rev B 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 r
104. hone 44 01442 61144 Fax 44 01442 227227 EPSON IBERICA S A Avda de Roma 18 26 08290 Cerdanyola del Valles Balcerona Spain Phone 582 15 00 Fax 582 15 55 EPSON AUSTRALIA PTY LIMITED 1 70 Gibbes Street Chatswood 2067 NSW Australia Phone 2 9903 9000 Fax 2 9903 9177 EPSON HONG KONG LTD Rooms 4706 10 47 F China Resource Bldg 26 Harbour Road Wanchai Hong Kong Phone 2585 4300 Fax 2827 7083 EPSON PORTUGAL S A R do Progresso 471 1 Perafita 4460 Matosinhos Portugal Phone 02 996 14 02 Fax 02 996 14 11 SEIKO EPSON CORPORATION Imaging amp Information Products Division EPSON DEUTCHLAND GmBH Z lpicher StraBe 6 4549 D sseldorf Germany Phone 0211 56030 Telex 8584786 EPSON FRANCE S A 68 bis rue Marjolin 92300 Levallois Perret France Phone 1 4087 3737 Telex 610657 EPSON ITALIA S P A V le F Casiraghi 427 20099 Sesto S Giovanni MI Italy Phone 2 262331 Fax 2 2440750 EPSON SINGAPORE PTE LTD No 1 Temasek Avenue 36 00 Millenia Tower Singapore 039192 Phone 065 337791 1 Fax 065 3341185 EPSON TAIWAN TECHNOLOGY amp TRADING LTD 10F No 287 Nonking E Road Sec 3 Taipei Taiwan R O C Phone 02 717 7360 Fax 02 712 9164 80 Harashinden Hirooka Shiojiri Shi Nagano Ken 399 07 JAPAN Phone 0263 52 2552 Fax 0263 54 4007 As of September 1996 EPSON SEIKO EPSON CORPORATION
105. ification 37 Line 5V DC Line Rating Output Voltage 37 0 VDC 5 0 VDC Available Output 35 5 37 5 VDC 4 75 5 25 VDC Voltage Fluctuation Rating Output Current Current Fluctuation Reset Method controlled by C204 MAIN board with PD signal Over Voltage Protection Turn the power switch off then turn it again Automatically recovered Reset Method Over Voltage Limit Value 42 VDC 7 VDC 1 37 V DC line Maximum in total is 13 0 A Rev B 2 13 DFX 8500 2 2 1 Power Supply Overview Figure 2 14 shows a block diagram of the C204 PSB PSE board AC Inlet AC Source 2 14 Switching 1 2 37V Line Power Down Over Voltage 1 Protection Surge Cut CN1 at Power On SOL Fuse FH Input Filter Rectifier Smoothing Circuit Circuit Circuit T1 37V Over Current Control Protection GP1 GP2 Current Limit Monitoring gu Ls Constant Voltage Control 37V Line Switching 2 2 5V Regulator 5V Regulator SD VP3 Down Monitoring PD DRERR Circuit Overcurrent 5V Protection O GL 37V e O vP3 Constant Control Voltage je Cur
106. igure3 4 Dial gauge master F612_ 7 8101946800 Figure3 5 ae Thickness gauge t 0 80mm Fhilips head torque adjustable Commercially available EPSON exclusive Mandatory Recommended I m gt Rev B 3 3 DFX 8500 Figure 3 3 Dial Gauges Figure 3 4 Dial Gauge Base Figure 3 5 Thickness Gauge Figure 3 6 Dial Gauge Master 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 Screw Abbreviations CBS SP CP SP CPS SP CPN O CPN SP Cross Pan head screw with Spring lock washer 4 Plain washer CPT O Cross Pan head Tapping screw with Outside toothed lock washer Table 3 3 Screw Names and Illustrations 1 Cross recessed head with Notch AAA 2 Outside toothed lock washer 2 Pan mo GR 4 Tapping 3 Spring washer Rev B 3 5 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 Is Check required Maintenance all necessary adjustments completed Are Checked Not necessary the results of the adju
107. ion a b c Figure 1 15 Perforations 3 Figure 1 18 Sprocket Hole 1 x Figure 1 19 Sprocket Hole 2 Figure 1 17 Unsuitable Paper NG Figure 1 20 Bad Folded Paper 1 18 Rev B 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 1 Parallel Interface Forward channel Data transmission mode 8 bit parallel IEEE 1284 compatibility mode Synchronization STROBE pulse Connector type 57 30360 AMPHENOL 36 pin plug or equivalent Handshaking BUSY and ACK handshaking Notes 1 BUSY signal is set high before setting either ERROR low or PE high and held high until all these signals return to their inactive state BUSY signal is at a high level in the following cases During data entry see data transmission timing When input data buffer is full During INIT signal is at a low level or during hardware initialization During printer error see ERROR signal During test printing or during setting printing During SelecType When the parallel interface is not selected Notes 2 ERROR signal is at a low level when the printer is in one of the following states Printer hardware error fatal error Paper out error Paper jam error Cover open status Incomplete paper change Paper size error Ribbon jam error Notes 3 PE signal is a
108. ion before this mode This mode is terminated also by the data arrival from host computers Copy Pressing it select copy mode or normal mode Pitch Pressing it selects one of following pitches 10 cpi 12 cpi 15 cpi 17 cpi 20 cpi and PS proportional spacing Font Pressing it selects one of following fonts Super Draft Draft Roman Sans serif Rev B 1 31 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 So cut at the top of paper and push Pause switch then the printer feeds backward After the paper is put the printer loads selected paper If incomplete changing paper error is occurred set the selected paper and push Pause switch Overlapping multi part forms or continuous forms with labels is set or pull tractor is used Incomplete changing paper error is occurred immediately Cut the bottom of paper at current page and push Pause switch then the printer feeds the paper forward After the paper is out the printer loads the selected paper If incomplete changing paper error is occurred set the s
109. is incorrect PG adjustment values are incorrect CR motor circuit shortage error Cutter error Platen gap error 1 2 3 Carriage lock 4 error Carriage load measurement error shortage error error setting error EEPROM data PW sensor is defective Auto power off e The CR encoder sensor is defective The head fan driver IC is shorted The head fan of the print head is immediately defective The coil of the print head is defective immediately defective after 12 seconds compare error is defective Tractor change e Tractor select mechanism is Auto power off Watch dog C205 MAIN board has trouble Note 1 The 7 segment LED indicates error No and E alternately Note 2 The descriptions show how the beeper sounds Beeper sounds 100 ms and interval is 100 ms Beeper sounds 500 ms and interval is 100 ms Note 3 Turn the printer power off while the 7 segment LED are on or the printer shuts power down automatically You can t turn the printer back on for 5 minutes after the printer shuts power down automatically Rev B 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 Cover Open NE Sensor 3 9 LE Interlock SW R
110. iver power is cut by the interlock switch The ENCA pulse that the carriage encoder outputs is input to general purpose port CRENCA of the gate array and the ENCB pulse that the carriage encoder outputs is input to general purpose port CRENCB of the gate array The gate array counts these pulses using the internal counter and determines the amount and direction of motor rotation 37 VDC Table 2 6 CR Motor Specifications ___ m Internal Coil 1 66 ohms 10 95 Resistance Current Accerelation Deceraration Consumption 1 4 6 A AV Q4 R1 02 Constant Speed 1 at Super draft printing 10 GP3 GND Figure 2 19 CR Motor Internal Circuit ENCA ENCB y Interlock SW A Board STK681 050 IC1 Carriage Encoder Sensor gt VCC1 1 t 1 2 016 034 QCRBX gt 7 gt Q35 1 gt CRCX 918 702 gt gt r y Plate 4 9 a IN D OUT CRA 9 9 Carriage E ss S CRCLK gt CLK OUT2 Motor H GP GP CRB Vref A GP3 Av lt Q5 AIN 5V gt d AIN AOUT Vref uPC393C IC3 201 43V CRCLM CPU GP3 TMP85C061 CRINS Partical
111. justment 4 1 6 Platen Angle Adjustment 4 1 7 Platen Gap Motor Value Adjustment The parameters to be written to the EEPROM on the C204 Main board in this adjustment are as follows 1 Measurement seeking 2 Print head flight time adjustment value 3 Bi directional printing alignment value for each speed mode Super Draft Draft and NLQ 47 If the DIP SW 3 5 is set to the mode On it can not perform the Bi D adjustment Therefore when you perform the Bi D adjustment set the DIP SW 3 5 to Off amp 7 When replace the C204 Main board the ALPHA and BETA values are not written into the memory In reality 0 value is installed on the Main board Since this reason Since PG is too large it can not print the each current value to the paper Due to this Perform the platen gap value adjustment before perform this adjustment Rev B 4 15 DFX 8500 START Mount the ribbon cartridge Turn the power SW on while pressing Micro Feed and Micro Feed v SWs The printer performs carriage measurement seeking automatically It goes to ON LINE status after this operation Turn the printer power off NY Figure 4 20 Carriage Measurement Seeking 4 16 Rev ADJUSTMENT START y Mount the ribbon cartridge y Turn the power SW on while pressing Tear Off Micro Feed and Front Rear SWs Y Set the 15 fanfold paper at Front or Rear tractor and load the paper by pressing LF FF Loa
112. l 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 OPERATING PRINCIPLES Describes the theory of printer operation CHAPTER 3 DISASSEMBLY AND ASSEMBLY Includes a step by step guide for product disassembly and assembly CHAPTER 4 ADJUSTMENT Includes a step by step guide for adjustment CHAPTER 5 TROUBLESHOOTING Provides EPSON approved techniques for troubleshooting CHAPTER 6 MAINTENANCE Describes preventive maintenance techniques and lists lubricants and adhesives required to service the equipment APPENDIX Describes connector pin assignments circuit diagrams circuit board component layout and exploded diagram The contents of this manual are subject to change without notice REVISION SHEET Issued Data 18 1998 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 APPENDIX GENERAL DESCRIPTION OPERATING PRINCIPLES DISASSEMBLY AND ASSEMBLY ADJUSTMENT TROU
113. les can not be selected by DIP switch B International character sets 13 countries USA France Germany U K Denmark 1 Sweden Italy Spain 1 Japan Norway Denmark 2 Spain 2 Latin America Note The international and legal characters are these 12 codes 23h 24h 40h 5Bh 5Ch 5Dh 5Eh 60h 7 7 7Dh 7Eh Typeface Bit map font EPSON Draft 10 CPI 12 CPI 15 CPI EPSON Roman 10 CPI 12 CPI 15 CPI Proportional EPSON Sans Serif 10 CPI 12 CPI 15 CPI Proportional a Bar code EAN 13 EAN 8 Interleaved 2 of 5 UPC A UPC E Code 39 Code 128 POSTNET 1 4 Rev B GENERAL DESCRIPTION Character tables and type faces Refer to Table 1 4 Table 1 4 Character tables and type faces Standard version Italic Table EPSON Draft PC437 US Standard Europe EPSON Roman PC850 Multilingual EPSON Sans Serif PC860 Portuguese PC861 Icelandic PC863 Canadian French PC865 Nordic Abicomp BRASCII Roman 8 ISO Latin 1 Italic table NLSP version Italic Table EPSON Draft PC437 US Standard Europe EPSON Roman PC850 Multilingual PC437 Greek EPSON Sans Serif PC852 East Europe PC853 Turkish PC855 Cyrillic PC857 Turkish PC866 Russian PC869 Greek MAZOWIA Poland Code CSFR ISO 8859 7 Latin Greek ISO Latin 1T Turkish Bulgaria Bulgarian Estonia Estonia 774 LST 1283 1993 150 8859 2 ISO Latin 2 PC 866 LAT Latvian PC 866 UKR PC 860 PC 861 PC 865 PC APTEC PC 708 PC 720 PC 864 PC
114. low earth cable and the earth plate together Earth Cable CBS O Screw M4x8 C204 PSB PSE Board Bottom Panel Assembly Right side Figure 3 23 Connector and Earth Cable Removal right side 3 18 Rev B 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 Earth Cable Flat Cable Connector 50 pin Mechanism 4 pin CR Connector e 9 7 pin Option Cutter Flat Cable Connector 50 Printhead 2 Cover Open Sensor 5 14 pin Panel Unit Figure 3 24 Connector and Earth Cable Removal left side Step 5 Open the rear cover Remove the four CBB M3x12 screws and two CB M3x12 screws securing the interface cover and remove the cover Step 6 Remove the 2 CB M3x12 screws securing the optional interface cover and remove the cover CB M3X12 Optional Interface Cover Interface Cover MN p 3 E CBB M3X12 Rear Cover Figure 3 25 Interface Cover Removal Rev B 3 19 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
115. lunger 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 CR motor drive IC STK561 IC1 PF motor drive IC STK5713B IC2 Comparator IC uPC393C IC3 Figure 1 27 C204 DRV Board 1 40 Rev B GENERAL DESCRIPTION 1 5 4 C204 DRV B Board The C204 DRV B board is the 1 2 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 3 lode Figure 1 29 C204 SUB Board Unit Rev B 1 41 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 B 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
116. mation you need to assemble printer components is provided in notes labeled ASSEMBLING POINT Adjustments required before assembly are described in notes labeled ADJUSTMENT REQUIRED Be sure to follow the instructions in these notes Rev B 3 7 DFX 8500 3 2 1 ROM Replacement 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 thick soft cloth under the printer before you follow the steps below Remove the ROM carefully to avoid damaging the board Before you install a new ROM check the INDEX mark on the socket to be sure the ROM is oriented correctly Insert the ROM carefully to avoid damaging the ROM pins and the board When transporting the printer a long distance pack it using the original packing material Step 1 Tilt back the printer and lay it on its back Hold the top cover closed if it is not removed Step 2 Remove the CBB M3x10 screw securing the ROM cover remove the cover and replace the ROM using the ROM holder s uu Hu E tL CBB M3X10 Figure 3 7 ROM Replacement 3 8 Rev B DISASSEMBLY AND ASSEMBLY 3 2 2 Printhead and Ribbon Mask Assembl
117. mergency and service Clear Driving Line count for ribbon change timing Resets the printer to the standard factory setting only driving line count for ribbon change timing Paper memory setting This makes it possible to print properly on the forms which contain two areas having different thickness in a form and paper type Mechanism adjustment Starts the mechanism parameter adjustment mode You can adjust Beta parameter flight time parameter and Bi D parameter through this mode Platen gap adjustment Starts the platen gap parameter adjustment mode You can input Alpha parameter and adjust Beta parameters through this mode Measurement seeking Starts the measurement seeking automatically The carriage stopping length is measured and saved in the EEPROM Rev B 1 33 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 The print patterns which exceed that end won t be printed Automatic paper thickness adjustment This printer measures the paper thickness after every paper loading The distance betw
118. monitored by the analog port of the CPU 15 PSB PSE board power off sensor signal interface 2 22 CPU 95 061 122 NV LNY 3304 8 uoneinsu 42 QA ES 43400 GINI 8 N N U E 8 3 g T g 5 5 5 s F 3 3 i 8 a E 5 CN10 CN14 CN3 CN1 ENCA ENCB PGENCA PGENCB PG Home E05B36 TRSEL PTRCT PJAM FPE RPE TPE RBJAM 148 149 PGENCA PGENCB PG Home Tractor Select Pull Tractor Paper Jam Front PE Rear PE Top PE Ribbon Jam Figure 2 18 Sensor Circuit Block Diagram ENCA CN4 ENCB CR Encoder CN14 Rev B 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 Paper jam sensor Detection form Magnetic transistor Output form Rectangle wave 1 channel TTL level Logical Paper feed Level changes continuously Paper jam Level remains the same Supplement The magnetic transistor is a
119. n feed motor to the ribbon feed motor frame and remove the motor Step 3 Remove the E ring 3 securing the upper lower tractor select levers and remove the levers Step 4 Remove the E ring 3 securing the tractor select cam and remove the cam Step 5 Remove the CPS P1 M2x10 screw securing the tractor select sensor and remove the sensor Step 6 Using wire cutters cut the wire band securing the ribbon feed motor and tractor select sensor cables to the ribbon feed motor frame Tractor Select Cam Washer S Leaf Spri E ring 3 5 eaf Spring Tractor Select Transmission Gear Tractor Select Lever put ey E ring 3 Upper 248s 9 dl Tractor Select Lever Spring ad em Transmission Gear CPS P1 M2X10 ZA EUN Pd 22 4 M 9 Is si Tractor Select ZF Sensor Tractor Select i Lever lower Ribbon Feed Motor ai Y Frame Ribbon Feed Motor en CP S P1 M3X6 Figure 3 49 Tractor Select Lever Disassembly ASSEMBLING POINT Attach the tractor select levers to the tractor select cam as shown in Figure 3 50 Ribbon Feed Motor Frame Ribbon Feed Change Lever Upper and Lower Figure 3 50 Tractor Select Lever Installation 3 34 Rev B 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 con
120. n 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 Note It is necessary to clean the carriage encoder belt periodically When this printer is returned for service clean the surface of carriage encoder belt 6 2 LUBRICATION AND ADHESIVE APPLICATION EPSON recommends that the printer be lubricated at the points illustrated in Figures 6 2 6 3 and 6 4 using EPSON lubricants O2 and G26 These lubricants have been extensively tested and found to comply with needs of the printer Refer to Table 6 1 for information on lubricants O2 and G26 Table 6 2 lists the appropriate lubricant for each point Make sure the parts to be lubricated are clean before applying lubricant Also avoid applying too much lubricant because it may damage related parts Adhesive application is necessary at the points indicated in Table 6 3 when parts are disassembled or replaced EPSON recommends Neji Lock 2 adhesive be applied to the points indicated in Figures 6 2 6 3 and 6 4 Avoid allowing excess adhesive to overflow onto related parts Table 6 1 Recommended Lubricants Type Quantity Availability B702600001 B710200001
121. nector 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 CP S P1 M3x6 Front Rear Tractor Select Lever Assembly Figure 3 51 Ribbon Jam Sensor Removal Rev B 3 35 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 S P1 M3x6 screws securing the connector junction board assembly to the printer mechanism and then remove the connector junction board assembly Step 3 Remove the front rear tractor select lever assembly Refer to Section 3 2 6 2 Step 4 Disconnect the connector for the CR sensor encoder from the FPC board assembly Step 5 Remove the 2 CBS M3x8 screws securing the FPC cover and remove the cover Refer to Figure 3 10 Then remove the CPS P 1 M3x6 screw securing the FPC board assembly to the printer mechanism and remove the FPC board assembly Connector Junction Board CR Encoder Connector CPS P1 M3x6 CPS SP 1 M3x6 Figure 3 52 Connector Junction Board Removal ASSEMBLING POINT When you connect the cables to the connector junction board assembly note that the matching connectors have the same color an
122. nectors Is the fault corrected Manually move the carriage to see if movement is smooth or not Refer to Section 5 3 Repair of the Printer Mechanism Perform repair necessary Check the CR motor and CR motor drivers using a multimeter OK No Is the fault corrected If the motor is bad replace If drivers are bad replace at the same time Y Is the fault corrected Replace the C204 MAIN board and or C204 DRV board NOTE 1 Check the following connectors Junction board connector to interlock switch Junction board connector to CR motor Head junction board connectors to printhead CN4 of C204 MAIN board to head junction board 5 6 Rev B TROUBLESHOOTING 3 Carriage operation is normal but the self test is printed incorrectly 1 3 NE MN Perform the self test Does the printer perform self test pe Is there any dot missing or dragging Are the connectors listed in NOTE 1 inserted securely Yes Reinsert correctly Y 15 the No ault corrected Check printhead cable continuity Visually check printhead pins Replace END any bad part Yes v Perform the bidirectional printing adjustment NOTE 1 Check the following connectors Three head junction board connectors to printhead CN1 of C
123. ng must be outside of printable area Multi part paper should be bound firmly to each other and the binding must not be too large Refer to Section 1 2 12 5 Refer to Section 1 2 12 6 Surface Less than 1 BO Figure 1 7 Dotted Paste Positions 1 1 GENERAL DESCRIPTION Printable surface Less than paper thickness Figure 1 8 Paper stapling Height Paper feeding direction X y OK NG lt Figure 1 9 Paper stapling Method 1 NG Figure 1 10 Paper stapling Method 2 Rev B 1 13 DFX 8500 1 2 12 2 Labels Table 1 6 Labels Front Entry Rear Entry Minimum Label Size Refer to Figure 1 11 Backing Sheet Width inch mm mm mm 0 0 Total Thickness inch 0 0025 0 0075 mm 0 065 0 19 Quality AVERY CONTINUOUS FORM LABELS AVERY MINI LINE LABELS or the same quality labels Refer to section 1 2 12 5 Notes The easy cone off label should not be used Every label must be put on the carrier Each comer of those labels must be rounded Each label and backing sheet should not have any folds or creases Between each label there should be the same sheet as those labels The backing sheet must be continuous paper Labels should be inserted from front entrance Refer to Section 1 2 12 6 Figure 1 11 Label Size 1 14 Rev B GENERAL DESCRIPTION 1 2 12 3 Continuous Forms with Labels Table 1 7 Continu
124. nnector Connection Pin Number Tableto Refer C204 MAIN Board CN8 gt C204 DRV B board Table A 9 gt IEEE 1284 Tables 1 10 an 1 11 CN14 gt C204 DRV board able A 13 CN15 gt C204 SUB board able A 14 CN16 gt C204 SUB board 7pins Table A 15 C204 DRV Board gt C204 MAIN board 50 pins X2 Table A 13 N2 gt Printer mechanism 50pins Table A 16 N3 gt C204 PSB PSE board able A 17 C204 DRV B Board gt Mechanism Printhead 30pins Table A 18 N2 C204 MAIN board Table A 9 N3 gt C204 MAIN board able A 3 C204 PSB PSE board 19 gt C204 MAIN board Table A 7 CN3 gt C204 MAIN CN7 and C204 DRV 12 A 8 and 17 CN3 boards gt C204 MAIN board 8 Table 11 Cooling fan motor 2 Table A 20 Rev B APPENDIX Table A 2 C204 MAIN Board Connector CN1 Pin vo Function k pPrntheadpinfiO 250 10 2 0 pPrntheadpinfl2 4 2 5 o Phe pPrntheadpinfl a Printhead pin 17 591 ______ GND 1 0 O 12710 _____ 13 1 0 PPrntheadpinfoO O 3 ____ 0 Oi 15 P2 0 PPrntheadpinf2 O 16 Pet 10 pPrntheadpnsti O 17 0 __ 7 IR S 222 35 1 PFmofo
125. nterface selection When the parallel interface is not selected the interface got into a busy state When the serial interface is not selected the interface sends X OFF and sets the DTR signal MARK When the optional interface is not selected the printer sends disable commands to the optional interface When the printer is initialized or returned to the idle state the parallel interface got into a ready state the serial interface sends X ON and sets the DTR SPACE and the printer sends enable commands to the optional interface Caution that the interrupt signal such as a INIT signal on the parallel interface is not effective while that interface is not selected Prevention Hosts from Data Transfer Time out Generally hosts abandons data transfer to peripherals when a peripheral is in busy state for dozens of seconds continuously To prevent hosts from this kind of time out the printer receives data very slowly several bytes per minute even if the printer is in busy state This slowdown is started when the rest of the input buffer becomes several hundreds of bytes At last when the input buffer is full the printer is in busy state continuously Rev B 1 23 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 printe
126. ntrol Signals Level TTL High 37 VDC 37 VDC 5 VDC Power Down 0 VDC 37 VDC 5 VDC Head coil driver error Low 37 VDC 37 VDC 5 VDC Source Down Indefiniteness lt 30 VDC 5VDC Te 37 VDC 37 VDC 5 VDC 35 VDC 35 VDC 5 VDC 1 From the view of the PSB PSE board 2 VP1 GP1 and VP2 GP2 3 VP3 GP3 and 5V GL 4 Due to high duty printing 2 16 Rev B 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 122 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 205836 IC1 The CPU accesses the internal RAM and external RAM IC14 The CPU also controls the EEPROM IC11 used to store the parameters such as the tear off position while the printer is turned off The CPU controls all the printer operations via the peripheral IC E05B36 IC1 and controls the printer mechanism The main functions of the E05B36 IC1 are CS Chip Select signal creation address decoding printhead driver control carriage driver control encoder pulse circuit control PG and HF phase signal creation interface control CR and PF motor driver
127. o 0 01 inches between the PG motor pinion gear and PG transmission gear cog Then tighten the two screws N d MS VO 4 a PG Transmission Gear 0 05 0 15mm PG Motor Pinion Gear Screws PG Motor Figure 4 1 PG Motor Mounting Position Adjustment Rev B 4 1 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 Step 1 Loosen the three tension adjustment screws on the CR motor Confirm that the carriage timing belt is attached properly and that no load is applied to it Step 2 Insert the tension gauge hook through the hole in the tension lever Step 3 Pull the tension gauge horizontally to apply a 7 kg 15 4 Ib force Step 4 Move the belt left and right while pulling the tension gauge and move the motor pulley slightly Step 5 Tighten the three CPS M4x10 tension adjustment screws and secure them while the 7 kg 15 4 Ib force is applied Step 6 Finish tightening the three tension adjustment screws with 12 Kg cm torque CPS M4X10 Figure 4 2 Carriage Timing Belt Tension Adjustment 4 2 Rev B ADJUSTMENT 4 1 3 Tractor Wire Spring Tension Adjustment This section describes the tractor wire spring tension adjustment If the spring is not adj
128. o positions shown in Figure 4 5 is less than 0 015 mm Since this value is extremely small you must use the two dial gauges dial gauge base and dial gauge master supplied by EPSON Do not adjust the parallelism using any other method amp 7 Dial gauges x 2 F610 Part No B1019466 87 Dial gauge base F611 Part No B1019467 amp 7 Dial gauge master F612 Part No B1019468 Before performing the carriage guide shaft parallelism adjustment you must assemble the two dial gauges dial gauge base and dial gauge master to form one tool Follow these steps Step 1 Attach the two thumb screws for the dial gauge base to the dial gauge master To eliminate any play between the dial gauge base and the dial gauge master pull the tie band to secure the dial gauge base and the dial gauge master before you securing the thumb screws Do procedure with two men Figure 4 5 Set Dial Gauge to Dial Gauge Base Step 2 Attach a dial gauge needle to the surface of the dial gauge master approx 2 00 mm depth then tighten the hexagonal screw securing the dial gauge to the dial gauge base 2 Tighten the hexagonal screw 1 Attach the gauge needle to the master surface Figure 4 6 Dial Gauge Set Up 1 Rev B 4 5 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
129. oard Replace the C204 PNL board No No Replace the C 204 PNL board Yes v Replace the 204 MAIN board Do the buttons work Rev B 5 11 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 Troubleshoot printer using the previous flowcharts Which I F are Built in Parallel you using i Serial or Optional Check the cable connection from the host computer Are the DIP Switches set correctly See Tables 1 16 1 21 1 22 and 1 23 Set switches correctly our parallel cable is shielded twisted pair cable less than 2 m and does it work with another printer If you are using a serial I F is your cable a null modem cable Yes Replace C204 MAIN board y Yes Replace cable Replace C204 MAIN board NEN Not using serial If you are using a Type B optional I F for a network is e network configured correctly Replace Type B interface v Reconfigure network 5 12 Rev B TROUBLESHOOTING 5 2 CIRCUIT BOARD REPAIR This section provides detailed troubleshooting methods to isolate components in the po
130. of the CPU and also to the gate array itself INIT Signal Reset When the gate array receives the INIT signal from the host computer the signal is transferred to the INT4 of the CPU then CPU performs the INIT reset operation R215 3 Type B R218 113 your AAA RESETX Parallel 52 INIT signal PST591 E05B36 T eid IRSTOUTX v XX INITRQ ERRCRPFX 30 36 T XRESET INT4 lt ene CPU TMP95C061 IC2 Figure 2 17 Reset Circuit Block Diagram Rev B 2 21 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 Front and rear PE sensors use a photo interrupter Top PE sensor to detect the TOF position uses a photo interrupter Paper jam sensor uses a magnetic transistor Tractor select sensor uses a micro mechanical switch Pull tractor sensor uses a micro mechanical switch CR encoder sensor uses a photo interrupter PG encoder sensor uses a photo interrupter PG home sensor uses a micro mechanical switch Ribbon jam sensor uses a photo interrupter 10 Cover open sensor uses a micro mechanical switch 11 Printhead temperature sensor uses a thermistor 12 Head fan temperature sensor uses a thermistor 13 Paper width sensor uses a photo reflector 14 CR motor isolation resistance sensor
131. on 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 B DISASSEMBLY AND ASSEMBLY 3 1 2 Tools This section describes the tools required for assembling disassembling or adjusting the printer Note Hefer 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 Driver No 2 B743800200 20 mm or more shaft length with magnetization is recommended DriverNot O Driver No 1 Box screw driver 7 mm 0 28 inches across E ring holder No 3 740800500 E ring holder No 6 B740800800 Round nose piers 87404000 Diagoalwiecuters 1 874050010 Tweezers B741000100 B743800400 B741700200 7 m mee Electric soldering iron 1 874020010 ___ Tension gauge e A 187 7503011 m Tension gauge 2009 __ 87651146011 eae 6100 8101946600 Figure3 3 Dial gauge base F611 8101946700 F
132. on the C204 MAIN board assign the common voltage for the printhead coil Pins 1 2 7 9 10 11 12 16 and 17 are supplied by the VP2 GP2 line CN1 on the C204 MAIN Pins 3 4 5 6 8 13 14 15 and 18 are supplied by the VP1 GP1 line CN1 on the C204 DRV B board The CPU monitors the printhead temperature and head fan HF temperature When the temperature rises abnormally printing stops at once until the temperature cools The CPU also monitors the printhead driver status P channel and N channel FET respectively If the printhead driver FET shorts CPU IC2 port PDRERR P channel NDRERR N channel detects HIGH level and the E05B36 IC1 sends the DRERR Driver Error signal to the C204 PSB PSE board When the C204 PSB PSE board receives this signal it stops the output voltage and the printer beeps MAIN Board EINE HF Motor Thermistor 4 5 gt E05B36 IC1 HF Motor FANAX E gt TMP95C061A c2 Bee AE 2544 sw VX VP2GP2 A NF an gt Printhead Coils 1 2 Printhead Driver Circuit 2 2 Printhead Coils 2 2 i z lese an Printhead Thermistor R100 Monitoring NPNs Short Circuit Monitoring PNPs R101 Short Circuit Figure 2 27 Printhead Drive Circuit Block Diagram Rev B 2 33 DFX 8500 Printhead high temperature feedback o
133. orm this measurement and correct the value written on the label because the value is necessary when the other units board printhead are changed NCAUTION amp 7 This measurement is important because it determines the platen gap so be sure to use the exclusive thickness gauge set and tension gauge Thickness gauge 0 43 Thickness gauge 0 80 Tension gauge 200 g 545 EPSON No B765114601 Do not turn the printer off during adjustment When adjusting the platen gap to narrower or wider using the Micro Feed and Micro Feed v switches be sure to adjust the gap by 1 step at a time 4 After perform this adjustment perform the Bi Directional adjustment as explained in section 4 1 8 Printhead Side Frame Left BETA Value 31600000X x XX KX amp ALPHA Value Print Frame Front Production No Figure 4 17 ALPHA Value Print Figure 4 18 BETA Values Print 4 12 Rev ADJUSTMENT Step 1 Remove the paper ribbon cartridge and ribbon mask holder from the printer Then confirm the ALPHA value written on the print head nose Step 2 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 v
134. orts PGOO to PGO03 The PF motor is controlled using open loop phase switching based on the specified time data and the phase driving method is 1 2 phase excitation When the PF motor is held the phase driving method is 1 phase excitation The CPU selects the most suitable driving mode from the modes below according to conditions such as the paper feed length and the pull tractor condition Micro feed adjust mode lt 20 432 inches Middle speed mode gt 20 432 inches and lt 60 432 inches or with optional pull tractor Normal speed mode gt 60 432 inches Each phase switching FET in driver IC2 is an open collector When the phase switching data is HIGH the motor is turned on The PFA port of the gate array monitors the phase A signal of the PF motor and checks whether it is operating normally The PFA port is used as the WDT watch dog timer If PF motor operation is abnormal the gate array outputs the RSTOUT reset request signal to the system reset IC IC13 Refer to Section 2 3 2 Reset Circuit MAIN DRV Gate Array Board E05B36 IC1 PFH R H Ref Voltage i Setting Circuit Q9 Vref H 1 4 B 4 3 VDC Y Y lt lt CPU TMP95C061A 2 GP3 22 VP3 PG00 srKe743B 4 PG01 gt INXA IC2 PGo2 PINB OUTA P gt gt
135. ous Forms with Labels Front m Rear Label Size Refer to Section 1 2 o 5 mm 2 Width inch ge I mm 101 406 EIL on 101 431 9 multi part 14 22 one sheet of multi part Ib 11 15 0 Label Thickness inc 0 0 0 0047 oo Total Thickness inch 0 0025 0 021 mm Quality Multi part forms Plain paper reclaimed paper __ c multi part forms Quality Label AVERY CONTINUOUS FORM LABELS AVERY MNI LINE LABELS or the same quality labels Multi part binding e Rough bindings of multi part paper cause paper jam e The each sheet of multi part paper should normally be put together by spot gluing paper stapling tape stitching Spot gluing is recommended for the better printing quality Spot gluing must be applied on both sides of paper Refer to Figure 1 7 The spot glued parts must be pressed flat There must be no creases in the paper The paper stapling must be applied from the front of paper and the paper must be flat Refer to Figure 1 8 Paper stapling must be applied for both feeding directions Refer to Figure 1 9 The paper stapling should be flat Refer to Figure 1 10 Never use metal staples The position of binding must be outside of printable area Multi part paper should be bound firmly to each other and the binding must not be too large Notes e The easy cone off label should not be used Every label must be put on th
136. per path How to recall memories You can recall paper memories which you have already written some information in advance when you selects paper No a or No b by paper select switch No a recall the memory a No b recall the memory b Notes 1 1 skip perforation area is automatically included for the overlapping multi part forms 2 ESC C ESC C ESC c is valid while the paper memory function is used 3 ESC Nis valid while the paper memory function is used but if the skip length is less than 1 inch the setting will be ignored when overlapping multi part forms is used 4 ESC 0 is invalid while the paper memory function for overlapping multi part forms is used 5 The loading position must be adjusted for overlapping multi part forms at every loading 6 If paper position doesn t correspond with TOF when turn on the printer paper is advanced to the top of the next page automatically How to write the information of a paper except Continuous forms with labels 1 Make sure the printer is turns off 2 Select the memory you want to write the information See DIP SW setting 3 Select the page length See DIP SW setting 4 Select the paper type See DIP SW setting 5 Turn the printer on while both sides of Paper Select switch are depressed 6 The printer writes the information in the memory you selected and beeps How to write the information of Continuous forms with labels 1 Make sure the
137. peration The printer supports the printhead temperature detection sequence which consists of the following steps 1 When the printhead temperature is less than 110 the printer performs normal printing 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 3 When the printhead temperature exceeds equal or more than 120 C the printer stops printing until the temperature goes down to 100 C or less 4 When the printhead temperature returns less than 100 the printer performs normal printing again HF temperature feedback operation The printer supports the printhead fan HF temperature detection sequence which consists of the following steps 1 When the printhead fan temperature is less than 65 C the HF fan stops 2 When the printhead fan temperature exceeds equal or more than 65 C the HF rotates 3 When the printhead temperature goes down to 50 or less the HF stops again 2 34 Rev B CHAPTER 3 DISASSEMBLY AND ASSEMBLY So OVERVIEW n 3 1 3 1 1 Precautions for Disassembly and Assembly seen 3 1 3 2 TOONS reas ah cea creat ena ae acre aaa a D 3 3 3 1 3 Specification for e 3 5 3 1 4 Service Checks After
138. 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 The housing large openings in both the front and rear for paper entrance and exit It also has a lid on the both plate to enable the PROM on the main board to be easily replaced Figure 1 31 Housing Rev B 1 43 2 1 2 2 2 3 2 OPERATING PRINCIPLES PRINTER MECHANISM 2 2 2 2 4 2 1 2 1 1 Printhead Mechanism 2 4 2 12 Carri ge Mechanism 2 5 2 1 3 Platen Gap Adjustment Mechanism eese tnnt nnn 2 6 2 1 4 Paper Feed 2 7 2 1 4 1 Tractor Wire enne nnne enn snnt snnt nnns 2 9 2 1 5 Ribbon Feed and Tractor Select Mechanisms esee 2 10 2 1 6 Plunger 2 12 POWER SUPPLY OPERATION ecce coco coe co e cree coser to recurre co e cre ere cux 2 13 2 2 1 Power Supply
139. r operations The panel consists of indicator lights and buttons Power Top of LF FF Micro Pause Tractor Selec Paper Font Pitch Copy Form Load Feed PAPER SELECT Le 1 Out SperDraf 10 cpi BL BOG 12 Roman 15 Ribbon Sans serif EB 17 cpi E 120 cpi Tear Off Reset Paper Selec m Front Rear LED Off LED Figure 1 22 Control Panel 1 24 Rev B 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 Swith Alternates printing and no printing status Enables reset function holding it down for three seconds LF FF Load Loads the paper when the paper is empty Executes line feed pressing it shortly Executes form feed holding it down for a few seconds TOF top of form Set current point to top of form when the cover opens Enables loading position adjustment and tear off position adjustment when the cover opens Operation at power on Tuning the printer on while pressing panel switches
140. r or gate array power supply board waveform for the head driver Refer to HIGH level turns off the head driver waveform figure the power suppl The reset circuit is not Check the logic level at pint VOUT of Replace IC13 operational forlogic IC13 The driver circuits The pull up voltage When the collector of Q15 is high Replace Q15 don t operate at VX is not generated Check the logic level at collector of Q14 all VX When the collector of Q15 is high VX is HIGH Serial interface 15 The level converter IC Check the signal level change between Replace IC9 dead is defective in and out port of the 129 5 16 Rev B TROUBLESHOOTING Table 5 6 C204 MAIN DRV DRV B boards Component Repair 2 7 Checkpoint The printer does The control ROM is Confirm that the PROM is inserted the Replace 1605 not operate atall defective Socket correctly The gate array IC1 Check pin 86 DO 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 IC1 The DRAM IC14 is Observe pin 2 DO of IC14 fora Replace IC14 defective change in the signal HIGH or LOW Rev B 5 17 DFX 8500 The carriage operates abnormally 5 18 Table 5 6 C204 MAIN DRV DRV B boards Component Repair E Checkpoint IC1 on the C204 Check the signals for the carriage Replace aioe o MAI
141. r the measured BETA values BETA2 and BETA4 are out of range Refer to Table 4 1 or the below formula is not satisfied the printer sounds five beeps and not written the values to the EEPROM Formula 1 0 43 BETA2 and 0 0134 lt A1 lt 0 0187 2 0 80 0 43 4 and 0 0115 lt 2 lt 0 0195 Step 20 Install the ribbon mask holder and the ribbon cartridge Rev B 4 13 DFX 8500 Platen LEE LETT I Tension Gauge 1 135 165 gf Thickness Gauge 0 43mm Figure 4 19 Thickness Gauge Setting Method Table 4 1 BETA Values Adjustment BETAS O483mmwihisogpul BETAS 405 437 4 418 475 1 When EEPROM is reset 4 14 Rev B 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 bi directional 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 2 Carriage Timing Belt Tension Adjustment 4 1 5 Carriage Guide Shaft parallelism Ad
142. rent Limit Monitoring Abnormal Current VP1 VP2 Monitoring GP3 GP3 Fan Driver IO FANDR Figure 2 14 Power Supply Board Block Diagram O vP1 VP2 CN3 4 2 5 Rev B 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 1 2 and 2 2 The one convert the voltage to the 37 VDC specially for the print head coils drive requirement The other convert the AC voltage to the 37 VDC for the printer mechanism drive power requirement motors solenoid etc and for the source of 5 V DC regulator circuit requirement Refer to Table 2 3 37V line block 7 The generated 37 VDC is divided into two destinations nine of the eighteen printhead pins pins 1 2 7 9 10 11 12 15 and 17 the other to nine of the eighteen printhead pins pins 3 4 5 6 8 13 14 16 and 18 37V line block 2 2 The generated 37 VDC is supplied to the motors and plunger on the printer mechanism it also supplied to the 5VDC regulator circuit and it output 5V DC is supplied to the logic circuit on the main circuit Cooling fan The C204 PSB PSE board includes a cooling fan that is
143. res WARNING 1 ALWAYS DISCONNECT THE PRODUCT FROM BOTH THE POWER SOURCE AND PERIPHERAL DEVICES PERFORMING ANY MAINTENANCE OR REPAIR PROCEDURES 2 NO WORK SHOULD BE PERFORMED ON THE UNIT BY PERSONS UNFAMILIAR WITH BASIC SAFETY MEASURES AS DICTATED FOR ALL ELECTRONICS TECHNICIANS IN THEIR LINE OF WORK 3 WHEN PERFORMING TESTING AS DICTATED WITHIN THIS MANUAL DO NOT CONNECT THE UNIT TO A POWER SOURCE UNTIL INSTRUCTED TO DO SO WHEN THE POWER SUPPLY CABLE MUST BE CONNECTED USE EXTREME CAUTION IN WORKING ON POWER SUPPLY AND OTHER ELECTRONIC COMPONENTS CAUTION 1 REPAIRS ON EPSON PRODUCT SHOULD BE PERFORMED ONLY BY EPSON CERTIFIED REPAIR TECHNICIAN 2 MAKE CERTAIN THAT THE SOURCE VOLTAGE IS THE SAME AS THE RATED VOLTAGE LISTED ON THE SERIAL NUMBER RATING PLATE IF THE EPSON PRODUCT HAS A PRIMARY AC RATING DIFFERENT FROM AVAILABLE POWER SOURCE DO NOT CONNECT IT TO THE POWER SOURCE 3 ALWAYS VERIFY THAT THE EPSON PRODUCT HAS BEEN DISCONNECTED FROM THE POWER SOURCE BEFORE REMOVING OR REPLACING PRINTED CIRCUIT BOARDS AND OR INDIVIDUAL CHIPS 4 IN ORDER TO PROTECT SENSITIVE MICROPROCESSORS AND CIRCUITRY USE STATIC DISCHARGE EQUIPMENT SUCH AS ANTI STATIC WRIST STRAPS WHEN ACCESSING INTERNAL COMPONENTS 5 REPLACE MALFUNCTIONING COMPONENTS ONLY WITH THOSE COMPONENTS BY THE MANUFACTURE INTRODUCTION OF SECOND SOURCE ICs OR OTHER NONAPPROVED COMPONENTS MAY DAMAGE THE PRODUCT AND VOID ANY APPLICABLE EPSON WARRANTY PREFACE This manua
144. rface 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 Upon receiving the STROBE pulse IC1 latches the data into ports PDATA 1 8 and sets the BUSY signal to HIGH 2 The CPU reads the latched data from the MMIO port checks whether the data is a print command CR code and stores it in the input data buffer if it is not 3 After checking the data the CPU makes IC1 clear the BUSY signal and output the ACKNLG signal via the MMIO accesses When either a CR code is received or the input data buffer becomes full the CPU sets the BUSY signal to HIGH and executes printing 4 The CPU reads the data from the input data buffer analyzes each byte to determine whether it is a character or a command and converts it to print data The print data consists of 1 byte character codes and 2 byte attributes Character data is stored as character codes and commands or character types are stored as attributes 5 The print data is stored in the line buffer in units of one line of data 6 The CPU reads the print data stored in the line buffer byte by byte accesses the CG Character Generator and expands the data in the image buffer in the case of download characters in the download CG A row of expanded data is output to the printhead control circuit as printhead data Note
145. rtemperaure puc 1 0 2t EANCOM __________0___ _ 22 Print head temperature 35 HEANR JF motor phase A 29 11 2 L2 2728 23 24 26 27 28 Table 3 C204 MAIN Board Connector CN2 Pin SignlNam vo Funcin 1 O Printhead coil 6 drive signal 2 O Printhead coil 4 drive signal S Print head coil 18 drive signal RN 0 Jpritheadcoilf4drvesignal 5 05 Print head coil 14 drive signal 6 Print head coil 14 drive signal Z Print head coil 18 drive signal ____ 1 O Printhead cooil 6 drive signal 1 Printhead coil 15 drive signal _ Print head coil 5 drive signal Print head coil 13 drive signal _____ 02 Print head coil 3 drive signal Print head coil 15 drive signal 4 Print head coil 13 drive signal 15 Printhead coil 5 drive signal 60 Print head coil 3 drive signal 7 HR4P 1 Print head coil 8 drive signal 8 HRAN O ___ coil 8 drive signal 9 HRSENS Print head coil shortage monitoring 20 JHNSENS Print head shortage monitoring Table A 4 C204 MAIN Board Connector CN3 Pin Signal Name WO Function COPEN 1 Ooveropenstatus pT __2 _
146. s 95 S C24 LS d 2 123 O _ gt 5 amp Figure A 9 C204 DRV Board Component Layout 1 Ci C us aii c 8 27 RY ui O ws Be Soe m 835 mcg Rs CR m 82 cae 1 RSB Sog et E rec L R55 RCO R47 coc R48 45 e So C2 R58 BEN R42 57 8 cs HORS EE m 026 RSI 016 2223804 00 Figure A 10 C204 DRV Board Component Layout 2 Rev B A 23 DFX 8500 mmc 8 axe C204 DRV B 5 019 025 021 028 025 022 C OND 1 Figure 11 C204 DRV B Board Component Layout 1 mI oy EC R36 NM SE EIER UE NH E 1 Cy a 222 Rug T 4 10 07 418 OG c3 c3 e eu uo mec 25 amp R14 017 645 ES C ma 10 R22 c 8 c pig 28 en R12 RY R25 cH a Figure A 12 C204 DRV B Board Component Layout 2 A 24 Rev B C4 ca 52 oz gt 15 125 208 205 Ed 1 5 T 8 d MM 206 5 2 R207 297 PTS B 3 Me RING 5 Utm
147. s fed in only one direction Counterclockwise rotation of the RF motor is transmitted to the ribbon feed gear through the ribbon feed select gear and ribbon feed transmission gear The ribbon feed drive gear engages the winding roller on the ribbon cartridge to feed the ribbon Winding Roller Ribbon Cartridge RF Select Gear RF Drive Gear RF Transmission Gear RF Motor Figure 2 11 Ribbon Feed Mechanism 2 10 Rev B 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 When the tractor select lever is set to the left the tractor select gear engages the rear tractor assembly train and the PF motor rotates the rear tractor assembly When the tractor select lever is set to the right the tractor select gear engages the front tractor assembly The tractor Select sensor contacts the cam and closes when it reaches the convex portion The ribbon jam sensor is used to detect ribbon jam condition and to count ribbon life Tractor Drive MUS Tractor Select Transmission Gear Trac
148. s must have an uncut part in each end of the paper Refer to Figure 1 14 e Atthe intersection of horizontal and vertical perforations the cut part of the perforations must not cross each other Refer to Figure 1 15 e The raised part at the perforation must be less than 1 mm when the bottom layer kept by force Refer to Figure 1 16 1 2 12 6 Notes Clean paper with no folds creases tears should be used Refer to Figure 1 17 The sprocket hole must be circular The hole may have teeth Refer to Figure 1 18 The sprocket hole of each layer must not be shifted Refer to Figure 1 19 The litter of sprocket holes must be removed from the paper Paper should be fan folded at horizontal perforations Never use one that is not fan folded property Refer to Figure 1 20 No hole is acceptable in the printable area Paper must be torn off accurately along perforations 1 1 Rev B GENERAL DESCRIPTION 19 or more era ee spotglued part lo or base shest 29 2 Page Width Spot glued part Unit mm Figure 1 12 Paper Width Overlapping Area Uncut Cut Fl i Paper edge N 3 Uncut Figure 1 13 Perforations 1 Figure 1 14 Perforations 2 Rev B 1 17 DFX 8500 Perforations Printable surface Figure 1 16 Raised Portion at a Perforat
149. sary to remove the tension roller shaft be fore performing this adjustment Refer to Section 3 2 6 7 The parallelism is adjusted so that the difference between the distances from the rear carriage guide shaft to the platen measured at the two positions shown in Figure 4 7 is less than 0 015 mm Since this value is extremely small you must use the two dial gauges dial gauge base and dial gauge master supplied by EPSON Do not adjust the parallelism using any other method amp 7 Dial gauge F610 Part No B1019466 87 Dial gauge base F611 Part No B1019467 87 Dial gauge master F612 No B1019468 Step 1 Perform the carriage guide shaft parallelism adjustment Refer to section 4 1 5 After the adjustment is finished leave the dial gage unit on the carriage Step 2 Remove the pull tractor sensor Refer to Section 3 2 6 10 Step 3 Loosen but do not remove the two hexagonal screws securing the platen stay to both side frames CR oue Screws 4 8 RA n Poa Platen Stay L i Platen Stay R Positioning Tab 1 1 1 Q Figure 4 13 Loosing Hexagonal Screws Rev B 4 9 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 Side Frame L Attach both needles
150. signals at pins 38 PTS1 Replace the IC2 C204 MAIN board is and 42 PTS2 of the IC2 defective 5 22 Rev B 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 lf a symptom recurs following a repair attempt look for other possible causes and solutions in the table below Table 5 7 Printer Mechanism Repair 1 4 Checkpoint The CR motor does not operate The transport locking bracket used to hold the carriage in place when the printer is moved has not been removed Foreign objects are lodged in the gears or elsewhere e g paper dust on the carriage encoder belt in the mechanism The CR motor is defective The carriage timing belt is defective The carriage guide shaft parallelism value is incorrect The CR encoder sensor is defective The carriage encoder belt is damaged or covered with dust The printhead FPC common wires are broken The carriage moves but no printing is performed Rev B Remove bracket Refer to Section 3 1 Verify that the transport locking bracket has been removed Manually move the carriage to see if the motor rotates Remove any foreign objects Replace the CR motor Perform the carriage timing belt tension adjustment as described in Section
151. stments within the specified tolerances Refer to CHAPTER 4 Check that lubrication and adhesion are correct Checked Not necessary Refer to CHAPTER 6 Operation At the operate switch turns on does the printer Checked Not necessary perform power on initialization correctly Does the printer work exactly with using the Checked Not necessary attached utility program ROM Grade What it the ROM version up dated Checked Not necessary up Is any dust removed from the inside of the Checked Not necessary printer Is the exterior housing clean Checked Not necessary Return to Is the operate switch turned off Checked Not necessary customer Is the ribbon cartridge removed Checked Not necessary Attached Attachments power cord optional units etc Checked Not necessary goods are inserted 3 6 Rev B DISASSEMBLY AND ASSEMBLY 3 2 DISASSEMBLY AND ASSEMBLY amp 7 Before you disassemble or assemble the printer be sure to read and follow the instructions in Section 3 1 OVERVIEW amp 7 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 To assemble the printer follow the disassembly instructions in this chapter in reverse Any extra infor
152. t 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 2 K ohms a carriage error is detected and the printer beeps 15 PSB PSE Board power off sensor signal interface When the 37 VDC line voltage drops the PSB PSE board sends a HIGH POFF signal to the C204 board 2 24 Rev B 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 If the current exceeds the set value it is fed back to the gate array E05B36 and then the gate array outputs the signal for the current setting transistors Q5 Q6 and Q7 When the printer is turned on CPU analog port AN2 measures the isolation resistance in the CR motor If the isolation resistance is equal or less than 2 2 K ohms the printer change the status to the carriage error If the printer cover is open during power on the CR motor dr
153. t a high level during paper out error Data transmission timing Refer to Figure 1 21 DATA n DATA n 1 DATA STROBE BUSY ACKNLG Parameter Minimum Maximum Parameter Minimum Maximum tsetup 500ns tack 500ns 10 thod 500ns tnbusy 0 tnext tstb 500ns _ tredy 0 tto 120ns tbusy 50008 ttin 200ns_ Note Rise and fall time of output signals Rise and fall time of input signals Figure 1 21 Data Transmission Timing Rev B 1 19 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 0 1 5 55V 024 VOH 24V mA VOL 04V 2 CO 1 Op G y VU 7 O _ 032mA VIH 24V 124 VIL 08V Note Alow 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 The receiver shall provide an impedance equivalent to 7 5 K ohms to ground Connector pin assignments and signals Refer to Table 1 10 Table 1 10 Signal and Connector Pin Assignment Forward channel m Tu Signal Name Return GND In Out Functional Description STR
154. tage of Q11 Replace Q10 or switching transistor on Q11 the C204 DRV board is defective The phase switching For transistors Q12 Q15 observe the if there is no output transistor on the C204 output signal collector signal replace the DRV board is abnormal transistor defective Fuse F2 on the C204 Check if fuse F2 is defective Replace F2 DRV board is defective The PG sensor is Observe the PG sensor output signal at Replace the PG defective pins 35 PGENCA and 34 PGENCB sensor of CN14 The PG home Observe the PG HP sensor signal level Replace the PG position sensor is for pin 36 PGHOME of CN14 home position defective 2 home LOW level other HIGH sensor defective IC1 on the C204 When paper is loaded into the printer MAIN board is look at the switching signal at pins 16 defective PLP and 17 PLN of IC1 Plunger drive Observe the Q31 collector voltage at Replace Q31 Q30 transistor on the C204 paper loading or Q32 DRV board is defective Rev B 5 21 DFX 8500 Table 5 6 C204 MAIN DRV DRV B boards Component Repair TTE Checkpoint The self test is IC1 on the C204 Observe the output signal at pins 136 Replace ae o printed incorrectly 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 122 on the Observe the
155. the bottom panel unit assembly 4 16 N AA Figure 3 26 Bottom Panel Assembly Removal 3 20 Rev B DISASSEMBLY AND ASSEMBLY 3 2 4 2 Cooling Fan and C204 Power Supply Board Unit Removal Step 1 Step 2 Step 3 Step 4 Rev B Remove the bottom panel assembly Refer to Section 3 2 4 1 If you need to remove the cooling fan disconnect connector CN5 and remove the four CCN M3x30 Screws securing it and remove the fan Disconnect connectors CN2 CN3 and Remove the six CBB M3x12 screws and CPN O M3x8 screw securing the C204 power supply board unit and remove the board CBB M3X12 CN1 C204 PSB PSE Board C204 MAIN Board CN4 AC Inlet Set CCN M3X30 CPN OJ M3X8 Figure 3 27 C204 PSE PSB Board Removal 3 21 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 3 8 C204 SUB Board Unit C204 MAIN Board Figure 3 28 C204 SUB Board Unit Removal 3 22 Rev B 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
156. the steps below Step 1 Remove the upper case Refer to Section 3 2 3 4 Step 2 Remove the interlock switch assembly Refer to Section 3 2 5 Step 3 Remove the two CBS O M4x8 screws securing the green and yellow earth cables to the grounding plate Then disconnect connectors 1 through 4 as shown in Figure 3 41 Ensure all connectors 1 through 7 indicated in the figure are disconnected Step 4 Remove the CBS O M4x8 screw securing the earth cable as shown in Figure 3 42 Flat Cable Connector 50 pin Mechanism CN4 4 CR Connector CN 7 pin Option Cutter o Flat Cable Connector 50 pin Printhead Interlock Switch Cable 2 pin Q CN3 2 pin Cover Open Sensor CN5 14 pin Panel Unit Earth Cable Earth Cable Figure 3 41 Connector Removal left side Earth Cable CBS O Screw M4x8 C204 PSB PSE Board Bottom Panel Assembly Right side Figure 3 42 Connector Removal right side Rev B 3 29 DFX 8500 Step 5 Remove the four screws securing the printer mechanism to the lower case Screws Screws 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
157. the Connector Junction Board See the figure bellow for the connector arrangement on the connector junction board 6 2 5 5 9 2 5 6 5 o 5 9 9 5 o0 5 5 2 5 9 2 0 5 S 6 _ amp S wu yy 9 gt 5 Connector Colors S s c amp BS a EJ Black 5 gt c 5 8 5 9 8 o D o B3 Red LE c a a m Whit 9 9g 9 9 9 White Gray i Yellow E mu uu 2 pins 2 pins 4 pins pins pins 3pins 4 pins 6 pins 6pins 2 pins 2 pins to CR Motor to Paper Feed Motor Rev B Ribbon Jam Sensor 4 pins to Interlock Switch 2 pins to Fan NS to Option Cutter Power d to CR Motor Fan Figure A 15 Connectors on the Connector Junction Board A 27 DFX 8500 A 5 Part List Table A 20 Part List 1 3 Part Names Part Names CONNECTOR LOCK NUT for USA COVER PAPER SUPPORT CONNECTOR LOCK NUT for others HOUSING SUB ASSY TOP PLATE HOUSING RIGHT 201 SCREW for EUR S E ASIA ACEANIA 120 PAPER SUPPORT SUB ASSY 204 SHIELD PLATE MAIN 122 SHIELD PLATE 206 HARNESS 135 C P PS SCREW 4 8 145 FERRITE CORE GEAR A 28 Rev B APPENDIX Table A 20 Part List 2 3 529 BOARD ASSY
158. the distance between the right side of the platen and print head nose narrows a little bit Repeat steps 11 and 12 until the distance between the distance measured at the two positions is less than 0 015 mm The 610 dial gauge matches the 15 notches When the distance is within the specified range tighten the two CP PS M4 X 6 screws securing the parallelism adjustment lever Then measure the distances again as described in step 11 If the distance between the measured distances is within the specified range apply screw lock to the two screws Refer to Section 6 2 for lubrication and adhesive application instructions Go to Section 4 1 6 platen angle adjustment Carriage Guide Shaft Rear Parallelism Adjustment Lever CP PS M4X6 Guide Shaft Holder Lever Right 4 Guide Shaft Holding Spring CP PS M4X6 CBS O M4X8 Figure 4 12 Parallelism Adjustment Lever Operation Rev B 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 If remove the printer mechanism from the lower case the adjust value will be out of order when you reassemble the printer mechanism to the lower case Also it is neces
159. 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 B ADJUSTMENT Step 6 Remove CP PS M3X6 screw securing the timing belt holder to the timing belt then remove the timing belt holder Carriage Guide Shaft Rear CP PS M3X6 Timing Belt Holder 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 Step 10 X Attach the dial gauge base with the dial gauge in the same way as you attach the print head Then you attach this tool to the carriage tighten the two thumb screws while you pulling the dial gage base toward you Step 11 Using the carriage guide shaft gear adjust the gauge mounting position so that the tips of the gauges portions A and B in the Figure 4 10 are securely attached to the platen Dial Gauge Master Platen rriage Refer to 4 Figure 4 10a Dial Gauge Base 3 Q Dial Gauge x2 9 8 3 D eo e I D Q 2 o Q E Figure 4 10 Dial Gauge Attachment CR Guide Shaft Gear Transmission Gear Vy Figure 4 10a CR
160. the interface cable before disassembling or assembling the printer The printhead reaches very high temperatures and if you place your hand on it it could burn you Always be sure that the printhead is cool coot when you handle it RAN Wear gloves to protect your hands when hanaling the printer Handle frame edges with care since this printer has a considerable amount of metal materials To prevent damage to ICs from static electricity do not touch the ICs on the circuit board or the terminals of peripheral electrical components with your hands Use only the recommended 1ools to ensure safe and efficient maintenance work Inappropriate tools may damage the printer This printer must be properly packed in the correct container for transportation as described on next page If the unit is not properly packed it could be damaged during transportation The paper and ribbon cartridge should be removed before transportation or disassembly Because you may need to turn the printer while you disassemble or assemble it place it on a clean thick cloth such as a blanket before starting After finishing the assembly do not forget to lubricate and reassemble the unit following the instructions in CHAPTER 6 because a considerable amount of oil may be removed during maintenance or repair work Also be sure to clean the unit as described in CHAPTER 6 Rev B 3 1 DFX 8500 Before transporting the printer remove the paper and ribb
161. the power supply and control circuits Figure 2 1 shows the Model 3160 printer mechanism Printhead Paper Bail Assembly Plunger TIMING BELT PF Connector Junction Board Tractor Assembly Front N RF Motor PG Motor Figure 2 1 M 3160 Printer Mechanism The printer mechanism consists of the following main components Printhead The printhead is the component that actually prints characters dot matrix patterns Printing is performed by striking the pins arranged in a vertical line against the surface of the paper and the ribbon A character is printed by repeating this printing operation in the horizontal direction as the printhead moves The printhead includes a head fan and temperature sensor The head fan also has a thermistor When the printhead or fan is too hot the printer stops printing until it cools Refer to Section 2 3 9 Printhead Drive Circuit Plunger mechanism During printing the paper bail assembly holds the paper under tension so that it is fed smoothly When paper is loaded or ejected or when the tear off function is executed the paper bail assembly needs to move up to prevent a paper jam The plunger moves the paper bail assembly up Rev B 2 1 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 posi
162. tialization The initialization of this level is activated by the control code ESC for ESC P or ESC K for IBM LEXMARK2381 Plus This initialization is to make the printer setting to default 1 4 6 3 Panel Initialization The initialization performed by the control panel operation This initialization is to clear all data in the buffer to execute software initialization 1 36 Rev B GENERAL DESCRIPTION 1 5 MAIN COMPONENT The main components of the DFX 8500 are as follows Printer mechanism M 3160 Main control board C204 MAIN board Mechanism driver board C204 DRV board 1 Printhead driver board C204 DRV B board DIP SW board C204 SUB board Power supply board C204 PSB PSE board unit Control Panel Panel unit Housing CR Connector Junction Board Panel Unit Head Cable Board C204 PSB PSE Board Connector Junction Board C204 MAIN Board C204 DRV Board C204 DRV B Board and C204 SUB Board Figure 1 24 Main Components Rev B 1 37 DFX 8500 1 5 1 M 3160 Printer Mechanism The 3160 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
163. tion 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 4 CR Motor Drive Circuit Interlock switch Because the carriage moves at a very high speed it would be dangerous if a hand or finger were inserted inside the printer mechanism during printing Therefore as a safety measure when the top cover is opened the interlock switch cuts the drive voltage to the CR motor to slow down the carriage speed and prevent accidents A control circuit controls CR motor driver deceleration Refer to Section 2 3 4 CR Motor Drive Circuit Printing resumes when the top cover is closed Auto platen gap adjustment mechanism The printer mechanism has an automatic platen gap adjustment function that measures the thickness of the paper and provides the appropriate gap between the platen and printhead The platen gap is adjusted by moving the carriage and printhead either forward or backward Because the front and rear carriage guide shafts which hold the carriage are purposely mounted off center the carriage moves as the PG motor rotates the shafts The PG sensor transmits the amount of movement gap to the control circuit Ribbon feed mechanism The printer s ribbon cartridge contains an endless ribbon The ribbon feed mechanism takes up t
164. tor Select Gear Holder Tractor Select Lever Lower Tractor Select Lever Upper Tractor Select Cam Tractor Select Transmission Gear Ribbon Feed Select Gear RF Motor Ribbon Jam Sensor Ribbon Feed Gear Figure 2 12 Tractor Select Mechanism Rev B 2 11 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 Figure 2 13 Plunger Mechanism 2 12 Rev B 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 Table 2 1 shows the input voltages and fuse ratings of the boards and Table 2 2 shows the PSB PSE board output specification Table 2 1 Power Supply Boards Input Input Voltage Fuse Ratings C204 PSB board 120 VAC 12 A 125 C204 PSE board 220 240 VAC 6 3 A 250 VAC Table 2 2 Power Supply Board Output Spec
165. ttached to the carriage timing belt and moves horizontally The printer does not have a carriage home position sensor the home position is detected using disordered pulses of the CR motor and CR encoder sensor linear belt type The head dumpers are attached to the left and right sides of the frame These pads are used for the absorbs the carriage hit shock for both side The control circuit monitors the CR motor s pulse when it is disordered the control circuit recognizes the carriage home position The encoder belt has equally pitched slits and is mounted under the timing belt A photo interrupter CR encoder surrounds the encoder belt and converts the carriage movement into a pulse train Head Dumper Left Paper Width Sensor Ribbon Mask Holder SHAFT CR GUIDE REAR CR Motor CR Encoder Sensor SHAFT CR GUIDE FRONT CR Encoder Belt TIMING BELT CR Figure 2 5 Carriage Mechanism Rev B 2 5 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 When the motor rotates the PC sensor detects it and o
166. ttached to the tension roller on the paper tension unit 4 Tractor select sensor Detection form Micro mechanical switch Logical Front tractor LOW closed Rear tractor HIGH open 5 Pull tractor sensor Detection form Micro mechanical switch Logical Pull tractor installed LOW closed Pull tractor not installed HIGH open 6 Carriage encoder sensor Detection form Photo reflector Transaction Rectangle wave A and B phases respectively 7 Platen Gap encoder sensor Detection form Photo interrupter Output form Rectangle wave 2 channel PG ability T 0 015 mm pulse Available range 0 lt lt 0 7 8 Platen Gap home position sensor Detection form Micro mechanical switch Logical Home LOW closed Out of home HIGH open 9 Ribbon jam sensor Detection form Photo interrupter Function The main board monitors signal change during ribbon feed 10 Cover open sensor Detection form Micro mechanical switch Logical Cover closed LOW Cover open HIGH 11 Printhead temperature sensor uses a thermistor The thermistor is included on the printhead 12 Head fan temperature sensor uses a thermistor The thermostor is included on the head fan Rev B 2 23 DFX 8500 13 Paper width sensor Detection form Photo reflector Output form Emitter follower Judgemwnt No paper present Standard voltage level Paper presen
167. ually parallelism Check that foreign objects are not adjustment as lodged in the printer mechanism described in Section 4 1 5 The RF motor The RF motor is Check the coil resistance of the RF Replace the RF does not operate defective motor It should be about 150 ohms motor 10 The PG motor The backlash value is Check whether the carriage guide shaft Loosen the 2 screws does not operate incorrect rotates smoothly when rotated securing the PG manually motor to the left side frame Then adjust the backlash between the PG motor pinion gear and the carriage guide shaft gear as described in Chapter 4 Adjustments Check the output signal of the PG sensor is defective encoder sensor Refer to Table 5 6 encoder sensor The encoder plate is Check whether the encoder plate is Replace the PG encoder plate The PG home sensor Check the continuity of the sensor Replace the PG is defective Check the status of the two micro home sensor micro switches switch type The PG motor is Check fe coil resistance of the PG Replace the PG defective motor It should be about 250 ohms motor 18 Printing continues The front rear or top Check the PE sensor Replace the PE past the end of PE sensor is sensor the paper defective When paper jams The paper jam sensor Check the paper jam sensor Replace the paper the printer does is defective jam sensor not beep Ribbon Jam error Ribbon jam sensor
168. usted 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 Remove the printer mechanism Refer to Section 3 2 6 Step 2 Release the release levers for the tractor sprockets on the front Step 3 At the left side frame loosen the CBS M4 X 8 screws securing the wire holding plate L Step 4 Pull the tractor wire left to make correct tension to the tractor wire wire holding plate R and the tip of the gold seal are 5 mm 0 2 inches apart Step 5 Fix the CBS M4 X 8 screws on the wire holding plate L Step 6 As the same manner adjust the tractor spring tension for the rear tractor Wire Holding Plate R Tractor Wire Gold Seal MP Tension Spring Tractor Wire Tension Spring Tractor Release Lever Pull adjust fix 4 10 x Figure 4 3 Tractor Wire Tension Adjustment Front Rev B 4 3 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
169. ustment described in Section 4 1 8 Rev B 3 25 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 M4x6 screw securing the grounding plate to the bottom panel assembly and remove the grounding plate CBB M3X8 Bottom Panel Assembly Grounding Plate AC Inlet Set Figure 3 35 Grounding Plate Removal Step 4 Remove the two CFS M3x10 screws securing the AC inlet to the grounding plate and remove the AC inlet AC Inlet Set Grounding Plate CFS M3X10 Figure 3 36 AC Inlet Removal 3 26 Rev B 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 4 10 225 gt gt lt p AIS N LZ Front Panel C204 PNL Board Figure 3 37 C204 Board Removal Rev B 3 27 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 Cover
170. utputs the pulses Each pulse corresponds to detection of a 0 0025 mm resolution horizontal distance The system range is 0 35 to 0 84 mm Platen Assembly Ribbon Mask Holder Platen Roller Gear Platen Gap Sensor Platen Gap Encoder Plate cw Platen Gap lt CCW Motor Figure 2 6 Platen Gap Adjustment Mechanism Rev B 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 The tractor select mechanism alternates the engagement of the rear tractor assembly gear train and front tractor assembly gear train Refer to Section 2 1 5 Ribbon Feed and Tractor Select Mechanisms The front and rear PE sensors are incorporated in the tractor sprocket When paper is loaded the paper pushes the leaf spring and blocks the photo interrupter When no paper is loaded the photo interrupter is not blocked The top PE sensor is attached to the upper paper guide and is used with the reflection plate on the paper bail assembly When there is no paper the reflection plate reflects the beam when paper is loaded the
171. wer 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 The table provides the following four columns Symptom Check this column for a list of common printer problems Cause Use this column to identify possible causes that could produce this symptom Checkpoint Follow the troubleshooting checks in this column to isolate your problem lt Solution Repair the printer using the instructions in this column 5 2 1 C204 PSB PSE Board Repair Table 5 4 indicates majour components which is used for the C204 PSB PSE board and Table 5 4 shows the C204 PSB PSE board component level troubleshooting Table 5 4 C204 PSB PSE Board Main Parts List QF101 Switching FET for VP1 and VP2 Table 5 5 C204 PSB PSE Board Component Repair 1 3 Symptom Cause 1 Checkpoint No DC voltage is present PD signal is HIGH sent Measure the signal level Wait until the printer at the output Fan on from the main board of the PD signal at prints again the power supply board Replace the E05B36 on doesn t rotate at all the C204 MAIN board The DRERR signal is Measure the signal level Replace the printhe
172. y 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 Printhead Unit SS Oil O 2 fes Aa Head Cable Protection Sheet lt gt Ribbon Mask Assembly Figure 3 8 Printhead Kit The description hereafter is the same as the above instruction Manual so you may refer to this section or to the Instruction Manual Rev B 3 9 DFX 8500 amp 7 When you remove the connector cover be careful not to break the tabs amp 7 When you remove the printhead cable holder be careful not to break the printhead holder latch Use a slotted screwariver 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 When disconnect the cables hold the cable close to the connector Note 2 When disconnect the cable hold the connector to prevent it from being pulled off the board Note 3 When disconnect the cable pull it slowly and horizontally to the right as viewed from the front side CBS M3X8 FPC Cover Printhead Cables FPC Board Figure 3 9 Ribbon Cartridge Removal Figure 3 10 Head Cable Removal Step 4 Unlo

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