Epson All in One Printer DFX 8500 User Manual

EPSON

IMPACT SERIAL DOT MATRIX PRINTER

DFX-8500

SERVICE MANUAL

SEIKO EPSON CORPORATION

4009310

PRECAUTIONS

Precautionary notations throughout the text are categorized relative to 1) personal injury and 2)

damage to equipment.

WARNING

CAUTION

Signals a precaution which, if ignored, could result in serious or fatal personal injury.

Great caution should be exercised in performing procedures preceded by

WARNING Headings.

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 procedures.

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.

iii

PREFACE

This manual describes functions, theory of electrical and mechanical operations, maintenance, and

repair of DFX-8500.

The instructions and procedures included herein are intended for the experience repair technician,

and attention should be given to die precautions on the preceding page. The Chapters are

organized as follows:

CHAPTER 1. GENERAL DESCRIPTION

Provides a general product overview, lists specifications, and illustrates the main components of the

printer.

CHAPTER 2. 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

Revision

Rev. A

Rev. B

Issued Data

Contents

May 18, 1998/

June 25, 1998

First issue

Second issue due to minor correction on the

manual contents.

TABLE OF CONTENTS

CHAPTER 1.

GENERAL DESCRIPTION

OPERATING PRINCIPLES

DISASSEMBLY AND ASSEMBLY

ADJUSTMENT

TROUBLESHOOTING

MAINTENANCE

CHAPTER 2.

CHAPTER 3.

CHAPTER 4.

CHAPTER 5.

CHAPTER 6.

APPENDIX

CHAPTER 1

GENERAL DESCRIPTION

1.1 FEATURES.............................................................................................................1-1

1.2 SPECIFICATIONS..................................................................................................1-3

1.2.1 Printing Specification............................................................................................................. 1-3

1.2.2 Paper Feeding......................................................................................................................... 1-6

1.2.3 Electrical Specification .......................................................................................................... 1-6

1.2.4 Environmental Condition....................................................................................................... 1-6

1.2.5 Reliability................................................................................................................................. 1-6

1.2.6 Safety Approvals .................................................................................................................... 1-7

1.2.7 CE Marking.............................................................................................................................. 1-7

1.2.8 Acoustic Noise........................................................................................................................ 1-7

1.2.9 Ribbon Cartridge .................................................................................................................... 1-7

1.2.10 Physical Specifications........................................................................................................ 1-7

1.2.11 Printable area ........................................................................................................................ 1-8

1.2.12 Paper and Media................................................................................................................. 1-12

1.2.12.1 Continuous paper (Single sheet and multi-part).................................................... 1-12

1.2.12.2 Labels.................................................................................................................... 1-14

1.2.12.3 Continuous Forms with Labels.............................................................................. 1-14

1.2.12.4 Overlapping Multi-part Form.................................................................................. 1-16

1.2.12.5 Perforation............................................................................................................. 1-16

1.2.12.6 Notes..................................................................................................................... 1-16

1.3 INTERFACES.......................................................................................................1-19

1.3.1 Parallel Interface (Forward channel)................................................................................... 1-19

1.3.2 Parallel Interface (Reverse channel)................................................................................... 1-21

1.3.3 Serial Interface...................................................................................................................... 1-22

1.3.4 Optional Interface................................................................................................................. 1-22

1.3.5 Interface Selection................................................................................................................ 1-23

1.3.6 Prevention Hosts from Data Transfer Time-out................................................................. 1-23

1.4 OPERATING INSTRUCTIONS.............................................................................1-24

1.4.1 Control Panel ........................................................................................................................ 1-24

1.4.1.1 Switches .................................................................................................................. 1-25

1.4.1.2 Indicators................................................................................................................. 1-26

1.4.2 Errors and Buzzers............................................................................................................... 1-27

1.4.3 DIP Switch Settings.............................................................................................................. 1-28

1.4.4 Functions .............................................................................................................................. 1-31

1.4.4.1 Usual operation ....................................................................................................... 1-31

1.4.4.2 Operation at Power On............................................................................................ 1-33

1.4.4.3 Built-in Detection ..................................................................................................... 1-34

1.4.5 Paper Memory Function....................................................................................................... 1-35

1.4.6 Initializations......................................................................................................................... 1-36

1.4.6.1 Power-on Initialization ............................................................................................. 1-36

1.4.6.2 Software Initialization............................................................................................... 1-36

1.4.6.3 Panel Initialization.................................................................................................... 1-36

1.5 MAIN COMPONENT ...........................................................................................1-37

1.5.1 M-3I60 Printer Mechanism ................................................................................................... 1-38

1.5.2 Main Control Board (C204 MAIN Board)............................................................................. 1-39

1.5.3 C204 DRV Board ................................................................................................................... 1-40

1.5.4 C204 DRV-B Board................................................................................................................1-41

1.5.5 C204 SUB Board....................................................................................................................1-41

1.5.6 C204 PSB/PSE Board............................................................................................................1-42

1.5.7 Control Panel.........................................................................................................................1-43

1.5.8 Housing..................................................................................................................................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 features of the printer are:

‰ꢀ

„ꢀ

‰ꢀ

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.

Figure 1-1. DFX-8500 Exterior View

1-1

Rev. B

DFX-8500

The following table shows options.

Table 1-1. Option

Name

Code

#8766

Ribbon cartridge

#8767

Ribbon pack

#8309

Pull tractor unit

C81500X

C81507X

C82305*

C82306*

C82307*

C82308*

C82310*

C82311*

C82312*

C82313*

C82314*

C82315*

C82357*

C82345*

C82362

C82364

Paper cutter

Perforation cutter

Serial interface card (inch screw)

Serial interface card (mm screw)

32-KB intelligent serial I/F card (inch screw)

32-KB intelligent serial I/F 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 I/F card

Coax I/F card

Twinax I/F card

Ethernet I/F card

IEEE-1284 parallel I/F card

Ethernet I/F card

1-2

Rev. B

GENERAL DESCRIPTION

1.2 SPECIFICATIONS

This section describes the specifications for DFX-8500.

1.2.1 Printing Specification

‰ꢀ

Print method

Number of pins

Print pin arrangement : 9 x 2

Print pin diameter

Color

Impact dot matrix

18-pin (Refer to Figure 1-2.)

0.0114 inches (0.29 mm)

Black

Bi-directional with logic seeking

‰ꢀ Print direction

‰ꢀ

Print speed and printable columns:

Refer to Table 1-2.

0.35 mm (1/72")

2.82 mm (8/72")

1.69 mm (1/15")

Figure 1-2. Printhead Pin Configuration

Table 1-2. Print Speed and Printable Columns

Print Mode

Character Pitch

Printable Columns

Print Speed (cps)

Normal

High Duty

1066

800

High speed draft

Draft

10 cpi

12 cpi

15 cpi

17 cpi

20 cpi

10 cpi

12 cpi

15 cpi

17 cpi

20 cpi

136

163

204

233

272

136

163

204

233

272

1120

840

1008

630

720

840

420

210

252

200

171

200

960

630

685

800

400

200

240

200

Draft condensed

Draft emphasized

NLQ

NLQ condensed

171

200

Notes 1: The line including graphic B0h - 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 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.

1-3

Rev. B

DFX-8500

‰ꢀ

Resolution:

Refer to Table 1-3.

Table 1-3. Resolution

Print Mode

High speed draft

Draft

Horizontal Density

Vertical Density

72 dpi

Adjacent Dot Print

90 dpi

120 dpi

72 dpi

Draft condensed

Draft emphasized

NLQ

240 dpi

120 dpi

240 dpi

72 dpi

144 dpi

72 dpi

Yes

60, 72, 80, 90, 120 or 144

dpi

Yes

Bit image

120 or 240 dpi

72 dpi

‰ꢀ

„ꢀ

Control code:

Character tables:

ESC/P and IBM 2381 Plus emulation

Standard version (11 character tables):

Italic table

PC437 (US, Standard Europe)

PC850 (Multilingual)

PC861 (Icelandic)

PC865 (Nordic)

BRASCII

PC860 (Portuguese)

PC863 (Canadian-French)

Abicomp

Roman 8

ꢀ

ISO Latin 1

„ꢀ

NLSP version (35 character tables):

Italic table

PC437 (US, Standard Europe)

PC437 Greek

PC850 (Multilingual)

PC852 (East Europe)

PC855 (Cyrillic)

PC866 (Russian)

MAZOIWA (Poland)

ISO 8859-7 (Latin / Greek)

Bulgaria (Bulgarian)

PC 774 (LST 1283:1993)

PC 866 LAT. (Latvian)

PC 860

PC853 (Turkish)

PC857 (Turkish )

PC869 (Greek)

Code MJK (CSFR)

ISO Latin 1T (Turkish)

Estonia (Estonia)

ISO 8859-2 (ISO Latin 2)

PC866 UKR

PC 861

PC 865

PC APTEC

PC 708

PC 720

PC AR864

Abicomp*

PC 863(Canadian French) *

BRASCII*

Roman 8*

ISO Latin 1*

Hebrew 7*

Hebrew 8*

PC862*

Note: These tables can not be selected by DIP switch.

„ꢀ

International character sets : 13 countries

USA

U.K

Italy

France

Denmark 1

Spain 1

Germany

Sweden

Japan

Norway

Latin America

Denmark 2

Spain 2

Note : The international and legal characters are these 12 codes;

23h, 24h, 40h, 5Bh, 5Ch, 5Dh, 5Eh, 60h, 7Bh, 7Ch, 7Dh, 7Eh.

‰ꢀ

Typeface:

Bit map font:

„ꢀ

EPSON Draft

10 CPI, 12 CPI, 15 CPI

EPSON Roman

EPSON Sans Serif

10 CPI. 12 CPI, 15 CPI, Proportional

10 CPI, 12 CPI, 15 CPI, Proportional

„ꢀ

Bar code:

EAN-13

EAN-8

Interleaved 2 of 5

UPC-E

Code 128

UPC-A

Code 39

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

Character Table

Bitmap Font

EPSON Draft

Standard version

Italic Table

PC437 (US, Standard Europe)

PC850 (Multilingual)

PC860 (Portuguese)

PC861 (Icelandic)

PC863 (Canadian French)

PC865 (Nordic)

Abicomp

EPSON Roman

EPSON Sans Serif

BRASCII

Roman 8

ISO Latin 1

Italic table

NLSP version

Italic Table

EPSON Draft

PC437 (US, Standard Europe)

EPSON Roman

EPSON Sans Serif

PC850 (Multilingual)

PC852 (East Europe)

PC855 (Cyrillic)

PC437 Greek

PC853 (Turkish)

PC857 (Turkish)

PC869 (Greek)

Code MJK (CSFR)

PC866 (Russian)

MAZOWIA (Poland)

ISO 8859-7 (Latin / Greek) ISO Latin 1T (Turkish)

Bulgaria (Bulgarian)

PC 774(LST 1283:1993)

PC 866 LAT.( Latvian)

PC 860

Estonia (Estonia)

ISO 8859-2 (ISO Latin 2)

PC 866 UKR

PC 861

PC 865

PC 708

PC APTEC

PC 720

PC AR864

PC 863*¹

Abicomp*¹

BRASCII*¹

Roman 8*¹

ISO Latin 1

Hebrew 7*¹

Hebrew 8*¹

PC 862*¹

*1) These tables can not be selected by DIP switches.

Note : ESC R command is effective on all the character tables.

‰ꢀInput data buffer:

0K byte or 128 K bytes (depend on DIP switch settings)

1-5

Rev. B

DFX-8500

1.2.2 Paper Feeding

‰ꢀ

Feeding method:

Push tractor feed (front / rear)

Push and pull tractor feed (front / rear)

Front push tractor, rear push tractor, pull tractor (option)

Paper insertion side alignment :

Left

‰ꢀ

ꢀ

Feeder:

‰ꢀ

Paper path:

Tractor (front in, rear in, top out)

‰ꢀ Line spacing:

‰ꢀ Feed speed:

1 / 6 inches or programmable in increments of 1 / 216 inches.

„ꢀ

1/ 6-inch feed:

26.5 ms

„ꢀ

Continuous feed: 0.251 mps (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 :

Input voltage range :

„ꢀ

120 V AC

99 to 132 V AC

„ꢀ

Rated frequency range : 50 to 60 Hz

Input frequency range :

Rated current :

49.5 to 60.5 Hz

3.5 A (max.7.5 A)

Approx.160 W (ISO/IEC10561 Letter pattern)

Energy Star compliant

Power consumption :

„ꢀ

Insulation resistance :

Dielectric strength :

10 M ohms min. (between AC line and chassis, 500 V DC)

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

198 to 264 V AC

Input voltage range :

Rated frequency range : 50 to 60 Hz

Input frequency range :

Rated current :

Power consumption :

49.5 to 60.5 Hz

1.4 A (max.3.5 A)

Approx.160 W (ISO/IEC10561 Letter pattern)

Energy Star compliant

„ꢀ

Insulation resistance :

Dielectric strength :

10 M ohms min. (between AC line and chassis, 500 V DC)

1500 AC Vrms. 1 min. (between AC line and chassis)

1.2.4 Environmental Condition

‰ꢀ

Temperature :

5 to 35 ^oC (operating)

-30 to 60 ^oC (non-operating)

‰ꢀ

Humidity :

10 to 80 % RH (operating) *1)

5 to 85 % RH (non-operating) *1)

1 G, within 1 ms (operating)

2 G, within 2 ms (non-operating) *2)

0.25 G, 10 to 55 Hz (operating)

0.50 G, 10 to 55 Hz (non-operating) *2)

Resistance to shock :

Resistance to vibration :

*1: Without condensation

*2: With shipment container

1.2.5 Reliability

‰ꢀ

Total print volume :

26 million lines (except print head)

10,000 POH (25 % duty)

‰ꢀ MTBF :

‰ꢀ Print head life :

‰ꢀ Ribbon life :

400 million characters at 14 dots/character

15 characters at 14 dots /character

1-6

Rev. B

GENERAL DESCRIPTION

1.2.6 Safety Approvals

‰ꢀ

120 V version:

Safety standards :

„ꢀ

UL1950 with D3

CSA C22.2 No.950 with D3

FCC part 15 subpart B class B

CSA C108.8 class B

„ꢀ

EMI :

‰ꢀ

„ꢀ

230 V version:

Safety standards :

EMI :

EN60950 (VDE, NEMKO)

EN55022 (CISPR pub.22) class B

AS / NZS 3548 class B

1.2.7 CE Marking

‰ꢀ

230 V version:

Low Voltage Directive 73/23/EEC : EN60950

„ꢀ

EMC Directive 89/336/EEC :

EN55022 class B

EN61000-3-2

EN61000-3-3

EN50082-1

IEC801-2

ꢀ

IEC801-3

ꢀ

IEC801-4

1.2.8 Acoustic Noise

‰ꢀ

Level:

58 dB(A) (ISO 7779 pattern)

1.2.9 Ribbon Cartridge

‰ꢀ

Type :

Fabric

Black

‰ꢀ Color :

‰ꢀ Ribbon life :

‰ꢀ Dimensions :

15 million characters (draft 10 cpi, 14 dots / character)

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)

APPROX. 29 Kg

‰ꢀ Weight :

1-7

Rev. B

DFX-8500

1.2.11 Printable area

‰ꢀ

Continuous paper :

Refer to Figure 1-3.

Continuous Paper

PW (width)

PL (length)

LM (left margin)

Refer to Section 1.2.12.

13 mm to 31mm

RM (right margin)

TM (top margin)

13 mm or more

2.6 mm or more

BM (bottom margin)

4.2 mm or more

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)

PL (length)

LM (left margin)

RM (right margin)

TM (top margin)

Refer to Section 1.2.12.

13 mm to 31mm

13 mm or more

2.6 mm or more

BM (bottom margin)

4.2 mm or more

Notes 1: Feeding backward or paper (PATH) selection are prohibited.

Notes 2: If In 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 1-4. Label Printable Area

1-9

Rev. B

DFX-8500

‰ꢀ

Continuous forms with labels :

Refer to Figure 1-5.

Continuous Paper

PW (width)

PL (length)

LM (left margin)

RM (right margin)

TM (top margin)

BM (bottom margin)

LFL (left margin from label)

RFL (right margin from label)

TFL (top margin from label)

BFL (bottom margin from label)

LOL (left margin on label)

ROL (right margin on label)

TOL (top margin on label)

BOL (bottom margin on label)

Refer to Section 1.2.12.

13 mm to 31mm

13 mm or more

2.6 mm or more

4.2 mm or more

65 mm or more

12.5 mm or more

5 mm or more

2 mm or more

Notes 1: Feeding backward or paper (PATH) selection are prohibited.

Notes 2: If In 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

Rev. B

GENERAL DESCRIPTION

‰ꢀ

Overlapping multi-part forms :

Refer to Figure 1-6.

Continuous Paper

PW (width)

PL (length)

LM (left margin)

RM (right margin)

TM (top margin)

Refer to Section 1.2.12.

19 mm to 31mm

19 mm or more

21.2 mm or more

4.2 mm or more

BM (bottom margin)

OL (overlapping length)

NA (non printable area)

Less than 13.3 mm

25.4 mm or more

Notes 1: Feeding backward or paper (PATH) selection are prohibited.

Notes 2: If In 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 1-6. Overlapping Multi-part Form Printable Area

1-11

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

Front Entry

Rear Entry

Maximum

Minimum

4.0

Maximum

16.0

Minimum

4.0

Width

(inch)

(mm)

(inch)

(mm)

16.0

406

17.0

431

101

406

101

4.0

101

Length

4.0

17.0

101

431

Copies

1 original + 6 copies

1 original + 5 copies

Total Thickness

(inch)

(mm)

(g/m²)

(lb)

0.0025

0.065

52.6

41.4

0.021

0.53

82.7

56.4

0.0025

0.065

52.6

41.4

0.018

0.46

82.7

56.4

Weight

(not multi-part)

Weight

(one sheet of multi-part)

Quality

(g/m²)

(lb)

Plain paper, Reclaimed paper, Carbonless multi-part forms

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 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.

Perforation

Notes

Refer to Section 1.2.12.5.

Refer to Section 1.2.12.6.

Figure 1-7. Dotted Paste Positions

1-12

Rev. B

GENERAL DESCRIPTION

Figure 1-8. Paper-stapling Height

Figure 1-9. Paper-stapling Method 1

Figure 1-10. Paper -stapling Method 2

1-13

Rev. B

DFX-8500

1.2.12.2 Labels

Table 1-6. Labels

Front Entry

Rear Entry

Minimum Maximum

Minimum

Maximum

Label Size

Refer to Figure 1-11.

Backing Sheet Width

(inch)

(mm)

(inch)

(mm)

(inch)

(mm)

(inch)

(mm)

4.0

101

3.5

0.0

0.0025

0.065

16.0

406

17.0

431

0.0047

0.12

Backing Sheet Length

Label Thickness

Total Thickness

Quality

0.0075

0.19

AVERY CONTINUOUS FORM LABELS,

AVERY MINI-LINE LABELS, or the

same quality labels

Perforation

Notes

Refer to section 1.2.12.5.

•

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.

Width

Height

Inch

2.5

4.0

63.5

101

Inch

15/16

17/16

23.8

27.0

4.0

Figure 1-11. Label Size

1-14

Rev. B

GENERAL DESCRIPTION

Rear Entry

1.2.12.3 Continuous Forms with Labels

Table 1-7. Continuous Forms with Labels

Front Entry

Minimum

Maximum

Minimum

Maximum

Label Size

Width

Refer to Section 1.2.12.2.

(inch)

(mm)

(inch)

(mm)

(g/m²)

(lb)

4.0

101

4.0

101

52.6

41.4

0.0

16.0

406

17.0

431

82.7

56.4

0.0047

0.12

0.021

0.53

Length

Weight

(not multi-part)

Weight

(one sheet of multi-part)

Label Thickness

(g/m²)

(lb)

(inch)

(mm)

(inch)

(mm)

0.0

0.0025

0.065

Total Thickness

Quality (Multi-part forms)

Quality (Label)

Plain paper, reclaimed paper, carbonless

multi-part forms

AVERY CONTINUOUS FORM LABELS,

AVERY MNI-LINE LABELS, or the same

quality labels

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 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.

Perforation

Notes

Refer to Section 1.2.12.5.

•

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.

Continuous forms with labels should be inserted from front

entrance.

Refer to Section 1.2.12.6.

1-15

Rev. B

DFX-8500

1.2.12.4 Overlapping Multi-part Form

Table 1-8. Overlapping Multi-part Form

Front Entry

Maximum

Rear Entry

Maximum

Minimum

4.0

Minimum

Width

(inch)

(mm)

(inch)

(mm)

(g/m²)

(lb)

16.0

406

17.0

431

82.7

101

4.0

101

52.6

Length

Weight

(not multi-part)

Weight

(g/m²)

(lb)

41.4

56.4

(one sheet of multi-part)

Copies

1 original + 5 copies + 1 backing

sheet

Total Thickness

(print area)

Total Thickness

(overlap area)

Overlapping Length

(inch)

(mm)

(inch)

(mm)

(inch)

(mm)

0.0025

0.065

0.005

0.021

0.53

0.028

0.70

0.39

0.13

more than 0

Quality (multi-part forms)

Multi-part binding

Plain paper, reclaimed paper,

carbonless multi-part forms

•

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.

Perforation

Notes

Refer to Section 1.2.12.5.

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.).

•

Horizontal perforations must have an uncut part in each end of the paper (Refer to Figure 1-14.).

At the intersection of horizontal and vertical perforations, the cut part of the perforations must not cross

each other (Refer to Figure 1-15.).

•

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.

1-16

Rev. B

GENERAL DESCRIPTION

Figure 1-12. Paper Width Overlapping Area

Figure 1-13. Perforations 1

Figure 1-14. Perforations 2

1-17

Rev. B

DFX-8500

Figure 1-16. Raised Portion at a Perforation

Figure 1-15. Perforations 3

Figure 1-18. Sprocket Hole 1

Figure 1-19. Sprocket Hole 2

Figure 1-17. Unsuitable Paper

Figure 1-20. Bad Folded Paper

1-18

Rev. 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:

Synchronization:

Connector type:

8-bit parallel, IEEE-1284 compatibility mode

/STROBE pulse

57-30360 (AMPHENOL) 36-pin plug or equivalent

BUSY and /ACK handshaking

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 at a high level during paper out error.

‰ꢀ

Data transmission timing:

Refer to Figure 1-21.

(

)

(

)

Parameter

t setup

t hold

Minimum

500 ns

Maximum Parameter

Minimum

Maximum

10 us

---

120 ns

200 ns

---

500 ns

t ack

t nbusy

t next

---

t stb

---

500 ns

---

t ready

t busy

t reply

tt-out*

tt-in**

---

Note: * Rise and fall time of output signals

** Rise and fall time of input signals.

Figure 1-21. Data Transmission Timing

1-19

Rev. B

DFX-8500

‰ꢀ

Signal Level:

TTL-level compatible, IEEE-1284 level 1 device

Refer to Table 1-9.

Table 1-9. Signal Level

Parameter

VOH*

VOL*

IOH*

IOL*

Minimum

-0.5 V

Maximum

5.5 V

0.32 mA

12 mA

50 pF

2.0 V

Condition

VOH = 2.4 V

VOL = 0.4 V

VIH

VIL

0.8 V

IIH

IIL

0.32 mA

12 mA

50 pF

VIH = 2.4 V

VIL = 0.8 V

Note: * A low logic level on the logical high signal is 2.0 V or less when the printer is powered off.

And this signal is equal or exceeding 3. 0 V when the printer is powered on. 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)

Pin No.

Signal Name Return GND pin In/Out*

Functional Description

/STROBE

The strobe pulse. Read-in of data is performed

at the falling edge of this pulse.

2-9

DATA 0-7

20-27

The DATA0 through DATA7 signals represent

data bits 0 to 7, respectively. Each signal is at

high level when data is logical 1 and low level

when data is logical 0.

/ACKNLG

BUSY

Out This signal is a negative pulse indicating that

the printer can again accept data.

Out A high signal indicates that the printer cannot

receive data.

SLCT

Out A high signal indicates paper-out error.

Out Always at high level when the printer is

powered on.

/AFXT

/INIT

Not used.

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.

/ERROR

/SLIN

Logic H

+5V

Out A low signal indicates printer error condition.

In Not used.

Out Pulled up to +5V via 3.9K ohm resistor.

Out Pulled up to +5V via 3.3K ohm resistor.

Chassis GND

GND

Chassis GND.

Signal GND.

Not connected.

16,33,19,30

15,34

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:

Connector type:

Synchronization:

Handshaking:

Data transmission timing:

Signal Level:

IEEE-1284 nibble mode

57-30360 (AMPHENOL) 36-pin plug or equivalent

No Info.

No info.

TTL-level compatible, IEEE-1284 level 1 device

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

04h : Request device ID in nibble mode of reverse channel transfer

Extensibility request :

‰ꢀ

Device ID :

[00h][3Ah]

MPG:EPSON;

CMD:ESCP9,PRPII9,BDC;

MDL:DFX-8500;

CLS:PRINTER;

‰ꢀConnector pin assignments: Refer to Table 1-11.

Table 1-11. Signal and Connector Pin Assignment (Reverse channel)

Pin No. Signal Name I/O* Description

IN HostCIk: This signal is a strobe pulse used to read extension

/STROBE

DATA 1-8

request values from the host computer during negotiation.

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

2-9

/ACKNLG

BUSY

OUT

PtrCIk: Printer data sending clock.

PtrBusy: Printer sending data bits 3 and 7 during data transfer to

the host computer

OUT

AckDataReq: Printer sending data bits 2 and 6 during data transfer

to the host computer

Xflag: Printer sending data bits 2 and 6 during data transfer to the

host computer.

HostBusy: This signal informs the printer of the host computer

state. When the signal is HIGH, the host computer cannot accept

data.

SLCT

/AUTO-FEED

GND

CHASSISGND

Not used.

Logic ground level

Connected to the printer chassis. The printer chassis GND and the

signal GND are connected to each other.

Not connected.

19-30

GND

/INIT

Ground level for the twisted pair return signal.

nlnit: High level fixed

/ERROR

OUT

nDataAvaiI: Printer sending data bits 0 and 4 during data transfer to

the host computer.

GND

Same as for ins19to30.

Not used.

Pulled up to +5V through 1.0K ohm resistor.

1284Active: If this signal is set to HIGH, this printer active

P1284(reverse mode).

/SLCT IN

Note: * In/Out refers to the direction of signal flow from the printer’s point of view.

1-21

Rev. B

DFX-8500

1.3.3 Serial Interface

‰ꢀ

„ꢀ

‰ꢀ

Synchronization :

Signal level (ELA-232D) :

MARK (logical 1) :

SPACE (logical 0) :

Word length :

Asynchronous

-3Vto-25V

+3Vto+25V

„ꢀ

Start bit :

Data bit :

Parity bit :

Stop bit :

1 bit

8 bit

Odd, Even, Non, of Ignore

1 bit or more

‰ꢀ

„ꢀ

Baud rate :

2400, 4800, 9600 or 19200 bps

DTR signal or X-ON / X-OFF

Indicates that the printer cannot receive data.

Indicates that the printer is ready to receive data.

Handshaking :

DTR=MARK, X-OFF :

DTR=SPACE, X-ON :

Note: The DTR signal is MARK and X-OFF code (DC3, 13h) is transmitted when the rest of the

input buffer becomes 256-byte. The DTR signal is SPACE and X-ON code (DC1, 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.

25 pin sub-miniature D-shell connector (female)

ꢀ

‰ꢀ

Connector :

Connector pin assignment and signals : Refer to Table 1-12.

Table 1-12. Signal and Connector Pin Assignment (EIA-232D)

Pin No. Signal Name In / Out*

Functional Description

TXD

DTR

REV

RTS

Out

Transmit data.

Indicates that the printer is ready to receive data or not.

Connected directly to the DTR signal.

Request to send. always SPACE level when the printer is

powered on. Pulled up to +12 V via 4.7K-ohm resistor.

Receive data

RXD

Signal GND

Chassis

GND

Signal GND

Chassis GND

Other

Not used. 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

GENERAL DESCRIPTION

1.3.5 Interface Selection

The printer has three interfaces; the parallel interface, serial interface, and optional Type-B interface.

These interfaces are selected manually by DIP SW or selected automatically.

‰ꢀ

ꢀ

Manual selection:

One of three interfaces can be selected by DIP SW setting.

ꢀ

‰ꢀ

Automatic selection:

The automatic interface selection is enabled by DIP SW setting. 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 interface 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.

1.3.6 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.

1-23

Rev. B

DFX-8500

1.4 OPERATING INSTRUCTIONS

This section describes the functions performed through the control panel, such as test print, hexadecimal

dump, and paper memory function.

1.4.1 Control Panel

The printer control panel gives you easy control over most common printer operations. The panel consists

of indicator lights and buttons.

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

Switch

Function

Front / Rear

Pause

Change the front and rear paper path alternately.

„ꢀAlternates printing and no-printing status.

„ꢀEnables reset function, holding it down for three seconds.

Executes micro feed forward.

Micro Feed ↑

Micro Feed ↓

LF / FF Load

Executes micro feed backward.

„ꢀLoads the paper when the paper is empty.

„ꢀExecutes line feed, pressing it shortly.

„ꢀExecutes form feed, holding it down for a few seconds.

„ꢀSet current point to top of form when the cover opens.

„ꢀEnables loading position adjustment and tear off position adjustment

when the cover opens.

TOF (top of form)

Tear Off

Copy

Advances continuous paper to the Tear off position adjustment.

Alternates copy mode or not.

Pitch

Selects pitch.

Font

Selects font.

Paper Select

Selects paper No.

‰ꢀOperation at power on:

Tuning the printer on while pressing panel switches executes the function shown in Table 1-14.

Table 1-14. Switch Function at Power On

Switch

Function

LF / FF Load

Draft self test

Tear off

NLQ self test

Tear off and LF / FF

Data dump

Pause

DIP SW setting print

Clear EEPROM at area 2

Clear EEPROM at area 1

Clear driving line count for ribbon change timing

Paper memory

LF / FF Load and Micro Feed ↓ and Pause*1)

Pause and Front / Rear*2)

Copy

Paper Select

Mechanism adjustment (Refer to Chapter 4.)

Platen gap adjustment (Refer to Chapter 4.)

Measurement seeking (Refer to Chapter 4.)

Tear Off, Micro Feed ↑, and Front/Rear

Tear Off, Micro Feed ↓, and Front/Rear

Micro Feed ↑ and Micro Feed ↓

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.

1-25

Rev. B

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) :

„ꢀThe LED 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 cpi

ꢀ ❏ ■ ❏ : 12 cpi

ꢀ ❏ ■ ■ : 15 cpi

ꢀ ■ ❏ ❏ : 17 cpi

ꢀ ■ ❏ ■ : 20 cpi

ꢀ ■ ■ ❏ : PS

(❏ : LED off, ■ : LED on.)

‰ꢀFont (Green) :

„ꢀThe status of Font selection is displayed by two Font LEDs.

ꢀ ❏ ❏ : Super draft

ꢀ ❏ ■ : Draft

ꢀ ■ ❏ : Roman

ꢀ ■ ■ : Sans Serif

‰ꢀPower (Green) :

(❏: LED off, ■ : LED on.)

„ꢀThe LED is on when the printer is powered on, 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.

„ꢀ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) :

„ꢀThe LED 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

Error/Warning

PAUSE

LED

Off

Paper Out

LED

Off

Ribbon Beeper *1)

LED

Off

Description

On Line

Pause

Off

Head hot

Head Fan hot

Paper out error

Blinking Off

Off

. . .

When the printer fails to load a

sheet, it goes paper out error.

When the printer’s cover is

open, it goes cover open error.

When the printer fails to change

the paper, it goes incomplete

changing paper path error.

Cover open error

Incomplete

changing paper

Incomplete back-

feed paper

Paper size error

Blinking

Off

. . .

When paper width of the setting

data and the current paper are

different, it goes Paper size

error.

Paper jam error

Ribbon jam error

Blinking

Off

- - - - -

When the printer fails to eject a

sheet, it goes paper jam error.

When the ribbon is in a jam

status, it goes ribbon jam error.

When carriage breaking length

Blinking - - - - -

Measurement

seeking error

Blinking

abnormal,

goes

Measurement seeking error.

Illegal panel

operation

Note 1: The descriptions “.”and “-“ 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

Fatal Error

7-segment LED Beeper *2)

Indication *1)

Description *3)

CR motor circuit shortage error

Cutter error

Platen gap error

Carriage lock error

Carriage load measurement

error

- -

- - -

- - - -

- - - - - -

Auto power off after 12 seconds

Head fan error

Head circuit shortage error

RAM check error

Paper memory setting error

EEPROM data compare error

Tractor change error

Watch dog error

- - - - - - -

- - - - - - - -

- - - - - - - - -

- - - - - - - - - -

- - - - - - - - - - -

- - - - - - - - - - - -

Head power off immediately

Auto power off after 12 seconds

Note 1: The 7 segment LED indicates error No. and “E” alternately.

Note 2: The descriptions “.”and “-“ 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

1-27

Rev. B

DFX-8500

1.4.3 DIP Switch Settings

There are five DIP switches that are located at the front paper entrance of the printer. These DIP switches

can set the printer defaults.

When power is applied or the printer is reset, the DIP switch selections are treated as the default setup. If

the setup is changed, the power should be cycled or the printer should be reset.

Table 1-16 shows the DIP switch selections for this printer.

Table 1-16. DIP Switch Settings

Switch No.

1-1 to 1-6

1-7

Function

Off

Factory Setting

All Off

Off

Character table

Skip over perforation

Print direction

Refer to Tables 1-17 or 1-18.

Inactive

Bi-d.

Active

Uni-d.

1-8

Off

2-1 to 2-4

2-5 to 2-8

3-1

Page length for front tractor

Page length for rear tractor

Auto tear-off

Refer to Table 1-19.

Refer to Table 1-20.

Inactive

All Off

Off

Active

3-2

Zero slash

Inactive

Active

Off

3-3

Auto line feed

Inactive

Active

Off

3-4

3-5

3-6

3-7

Buzzer

Active

Inactive

Table 2

Inactive

Active

Table 1

Active

Off

Auto CR (IBM 2381 Plus)

IBM character table

Auto cut mode

3-8

4-1

4-2

4-3 to 4-4

4-5 to 4-6

4-7 to 4-8

5-1

5-2

5-3

Software

Input buffer

Auto I/F wait time

I/F mode

Serial I/F parity

Serial I/F baud rate

Overlapping multi-part forms

Continuous forms with labels

Skip over binding

Paper memory

ESC/P

Active

10 sec.

Refer to Table 1-21.

Refer to Table 1-22.

Refer to Table 1-23.

Inactive

IBM 2381Plus

Inactive

30 sec.

Off

All Off

Off

Active

Memory b

5-4

5-5 to 5-8

Memory a

Off

(reserved)

1-28

Rev. B

GENERAL DESCRIPTION

Table 1-17. Character Table Setting (Standard)

SW 1-1 SW1-2 SW1-3 SW1-4 SW1-5 SW1-6 Character table

Off

PC437 (US, standard Europe)

PC850 (Multilingual)

PC860 (Portuguese)

PC861 (Icelandic)

PC863 (Canadian-French)

PC865 (Nordic)

Abicomp

BRASCII

Roman 8

ISO Latin 1

Italic USA

Italic France

Italic German

Italic U.K

Italic Denmark

Italic Sweden

Italic Italy

Italic Spain

Others PC437

Table 1-18. Character Table Setting (NLSP)

SW 1-1 SW1-2 SW1-3 SW1-4 SW1-5 SW1-6 Character table

Off

PC437 (US, standard Europe)

PC850 (Multilingual)

PC437 Greek

PC852 East Europe

PC853

PC855 (Cyrillic)

PC857 (Turkish)

PC866 (Russian)

PC869 (Greek)

MAZOWIA (Poland)

Code MJK (CSFR)

ISO 8859-7 (Latin/Greek)

ISO Latin 1T (Turkish)

Bulgaria (Bulgarian)

Estonia (Estonia)

PC774 (LST 1283:1993)

ISO8859-2

PC866LAT (Latvian)

PC866 UKR

PCAPTEC

PC708

PC720

PC AR864

PC860(Portuguese)

PC861(Ielandic)

PC865(Nordic)

Italic USA

Italic France

Italic German

Italic U.K

Italic Denmark

Italic Sweden

Italic Italy

Italic Spain

Others PC437

1-29

Rev. B

DFX-8500

Table 1-19. Front Tractor Page Length

SW2-1

Off

SW2-2 SW2-3 SW2-4 Page length for front tractor

Off

11 inches

3 inches

3.5 inches

4 inches

5.5 inches

6 inches

7 inches

8 inches

8.5 inches

70 / 6 inches

12 inches

14 inches

17 inches

Others

Others 11 inches

Table 1-20. Rear Tractor Page Length

SW2-1

Off

SW2-2 SW2-3 SW2-4 Page length for rear tractor

Off

11 inches

3 inches

3.5 inches

4 inches

5.5 inches

6 inches

7 inches

8 inches

8.5 inches

70 / 6 inches

12 inches

14 inches

17 inches

Others

Others 11 inches

Table 1-21. I/F Selection

SW4-3

Off

SW4-4

Off

I/F Mode

Auto

Off

Parallel I/F

Serial I/F

Optional I/F

Table 1-22. Serial I/F Parity Setting

SW4-5

Off

SW4-6

Off

Serial parity

None

Off

Odd

Off

Even

Ignore

Table 1-23. Serial I/F Baud Rate Setting

SW4-7

Off

SW4-8

Off

Baud rate

19200

9600

Off

4800

2400

1-30

Rev. B

GENERAL DESCRIPTION

1.4.4 Functions

1.4.4.1 Usual operation

‰ꢀFront / Rear:

Changes the front and rear paper path alternately.

„ꢀNormal paper is set and the pull tractor is not used:

The printer feeds the paper to the tear off position and cut the paper by the cutter, and feeds backward to

paper park position. If the cutter is not used, it goes incomplete changing paper error. So cut the paper at

the top of paper and push Pause switch or Front/Rear switch, and the printer feeds the paper backward.

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, 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 is

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 Off:

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 Off” 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 position 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

1-31

Rev. B

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 selected paper and push Pause

switch.

Current paper No. is a or b :

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 not a or b :

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 emergency 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.

1-33

Rev. B

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 between 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 paper 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-inch 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 N is 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

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 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.

a) 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.

e) 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.

Figure 1-23. Pointer

1-35

Rev. B

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 Initialization

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:

Main control board:

Mechanism driver board: C204 DRV board

½ Printhead driver board: C204 DRV-B board

DIP SW. board:

Power supply board:

Control Panel:

Housing:

M-3I60

C204 MAIN board

C204 SUB board

C204 PSB/PSE board unit

Panel unit

Figure 1-24. Main Components

1-37

Rev. B

DFX-8500

1.5.1 M-3I60 Printer Mechanism

The M-3I60 printer mechanism is a 18-pin (9-pin two lows), serial impact dot matrix printer mechanism

developed for the DFX-8500. It is designed to provide high-speed, high-volume printing, and is especially

heavy and durable when compared with existing terminal printer mechanisms, Its paper feeding

mechanism uses several kinds of fan-fold paper, and an automatic mechanism is included to provide

enhanced paper handling.

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.

Figure 1-25. M-3I60 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:

Gate array:

PROM (including C.G.) : 2M-bit (IC5)

TMP95C051A; 24.57 MHz (IC2)

E05B36 (IC1)

RAM

4M-bit (IC14)

RS-232C level converter (IC9)

PST391D(IC13)

ADM232L

RESET IC

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

For USA and Pacific

Inch

For Europe

Metric

Serial I/F Hexagonal-head screw type

1-39

Rev. B

DFX-8500

1.5.3 C204 DRV Board

The C204 DRV board is the driver board specially for the printer mechanism. The ½ printhead, printhead

fan, plunger, PF (paper feed) motor, CR (carriage) motor, CR fan, PG (platen gap) motor, and RF (ribbon

feed) motor drive circuits are located on the driver boards.

Sensor signals from the printer mechanism are connected to the main board via these boards.

Major ICs on the DRV are as follows:

‰ꢀ

CR motor drive IC:

PF motor drive IC:

Comparator IC:

STK561 (IC1)

STK5713B (IC2)

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 ½ printhead driver board. The drive part is mainly consists of the discrete

bipolar FETs.

Figure 1-28. C204 DRV-B Board

1.5.5 C204 SUB Board

The C204 SUB board consists of five DIP switch units. It is located behind the front paper cover.

Figure 1-29. C204 SUB Board Unit

1-41

Rev. B

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 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

1-43

Rev. B

CHAPTER 2

OPERATING PRINCIPLES

2.1 PRINTER MECHANISM OPERATION..................................................................2-1

2.1.1 Printhead Mechanism ........................................................................................................... 2-4

2.1.2 Carriage Mechanism ............................................................................................................. 2-5

2.1.3 Platen Gap Adjustment Mechanism .................................................................................... 2-6

2.1.4 Paper Feed Mechanism......................................................................................................... 2-7

2.1.4.1 Tractor Wire Operation............................................................................................. 2-9

2.1.5 Ribbon Feed and Tractor Select Mechanisms.................................................................. 2-10

2.1.6 Plunger Mechanism............................................................................................................. 2-12

2.2 POWER SUPPLY OPERATION..........................................................................2-13

2.2.1 Power Supply Overview...................................................................................................... 2-14

2.3 CONTROL CIRCUIT ...........................................................................................2-13

2.3.1 Control Circuit Operation Overview .................................................................................. 2-17

2.3.2 Reset Circuit......................................................................................................................... 2-21

2.3.3 Sensor Circuits .................................................................................................................... 2-22

2.3.4 CR Motor Drive Circuit........................................................................................................ 2-25

2.3.5 PF Motor Drive Circuit......................................................................................................... 2-29

2.3.6 RF Motor Drive Circuit ........................................................................................................ 2-30

2.3.7 PG Motor Drive Circuit........................................................................................................ 2-31

2.3.8 Plunger Drive Circuit........................................................................................................... 2-32

2.3.9 Printhead Drive Circuit........................................................................................................ 2-33

OPERATING PRINCIPLES

2.1 PRINTER MECHANISM OPERATION

This section describes the Model 3I60 printer mechanism and explains how the printer works. The Model

3I60 printer mechanism features a 18-pin, impact dot printhead for serial printing. The printer mechanism is

the main component of the printer and is supported by the other components (the power supply and control

circuits). Figure 2-1 shows the Model 3I60 printer mechanism.

Printhead

Paper Bail Assembly

Plunger

TIMING BELT, PF

Connector

Junction

Board

Tractor Assembly (Front)

RF Motor

PG Motor`

Figure 2-1. M-3I60 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.

2-1

Rev. B

DFX-8500

‰ꢀCarriage mechanism :

The carriage mechanism moves the printhead in the horizontal direction. The CR motor drives the carriage,

with the printhead on it. The CR encoder sensor detects the CR motor speed and carriage position. The CR

motor is closed-loop controlled. Because the CR motor is driven at a very high speed, it includes an isolation

resistance sensor to detect abnormal resistance. The sensor detects an error if the resistance is less than

2.2 K ohms. (Refer to Section 2.3.4 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 the ribbon so

that the portion hit by the pins is constantly changing. The RF motor drives the ribbon feed mechanism.

Interlock Switch

SHAF, CR, GUIDE, REAR

CR Motor

PG Motor

Printhead

TIMING BELT, CR

RF Motor

Carriage Encoder Belt

DETECTOR, CR

PG Home

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 gears. The tractor select sensor detects the selected tractor and signals

that information to the control circuit.

Paper

Pull Tractor Unit

Paper Bail Assembly

Pull Tractor Sensor

Plunger

Top PE Sensor

Printhead

Paper Jam Sensor

Tractor Select Sensor

Rear PE Sensor

Front PE

Sensor

Rear Tractor Sprocket

PF Motor

RF Motor

Front Tractor

Sprocket

Figure 2-3. Printer Mechanism Operation 2

2-3

Rev. B

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.

Actuating Spring

+35 VDC

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 attached 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.

(

)

Figure 2-5. Carriage Mechanism

2-5

Rev. B

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 outputs 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.

Figure 2-6. Platen Gap Adjustment Mechanism

2-6

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 beam is absorbed (not reflected). The Pull tractor sensor monitors whether the pull tractor is installed.

Paper Bail Lever

Pull Tractor Sensor

Top PE Sensor

TIMING BELT, PF

Platen Gear

Tension Roller

Tension Pulley

Tractor Select Gear

Paper Feed

Transmission Gear

PF Motor

Pinion Gear

Figure 2-7. Tension Roller and PF Roller Operation

2-7

Rev. B

DFX-8500

Paper

Paper Bail

Tension Roller

Tractor Select Gear

Front PE Sensor

PF Motor

Pinion Gear

Tractor Sprocket (Front)

PF Transmission Gear

Figure 2-8. Front Tractor Assembly Operation

Paper

Paper Bail

Tension Roller

Tractor Select Gear

Rear PE Sensor

PF Transmission Gear

Tractor Sprocket (Rear)

PF Motor

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. When 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.

Tension

Tractor Wire

Tension Spring

(in case of front enterance)

Figure 2-10. Tractor Wire Operation

2-9

Rev. B

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 is 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.

Figure 2-12. Tractor Select Mechanism

2-11

Rev. B

DFX-8500

2.1.6 Plunger Mechanism

Figure 2-13 shows the plunger mechanism. The paper bail assembly is attached to the end of the plunger's

iron core. The paper bail assembly axis is connected to the frame. When the plunger coil is energized, the

force of the paper bail spring returns the paper bail assembly to its original position.

Paper Bail ASSY. Lever

Plunger

Iron Core

Coil

Tension Spring

Figure 2-13. Plunger Mechanism

2-12

Rev. 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

Board

C204 PSB board

C204 PSE board

Input Voltage

120 VAC

220-240 VAC

Fuse Ratings

12 A /125 VAC

6.3 A / 250 VAC

Table 2-2. Power Supply Board Output Specification

+37 VDC Line

+5V DC Line

Item

VP1

VP2

+37.0 VDC

35.5 - 37.5 VDC

VP3

Rating Output Voltage

Available Output

+5.0 VDC

4.75 - 5.25 VDC

Voltage Fluctuation

Rating Output Current

Available Output

1.5 A

0.0 - 4.5 A*1)

2.0 A

0.0 - 2.0 A

0.0 - 5.0 A*1)

Current Fluctuation

Over Current Protection

Reset Method

Short Circuit Current

Over Voltage Protection

Reset Method

Yes

Turn the power switch off, then turn it again. Or

controlled by C204 MAIN board with /PD signal.

Less than 1.0 A

Automatically recovered.

Less than 1.0 A

Yes

Automatically recovered.

Yes

Turn the power switch off, then turn it again.

Over Voltage Limit Value

42 VDC

7 VDC

*1): +37 V DC line Maximum in total is 13.0 A.

2-13

Rev. B

DFX-8500

2.2.1 Power Supply Overview

Figure 2-14 shows a block diagram of the C204 PSB/PSE board.

Surge Cut

(at Power On)

CN1

Fuse

Power

SW.

Input Filter

Circuit

Rectifier

Circuit

Smoothing

Circuit

AC Inlet

+37V

+37V Line

Switching

1/2

(VP1/VP2)

Smoothing

Circuit

CN3

CN4

GP1

GP2

GP1

Over Current

Protection

GP2

Current Limit

Monitoring

Power Down

Control

AC Source

PC101

PC102

DRERR

Constant

Voltage

Control

VP3 Down

Monitoring

Over Voltage

Protection

+5V Regulator

Circuit

PC1

+5V

Overcurrent

Protection

+5V Regulator

+37V Line

Switching

2/2

+37V

(VP3)

Smoothing

Circuit

CN2

CN5

GP3

Constant

Voltage

Control

Current Limit

Monitoring

Abnormal

Current

(VP1/VP2)

Monitoring

GP3

PC201

Fan Driver

FANDR

Figure 2-14. Power Supply Board Block Diagram

2-14

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 ½ and 2/2. The one convert the AC

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 ½ :

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 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

Voltage

Board

Application

+37V (VP1-GP1)

+37 V (VP2-GP2)

+37 V (VP3-GP3)

C204 DRV-B

C204 MAIN

C204 DRV

•

Printhead drive ½

Printhead drive 2/2

CR motor drive

PF motor drive

PG motor drive

RF motor drive

HF drive

CR fan drive

Plunger drive

Optional Cutter’s motor drive

Cooling fan on the PSB/PSE unit

All logic systems operating voltage

PF motor hold voltage

Plunger hold voltage

PG motor hold voltage

Power for all the sensors

Voltage for power system pull-up. It is switched

by VXCNT signal of the CPU (IC2).

C204 PSB/PSE

C204 MAIN

C204 DRV

C204 DRV-B

C204 PNL

+5 V -GL

VX-GL

C204 MAIN

C204 DRV

C204 DRV-B

2-15

Rev. B

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.

Table 2-4. PSB/PSE Board Control Signals

Signal

In /

Signal

Logic

Function

Out*1)

Level

TTL

Block 1*2)

37 VDC

Block 2*3)

/PD

High

37 VDC, 5 VDC

0 VDC, 0 VDC

(Power Down)

Low

0 VDC

DRERR

TTL

High

0 VDC

(Head coil/driver error)

Low

High

37 VDC

37 VDC, 5 VDC

> 30 VDC, 5VDC

/SD

Out

(Source Down)

Indefiniteness

37 VDC

Low

High

< 30 VDC, 5VDC

37 VDC, 5 VDC

(Current Limit*4)

Low

< 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 (IC2). This CPU is driven using a 24.57 MHz

external clock (CRU1). The CPU executes programs stored in the PROM (IC5). The CPU starts executing a

program upon receiving the reset signal from an external device (IC13) via the gate array E05B36 (IC1). 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 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.

2-17

Rev. B

DFX-8500

MAIN Board

Mechanism

CPU

TMP95C061

(IC2)

Cover Open

Sensor`

Printhead

Temperature

HTMP

EEPROM

(IC11)

Paper Width

Head Fan

Temperature

PWIDTH

HFTMP

24.57MHz

(CRU1)

Level Converter

(IC9)

DRV Board

TXD/RXD

POFF

CR Motor

Insulation

CRINS

RF Motor

Drive Circuit

RF Motor

PF Motor

Drive Circuit (IC2)

RAM

(IC14)

HPSENS,

HNSENS

DRV-B Board

Control

Printhead

Drive Circuit 1/2

Printhead 1/2

P-ROM

(IC5)

Printhead

Drive Circuit 2/2

PFA

Printhead 2/2

Interlock SW.

DTR/CTS

Optional

Type-B I/F

Card

CR Motor

Control & Drive

Circuit (IC1, IC3)

Current Monitoring

CRCLM

CR Motor

CR Encoder

ENCA,

ENCB

G/A

E05B36

(IC1)

PG Motor

Drive Circuit

PG Motor

PG Home

PGENCA,

PGENCB

PG Encoder

PE Signals

(Front, Rear, Top)

Paper Jam

Control

Ribbon Jam

Pull Tractor

CL,

PD,

DRERR

Control &

Monitoring

PSB/PSE

Board

Tractor Select

+37 VDC,

+5 VDC

PLG

FAN

Plunger Drive

Circuit

Plunger

Option

Cutter

Fan Drive

Circuit

19.55MHz

(CRU2)

Fan

LED,

Panel Unit

Head Fan

Drive Circuit

Head Fan

Reset IC

(IC13)

RESET,

RSTOUT,

ERRCRPFX

PDATA1-8,

/STB,

/ACK, BUSY

SWCNT

SWITCH

SUB Board

(DIP SWs)

Figure 2-15. Control Circuit Block Diagram

2-18

Rev. B

OPERATING PRINCIPLES

Table 2-5 describes the functions of the main components on the C204 MAIN and C204 DRV board.

Table 2-5. Main IC Functions

Board

IC Name

Location

Functions

C204 MAIN TMP95C061

(CPU)

IC2

Receives data from the host computer via the gate array, loads

the data to the input buffer in the RAM, and converts the image

data to print data.

E05B36

IC1

The main features are:

(Gate Array)

•

/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 I/O

Phase signal creation for the motors

I/O port control

Interface control

Abnormal CR and PF motor detection

/RESET signal creation

PROM

RAM

IC5

IC14

Contains the program that runs the CPU.

Holds the CPU working area and buffers (input,, line,, and

image buffers).

EEPROM

ADM232

PST591D

IC11

IC9

IC13

IC1

Memorizes the printer unique parameter during the power is off.

EIA to Logic level voltage level converter

System reset IC

C204 DRV

STK681-050

Drives the CR motor.

STK67138MK4 IC2

uPC393C IC3

Drives the PF motor.

Detects the current in the CR motor driver and feeds it back to

the gate array on the C204 MAIN board.

2-19

Rev. B

DFX-8500

Figure 2-16 shows the data flow for data input via the parallel interface. Although various circuits perform

data processing, the control core is the CPU and all operations are executed via the CPU. In this circuit, the

E05B36 IC (IC1) provides the interface between the external host computer and the CPU, and all data

processing is performed by read/write operations to MMIO (Memory Mapped Input / Output).

Data from the host computer is latched by repeating steps 1 through 3 below.

1. 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 : 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)

RAM (IC3)

/STROBE

DATA

Input Data Buffer

STBINT

Buffer full ?

Yes

CR command ?

Yes

DATA

MMIO

DATA

BUSY, /ACK

CPU (IC2)

Command

Analyzer

Attribute

Line Buffer

Character Gnerator

Down Load

Image Buffer

Controls

printer mechanism.

E05B36

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 VDC line on the C204 MAIN board. If it drops to 4.2 VDC or

smaller, the reset IC outputs a LOW signal to the CPU (IC2) and E05B36 (IC1) gate array.

‰ꢀForced Reset:

The gate array outputs the RSTOUTX or ERRCRPFX signals to the XRESET 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

VCC

Type-B,

Parallel I/F

/INIT signal

113

R218

C52

VOUT

/RESETX

PST591

(IC13)

E05B36

(IC1)

112

111

100

/RSTOUTX

INITRQ

/ERRCRPFX

INT4

XRESET

C56

CPU

TMP95C061

(IC2)

Figure 2-17. Reset Circuit Block Diagram

2-21

Rev. B

DFX-8500

2.3.3 Sensor Circuits

Figure 2-18 shows the sensor circuits in block diagram form. The printer is equipped with the following

sensors:

1. Front and rear PE sensors (use a photo interrupter)

2. Top PE sensor (to detect the TOF position, uses a photo interrupter)

3. Paper jam sensor (uses a magnetic transistor)

4. Tractor select sensor (uses a micro mechanical switch)

5. Pull tractor sensor (uses a micro mechanical switch)

6. CR encoder sensor (uses a photo interrupter)

7. PG encoder sensor (uses a photo interrupter)

8. PG home sensor (uses a micro mechanical switch)

9. 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 (monitored by the analog port of the CPU)

15. PSB/PSE board power off sensor (signal interface)

CPU

TMP95C061 (IC2)

21 20

19 22

CN10 CN14 CN3

CN1

148

149

ENCA

ENCB

ENCA

ENCB

CN4

CR Encoder

PGENCA

PGENCB

PG Home

PGENCB

PG Home

TRSEL

E05B36 (IC1)

Tractor Select

Pull Tractor

PTRCT

Paper Jam

Front PE

PJAM

FPE

CN14

Rear PE

Top PE

RPE

TPE

RBJAM

Ribbon Jam

Figure 2-18. Sensor Circuit Block Diagram

2-22

Rev. B

OPERATING PRINCIPLES

Each sensor is described below.

1. Front and rear paper end sensors

‰ꢀDetection form:

‰ꢀOutput form:

‰ꢀLogical:

Photo interrupter

Open collector (pulled up to 10 K ohms resistor)

Paper present: LOW

Paper out: HIGH

2. Top paper end sensor (to detect the TOF position)

‰ꢀDetection form:

‰ꢀOutput form:

‰ꢀLogical:

Photo reflector

Open collector

Paper present: LOW

Paper out: HIGH

3. Paper jam sensor

‰ꢀDetection form:

‰ꢀOutput form:

‰ꢀLogical:

Magnetic transistor

Rectangle wave (1 channel, TTL level)

Paper feed: Level changes continuously.

Paper jam: Level remains the same.

ꢀ

‰ꢀSupplement:

The magnetic transistor is attached to the tension roller on the paper tension unit.

4. Tractor select sensor

‰ꢀDetection form:

‰ꢀLogical :

Micro mechanical switch

Front tractor: LOW (closed)

Rear tractor: HIGH (open)

5. Pull tractor sensor

‰ꢀDetection form:

‰ꢀLogical :

Micro mechanical switch

Pull tractor installed: LOW (closed)

Pull tractor not installed: HIGH (open)

6. Carriage encoder sensor

‰ꢀDetection form:

‰ꢀTransaction:

Photo reflector

Rectangle wave, A and B phases respectively.

7. Platen Gap encoder sensor

‰ꢀDetection form:

‰ꢀOutput form:

‰ꢀPG ability:

Photo interrupter

Rectangle wave, 2 channel

T = 0.015 mm / pulse

0 < T < 0.7 mm

‰ꢀAvailable range:

8. Platen Gap home position sensor

‰ꢀDetection form:

‰ꢀLogical::

Micro mechanical switch

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:

‰ꢀLogical::

Micro mechanical switch

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.

2-23

Rev. B

DFX-8500

13. Paper width sensor

‰ꢀDetection form:

‰ꢀOutput form :

Photo reflector

Emitter follower

‰ꢀJudgemwnt :

No paper present: Standard voltage level.

Paper present: The voltage level is double the standard voltage level.

14. CR motor isolation resistance sensor (monitored by port AN2 of the CPU)

To provide information about the CR motor life, the analog port (AN2) of the CPU checks the isolation

resistance every time the printer is turned on. If the isolation resistance is equal or less than 2.2 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 MAIN

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 driver 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.

VP3 (+37 VDC)

Table 2-6. CR Motor Specifications

Specification

Form

Supply Voltage

Internal Coil

Resistance

Description

DC servo motor

37 VDC

Motor

1.66 ohms (+ 10 %)

Current

Consumption*1)

Accerelation / Deceraration:

4.6 A (AV.)

Constant Speed:

2.5 A (AV.)

*1): at Super draft printing, + 10 %

GP3 (GND)

Figure 2-19. CR Motor Internal Circuit

ENCA

ENCB

MAIN

Board

DRV

Board

VP3

Interlock SW

STK681-050(IC1)

E05B36 (IC1)

Carriage Encoder Sensor

VCC1

IN_A

CRAX

Q16,

Q34,

Q35,

ZD2

VCC1

Q17,

Q18,

Q19

IN_B

CRBX

CRCX

CRDX

IN_C

CR A

OUT1

IN_D

Carriage

Motor

CRCLK

CLK

OUT2

CR B

Vref

GP3

AIN+

AIN-

+5V

Q5,

Q6,

Vref

A OUT

uPC393C(IC3)

ZD1

4.3 V

CRCLM

CRINS

GP3

CPU

TMP85C061

(IC2)

Partical Pressure

Circuit

AN2

Figure 2-20. CR Motor Drive Circuit Block Diagram

2-25

Rev. B

DFX-8500

Table 2-7 lists the CR motor drive modes.

Table 2-7. CR Motor Drive Modes

Division

Drive Mode

CR Motor Speed

(rpm)

Acceleration /

Deceleration Control

Curve

Constant

Speed

Control

Note1)

Carriage moves

with printing.

Note 2)

Super Draft

Super Draft HD

Draft

2800

2666

2100

2000

1050

1000

888

Acceleration and

Deceleration 1

PI control

Draft HD

Bit image 1

Bit image 2

Bit image 3

NLQ

Acceleration and

Deceleration 3

NLQ HD

Super Draft X 1/3

Bit image 4

Draft X 1/3

933

666

Bit image 1 X 1/3

Bit image 2 X 1/3

Bit image 3 X 1/3

NLQ X 1/3

555

500

444

333

Draft X 1/6

333

Bit image 4 X 1/3

Bit image 3 X 1/6

277

222

Carriage

moves Home

position

500

without printing

Note 3)

seek

Paper

width

500

detection seek

Logical seek 0

Logical seek 1

Logical seek 2

2100

1050

333

Measurement seek

Notes 1: Refer to Table 2-8.

Notes 2: This division applies to all printing modes. PI 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.

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

Deceleration 1

Deceleration 2

Deceleration 3

Acceleration

Deceleration 1

Deceleration 2

Deceleration 3

Left -> Right

Right -> Left

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 I0, I1,

and I2 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 the 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:

•

When duty data becomes Duty_minbefore the carriage speed reaches SP2. Then, when the carriage

speed reaches SP2, the next sequence (SP2-) takes effect.

•

When the carriage speed reaches SP2 before duty data becomes Duty_min, the next sequence (SP2-)

takes effect.

SP2 -

When the carriage speed reaches SP2, PI control oversees the carriage speed.

SPref

SP2

SP1

Acceleration

Constant

Speed

Control

Deceleration 2

Figure 2-21. CR Motor Drive Circuit Block Diagram

2-27

Rev. B

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:

•

When duty data becomes Duty_min1before the carriage speed reaches SP3.

When the carriage speed reaches SP3 before duty data becomes Duty_min1, the next sequence (SP3 -

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

SP3

Deceleration 2

Deceleration 1

Deceleration 3

PWM Perodic Time

Note: 1, 2, and 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

Specification

Description

4-phase, 200-pole, HB* pulse motor

Form

Supply Voltage

Internal Coil Resistance

Frequency

37 VDC (applied to the drive circuit)

2.8 ohms + 10 % per phase at 25 ^oC

4274 pps** (normal mode,, constant driving): 9.9 ips***

2610 pps (middle speed mode,, constant driving): 6 ips

Driving: 1.75 A, + 0.20 A per phase (average)

Holding: 0.26 A, + 0. 2 A per phase (average)

Current Consumption

*HB …. Hybrid

**pps …. pulses per second

***ips …. inches per second

The motor pulse switching signals are transmitted from CPU ports PG00 to PG03. 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 : < 20 / 432 inches

‰ꢀMiddle speed mode:

‰ꢀNormal speed mode:

> 20 / 432 inches and < 60 / 432 inches, or with optional pull tractor

> 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

Board

DRV

Board

Gate Array

E05B36 (IC1)

+5V

Ref. Voltage

PFH/R

Setting Circuit (Q9)

Vref

PFA

4.3 VDC

CPU TMP95C061A

(IC2)

GP3

VP3

PG00

PG01

PG02

PG03

IN_A

INXA

IN_B

INXB

STK6713B

(IC2)

PF COM

OUT_A

OUTXA

PF A

PF B

OUT_B

OUTXB

PF C

PF D

GP3

Figure 2-23. PF Motor Drive Circuit Block Diagram

2-29

Rev. B

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

Specification

Description

4-phase, 48-pole, PM pulse motor

Form

Supply Voltage

Internal Coil Resistance

Frequency

37 VDC (applied to the drive circuit)

150 ohms + 10 % per phase at 25 ^oC

720 pps

Current Consumption

Driving Method

Driving: 0.10 A (average)

Constant voltage driving, 2-2 phase drive

VP 3

MAIN

Board

DRV

Board

E05B36

(IC1)

RFCOM

Q20,Q21

RF COM

Q22

Q23

RF A

RF B

RF C

RF D

PG10

PG11

RF Motor

TMP95C061A

(IC2)

Q24

Q25

PG12

PG13

PNP Transistor x4

Figure 2-24. RF Motor Drive Circuit Block Diagram

2-30

Rev. B

OPERATING PRINCIPLES

2.3.7 PG Motor Drive Circuit

Figure 2-25 shows a block diagram of the PG motor drive circuit, and Table 2-11 provides PG motor

specifications.

The PG motor is a stepping motor. The motor phase switching signals are output from the E05B36 ports

PGA to PGD. The motor common voltage (PGCOM) alternates between drive mode (+37 VDC) and hold

mode (+5 VDC) using the PG H/R signal of E05B36. The phase driver circuit is made by discrete transistors

Q12 to Q15.

The phase A 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

Specification

Description

Form

4-phase, 48-pole, PM pulse motor

37 VDC (applied to the drive circuit)

250 + 18 ohms per phase at 25 ^oC

Driving: 0.20 A (average)

Holding: 0.02 A + 5 mA

Supply Voltage

Internal Coil Resistance

Current Consumption

Frequency

285 pps

Driving Method

Constant voltage driving, 2-2 phase drive

MAIN Board

DRV Board

VP 3

+5V

D10

E05B36

(IC1)

Q10,

Q11

PG H/R

Q12,

Q13,

Q14.

Q15

PG A

PG B

PG C

PG D

Plsten Gap

Encoder

PG Motor

Figure 2-25. PG Motor Drive Circuit Block Diagram

2-31

Rev. B

DFX-8500

2.3.8 Plunger Drive Circuit

Figure 2-26 shows a block diagram of the plunger drive circuit, Table 2-12 provides the plunger specification,

and Table 2-13 provides the plunger switching pattern.

The plunger is driven using three switching patterns. Gate array E05B26 ports PLP and PLN output the

plunger coil drive signals. When the PNP port of the gate array turns on switching transistors Q30 and Q31

are turned on and the supply voltage (VP3) flows into the plunger coil. 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

Description

Form

DC solenoid

Supply Voltage

Internal Coil Resistance

Current Consumption

37 VDC (applied to the drive circuit)

9 ohms + 5 % at 25 ^oC

Driving: 3.7 A (MAX.)

Holding: 0.4 A

Table 2-13. Plunger Switching Pattern

Suspension Roller Status

Closed

Closed -> Opened

Closed with holding voltage

Q30 and Q31

Q32

Off

VP 3

NPN

Q30

Q31

PNP

E05B36

(IC1)

PLP

Q32

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 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 board). 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

FTMP

HF Motor Thermistor

HFANA

FANA

HF Motor

E05B36 (IC1)

HFANB

FANAX

TMP95C061A

(IC2)

VX VP1 GP1

VX VP2 GP2

Printhead Driver Circuit

1/2

Printhead Coils 1/2

DRV-B Board

Printhead Driver

Circuit 2/2

Printhead Coils 2/2

HTMP

VP2

HPSENS

Printhead Thermistor

R100

Monitoring NPNs

Short Circuit

Monitoring PNPs

Short Circuit

R101

ZD4

5.1V

ZD1

24V

R98

GP2

R99

GP2

Figure 2-27. Printhead Drive Circuit Block Diagram

2-33

Rev. B

DFX-8500

‰ꢀPrinthead high temperature feedback operation :

The printer supports the printhead temperature detection sequence, which consists of the following steps:

1. When the printhead temperature is less than 110 ^oC, the printer performs normal printing.

2. When the printhead temperature exceeds equal or more than 110 ^oC, 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 ^oC or less.

4. When the printhead temperature returns less than 100 ^oC, 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 ^oC, the HF fan stops.

2. When the printhead fan temperature exceeds equal or more than 65 ^oC, the HF rotates.

3. When the printhead temperature goes down to 50 C or less, the HF stops again.

2-34

Rev. B

CHAPTER 3

DISASSEMBLY AND ASSEMBLY

3.1 OVERVIEW ............................................................................................................3-1

3.1.1 Precautions for Disassembly and Assembly....................................................................... 3-1

3.1.2 Tools ........................................................................................................................................ 3-3

3.1.3 Specification for Screws........................................................................................................ 3-5

3.1.4 Service Checks After Repair.................................................................................................. 3-6

3.2 DISASSEMBLY AND ASSEMBLY.........................................................................3-7

3.2.1 ROM Replacement.................................................................................................................. 3-8

3.2.2 Printhead and Ribbon Mask Assembly Removal ................................................................ 3-9

3.2.3 Housing Removal ................................................................................................................. 3-13

3.2.3.1 Top Cover Removal................................................................................................. 3-13

3.2.3.2 Left, Right, and Front Covers Removal and Fuse Replacement............................. 3-14

3.2.3.3 Front Panel Unit Removal ....................................................................................... 3-16

3.2.3.4 Upper Case Removal.............................................................................................. 3-17

3.2.4 Circuit Boards Removal....................................................................................................... 3-18

3.2.4.1 Bottom Panel Assembly Removal........................................................................... 3-18

3.2.4.2 Cooling Fan and C204 Power Supply Board Unit Removal .................................... 3-21

3.2.4.3 C204 SUB Board Unit Removal .............................................................................. 3-22

3.2.4.4 C204 DRV-B and C204 DRV Board Units Removal ............................................... 3-23

3.2.4.5 C204 MAIN Board Unit Removal............................................................................. 3-24

3.2.4.6 AC Inlet Removal .................................................................................................... 3-26

3.2.4.7 C204 PNL Board Removal...................................................................................... 3-27

3.2.5 Interlock Switch and Cover Open Sensor Assembly Removal........................................ 3-28

3.2.6 Printer Mechanism Removal................................................................................................ 3-29

3.2.6.1 Fan Removal........................................................................................................... 3-31

3.2.6.2 Ribbon Feed Change Lever Unit Removal.............................................................. 3-32

3.2.6.3 Tractor Select Lever (Upper and Lower) Assembly Disassembly........................... 3-34

3.2.6.4 Ribbon Jam Sensor Removal.................................................................................. 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 ........................................................................ 3-37

3.2.6.7 Plunger and Paper Bail Assembly Removal............................................................ 3-38

3.2.6.8 Upper Paper Guide and Top PE Sensor Removal .................................................. 3-40

3.2.6.9 Tension Roller Shaft Removal................................................................................. 3-41

3.2.6.10 Platen Removal ..................................................................................................... 3-43

3.2.6.11 Paper Jam Sensor Removal.................................................................................. 3-44

3.2.6.12 Pull Tractor Sensor Removal................................................................................. 3-45

3.2.6.13 Paper Width (PW) Sensor Removal ..................................................................... 3-46

3.2.6.14 PG Home Sensor Removal.................................................................................... 3-47

3.2.6.15 PF Motor Removal ................................................................................................. 3-49

3.2.6.16 Left Side Frame Gear Removal ............................................................................ 3-50

3.2.6.17 Front Tractor Assembly Removal ........................................................................... 3-51

3.2.6.18 Rear Tractor Assembly Removal .......................................................................... 3-52

3.2.6.19 CR Motor Fan Removal.......................................................................................... 3-53

3.2.6.20 CR Motor Removal................................................................................................. 3-54

3.2.6.21 CR (Carriage Encoder) Sensor Removal.............................................................. 3-55

3.2.6.22 Carriage Mechanism Disassembly........................................................................ 3-56

3.2.6.23 Paper Support Assembly Removal ........................................................................ 3-59

3.2.6.24 PF Drive Roller Removal ....................................................................................... 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.

WARNING

;ꢀBecause the DFX-8500 weighs 29.0 kg (63.8 lb) and is much larger and heavier than most printers,

you must be careful when handling it. 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 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.

;ꢀWear gloves to protect your hands when handling the printer.

CAUTION

;ꢀ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 tools 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.

3-1

Rev. B

DFX-8500

Before transporting the printer, remove the paper and ribbon cartridge. Then attach the following packing

materials, as shown in Figure 3-1:

‰ꢀTransport locking bracket

‰ꢀCarriage guide shaft support bar

‰ꢀPrinthead protector

‰ꢀFoam packing for paper bail

Figure 3-1. Packing Material Attaching

After attaching the packing materials, pack the printer in its container as shown in Figure 3-2.

Figure 3-2. DFX-8500 Packing

Rev. B

3-2

DISASSEMBLY AND ASSEMBLY

3.1.2 Tools

This section describes the tools required for assembling, disassembling, or adjusting the printer.

Note : Refer to CHAPTER 4 for adjustment tools, CHAPTER 5 for troubleshooting tools, and

CHAPTER 6 for tools for maintenance, lubrication, and adhesives.

Table 3-1. Recommended Tools

Tool

Type

Class

Code

Reference

(+) Driver No.2

B743800200

(20 mm or more shaft length with

magnetization is recommended.)

(+) Driver No.1

Box screw driver (7 mm / 0.28 inches

across)

B743800400

B741700200

E-ring holder No. 3

E-ring holder No. 6

Round nose pliers

Diagonal wire cutters

Tweezers

Electric soldering iron

Tension gauge (7000 g)

Tension gauge (200 g)

Lift handles #E656

B740800500

B740800800

B740400100

B740500100

B741000100

B740200100

B777200301

B765114601

B765111001

B101946600

B101946700

B101946800

Dial gauges #F610

Figure 3-3

Figure 3-4

Figure 3-5

Figure 3-6

Dial gauge base #F611

Dial gauge master #F612

Thickness gauge (t=0.43mm)

Thickness gauge (t=0.80mm)

Motor screwdriver

(Phillips head, torque adjustable)

o: Commercially available

E: EPSON exclusive

A: Mandatory

B: Recommended

3-3

Rev. B

DFX-8500

Figure 3-3. Dial Gauges

Figure 3-4. Dial Gauge Base

Figure 3-5. Thickness Gauge

Figure 3-6. Dial Gauge Master

Rev. B

3-4

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

Abbreviation

Part Name

CBB

Cross-Bind head,, B-tight screw

CBS (O)

CBS (SP)

CFS

Cross-Bind head,, S-tight screw with Outside-toothed lock washer

Cross-Bind head,, S-tight screw with Spring lock washer + Plane washer

Cross-Flat head,, S-tight screw

CP (SP)

CP (PS)

CPB

Cross-Pan head with Spring lock washer + Plane washer

Cross-Pan head with Plane washer + Spring lock washer

Cross-Pan head B-tight screw

CPB (O)

CPS

Cross-Pan head B-tight screw with Outside toothed lock washer

Cross-Pan head S-tight screw

CPS (P)

CPS (SP)

CPN

Cross-Pan head S-tight screw with Plain washer

Cross-Pan head S-tight screw with Spring lock washer + Plain washer

Cross-Pan head screw

CPN (O)

CPN (SP)

CPT (O)

Cross-Pan head screw with Outside toothed lock washer

Cross-Pan head screw with Spring lock washer + Plain washer

Cross-Pan head Tapping screw with Outside toothed lock washer

Table 3-3. Screw Names and Illustrations

3-5

Rev. B

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 Are all necessary adjustments completed? Are [ ] Checked [ ] Not necessary

the results of the adjustments 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

attached utility program?

ROM Grade- What it the ROM version up-dated?

[ ] Checked [ ] Not necessary

Cleaning

Is any dust removed from the inside of the

printer?

Is the exterior housing clean?

Is the operate switch turned off?

Is the ribbon cartridge removed?

Attachments (power cord, optional units, etc.)

are inserted?

[ ] Checked [ ] Not necessary

Return to

customer

Attached

goods

Rev. B

3-6

DISASSEMBLY AND ASSEMBLY

3.2 DISASSEMBLY AND ASSEMBLY

WARNING

;ꢀBefore you disassemble or assemble the printer, be sure to read and follow the instructions in

Section 3.1, "OVERVIEW."

;ꢀBefore you disassemble the printer, be sure to turn the printer power off and disconnect AC cable.

This section describes how to disassemble the printer. See the APPENDIX for an exploded diagram of the

printer. Use this diagram for simple disassembly procedures not described here. To assemble the printer,

follow the disassembly instructions in this chapter in reverse. Any extra information 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.

3-7

Rev. B

DFX-8500

3.2.1 ROM Replacement

CAUTION

;ꢀIt is best to remove the top cover before you tilt back the printer as described in the steps below.

Refer to Section 3.2.3.1 for instructions on removing the top cover.

;ꢀIf you tilt back the printer with the top cover attached, be careful not to put too much weight on the top

cover or any other printer components.

;ꢀSpread a thick, soft cloth under the printer before you follow the steps below.

;ꢀRemove the ROM carefully to avoid damaging the board.

;ꢀ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.

(

)

Figure 3-7. ROM Replacement

Rev. B

3-8

DISASSEMBLY AND ASSEMBLY

3.2.2 Printhead and Ribbon Mask Assembly Removal

The printhead can be changed without disassembling the entire unit.

Use the exclusive printhead kit for printhead exchange on the DFX-8500. When you receive the kit, check

that all of the following are included.

(

)

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.

3-9

Rev. B

DFX-8500

CAUTION

;ꢀWhen you remove the connector cover, be careful not to break the tabs.

;ꢀWhen you remove the printhead cable holder, be careful not to break the printhead holder latch. Use

a slotted screwdriver if necessary.

Step 1: Open the top cover and remove the ribbon cartridge.

Step 2: Remove the two CBS (M3x8) screws securing the FPC cover to the bottom plate of the printer

mechanism.

Step 3: Disconnect the three printhead cables and a ground cable from the FPC board on the bottom plate.

Note 1. 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.

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Figure 3-9. Ribbon Cartridge Removal

Figure 3-10. Head Cable Removal

Step 4: Unlock 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

Rev. B

3-10

DISASSEMBLY AND ASSEMBLY

Step 5:Disconnect the narrow FPC cable from white connector (lock-type).

Step 6:Move the carriage to around 90^thcolumn, 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.

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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.

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.

3-11

Rev. B

DFX-8500

ASSEMBLING POINT

zꢀ Confirm that the cables are connected correctly. (Refer to Figures 3-12 and 5-3..)

zꢀ Tighten the screws while pulling the printhead as shown below to secure the printhead firmly.

Figure 3-14. Printhead Installation

Step 12:Install the cable cover and the FPC cover.

Step 13:Wipe off any stains from the carriage guide shaft, lubricate both ends of the carriage guide shaft

with the included oil (0-2), and spread the oil over the shaft by moving the carriage manually.

Figure 3-15. Lubricating to Carriage Guide Shafts

ADJUSTMENT REQUIRED

zꢀ When you install the printhead, perform the platen gap motor value adjustment (ALPHA value write

operation) described in Section 4.1.7).

Rev. B

3-12

DISASSEMBLY AND ASSEMBLY

3.2.3 Housing Removal

This section describes how to remove the housing.

3.2.3.1 Top Cover Removal

CAUTION

;ꢀTwo people are required to remove the top cover; one person must hold the top cover while the other

person removes the screws. If the top cover is not supported while the screws are removed, the

weight of the top cover may damage the rear hinges.

Step 1: Open the top cover.

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.

Figure 3-16. Top Cover Removal

3-13

Rev. B

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.

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Figure 3-17. Left and Right Side Covers Removal

ASSEMBLING POINT

zꢀ 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.

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Figure 3-18. Cabling for the Main Switch

Rev. B

3-14

DISASSEMBLY AND ASSEMBLY

Step 3: After you remove the right side cover, you can replace the input fuse for the C204 power supply

board unit.

WARNING

;ꢀMake sure the new fuse meets the printer's AC power specifications.

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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.

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Figure 3-20. Front Cover Removal

3-15

Rev. B

DFX-8500

3.2.3.3 Front Panel Unit Removal

Step 1: Remove the left and right side covers. (Refer to Section 3.2.3.2)

Step 2: Open the top cover and disconnect connector CN5 (the panel unit connector).

Step 3: Remove the two CBB (M4x16) screws from the front panel unit and remove the panel unit along

with the panel connector cable.

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Figure 3-21. Front Panel Removal

Rev. B

3-16

DISASSEMBLY AND ASSEMBLY

3.2.3.4 Upper Case Removal

Step 1: Remove the front panel unit. (Refer to Section 3.2.3.3)

Step 2: Remove the six CBB (M4x16) screws, and two CBB (M3x10) screws from the upper case. Then

remove the upper case.

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Figure 3-22. Upper Case Removal

3-17

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

CAUTION

;ꢀIt is best to remove the top cover before you tilt back the printer as described in the steps below.

Refer to Section 3.2.3.1 for instructions on removing the top cover.

;ꢀIf you tilt back the printer with the top cover attached, be careful not to put too much weight on the top

cover or any other printer components.

;ꢀSpread a thick, soft cloth under the printer before you follow the steps below.

;ꢀ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

yellow earth cable and the earth plate together.

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Figure 3-23. Connector and Earth Cable Removal (right side)

Rev. B

3-18

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.

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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.

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Figure 3-25. Interface Cover Removal

3-19

Rev. B

DFX-8500

Step 7: While supporting the top cover to protect it from scratches, tilt back the printer and lay it on its back.

Step 8: Remove the eight CBB (M4x16) screws securing the bottom panel assembly, and slowly remove the

bottom panel unit assembly.

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Figure 3-26. Bottom Panel Assembly Removal

Rev. B

3-20

DISASSEMBLY AND ASSEMBLY

3.2.4.2 Cooling Fan and C204 Power Supply Board Unit Removal

Step 1: Remove the bottom panel assembly. (Refer to Section 3.2.4.1)

Step 2: If you need to remove the cooling fan, disconnect connector CN5 and remove the four CCN (M3x30)

screws securing it, and remove the fan.

Step 3: Disconnect connectors CN2, CN3, and CN4.

Step 4: Remove the six CBB (M3x12) screws and CPN (O) (M3x8) screw securing the C204 power supply

board unit and remove the board.

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Figure 3-27. C204 PSE/PSB Board Removal

3-21

Rev. B

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.

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Figure 3-28. C204 SUB Board Unit Removal

Rev. B

3-22

DISASSEMBLY AND ASSEMBLY

3.2.4.4 C204 DRV-B and C204 DRV Board Units Removal

Step 1: Remove the bottom panel assembly. (Refer to Section 3.2.4.1)

Step 2: Disconnect connector CN3 and cable connector CN14 for the C204 DRV board.

Step 3: Disconnect connectors CN1 and CN2 on the C204 DRV-B board.

(

Figure 3-29. C204 DRV/DRV-B Boards Removal ½

Step 4: Remove the eight CBS (M3x8) screws securing the C204 DRV-B board and C204 DRV board via

shielding plate respectively.

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Figure 3-30. C204 DRV/DRV-B Boards Removal 2/2

3-23

Rev. B

DFX-8500

3.2.4.5 C204 MAIN Board Unit Removal

Step 1:Remove the bottom panel assembly. (Refer to Section 3.2.4.1)

Step 2:Remove the C204 SUB board unit (Refer to Section 3.2.4.3.)

Step 3:Remove the C204 DRV-B board and C204 DRV board units (Refer to Section 3.2.4.4.)

Step 4:Disconnect connectors CN6, CN7, CN8, and CN10.

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Figure 3-31. C204 MAIN Board Removal 1/4

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Figure 3-32. C204 MAIN Board Removal 2/4

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Figure 3-33. C204 MAIN Board Removal 3/4

Rev. B

3-24

DISASSEMBLY AND ASSEMBLY

Step 5:Remove the four CBB (M3x12) screws and two CBS (O) (M3x8) screws securing the C204 MAIN

board unit and remove the board.

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Figure 3-34. C204 MAIN Board Removal 4/4

ADJUSTMENT REQUIRED

When you install the C204 MAIN board assembly, perform the following adjustments:

zꢀ Platen gap motor value (platen gap) adjustment (described in Section 4.1.7).

zꢀ Bidirectional printing adjustment (described in Section 4.1.8).

3-25

Rev. B

DFX-8500

3.2.4.6 AC Inlet Removal

Step 1: Remove the C204 power supply board assembly. (Refer to Section 3.2.4.2)

Step 2: Remove the C204 MAIN board assembly. (Refer to Section 3.2.4.5)

Step 3: Remove the three CBB (M3x8) screws and one CB (O) (M4x6) screw securing the grounding

plate to the bottom panel assembly and remove the grounding plate.

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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.

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Figure 3-36. AC Inlet Removal

Rev. B

3-26

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.

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Figure 3-37. C204 PNL Board Removal

3-27

Rev. B

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.

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.

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Figure 3-39. Interlock Switch Assembly Removal

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Figure 3-40. Interlock Switch and Cover Open Sensor Removal

Rev. B

3-28

DISASSEMBLY AND ASSEMBLY

3.2.6 Printer Mechanism Removal

This section describes how to remove and disassemble the printer mechanism. Before following the steps in

this section, remove the printer mechanism from the printer as described in Section 3.2.6.

WARNING

Because the printer mechanism is large and heavy, you must be careful when you remove it. When

you lift or lower the printer mechanism, follow these precautions:

;ꢀTwo people are required to remove or install the printer mechanism.

;ꢀUse the lift handles (#E656, part number B765111001) designed for lifting or lowering the printer

mechanism when you remove or install it.

;ꢀTo avoid straining your waist, hands, or feet, place the printer on a low table before following 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.

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Figure 3-41. Connector Removal (left side)

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Figure 3-42. Connector Removal (right side)

3-29

Rev. B

DFX-8500

Step 5: Remove the four screws securing the printer mechanism to the lower case.

Figure 3-43. Printer Mechanism Removal 1/2

Step 6: Install the lift handles from the inside of the printer mechanism. Insert each handle through the

two holes in the side frames of the printer mechanism. Then slowly lift up the printer mechanism

using the handles and remove it from the lower case.

Figure 3-44. Printer Mechanism Removal 2/2

ASSEMBLING POINT

When you install the printer mechanism, route the cables as shown in Figures 3-41 and 3-42. Make sure

the cables do not get caught between the printer mechanism and lower case.

ADJUSTMENT REQUIRED

When you install the printer mechanism, perform the following adjustments:

Platen gap motor value (platen gap) adjustment (described in Section 4.1.7)

Bidirectional printing adjustment (described in Section 4.1.8)

Rev. B

3-30

DISASSEMBLY AND ASSEMBLY

3.2.6.1 Fan Removal

Step 1: Remove the upper case unit. (Refer to Section 3.2.3.4.)

Step 2: Remove the right cover. (Refer to Section 3.2.3.2.)

Step 3: Disconnect the connector for the fan from the relay connector.

Step 4: 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.

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Figure 3-45. Fan Removal

3-31

Rev. B

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 Section 3.2.6.1.)

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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.

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Figure 3-47. Ribbon Feed Change Lever Unit Removal (2/2)

Rev. B

3-32

DISASSEMBLY AND ASSEMBLY

Figure 3-48. Removing Connectors

ASSEMBLING POINT

When you install the ribbon feed change lever unit, join the tip of the tractor select lever and the tractor

select gear holder correctly. (Refer to Figure 2-12.)

3-33

Rev. B

DFX-8500

3.2.6.3 Tractor Select Lever (Upper and Lower) Assembly Disassembly

This section describes how to disassemble the tractor select lever assembly, including how to remove the

ribbon feed motor and tractor select sensor.

Step 1: Remove the ribbon feed change lever unit. (Refer to Section 3.2.6.2.)

Step 2: Remove the two CP(S-P1)(M3x6) screws, leaf springs, and washers securing the ribbon feed

motor to the ribbon feed motor frame and remove the motor.

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.

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Figure 3-49. Tractor Select Lever Disassembly

ASSEMBLING POINT

zꢀ Attach the tractor select levers to the tractor select cam as shown in Figure 3-50.

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Figure 3-50. Tractor Select Lever Installation

Rev. B

3-34

DISASSEMBLY AND ASSEMBLY

3.2.6.4 Ribbon Jam Sensor Removal

Step 1: Remove the right cover. (Refer to Section 3.2.3.2)

Step 2: Disconnect the connector for the sensor from the connector junction board.

Step 3: Remove the CP(S-P1) (M3x6) screw securing the sensor to the bracket, and remove the sensor.

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Figure 3-51. Ribbon Jam Sensor Removal

3-35

Rev. B

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.

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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 and number of pins (Refer to APPENDIX Figure A-15.).

Rev. B

3-36

DISASSEMBLY AND ASSEMBLY

3.2.6.6 PG Sensor and PG Motor Removal

CAUTION

When you remove or install the PG sensor, be careful not to bend the PG motor encoder plate.

Step 1: Remove the connector junction board assembly. (Refer to Section 3.2.6.5)

Step 2: Remove the CBS screw (3X6) securing the PG sensor unit to the left frame. Then take out the

unit to the front and remove it.

Step 3: Remove the screw securing the PG sensor to the unit, and remove the sensor.

Step 4: Remove two CP (S-P1) (M3x6) screws securing the PG motor and remove the motor.

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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 motor 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.

3-37

Rev. B

DFX-8500

3.2.6.7 Plunger and Paper Bail Assembly Removal

This section describes how to remove the plunger (loading solenoid) and paper bail assembly.

Step 1: Disconnect the black, 2-pin plunger connector from the connector junction board assembly, and

remove the plunger cable from the connector junction board assembly.

Step 2: Remove the two CP(S-P1) (M3x6) screws securing the plunger to the left side frame and remove

the plunger.

Step 3: Remove the iron core of the plunger from the paper bail shaft.

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Figure 3-54. Plunger Removal

Rev. B

3-38

DISASSEMBLY AND ASSEMBLY

Step 4: Remove the left tension roller lever spring.

Step 5: Remove the E-ring (6) securing the paper bail shaft to the left frame and remove the platen roller

shaft holder and paper bail lever.

Figure 3-55. Paper Bail Assembly Removal 1/2

Step 6: Disconnect 2 fan harnesses and remove 2 screws (CPS-P1) securing the CR fan duct. Then

remove the CR fan duct along with the CR fan. (Refer to Section 3.2.6.1.)

Step 7: Remove the right tension roller lever spring.

Step 8: Remove 2 E-rings to release the release tension lever at the inner side of the left frame.

Step 9: 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.

Step 10: 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.

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Figure 3-56. Paper Bail Assembly Removal 2/2

3-39

Rev. B

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.

Figure 3-57. Top PE Sensor Connector Removal

Step 3: Remove the two CBS (M4x6) screws securing the upper paper guide to both frames and remove the

paper guide.

Step 4: Remove the two CPS(SP) (M3x8) screws securing the top PE sensor to the upper paper guide and

remove the sensor.

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Figure 3-58. Top PE Sensor Removal

Rev. B

3-40

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: Remove the connector junction board assembly. (Refer to Section 3.2.6.5.)

Step 2: Remove the paper bail assembly. (Refer to Section 3.2.6.7.)

Step 3: While pushing the tension pulley to the front, remove the CR timing belt.

Step 4: Remove the upper paper guide. (Refer to Section 3.2.6.8.)

Step 5: Using tweezers, unlock the locking tab of the tension roller gear at the left end of the tension roller

shaft, and remove the gear.

Step 6: Remove the E-ring (6) on the left end of the tension roller shaft and remove the shaft holder.

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Figure 3-59. Tension Roller Gear Removal

3-41

Rev. B

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.

Figure 3-60. Shaft Holder Removal

Figure 3-61. Tension Roller Shaft Removal

Rev. B

3-42

DISASSEMBLY AND ASSEMBLY

3.2.6.10 Platen Removal

Step 1: Remove the paper bail assembly. (Refer to Section 3.2.6.7.)

Step 2: Remove the upper paper guide. (Refer to Section 3.2.6.8.)

Step 3: Remove the four hexagon socket screws securing the platen to the platen holders. Then remove

the platen with the lower paper guide composed of 3 parts in it.

Step 4: Slide the 3 parts of the lower paper guide to release the notches and remove them one by one

from the platen.

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Figure 3-62. Platen Removal

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)

Platen angle (right angle) adjustment (described in Section 4.1.6)

Platen gap motor value (platen gap) adjustment (described in Section 4.1.7)

3-43

Rev. B

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.

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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.

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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).

Rev. B

3-44

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.

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Figure 3-66. Pull Tractor Sensor removal

3-45

Rev. B

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.

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Figure 3-67. PW Sensor Removal

Rev. B

3-46

DISASSEMBLY AND ASSEMBLY

3.2.6.14 PG Home Sensor Removal

Step 1: Remove the front/rear tractor select lever assembly. (Refer to Section 3.2.6.2.)

Step 2: Remove the E-ring securing the carriage guide shaft gear to the rear carriage guide shaft.

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)

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.

(

)

Figure 3-69. PG Home Sensor Removal

3-47

Rev. B

DFX-8500

ASSEMBLING POINT

When you install the CR guide shaft gear, align the rib in the CR guide shaft gear with the PG adjustment

transmission gear as shown in the figure below, then rotate the CR guide shaft gear 10 mm in CCW.

(

)

Figure 3-70. CR Guide Shaft Gear Phase Alignment

Rev. B

3-48

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

3-49

Rev. B

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

Rev. B

3-50

DISASSEMBLY AND ASSEMBLY

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.

(

)

(

)

(

)

Figure 3-73. Tractor Wire Removal

(

)

(

)

Figure 3-74. Front Tractor Assembly Removal

ADJUSTMENT REQUIRED

•

When you install the front tractor assembly, perform the tractor wire spring adjustment, as described

in Section 4.1.3.

3-51

Rev. B

DFX-8500

3.2.6.18 Rear Tractor Assembly Removal

This section describes how to remove the rear tractor assembly.

Step 1: Disconnect the connector white 3-pin rear PE sensor from the connector junction board.

Step 2: Remove the connector junction board assembly. (Refer to Section 3.2.6.5.)

Step 3: Remove the flange nut securing the wire holder spring set to the right side frame, and remove the

set.

Step 4: Loosen the flange nut securing the rear tractor assembly to the left side frame.

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.

(

)

(

)

(

)

(

)

Figure 3-75. Rear Tractor Assembly Removal

ADJUSTMENT REQUIRED

When you install the rear tractor assembly, perform the tractor wire spring adjustment, as described in

Section 4.1.3.

Rev. B

3-52

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.

Figure 3-76. CR Motor Fan Removal

3-53

Rev. B

DFX-8500

3.2.6.20 CR Motor Removal

Step 1: Remove the right cover. (Refer to Section 3.2.3.2.)

Step 2: Disconnect the red and black cables from the terminals on the CR motor. (two cables for each

terminal)

Step 3: Remove the three CP(S) (M4x10) screws securing the CR motor to the right side frame and remove

the motor.

(

)

(

)

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.

Rev. B

3-54

DISASSEMBLY AND ASSEMBLY

3.2.6.21 CR (Carriage Encoder) Sensor Removal

Step 1: Remove the printhead. (Refer to Section 3.2.2.)

Step 2: Disconnect the red 4-pin CR sensor connector from the carriage connector junction board.

Step 3: Remove the two CP(S-P1) (M2.6 x 5) screws securing the CR sensor to the carriage and remove

the sensor.

Figure 3-78. CR Sensor Removal 1/2

(

)

(

)

Figure 3-79. CR Sensor Removal 2/2

3-55

Rev. B

DFX-8500

3.2.6.22 Carriage Mechanism Disassembly

This section describes how to disassemble the carriage mechanism, including removing the carriage, CR

timing belt, and front and rear carriage guide shafts.

Step 1: Remove the CR motor. (Refer to Section 3.2.6.20.)

Step 2: Remove the belt pulley from the belt pulley holder.

(

)

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

Rev. B

3-56

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: On the left side frame, remove the E-ring (6) securing the carriage guide shaft gear to the rear

carriage guide shaft, then remove the carriage guide shaft gear and paper thickness sensor holder.

Step 7: Unhook the spring securing the paper thickness sensor assembly and remove the sensor

assembly.

(

)

(

)

(

)

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 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.

(

)

(

)

(

)

(

)

(

)

(

)

Figure 3-83. Right Side Frame Removal

3-57

Rev. B

DFX-8500

ASSEMBLING POINT

When you install the front carriage guide shaft, tighten the screws while pushing the shaft toward the

platen.

ADJUSTMENT REQUIRED

When you assemble the carriage mechanism, perform the following adjustments:

•

Carriage timing belt tension adjustment (described in Section 4.1.2)

Carriage guide shaft parallelism adjustment (described in Section 4.1.5 and Section 4.1.6)

Platen gap motor value (platen gap) adjustment (described in Section 4.1.7)

Bidirectional printing adjustment (described in Section 4.1.8)

Rev. B

3-58

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 4.1.2)

Carriage guide shaft parallelism adjustment (described in Section 4.1.5 and Section 4.1.6)

Platen gap motor value (platen gap) adjustment (described in Section 4.1.7)

Bidirectional printing adjustment (described in Section 4.1.8)

3-59

Rev. B

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)

Platen gap motor value (platen gap) adjustment (described in Section 4.1.7)

Bidirectional printing adjustment (described in Section 4.1.8)

Rev. B

3-60

CHAPTER 4

ADJUSTMENT

4.1 PRINTER MECHANISM ADJUSTMENTS ............................................................4-1

4.1.1 PG Motor Backlash Adjustment........................................................................................... 4-1

4.1.2 Carriage Timing Belt Tension Adjustment.......................................................................... 4-2

4.1.3 Tractor Wire Spring Tension Adjustment........................................................................... 4-3

4.1.4 Pull Tractor Sensor Position Adjustment............................................................................ 4-4

4.1.5 Carriage Guide Shaft Parallelism Adjustment.................................................................... 4-5

4.1.6 Platen Angle Adjustment ...................................................................................................... 4-9

4.1.7 Platen Gap Motor Value Adjustment.................................................................................. 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.

CAUTION

;ꢀIf the PG motor backlash is too tight, PG motor doesn’t rotate smoothly and the panel indicates “E3.”

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 to 0.01 inches) between the PG motor pinion gear

and PG transmission gear cog. Then tighten the two screws.

Figure 4-1. PG Motor Mounting Position Adjustment

4-1

Rev. B

DFX-8500

4.1.2 Carriage Timing Belt Tension Adjustment

The carriage timing belt tension must be adjusted when any carriage mechanism part (such as the CR motor,

belt pulley, or carriage timing belt) is disassembled. Remove the printer mechanism before performing this

adjustment. (Refer to Section 3.2.6)

CAUTION

;ꢀBefore performing this adjustment, carefully secure the printer mechanism because a 7 kg (15.4 lb.)

force is applied to it when the tension lever is pulled in the horizontal direction.

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 lb.) 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 lb.)

force is applied.

Step 6: Finish tightening the three tension adjustment screws with 12 Kg cm torque.

(

)

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 adjusted properly, paper

jams may occur, because the continuous paper tension (in the horizontal direction) is incorrect. When you

remove the front or rear tractor assembly, perform this adjustment.

Step 1: 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.

(

)

(

)

Figure 4-3. Tractor Wire Tension Adjustment (Front)

4-3

Rev. B

DFX-8500

4.1.4 Pull Tractor Sensor Position Adjustment

This section describes the pull tractor sensor position adjustment. If the sensor position is incorrect, the

sensor is always on. When you replace or disassemble the platen, rear paper guide, platen roller shaft,

tension roller shaft, or pull tractor sensor, perform this adjustment. Figure 4-4 illustrates the pull tractor sensor

position adjustment.

When you assemble the pull tractor sensor or rear paper guide, check the following items:

•

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).

(

)

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.)

CAUTION

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 4-5) 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.

;ꢀDial gauges (x 2) #F610 (Part No. B1019466)

;ꢀDial gauge base #F611 (Part No. B1019467)

;ꢀ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

4-5

Rev. B

DFX-8500

Step 3: Attach the another needle to the master surface, APPROX. 2.00 mm depth, then correspond to the

another gauge measure, and tighten the hexagonal screw.

3. Tighten the hexagonal screw.

2. Attach the gauge needle to the

master surface, then correspond

to the another gauge measure.

Figure 4-7. Dial Gauge set Up 2

Step 5: Set the black marker to the "0" position.

Figure 4-8. Black Marker to “0” Position Setting

4-6

Rev. B

ADJUSTMENT

Step 6: Remove a CP(PS)(M3X6) screw securing the timing belt holder to the timing belt, then remove the

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:

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.

Figure 4-10. Dial Gauge Attachment

Figure 4-10a. CR Guide Shaft Gear Positioning

4-7

Rev. B

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.

Figure 4-11. Carriage Guide Shaft Parallelism Adjustment

Step 13:

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.

Notes 1: 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.

Notes 2: 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, the distance between the right side of the

platen and print head nose narrows a little bit.

Step 14:

Step 15:

Step 16:

Step 17:

Repeat steps 11 and 12 until the distance between the distance measured at the two positions is

less than + 0.015 mm.(The #F610 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)

Guide Shaft Holding Spring

CP(PS)(M4X6)

CBS(O)(M4X8)

Carriage Motor Holder

Figure 4-12. Parallelism Adjustment Lever Operation

Rev. B

4-8

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 necessary to remove the tension roller

shaft be fore performing this adjustment. (Refer to Section 3.2.6.7)

CAUTION

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.

;ꢀDial gauge #F610 (Part No. B1019466)

;ꢀDial gauge base #F611 (Part No. B1019467)

;ꢀDial gauge master #F612 (Part 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.

(

)

(

)

Figure 4-13. Loosing Hexagonal Screws

4-9

Rev. B

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).

(

)

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.)

Center Position

70 mm

Platen

3 0

2 0

3 0

2 0

3 0

2 0

3 0

2 0

3 0

2 0

3 0

2 0

1 0

3 0

1 0 2 0

3 0

1 0 2 0

Figure 4-15. Measuring Angle Difference 1

4-10

Rev. B

ADJUSTMENT

(

)

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.

CAUTION

After perform the adjustment, confirm the value of platen parallelism again. When this value is out of

order, readjust the platen parallelism and the platen angle adjustment until the value to be correct.

4-11

Rev. B

DFX-8500

4.1.7 Platen Gap Motor Value Adjustment

This section describes how to measure the parameter (ALPHA and BETA values) for the PG mechanism

unit. Since the ALPHA and BETA values are unique to each mechanism unit, it is written on the label as

shown in Figures 4-17 and 4-18, so that it can be confirmed at glance. Be sure to perform this measurement

and correct the value written on the label because the value is necessary when the other units (board,

printhead) are changed.

CAUTION

;ꢀ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 mm)

ꢀ Thickness gauge (0.80 mm)

ꢀ Tension gauge (200 g) : #F545 (EPSON Part 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.

;ꢀAfter perform this adjustment, perform the Bi-Directional adjustment as explained in section 4.1.8.

(

)

Figure 4-17. ALPHA Value Print

Figure 4-18. BETA Values Print

4-12

Rev. B

ADJUSTMENT

Step 1:

Step 2:

Remove the paper, ribbon cartridge, and ribbon mask holder from the printer. Then confirm the

ALPHA value written on the print head nose.

Close the top cover.

ALPHA Value Write Mode :

Step 3:

Turn the printer on while pressing the Tear Off, Micro Feed (v), and Front/Rear switches. At this

time the printer performs PG home position seek. and the carriage moves to the 15 column.

The panel indicates the current ALPHA adjustment value (Refer to Table 4-1.).

Write the ALPHA value written on the print head into the memory.

Step 4:

Step 5:

• 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.)

Contact the tension gauge to the hole of the thickness gauge and pull it straight to the right.

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.

Step 8:

Step 9:

• 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 BETA3’ value when the tension gauge indicates the 150 (135 - 165) gf, the tension gauge

can move to right in a degree.

Step 11:

Step 12:

After complete BETA3’ adjustment, press Pause SW to enter next step.

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:

Step 15:

Inset the 0.43 mm thickness gauge into the space between the platen and the print head nose.

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 16: After complete BETA3 adjustment, press Pause SW to enter next step.

Step 17:

Step 18:

Inset the 0.80 mm thickness gauge into the space between the platen and the print head nose.

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 BETA4 adjustment, press Pause SW then all of measured BETA values written

to the EEPROM, and turn the printer power off.

Note:

When either the measured BETA values (BETA2, BETA3, 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: A1 = 0.43 / (BETA3 - BETA2)

and

0.0134 < A1 < 0.0187

0.0115 < A2 < 0.0195

A2 = (0.80 - 0.43) / (BETA4 -BETA3) and

Step 20: Install the ribbon mask holder and the ribbon cartridge.

4-13

Rev. B

DFX-8500

(

)

Figure 4-19. Thickness Gauge Setting Method

Table 4-1. BETA Values Adjustment

Beta No.

BETA 3'

BETA 2

BETA 3

BETA 4

Reference Thickness Gauge

0.43 mm with 150gf pull

0.00 mm

Allowed Value Default Value*1)

367 - 419

405 - 437

418 - 475

408

435

461

0.43 mm

0.80 mm

*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 Adjustment

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

;ꢀIf the DIP-SW "3-5" is set to the IBM 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.

;ꢀ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.

4-15

Rev. B

DFX-8500

(

Figure 4-20. Carriage Measurement Seeking

4-16

Rev. B

ADJUSTMENT

(

)

(

)

(

)

Figure 4-21. Flight Time Adjustment

4-17

Rev. B

DFX-8500

Figure 4-22. Test Print Pattern

Table 4-2. LED indication and Adjustment Value Comparison

LED*1)

Off

+ (positive)

300

On*2)

(negative)

400

Ribbon

(Bi-d. adjustment)

(PG adjustment)

Pause

Top of Form

Tear Off

Copy

Pitch „„†

„††

†††

Font „†

††

7 Segment*3)

0 to 9

*1) „: off, †: On

*2) Indicates 2^ndcolumn.

*3) Indicates 1^stcolumn.

4-18

Rev. B

ADJUSTMENT

)

(

)

Figure 4-23. Bi-d. Adjustment

4-19

Rev. B

CHAPTER 5

TROUBLESHOOTING

5.1 PROBLEM ISOLATION..........................................................................................5-1

5.2 SELF DIAGNOSTIC FUNCTION............................................................................5-2

5.3 TROUBLESHOOTING ...........................................................................................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: For this printer, no special tools are necessary for troubleshooting to the unit level, with the

exception of a digital multi-meter. Some component-level troubleshooting may require an

oscilloscope.

5.1.1 Error Messages

The DFX-8500 indicates errors using beeps. Table 5-1 lists fatal errors.

Table 5-1. Fatal Error Information

Fatal Error

7-segment Beeper *2)

LED *1)

Description

Note*3)

CR motor

circuit

shortage error

Auto power off

after 12 seconds

•

The isolation resistance in the CR

motor is too low.

Cutter error

- -

- - -

Auto power off

after 12 seconds

Optional cutter cable is not connected

firmly.

•

Optional cutter is defective.

The PG home sensor is broken.

The PG motor is broken.

The parallelism adjustment is

incorrect.

Platen gap

error

Auto power off

after 12 seconds

•

PG adjustment values are incorrect.

PG backlash is too tight.

The carriage is locked.

The interlock switch doesn’t close

exactly.

Carriage lock

error

- - - -

Auto power off

after 12 seconds

•

The parallelism adjustment is

incorrect.

•

PG adjustment values are incorrect.

PW sensor is defective.

The CR motor is defective.

The CR encoder sensor is defective.

The head fan driver IC is shorted.

The head fan of the print head is

defective.

Carriage load

measurement

error

- - - - - -

Auto power off

after 12 seconds

Head fan error

- - - - - - -

Head power off

immediately

Head circuit

shortage error

RAM check

error

Paper memory

setting error

EEPROM data

compare error

Tractor change

error

- - - - - - - -

Head power off

immediately

Auto power off

•

The print head driver IC is shorted.

The coil of the print head is defective.

DRAM of C204 MAIN board is

defective.

- - - - - - - - -

- - - - - - - - - -

- - - - - - - - - - -

after 12 seconds

•

EEPROM on the C204 MAIN board

is defective.

Tractor select mechanism is

defective.

- - - - - - - - - - -

Auto power off

after 12 seconds

Auto power off

after 12 seconds

Watch dog

error

C205 MAIN board has trouble.

Note 1: The 7 segment LED indicates error No. and “E” alternately.

Note 2: The descriptions “.”and “-“ 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

5-1

Rev. B

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.

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.

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

Part

Coil Resistance

CR motor

PF motor

RF motor

PG motor

Head fan

Plunger

1.66 ohms + 10 %

2.80 ohms + 10 % at 25^oC

150 ohms + 10 % at 25^oC

250 ohms + 18 ohms at 25^oC

61 ohms + 4.3 ohms at 25^oC

9 ohms + 5 % at 25^oC

Printhead

2.93 ohms + 0.2 ohms at 25^oC

Shield Cable

Double-sided Adhesive Tape

Head FPC

Head Cable

Protection Sheet

Head Cable Board

Figure 5-3. Disconnect Printhead FPC

5-3

Rev. B

DFX-8500

FPC A

FPC B

FPC C

Load Pattern

MA : Fan motor phase A

MB : Fan motor phase B

MC : Fan motor common

MT : Fan motor thermistor

: Head coil GND side

: Head coil P/S side

: Head thermistor

PWD : Paper width sensor

+5V : +5 VDC

ENCA: Encoder A

GND : GND

P/S : Power supply (+37 VDC)

ENCB: Encoder B

HT : Head thermistor

Figure 5-4. Printhead Coil Resistance

5-4

Rev. B

TROUBLESHOOTING

1. The printer does not operate when power is turned on.

START

nte

befo

the

beep

heck Tab

ode

e 5

-1,

t d

the

Use the

C v

tage.

nput voltage

rmal?

Replace the fuse F1 and

disconnect CN2, CN3, and

CN4 on the C204 power

supply Board.

boa

e F1

on the

upp

wer

204

rd blown?

Reconnect CN2,

the

ed?

CN3, and CN4

and turn on the

printer.

hen

n on po

aga n, doe

you

wer

re the output

tage f

rom

e a

the

upp

boa d.

204

END

the

output

tage

boa

rd.

e the

upply

204

heck

oto

eno

d, p

nthead,

etest

and d

ng a

ete

e the

nthead. If d

ep e at the

e bad

oto

e t

eno

d, o

n no

rmal

bad,

ange?

the

Replace the C204 MAIN board,

C204 DRV board, and/or

C204 DRV-B board.

fau

ted?

the

fau

ted?

Section 5.3 to

repa

the p

nte

hanism

5-5

Rev. B

DFX-8500

2. Carriage operation is abnormal.

TART

connec

einsert the connectors.

inserted securely?

correc

ed?

END

anuall

carr age

ove en

ove

o see

s s ooth

the

smooth

not.

mooth

on 5

echan

necessary.

Repair

ism.

f the

heck the

and CR

s us

eter.

correc

ed?

If the

s bad

lace.

s a

e bad

lace at

he sa

ime.

Yes

corrected?

END

Replace the C204 MAIN board and/or

C204 DRV board.

Check the following connectors:

NOTE 1:

Junction board connector to interlock switch

Junction board connector to CR motor

Head junction board connectors to printhead

END

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).

rfo

the

elf-test.

Does the

printer perform

self-test ?

re the

onnectors

securely?

Is there

any dot missing

or dragging ?

Reinsert correctly.

the

fau

ted?

heck

ont nu

nthead p

nthead

ually check

cable

Vis

lace

bad pa

the

fau

ted?

the bidirectional

nt ng ad

ent.

Check the following connectors:

NOTE 1:

Three head junction board connectors to printhead

CN1 of C204 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

5-7

Rev. B

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.

the

head

resistance

rrect?

Yes

heck

the p

head d

heck the printhead drivers.

If the p

head d

head

rivers

the

OK?

If the p

head d

head

rivers

the

OK?

Yes

Replace the C204 MAIN and./or

C204 DRV-B board.

Yes

Replace the C204 MAIN and./or

C204 DRV-B board.

the p

Yes

OK?

han

tion 5

epa

of the

ism.

han

tion 5

epa

of the

ism.

5-8

Rev. B

TROUBLESHOOTING

3. Carriage operation is normal, but the self-test is printed incorrectly (3/3).

the p

rrec

bidirectional

justment.

o back to

of the nte

heck fo othe

on 5.3

epa

han

ism, and

rob

rfo

bidirectional

justment.

5-9

Rev. B

DFX-8500

4. Printing is normal, but paper feeding is abnormal.

TART

the

oaded

pape

orrectly?

Load the pape

rre

hen

e the

anuall , doe

ooth

oto

efe

han

on 5.3

epa of the

nte

ly?

oto

heck the

il and

tan

e of the

rivers

oto

tan

heck the

oto

e the

s sho

open?

ted o

the

tan

e the d

e the

and a

otor r

s shorted or

open?

Replace the

C204 MAIN board and/or

C204 DRV board.

Replace the

C204 DRV board

and the PF motor.

e the

efe

han

on 5.5,

epa

of the

motor.

nte

rfo

ng of

-test.

rfo

ng of

self-test.

the

OK?

of the

efe

on 5.3

han

epair

efe

and pe

oto back

hapte

nte

sm.

rfo

the

lash

ent.

the

OK?

efe

the

hapte

4 and perform

oto backlash

ent.

5-10

Rev. B

TROUBLESHOOTING

5. Panel unit operation is abnormal.

TART

Is CN5

between the C204 MAIN

and C204 PNL board

connected correctly?

connector CN

orrectly.

the

fau

ted?

the sw

204

ng a

ete

on the

check

hes

L boa

o the

hes w

ork

e the

204

boa

204

e the

PNL board.

the

fau

ted?

o the

buttons w

rk?

204

e the

PNL board.

e the

204

board.

5-11

Rev. B

DFX-8500

6. Data sent by the host computer is printed incorrectly.

Note : The flowchart below assumes the host computer is operating normally.

STA

self-test.

Troub

hoo

flowchar

ing the

iou

ilt

lle

ou using?

heck

onne

ction

ter.

iona

he ho

Are the DIP

switches set correctly?

(See Tables 1-16,1-21,

1-22,and 1-23.)

witches

ctly.

your parallel cable is a

shielded, twisted-pair cable

less than 2 m, and does it

work with another

e u

e a null

printer?

ng a

s you

ode

le?

204

board.

cable.

204

board.

ou a

ng a

he ne

ona

a ne

k con

orrectly?

econfigure network.

erface.

5-12

Rev. B

TROUBLESHOOTING

5.2 CIRCUIT BOARD REPAIR

This section provides detailed troubleshooting methods to isolate components in the power supply or on the

main board. This information is for use by service personnel who repair to the component level.

The table below provides causes, checkpoints, and solutions for different power supply circuit problems. The

checkpoints include waveforms for normal operation. By referring to the checkpoints, determine the defective

component. Then perform the proper repair. The table provides the following four columns:

‰ꢀSymptom:

‰ꢀCause:

‰ꢀCheckpoint:

‰ꢀSolution:

Check this column for a list of common printer problems.

Use this column to identify possible causes that could produce this symptom.

Follow the troubleshooting checks in this column to isolate your problem.<

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

Location

DB1

Description

Diode bridge

TY1

TRIAC

QF101

QF201

IC101

IC204

Switching FET for VP1 and VP2

Switching FET for VP3 and +5 VDC

PWM switching controller

+5 V regulator IC

Table 5-5. C204 PSB/PSE Board Component Repair 1/3

Cause Checkpoint

No DC voltage is present PD signal is HIGH (sent Measure the signal level Wait until the printer

Symptom

Solution

at the output . (Fan on from the main board).

the power supply board

doesn’t rotate at all.)

of the PD signal at CN4.

prints again.

Replace the E05B36 on

the C204 MAIN board.

The DRERR signal is Measure the signal level Replace the printhead

HIGH.

of the DRERR signal at driver on the C204 MAIN

CN4.

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

blows The line filter circuit is Check if any of pins Replace the abnormal

immediately

replacement.

after defective.

C1-C5 or R1 is shorting element.

the AC line.

5-13

Rev. B

DFX-8500

Symptom

The +37 VDC (VP1 /

VP2) line is dead.

Table 5-5. C204 PSB/PSE Board Component Repair 2/3

Cause Checkpoint

The main switching FETs Observe the voltage

Solution

Replace QF101.

QF101 is defective.

waveform between the

drain side and GND.

IC101 is defective.

Pin 5 (FB) must be HIGH Replace IC101.

then observe the voltage

waveform between pin 2

(VOUT) and pin 12

(GND) of IC101.

The +37 VDC (VP3) line

is dead.

The main switching FETs Observe the voltage

Replace QF201.

Replace Q201.

Replace Q202.

QF201 is defective.

waveform between the

drain side and GND.

Observe the voltage

waveform between the

collector side and GND.

Observe the voltage

waveform between the

collector side and GND.

Q201 is defective.

Q202 is defective.

5-14

Rev. B

TROUBLESHOOTING

Table 5-5. C204 PSB/PSE Board Component Repair 3/3

Symptom

The 5 VDC line is

defective.

Cause

IC204 is defective.

Checkpoint

Check the voltage level at pin 10 (V1)

and pin5 (GP).

Solution

Replace IC204.

Observe the drive waveform at pin 8

(VO) and pin 5 (GP).

Replace IC204 or

ZD211.

37 VDC line

(VP1/VP2) is

abnormal.

IC102 is defective. (If

this IC is defective, it

cannot monitor the 37 less than 1.3 VDC, the comparator

When the input voltage of the minus

port (pin 6 for VP1 and pin2 for VP2) is

Replace IC203.

VDC lines, and

outputs a HIGH signal.

printing operation

becomes abnormal.),

37 VDC line (VP3) IC203 is defective. (If

When the input voltage of the plus port

is bigger than 1.3 VDC, the comparator

Replace IC203.

is abnormal.

this IC is defective, it

cannot monitor the 37 outputs a HIGH signal.

VDC lines, and motor

operations become

abnormal.),

5-15

Rev. B

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

The printer does

not operate at all.

Cause

Checkpoint

Check the logic level of the DRERR

signal at CN10 or check the VP1 and

VP2 voltage.

Solution

The DRERR signal

was sent to the C204

power supply board

(HIGH level turns off

the power supply).

The PD signal was

sent to the C204

power supply board.

(HIGH level turns off

the power supply)

Replace the head

driver on the C204

MAIN board (VP1)

or C204 DRV-B

board (VP2).

Check the logic level of the PD signal

during power on and verify the voltage

waveform for the head driver. (Refer to

the head driver waveform figure,

above.)

Replace the head

driver or gate array.

The reset circuit is not Check the logic level at pin1 (VOUT) of Replace IC13.

operational (for logic). IC13.

The driver circuits The pull up voltage

When the collector of Q15 is high

Check the logic level at collector of Q14

(VX) (When the collector of Q15 is

high, VX is HIGH..

Replace Q15.

don’t operate at

all.

VX is not generated.

Serial interface is

dead.

The level converter IC Check the signal level change between Replace IC9.

is defective. in and out port of the IC9.

5-16

Rev. B

TROUBLESHOOTING

Table 5-6. C204 MAIN/DRV/DRV-B boards Component Repair 2/7

Symptom

The printer does

not operate at all.

Cause

The control ROM is

defective.

Checkpoint

Confirm that the PROM is inserted the

socket correctly.

Solution

Replace IC5.

The gate array (IC1)

is defective.

The CPU (IC2) is

defective

Check pin 86 (D0)of IC1 for a change

in the signal (HIGH or LOW).

Look at the oscillator at either pin 27

(x1) or pin 28 of the CPU.

Replace IC1.

Replace CRU1 or

IC1

The DRAM (IC14) is

defective

Observe pin 2 (D0) of IC14 for a

change in the signal (HIGH or LOW).

Replace IC14.

5-17

Rev. B

DFX-8500

Symptom

The carriage

operates

Table 5-6. C204 MAIN/DRV/DRV-B boards Component Repair 3/7

Cause

IC1 on the C204

MAIN board is

defective.

Q16, Q17, Q18, or

Q19 on the C204

MAIN board is

defective.

Checkpoint

Solution

Check the signals for the carriage

motor phases at pins 204 (CRA), 205

(CRB), 206 (CRC), and 5 (CRD) of IC1

Check the signals for the carriage

Replace IC1.

abnormally.

Replace Q16, Q17,

motor phases at collectors Q16 (CRA), Q18, or Q19.

Q17 (CRB), Q18 (CRC), and Q19

(CRD).

IC1 is doesn’t work.

Check the voltage level between Anode Replace ZD2, Q34,

and Kathode of ZD2 is APPROX. 6.2 V. or Q35.

IC1 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

(OUT1) and 5 (GP) of IC1 when the

carriage is operating. (The normal

voltage level is approximately 37

VDC.),

Replace IC1.

IC3 on the C204 DRV Observe the waveform at pin 1 of IC3.

board is defective.

Replace IC3.

5-18

Rev. B

TROUBLESHOOTING

Table 5-6. C204 MAIN/DRV/DRV-B boards Component Repair 4/7

Cause Checkpoint

The carriage encoder Observe the carriage encoder sensor

Symptom

The carriage

operates

Solution

Replace the

sensor is defective.

output signal at pins 4 (ENCA) and 3

(ENCB) of CN4 on the C204 MAIN

board.

carriage encoder

sensor.

abnormally.

Carriage operation is

unstable (due to a

Check the switching waveform for Q5,

Q6, and Q7.

Replace the

abnormal transistor.

lack of motor torque).

5-19

Rev. B

DFX-8500

Symptom

Paper feeding is

abnormal.

Table 5-6. C204 MAIN/DRV/DRV-B boards Component Repair 5/7

Cause

Checkpoint

Check the PF motor phase drive

signals at pins 2 - 5 of IC2.

Solution

The CPU IC2) on the

C204 MAIN board is

defective.

Replace IC2.

IC2 on the C204 DRV At IC2, check the output signals for

Replace IC2.

board is defective.

pins 2 (OUT_A), 3 (OUTXA), 6

(OUT_B), and 7 (OUTXB).

Check the RF motor phase drive

signals at pins 6 - 9 of IC2.

Ribbon feeding is

abnormal.

The CPU IC2) on the

C204 MAIN board is

defective.

The common

Check the collector voltage of Q21.

Replace Q20 or

Q21.

switching transistor on

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

abnormal transistor.

DRV board is

defective.

the output signal (collector).

Fuse F1 on the C204

DRV board is

defective.

Check if fuse F1 is defective.

Replace F1.

5-20

Rev. B

TROUBLESHOOTING

Table 5-6. C204 MAIN/DRV/DRV-B boards Component Repair 6/7

Symptom

The head fan

operation is

abnormal.

Cause

IC1 on the C204

MAIN board is

defective.

Checkpoint

Solution

Replace IC1.

Observe the PG motor phase signal at

pins 163 (FANA) and 164 (FANAX) of

IC1.

Q10 or Q11 on the

C204 MAIN board is

defective.

Observe the head fan phase drive

voltage level for pins 25 (HFANA) and

17 (HFANB) of CN1. (The normal

voltage is approximately 37 VDC.)

Observe the PG motor phase signal at

pins 10 (PGA), 12 (PGB), 14 (PGAX),

and 13 (PGBX) of IC1.

Replace Q10 or

Q11.

The PG motor

operates

abnormally.

IC1 on the C204

MAIN board is

defective.

Replace IC1.

The common

Check the collector voltage of Q11.

Replace Q10 or

Q11.

switching transistor on

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).

DRV board is

defective.

signal, replace the

abnormal transistor.

Fuse F2 on the C204

DRV board is

defective.

Check if fuse F2 is defective.

Replace F2.

The PG sensor is

defective.

Observe the PG sensor output signal at Replace the PG

pins 35 (PGENCA) and 34 (PGENCB)

of CN14.

sensor.

The PG home

position sensor is

defective.

Observe the PG HP sensor signal level Replace the PG

for pin 36 (PGHOME) of CN14.

(PG home = LOW level; other = HIGH

level.)

home position

sensor.

The plunger is

defective.

Fuse F3 is defective

Check if fuse F3 is defective.

Replace F3.

Replace IC1.

IC1 on the C204

MAIN board is

defective.

When paper is loaded into the printer,

look at the switching signal at pins 16

(PLP) and 17 (PLN)of IC1.

Plunger drive

transistor on the C204 paper loading.

DRV board is

Observe the Q31 collector voltage at

Replace Q31, Q30,

or Q32.

defective.

5-21

Rev. B

DFX-8500

Table 5-6. C204 MAIN/DRV/DRV-B boards Component Repair 7/7

Symptom

The self-test is

printed incorrectly MAIN board is

defective.

Cause

IC1 on the C204

Checkpoint

Observe the output signal at pins 136-

181 of IC1.

Solution

Replace IC1.

The head driver FETs Observe the voltage waveform at the

Replace the

on the C204 MAIN

and/or C204 DRV-B

boards are defective.

each FET drain side.

abnormal FET.

The CPU (IC2) on the Observe the signals at pins 38 (PTS1)

Replace the IC2.

C204 MAIN board is

defective.

and 42 (PTS2) of the IC2

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. If 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

Symptom

The CR motor

does not operate.

Cause

Checkpoint

Solution

The transport locking

bracket (used to hold

the carriage in place

when the printer is

moved) has not been

removed.

Verify that the transport locking bracket Remove bracket.

has been removed.

(Refer to Section

3.1.)

Foreign objects are

Manually move the carriage to see if

Remove any foreign

objects.

lodged in the gears or the motor rotates.

elsewhere (e.g. paper

dust on the carriage

encoder belt) in the

mechanism.

The CR motor is

defective.

Measure the coil resistance of the CR

motor. It should be approximately 1.66 motor.

Replace the CR

ohms + 10 %.

The carriage timing

belt is defective.

Manually check the carriage timing belt Perform the carriage

tension.

timing belt tension

adjustment, as

described in Section

4.1.2.

The carriage guide

shaft parallelism

value is incorrect.

Check whether the carriage moves

smoothly when moved manually.

(Check that foreign objects are not

lodged in the printer mechanism.),

Perform the carriage

guide shaft

parallelism

adjustment, as

described in Section

4.1.5.

The CR encoder

sensor is defective.

The carriage encoder Check the encoder belt (below the

belt is damaged or

covered with dust.

The printhead FPC

common wires are

broken.

Check the waveform for the carriage

encoder signal. (Refer to Table 5-6.),

Replace the CR

encoder sensor.

Replace or clean the

carriage encoder

belt.

carriage timing belt).

The carriage

moves, but no

printing is

Check the continuity of the common

wires for the printhead FPC.

Replace the FPC.

performed.

5-23

Rev. B

DFX-8500

Symptom

A particular dot

does not print.

Table 5-7. Printer Mechanism Repair 2/4

Cause

Checkpoint

Solution

Replace the

printhead.

Replace the

printhead.

Replace the

printhead.

The printhead is

defective.

Measure the printhead coil resistance.

(Refer to Figure 5-4 for details.)

Check whether a dot wire is worn.

The print is too

light or print

density is not

uniform.

The printhead is

defective.

Check if the tip of a dot wire is worn.

The parallelism value Print density differs at the right and left Perform the

is incorrect.

sides of the page (darker on one side

than the other).

parallelism

adjustment, as

described in Section

4.1.5.

The platen gap value

is incorrect.

Print density is too light even the new

ribbon cartridge is mounted.

Perform the

parallelism

adjustment, as

described in Section

4.1.5.

Printing is

Foreign objects are

Visually check the paper path.

Remove any foreign

substances.

performed, but the lodged in the paper

printer does not

feed paper or

does not feed it

correctly.

path.

The PF motor is not

driving the gear

properly.

Check whether the PF motor pinion

gear rotates smoothly when rotated

manually

Check backlash

between PF motor

pinion gear and

paper feed reduction

gear.

The PF motor is

defective.

Measure coil resistance for the PF

motor. (The correct resistance is

approximately 2.8 ohms + 10%.) Also

check the PF motor drivers.

Replace the PF

motor, and if drivers

are bad, replace

main board at the

same time

The ribbon feed

(RF) motor does

not operate.

The ribbon cartridge

is defective.

Remove the ribbon cartridge, rotate it,

and check whether it feeds the ribbon

normally.

Replace the ribbon

cartridge.

Foreign objects are

caught in the gears.

Check whether the ribbon driving gear

rotates when the cartridge is moved

manually.

Remove any foreign

objects or replace

damaged ribbon

feed mechanism

part (the ribbon feed

select gear, ribbon

feed transmission

gear, or ribbon feed

gear).

5-24

Rev. B

TROUBLESHOOTING

Table 5-7. Printer Mechanism Repair 3/4

Symptom

The RF motor

does not operate.

Cause

Checkpoint

Solution

Perform the

parallelism

adjustment, as

described in Section

4.1.5.

The parallelism value Check whether the carriage moves

is incorrect.

smoothly when moved manually.

(Check that foreign objects are not

lodged in the printer mechanism.)

The RF motor

does not operate.

The RF motor is

defective.

Check the coil resistance of the RF

motor. (It should be about 150 ohms +

10 %.)

Replace the RF

motor.

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

manually.

securing the PG

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.

Replace the PG

encoder sensor.

Replace the PG

motor or clean the

encoder plate.

The PG encoder

sensor is defective

The encoder plate is

defective.

Check the output signal of the PG

encoder sensor. (Refer to Table 5-6.)

Check whether the encoder plate is

broken or stained.

The PG home sensor Check the continuity of the sensor.

Replace the PG

home sensor (micro

switch type).

is defective

(Check the status of the two micro

switches.),

The PG motor is

defective.

Check the coil resistance of the PG

motor. (It should be about 250 ohms +

18 ohms.)

Replace the PG

motor.

Printing continues The front, rear, or top

Check the PE sensor.

Replace the PE

sensor.

past the end of

the paper.

PE sensor is

defective.

When paper jams, The paper jam sensor Check the paper jam sensor.

Replace the paper

jam sensor.

the printer does

not beep.

is defective.

Ribbon Jam error

occurs even the

ribbon is fed

correctly.

Ribbon jam sensor is

defective.

Check the ribbon jam sensor.

Replace the ribbon

jam sensor.

5-25

Rev. B

DFX-8500

Symptom

Printing occurs

outside the paper

width.

Table 5-7. Printer Mechanism Repair 4/4

Cause Checkpoint

Check the PW sensor.

Solution

Replace the PW

sensor.

The PW sensor is

defective.

The paper bail

assembly does

not work.

The plunger is

defective.

Check the coil resistance of the

plunger. (It should be about 9 ohms.)

Replace the plunger.

Continuous paper The tension value of

The distance between the frame and

Perform the tractor

wire spring tension

adjustment, as

described in Section

4.1.3.

becomes

the tractor wire spring the seal securing the white line should

crumpled at the

front or rear

is incorrect.

be about 3 mm (0.12 inches).

tractor assembly.

The tractor select

(front or rear)

function is not

working.

The tractor select

sensor is defective.

Check the continuity of the tractor

select sensor.

Replace the tractor

select sensor.

The tractor select

gear is disconnected

from the tractor select

cam.

Visually check the tractor select gear

holder.

Join the tip of the

tractor select lever to

the tractor select

gear holder.

5-26

Rev. B

CHAPTER 6

MAINTENENCE

6.1 PREVENTIVE MAINTENENCE..............................................................................6-1

6.2 LUBRICATION AND ADHESIVE APPLICATION...................................................6-1

MAINTENANCE

6.1 PREVENTIVE MAINTENANCE

To keep the printer in good condition, regularly clean the case exterior (using denatured alcohol) and vacuum

the mechanism's interior to remove dust and paper debris. After cleaning the printer, check that it is

adequately lubricated, as described in Section 6.2, below. Before returning the printer to the customer,

inspect the springs and paper feed rollers and check that the printer operates properly.

CAUTION

;ꢀDisconnect the printer from the external AC power source before performing maintenance. Do not

use thinner, trichloroethylene, or ketone-based solvents on the plastic components of the printer.

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 (G) 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

Grease

Oil

Name

G26

Quantity

40 g

40 cc

Part No.

Availability

B702600001

B710200001

B730200200

Adhesive

Neji Lock #2 (G)

1000 g

Note: E = EPSON exclusive product (not commercially available)

CAUTION

;ꢀDo not apply too much lubricant because it may create stains or cause the mechanism to

malfunction.

6-1

Rev. B

DFX-8500

Table 6-2. Lubrication Points

Lubrication Point

Carriage oil pad ring (on both left and right sides of carriage)

Carriage oil pad (under the carriage head cable holder),

Ref. No.

(1)

(2)

Ref. Figure

Lubricant

6-3

(3)

Hole holding the tip of the rear carriage guide shaft (in both left G26

and right side frames

(4)

(5)

6-3

Both edges of the rear carriage guide shaft

Parallelism adjustment lever (contact point with the rear carriage G26

guide shaft

G26

(6)

6-4

Rear carriage shaft holding lever (contact point with the rear G26

carriage guide shaft)

(7)

(8)

(9)

6-3

6-4

6-2

6-3

6-4

6-3

Carriage guide shaft (on the both front and rear shafts)

Platen roller shaft holder (contact point with the platen roller)

Paper bail gear

Shafts of paper feed gears (shafts on the left frame)

Paper feed gears (gears on the left frame)

Tension pulley (pulley shaft and hook for the tension pulley spring) G26

Fulcrum point for the paper bail shaft and plunger

Platen gap motor pinion

G26

G26,O2

G26

(10)

(11)

(12)

(13)

(14)

(15)

(16)

(17)

G26

Carriage guide shaft gear

Ribbon feed gears

Tractor select cam

Table 6-3. Adhesive Application Points

Ref. No.

Ref. Figure

Adhesive Application Point

Adhesive

(25)

6-3

Tractor tension wire

Neji Lock #2 (G)

Figure 6-1. Correct Adhesive Application

6-2

Rev. B

MAINTENANCE

Figure 6-2. Lubrication and Adhesive Diagram 1

6-3

Rev. B

DFX-8500

Figure 6-3. Lubrication and Adhesive Diagram 2

6-4

Rev. B

MAINTENANCE

Figure 6-4. Lubrication and Adhesive Diagram 3

6-5

Rev. B

APPENDIX

A.1 CONNECTOR PIN ASSIGNMENTS..................................................................... A-1

A.2 CIRCUIT DIAGRAMS ........................................................................................... A-9

A.3 COMPONENT LAYOUT...................................................................................... A-21

A.4 CONNECTOR JUNCTION BOARD CONNECTORS.......................................... A-27

A.5 PART LIST.......................................................................................................... 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.

Fan

CN3(20)

C204 DRV-B

CN5(2)

CN2(8)

C204 PSB/PSE

EIA-232D

AC Input

IEEE1284

CN12(36)

CN2(20)

CN13(7)

Cover Open Sensor

Printer Mechanism

CR Encoder

TYPE-B

CN11(36)

Printhead

C204 MAIN

CN8(8)

CN6(6)

Junction Board

CN15(6)

CN1(6)

CN2(7)

C204 SUB

Paper Cutter

Unit

CN7(12) CN14(50x2) CN16(7)

C204 DRV

CN1(50x2)

CN1(7)

CN2(7)

C204 PNL

Figure A-1. Cable Connection

A-1

Rev. B

DFX-8500

Table A-1. Board Connector Summary

Connection Pin Number Table to Refer

C204 MAIN Board

Connector

CN1

30 pins

20 pins

2 pins

Table A-2

=> Mechanism (Print head)

=> C204 DRV-B board

=> Cover Open

CN2

Table A-3

CN3

Table A-4

CN4

4 pins

Table A-5

=> Mechanism (Carriage encoder)

=> Panel unit

CN5

14 pins

6 pins

12 pins

8 pins

Table A-6

CN6

Table A-7

=> C204 PSB/PSE board

=> C204 DRV-B board

=> Optional paper cutter

=> C204 PSB/PSE board

=> Optional Type-B I/F card

=> IEEE-1284 I/F

CN7

Table A-8

CN8

Table A-9

CN9

7 pins

Table A-10

Table A-11

Table A-12

Tables 1-10 an 1-11

Table 1-12

CN10

CN11

CN12

CN13

CN14

CN15

CN16

8 pins

36 pins

7 pins

=> EIA 232D I/F

50 pins X 2 Table A-13

=> C204 DRV board

=> C204 SUB board

6 pins

7 pins

Table A-14

Table A-15

C204 DRV Board

CN1

CN2

CN3

50 pins X 2 Table A-13

=> C204 MAIN board

=> Printer mechanism

=> C204 PSB/PSE board

50 pins

6 pins

Table A-16

Table A-17

C204 DRV-B Board

CN1

CN2

CN3

30 pins

6 pins

Table A-18

Table A-9

Table A-3

=> Mechanism (Printhead)

=> C204 MAIN board

20 pins

C204 PSB/PSE board

CN1

CN2

CN3

3 pins

6 pins

Table A-19

=> AC inlet

=> C204 MAIN board

=> C204 MAIN (CN7) and C204 DRV

(CN3) boards

Table A-7

12 pins

Tables A-8 and A-17

CN4

CN5

=> C204 MAIN board

8 pins

2 pins

Table A-11

Table A-20

=> Cooling fan motor

A-2

Rev. B

APPENDIX

Table A-2. C204 MAIN Board Connector CN1

Signal Name

I/O

Function

Printhead pin #10

P+10

P-10

P+12

P-12

P+16

P-16

P-17

P-9

P+17

P-11

P+11

P-7

P+9

P-7

P+2

P+1

HFANB

P-1

FTMP

P-2

FANCOM

HTMP

HFANA

PWIDTH

GND

Printhead pin #12

GND

Printhead pin #16

GND

Printhead pin #17

GND

Printhead pin #11

GND

Printhead pin #9

GND

Printhead pin #2

Printhead pin #1

HF motor phase B

GND

HF motor temperature

GND

HF motor common

Print head temperature

HF motor phase A

Paper width signal

23, 24,, 26, 27, 28 GND

Table A-3. C204 MAIN Board Connector CN2

Signal Name

I/O

Function

HR3P

HR2P

HR9N

HR2N

HR7P

HR7N

HR9P

HR3N

HL8P

HL3N

HL8P

HL2N

HL8N

HL7N

HL3P

HL2P

HR4P

HR4N

Print head coil #6 drive signal

Print head coil #4 drive signal

Print head coil #18 drive signal

Print head coil #4 drive signal

Print head coil #14 drive signal

Print head coil #18 drive signal

Print head coil #6 drive signal

Print head coil #15 drive signal

Print head coil #5 drive signal

Print head coil #13 drive signal

Print head coil #3 drive signal

Print head coil #15 drive signal

Print head coil #13 drive signal

Print head coil #5 drive signal

Print head coil #3 drive signal

Print head coil #8 drive signal

167

HRSENS

HNSENS

Print head coil shortage monitoring

Table A-4. C204 MAIN Board Connector CN3

Signal Name

COPEN

I/O

Function

Cover open status

GND

A-3

Rev. B

DFX-8500

Table A-5. C204 MAIN Board Connector CN4

Signal Name

GND

I/O

Function

+5V

ENCB

ENCA

CR encoder B phase pulse

CR encoder A phase pulse

Table A-6. C204 MAIN Board Connector CN5

Signal Name

LED_DATA

LED_XLE

LED_CLK

LED_XOE

BUZZER

VCC

I/O

Function

LED data

LED data latch

LED data clock

LED light enable

Buzzer

+5 VDC

SW_INH

SW_S/XL

SW_DATA

SW_CLK

GND

Switch data transfer inhibit

Switch data shift/load select

Switch data

Switch data clock

4, 10, 912, 14

Table A-7. C204 MAIN Board Connector CN6

1, 2, 3

4, 5, 6

Signal Name

VP1

I/O

Function

+37 VDC

GND for VP1

GP1

Table A-8. C204 MAIN Board Connector CN7

1, 2, 3

4, 5, 6

Signal Name

VP2

I/O

Function

+37 VDC

GND for VP2

GP2

Table A-9. C204 MAIN Board Connector CN8

8, 7, 6

5, 4, 3

Signal Name

VP1

I/O

Function

+37 VDC

GND for VP1

GP1

GND

+5 VDC switched by reset status

Table A-10. C204 MAIN Board Connector CN9

Signal Name

CUTON

CUTDIR

CUTTER

CUTHPI

+5V

I/O

Function

Cut signal

Cut direction

Paper cutter mount/dismount

Cutter home position

GND

Reverse point signal

Table A-11. Digital Board Connector CN10

1, 2

3, 4

Signal Name

+5V

I/O

Function

GND

DRERR

/PD

Head driver error signal

Power down signal

Current limit signal

Power shutdown signal

A-4

Rev. B

APPENDIX

Table A-12. C204 MAIN Board Connector CN11

1, 2, 3, 4, 5, 6

Signal Name

I/O

Function

BTXD

XREADY

BRXD

Transmit data

Ready

Receive data

BXRST

INH

I/O

Reset signal

Inhibit signal output

Command request signal

Write ready signal

Read request signal

Write signal

XCMDREQ

XWRRDY

XRDREQ

XWR

XRD

XCS

GND

Read signal

Chip select signal

19, 20, 21, 22, 23, 24

Address bus 3

Address bus 2

Address bus 1

Address bus 0

Data bus 7

Data bus 6

Data bus 5

Data bus 4

Data bus 3

Data bus 2

Data bus 1

Data bus 0

A-5

Rev. B

DFX-8500

Table A-13. C204 MAIN Board Connector CN14

Signal Name

VP3

I/O

Function

+37 VDC

2, 3, 4

5, 6, 7, 8

9, 10

GND

FAN

PLN

RFH/R

RFC

RFA

PGD

PGB

CRINS

+5 VDC switched by reset status

HF control signal

Plunger N channel

RF motor common

RF motor C phase pulse

RF motor A phase pulse

PG motor D phase pulse

PG motor B phase pulse

CR motor insulation resistance

monitoring

26, 27

CRI1

CRCLM

CRD

CRB

PFH/R

PFC

CR motor current limit signal 1

CR motor current limit signal

CR motor bridge D signal

CR motor bridge B signal

PF motor common

PF motor C phase pulse

PF motor A phase pulse

PFA

GND

TR_SEL

P_TRCT

P_JAM

F_PE

R_PE

T_PE

PGENCB

PGENCA

PGHOME

RBJAM

PLP

RFD

RFB

PGH/R

PGC

PGA

Tractor select signal

Pull tractor mount/dismount

Paper jam detection

Front paper end

Rear paper end