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Epson DFX-8500 Service Manual
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Epson DFX-8500 Service Manual

Epson DFX-8500 Service Manual

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EPSON DFX-8500

Service Manual

Service Manual
Epson America, Inc.
TM-DFX8500

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Summary of Contents for Epson DFX-8500

  • Page 1: Service Manual

    EPSON DFX-8500 Service Manual Service Manual Epson America, Inc. TM-DFX8500...

  • Page 2: Fcc Compliance Statement

    Epson America, Inc., shall not be liable against any damages or problems arising from the use of any options or any consumable products other than those designated as Original EPSON Products or EPSON-Approved Products by Seiko Epson Corporation.
  • Page 3 TRADEMARKS EPSON® and ESC/P® are registered trademarks and ESC/P 2™ and EPSON Stylus are trademarks of Seiko Epson Corporation. MicroDot™ and Super MicroDot™ are trademarks of Epson America, Inc. General Notice: Other product names used herein are for identification purposes only and may be trademarks of their respective companies.
  • Page 4 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 the available power source, do not connect it to the power source.

  • Page 5: Table Of Contents

    CHAPTER 1 PRODUCT DESCRIPTION FEATURES __________________________________________________________________ 1-1 SPECIFICATIONS____________________________________________________________ 1-3 Printing Specifications _____________________________________________________________________ 1-3 Paper Feeding Specifications ________________________________________________________________ 1-6 Electrical Specifications ____________________________________________________________________ 1-6 Environmental Specifications ________________________________________________________________ 1-6 Reliability _______________________________________________________________________________ 1-6 Safety Approvals __________________________________________________________________________ 1-7 CE Marking _____________________________________________________________________________ 1-7 Acoustic Noise ___________________________________________________________________________ 1-7 Ribbon Cartridge__________________________________________________________________________ 1-7 Physical Specifications _____________________________________________________________________ 1-7 Printable Area ____________________________________________________________________________ 1-8...
  • Page 6 C204 Main Board_________________________________________________________________________ 1-42 C204 DRV Board _________________________________________________________________________ 1-43 C204 DRV-B Board _______________________________________________________________________ 1-44 C204 SUB Board _________________________________________________________________________ 1-44 C204 PSB/PSE Board _____________________________________________________________________ 1-45 Control Panel ____________________________________________________________________________ 1-46 Housing ________________________________________________________________________________ 1-46...

  • Page 7: Features

    PRODUCT DESCRIPTION 1.1 FEATURES The EPSON DFX-8500 is an 18-pin, serial impact dot matrix printer designed for business use. This printer provides high-speed, high-volume printing with continuous-sheet handling. Main features include: Advanced paper handling: Paper jam detection Paper width detection...
  • Page 8 DFX-8500 The following table shows options. Table 1-1. Options Code Name #8766 Ribbon cartridge #8767 Ribbon pack #8309 Pull tractor #8502 Printer stand C815001 Paper cutter C815071 Perforation cutter C823051 Serial interface card C823071 32KB serial I/F card C823121 Local Talk I/F card...

  • Page 9: Specifications

    PRODUCT DESCRIPTION 1.2 SPECIFICATIONS This section contains the specifications for the DFX-8500. PRINTING SPECIFICATIONS Print method: Impact dot matrix Number of pins: 18-pin (See Figure 1-2.) Pin arrangement: 9 x 2 Pin diameter: 0.0114 inches (0.29 mm) Color: Black Print direction:...
  • Page 10 DFX-8500 Resolution: See Table 1-3. Table 1-3. Resolution Print Mode Horizontal Resolution Vertical Resolution Adjacent Dot Print High speed draft 90 dpi 72 dpi Draft 120 dpi 72 dpi Draft condensed 240 dpi 72 dpi Draft 120 dpi 72 dpi...
  • Page 11 Table 1-4. Character tables and typefaces Character Table Bitmap Font Standard version Italic Table EPSON Draft PC437 (US, Standard Europe) EPSON Roman PC850 (Multilingual) EPSON Sans Serif PC860 (Portuguese) PC861 (Icelandic) PC863 (Canadian French) PC865 (Nordic) Abicomp BRASCII Roman 8 ISO Latin 1...

  • Page 12: Paper Feeding Specifications

    DFX-8500 PAPER FEEDING SPECIFICATIONS Feeding method: Push tractor feed (front and rear) Push and pull tractor feed (front and rear) Feeder: Front push tractor, rear push tractor, pull tractor (option) Paper insertion side alignment: Left Paper path: Tractors (front in, rear in, top out) Line spacing: 1/6-inch, or programmable in 1/216-inch increments.

  • Page 13: Safety Approvals

    PRODUCT DESCRIPTION SAFETY APPROVALS 120 V version: Safety standards : UL1950 with D3 CSA C22.2 No.950 with D3 EMI : FCC part 15 subpart B class B CSA C108.8 class B 230 V version: Safety standards : EN60950 (VDE, NEMKO) EMI: EN55022 (CISPR pub.

  • Page 14: Printable Area

    DFX-8500 PRINTABLE AREA Continuous paper: See Figure 1-3. ABCD WXYZ ABCD WXYZ ABCD WXYZ Figure 1-3. Continuous Paper Printable Area Measurement Length Paper Width (PW) See “Paper and Media” on page 1-12. Paper Length (PL) See “Paper and Media” on page 1-12.
  • Page 15 PRODUCT DESCRIPTION Labels: See Figure 1-4. Label Label Label Label Figure 1-4. Label Printable Area Measurement Length Paper Width (PW) See “Paper and Media” on page 1-12. Paper Length (PL) See “Paper and Media” on page 1-12. Left Margin (LM) 0.51 to 1.22 inches (13 to 31 mm) Right Margin (RM) 0.51 inch (13 mm) or more...
  • Page 16 DFX-8500 Continuous forms with labels: See Figure 1-5. Label Label Non Printable Area ABCD WXYZ Printable Area Label Figure 1-5. Continuous Forms with Labels Printable Area Measurement Length Paper Width (PW) See “Paper and Media” on page 1-12. Paper Length (PL) See “Paper and Media”...
  • Page 17 PRODUCT DESCRIPTION Overlapping multi-sheet forms: See Figure 1-6. Perforations Carrier Figure 1-6. Overlapping Multi-sheet Form Printable Area Measurement Length Paper Width (PW) See “Paper and Media” on page 1-12. Paper Length (PL) See “Paper and Media” on page 1-12. Left Margin (LM) 0.51 to 1.22 inches (13 to 31 mm) Right Margin (RM) 0.51 inch (13 mm) or more...

  • Page 18: Paper And Media

    DFX-8500 PAPER AND MEDIA Continuous Paper (Single-sheet and Multi-sheet Forms) Table 1-5. Continuous Paper Measurement Units Front Path Rear Path Minimum Maximum Minimum Maximum Width inches 16.0 16.0 Length inches 17.0 17.0 Copies 1 original + 6 copies 1 original + 5 copies...
  • Page 19 PRODUCT DESCRIPTION Figure 1-8. Paper Stapling Height Figure 1-9. Paper Stapling, Method 1 Figure 1-10. Paper Stapling, Method 2 1-13...

  • Page 20: Labels

    DFX-8500 Labels Table 1-6. Labels Measurements Units Front Path Rear Path Minimum Maximum Minimum Maximum Label Size See Figure 1-11. — Backing Sheet Width inches 16.0 — — Backing Sheet Length inches 17.0 — — Label Thickness inches 0.0047 —...

  • Page 21: Continuous Forms With Labels

    PRODUCT DESCRIPTION Continuous Forms with Labels Table 1-8. Continuous Forms with Labels Measurements Units Front Path Rear Path Minimum Maximum Minimum Maximum Label Size See “Labels” on page 1-14. — Width inches 16.0 — — Length inches 17.0 — — Weight —...

  • Page 22: Overlapping Multi-Sheet Forms

    DFX-8500 Overlapping Multi-sheet Forms Table 1-9. Overlapping Multi-sheet Forms Measurement Units Front Entry Rear Entry Minimum Maximum Minimum Maximum Width inches 16.0 Length inches 17.0 Weight (single sheet) 52.6 82.7 Weight (multiple sheet) 41.4 56.4 Copies 1 original + 5 copies + 1 backing...

  • Page 23: Product Description

    PRODUCT DESCRIPTION 19 or more 19 - 31 13 + 3 13 + 3 Multi-part cut sheet Base sheet Spot-glued part Perforation of base sheet Spot-glued psrt Lower edge Page Width Spot-glued part Unit : mm Figure 1-12. A Spot Glued Multi-sheet Form Figure 1-13.
  • Page 24 DFX-8500 Figure 1-16. Raised Perforation Figure 1-15. Perforations (3) Figure 1-18. Sprocket Holes (1) Figure 1-19. Sprocket Holes (2) Figure 1-17. Examples of Unsuitable Paper Figure 1-20. Incorrectly Folded Paper 1-18...

  • Page 25: Interfaces

    PRODUCT DESCRIPTION 1.3 INTERFACES The DFX-8500 has a parallel interface, a serial interface, and a slot for an optional Type-B interface card. This section presents the specifications for each interface type. PARALLEL INTERFACE (FORWARD CHANNEL) Data transmission mode: 8-bit parallel, IEEE-1284 compatible mode...
  • Page 26 DFX-8500 Table 1-10. Data Transmission Timing Parameter Minimum Maximum Parameter Minimum Maximum 500 ns — 500 ns 10 us setup 500 ns — — hold nbusy 500 ns — — next — — 120 ns ready t-out — 500 ns —...

  • Page 27: Parallel Interface (Reverse Channel)

    00h: The printer enters reverse channel mode, allowing data to be sent to the host. 04h: The printer sends the device ID to the host. Device ID: [00h][3Ah] MPG: EPSON; CMD: ESCP9, PRPII9, BDC; MDL: DFX-8500; CLS: PRINTER 1-21...
  • Page 28 DFX-8500 Connector pin assignments: See Table 1-13 below. Table 1-13. Signal and Connector Pin Assignment (Reverse channel) Pin No. Signal Name I/O* Description HostClk This signal is a strobe pulse used to read extension request values from the host computer during negotiation.

  • Page 29: Serial Interface

    PRODUCT DESCRIPTION SERIAL INTERFACE Synchronization: Asynchronous Signal level (ELA-232D): MARK (logical 1): –3 V to –25 V SPACE (logical 0): +3 V to +25 V Word length: Start bit: 1 bit Data bit: 8 bit Parity bit: Odd, Even, None, or Ignore Stop bit: 1 bit or more Baud rate:...

  • Page 30: Interface Selection

    DFX-8500 INTERFACE SELECTION The printer has three interfaces: parallel, serial, and optional Type-B. These interfaces are selected automatically or manually using DIP switches. Manual selection: One of three interfaces can be selected using DIP switches. Automatic selection: If the automatic interface is selected using DIP switch settings, the printer is initialized to an idle state, scanning all interfaces to see which receives data first.

  • Page 31: Operating Instructions

    PRODUCT DESCRIPTION 1.4 OPERATING INSTRUCTIONS This section describes the functions performed through the control panel, such as test printing, hexadecimal dumps, and paper memory functions. CONTROL PANEL The printer control panel gives you easy control over most common printer operations. The panel consists of the indicator lights and buttons shown in Figure 1-22.

  • Page 32: Buttons

    DFX-8500 Buttons The control panel contains eleven buttons. Button Functions during Normal Operation: During normal operation, control panel buttons perform the following functions. (See Table 1-15.) Table 1-15. Button Functions during Normal Operation Button Function Front/Rear Toggles between the front and rear paper paths.

  • Page 33: Indicators

    PRODUCT DESCRIPTION Indicators The control panel contains fifteen LEDs. Rear (2) (Green / Red): Green: The rear paper path is selected and has paper in it. Red: The rear paper path is selected has no paper in it. Off: The front paper path is selected. Front (2) (Green / Red): Green: The front paper path is selected and has paper in it.

  • Page 34: Errors And Buzzers

    DFX-8500 ERRORS AND BUZZERS Errors fall into 2 types: normal errors/warnings and fatal errors. See the tables below for detailed information. See Chapter 5 for more information about errors and troubleshooting. Table 1-17. Error/Warning Beeper Information Error/Warning Pause Paper Out...
  • Page 35 PRODUCT DESCRIPTION Table 1-18. Fatal Error Information † ‡ Fatal Error 7-segment Beeper Description LED Display * Carriage motor circuit Auto power off after 12 seconds shortage error Cutter error Auto power off after 12 seconds Platen gap error - - - Auto power off after 12 seconds Carriage lock error - - - -...

  • Page 36: Dip Switch Settings

    DFX-8500 DIP SWITCH SETTINGS There are 5 banks of 8 DIP switches located at the front paper entrance of the printer. The printer default settings are set using these DIP switches. When the printer is turned on or reset, the DIP switch selections are treated as the default setup.
  • Page 37 PRODUCT DESCRIPTION Table 1-20. Character Table Setting (Standard) SW1-1 SW1-2 SW1-3 SW1-4 SW1-5 SW1-6 Character table 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...
  • Page 38 DFX-8500 Table 1-21. Character Table Setting (NLSP) SW1-1 SW1-2 SW1-3 SW1-4 SW1-5 SW1-6 Character table 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)
  • Page 39 PRODUCT DESCRIPTION Table 1-22. Front Tractor Page Length SW2-1 SW2-2 SW2-3 SW2-4 Page length for front tractor 11 inches 3 inches 3.5 inches 4 inches 5.5 inches 6 inches 7 inches 8 inches 8.5 inches 70/6 inches 12 inches 14 inches 17 inches Others Others...

  • Page 40: Control Panel Functions

    DFX-8500 Table 1-26. Serial I/F Baud Rate Setting SW4-7 SW4-8 Baud rate 19200 9600 4800 2400 CONTROL PANEL FUNCTIONS Normal Operation Front / Rear: Toggles between the front and rear paper paths. If the printer is set to use normal paper and the pull tractor is not used: The printer feeds the paper to the tear off position, cuts the paper using the cutter, and feeds the paper backward to the paper park position.
  • Page 41 PRODUCT DESCRIPTION if it receives data from the host computer. Copy: This button toggles the printer between copy mode or normal mode. Pitch: Press this button to select among the following pitches: 10 cpi, 12 cpi, 15 cpi, 17 cpi, 20 cpi and PS (proportional spacing) Font: Press this button to select among the following fonts: Super Draft, Draft, Roman, Sans Serif...

  • Page 42: Advanced Control Panel Functions

    DFX-8500 Advanced Control Panel Functions See Table 1-16 on page 1-26 for instructions on how to access these functions. Self test: Prints the self test pattern. To cancel the self test, press the Pause button and turn off the printer.

  • Page 43: Automatic Detection Functions

    PRODUCT DESCRIPTION Automatic Detection Functions Cover open detection: When the cover is opened, the printer stops printing and pauses after several beeps. The printer stays paused until the cover is closed and the Pause button is pressed. Paper width detection: The printer detects the right paper edge and determines the right edge of the printable area.

  • Page 44: Paper Memory Functions

    DFX-8500 PAPER MEMORY FUNCTIONS Use the paper memory function to get better quality printouts on overlapping multi-sheet forms or continuous forms with labels. Before using paper memory, you must use the control panel and DIP switches to set the paper length. This function is available only when using the front paper path.

  • Page 45: Initializations

    PRODUCT DESCRIPTION INITIALIZATIONS Hardware Initialization Initialization occurs when the printer is turned on or when the printer receives an /INIT signal (negative pulse) or cold-reset command (remote RS command). Initialization does the following: initializes the printer mechanism clears all data buffers cancels downloaded character translation places the printer in a stand-by state performs a software initialization (see below)

  • Page 46: Main Components

    DFX-8500 1.5 MAIN COMPONENTS The main components of the DFX-8500 are: Printer mechanism: M-3I60 Main control board: C204 Main board Mechanism driver board: C204 DRV board Printhead driver board: C204 DRV-B board DIP switch board: C204 SUB board Power supply board:...

  • Page 47: M-3I60 Printer Mechanism

    The DFX-8500 includes a paper jam sensor. The DFX-8500 includes a ribbon sensor. The DFX-8500 includes a tractor wire at the front and rear tractors to prevent paper jams. The detection method of the carriage encoder sensor differs from previous printers. In the DFX-8000, the encoder plate was attached to the rotor of the carriage motor, while the DFX-8500 uses a belt-type encoder.

  • Page 48: C204 Main Board

    DFX-8500 C204 MAIN BOARD The C204 main board contains the following ICs: 16-bit CPU: TMP95C051A; 24.57 MHz (IC2) Gate array: E05B36 (IC1) PROM (including C.G.): 2M-bit (IC5) RAM: 4M-bit (IC14) ADM232L: RS-232C level converter (IC9) Reset IC: PST391D (IC13) EEPROM: 93C66 (IC11) There are two types of C204 main board, distinguished by the hex screw used to attach the serial interface.

  • Page 49: C204 Drv Board

    PRODUCT DESCRIPTION C204 DRV BOARD The C204 DRV board drives the printer mechanism. The printhead fan, plunger, paper feed (PF) motor, carriage (CR) motor, carriage fan, platen gap (PG) motor, and ribbon feed (RF) motor driver circuits are located on this board. This board contains half of the printhead driver circuits; the other half are on the C204 DRV-B board.

  • Page 50: C204 Drv-B Board

    DFX-8500 C204 DRV-B BOARD The C204 DRV-B board contains half of the printhead driver circuits; the other half are on the C204 DRV board. Most of this board is devoted to discrete bipolar FETs. Figure 1-27. C204 DRV-B Board C204 SUB BOARD The C204 SUB board consists of five banks of DIP switches.

  • Page 51: C204 Psb/Pse Board

    PRODUCT DESCRIPTION C204 PSB/PSE BOARD The C204 PSB/PSE board is a power supply circuit board that generates power for the main and driver boards. There is a cooling fan on the top of this board. The PSB board takes 100-120 VAC, and the PSE board takes 220-240 VAC.

  • Page 52: Control Panel

    The DFX-8500 housing has many more components than previous DFX housings. The lower case holds the mechanism and circuits, covered by the upper case, bottom plate and side cover. The housing has large openings in both the front and rear for paper entry and exit.
  • Page 53 CHAPTER 2 OPERATING PRINCIPLES PRINTER MECHANISM OPERATION__________________________________________ 2-1 Printhead Mechanism ______________________________________________________________________ 2-4 Carriage Mechanism_______________________________________________________________________ 2-5 Platen Gap Adjustment Mechanism ___________________________________________________________ 2-6 Paper Feed Mechanism _____________________________________________________________________ 2-7 Tractor Wire Operation___________________________________________________________________ 2-9 Ribbon Feed and Tractor Select Mechanisms___________________________________________________ 2-10 Plunger Mechanism ______________________________________________________________________ 2-12 POWER SUPPLY OPERATION _______________________________________________ 2-13 Power Supply Overview ___________________________________________________________________ 2-14 CONTROL CIRCUITS _______________________________________________________ 2-17...

  • Page 54: Printer Mechanism Operation

    OPERATING PRINCIPLES 2.1 PRINTER MECHANISM OPERATION This section describes the Model 3I60 printer mechanism and explains how the printer works. The printer mechanism features an 18-pin, impact dot printhead for serial printing. The printer mechanism is the main component of the printer and is supported by the power supply and control circuits. Figure 2-1 shows the printer mechanism.
  • Page 55 DFX-8500 Carriage mechanism: The carriage mechanism moves the printhead along the platen. The carriage motor drives the carriage. The printhead is attached to the carriage. The carriage encoder sensor detects the carriage motor speed and carriage position. The carriage motor is closed-loop controlled. Because the carriage motor is driven at a very high speed, it has an isolation resistance sensor to detect abnormal resistance.
  • Page 56 OPERATING PRINCIPLES Paper feed mechanism: The paper feed motor drives the paper feed mechanism, which controls both line and form feeding. The front, rear, and top paper end sensors detect paper in the paper path, and stop printing when there is no paper.

  • Page 57: Printhead Mechanism

    DFX-8500 PRINTHEAD MECHANISM The printhead is a charge-type, impact dot printhead. Figure 2-4 contains a diagram of printhead operation. The dot wire is attached to the actuating spring at point A. The actuating spring is pulled back (left in the figure) by magnetic force when the printer is on and not printing.

  • Page 58: Carriage Mechanism

    OPERATING PRINCIPLES CARRIAGE MECHANISM Figure 2-5 shows the carriage mechanism. The front and rear carriage guide shafts support the carriage. The carriage motor rotates, turning the carriage belt pulleys and the carriage timing belt. The printhead is mounted on the carriage, which is attached to the carriage timing belt. The printer does not have a carriage home position sensor;...

  • Page 59: Platen Gap Adjustment Mechanism

    DFX-8500 PLATEN GAP ADJUSTMENT MECHANISM Figure 2-6 shows the platen gap adjustment mechanism. The front and rear carriage guide shafts supporting the carriage are eccentrically mounted. The rotation of the platen gap motor is transmitted to the rear carriage guide shaft through the gear train. Counterclockwise rotation of the motor expands the platen gap, and clockwise rotation reduces it.

  • Page 60: Paper Feed Mechanism

    OPERATING PRINCIPLES 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 paper feed motor rotates the tension roller (Figure 2-7) and tractor select gear (Figures 2-8 and 2-9) and moves either the front or rear tractor assembly.
  • Page 61 DFX-8500 Paper Paper Bail Tension Roller Tractor Select Gear Front Paper End Sensor Paper Feed Motor Pinion Front Tractor Gear Paper Feed Transmission Gear Figure 2-8. Front Tractor Assembly Operation Paper Paper Bail Tension Roller Rear Paper Tractor Select Gear...

  • Page 62: Tractor Wire Operation

    OPERATING PRINCIPLES Tractor Wire Operation The printer is equipped with a tractor wire to straighten and maintain the proper horizontal tension in the paper and prevent paper jams. The tractor wire tension spring on the right frame pulls the wire. Figure 2-10 shows how the tractor wire operates.

  • Page 63: Ribbon Feed And Tractor Select Mechanisms

    DFX-8500 RIBBON FEED AND TRACTOR SELECT MECHANISMS The ribbon feed motor supplies power to both the ribbon feed and tractor select mechanisms. The rotation of the ribbon feed motor pinion swings the ribbon feed select gear like a pendulum, using the lever axis as a fulcrum.
  • Page 64 OPERATING PRINCIPLES Tractor select mechanism : Figure 2-12 shows the operation of the tractor select mechanism. When the ribbon feed motor turns clockwise, it rotates the ribbon feed select gear, which turns the tractor select transmission gear. These gears rotate the tractor select cam clockwise. A spring holds the tractor select lever against the cam; when the cam rotates, the tractor select lever moves horizontally.

  • Page 65: Plunger Mechanism

    DFX-8500 PLUNGER MECHANISM Figure 2-13 shows the plunger mechanism. The paper bail lever is attached to the end of the plunger's iron core. The paper bail shaft is connected to the frame. When current to the plunger coil is interrupted, the force of the paper bail spring returns the paper bail to its original position.

  • Page 66: Power Supply Operation

    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 the voltage supplied to the mechanism.

  • Page 67: Power Supply Overview

    DFX-8500 POWER SUPPLY OVERVIEW Figure 2-14 shows a block diagram of the C204 PSB/PSE board. Surge Cut (at Power On) Fuse Power Input Filter Rectifier Smoothing Switch. Circuit Circuit Circuit AC Inlet +37 V +37 V (VP1/VP2) Smoothing Switching Circuit...
  • Page 68 OPERATING PRINCIPLES Cooling fan: The C204 PSB/PSE board includes a cooling fan that is driven by +37 VDC. The fan lowers the temperature of the PSB/PSE board circuit components and the carriage motor. Table 2-3. PSB/PSE Board Output DC Voltages Voltage Board Application...
  • Page 69 DFX-8500 Table 2-4. PSB/PSE Board Control Signals Signal Input/ Signal Level Logic Function Output* Signal † ‡ Block 1 Block 2 High 37 VDC 37 VDC, 5 VDC (Power Down) 0 VDC 37 VDC, 5 VDC DRERR High 0 VDC...

  • Page 70: Control Circuits

    OPERATING PRINCIPLES 2.3 CONTROL CIRCUITS Figure 2-15 shows a block diagram of the control circuits, with the C204 main board at the center. 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).
  • Page 71 DFX-8500 Main Board Mechanism TMP95C061 Cover Open (IC2) Sensor` Printhead HTMP Temperature EEPROM Paper Width PWIDTH (IC11) Head Fan HFTMP Temperature 24.57MHz (CRU1) Level Converter DRV Board TXD/RXD (IC9) CR Motor CRINS Insulation RF Motor RF Motor POFF Drive Circuit...
  • Page 72 OPERATING PRINCIPLES Table 2-5 describes the functions of the main components of the C204 main and C204 DRV boards. Table 2-5. Main IC Functions Board IC Name Location Functions C204 Main TMP95C061 Receives data from the host computer via the gate array, loads the data to the input buffer in the RAM, and converts (CPU) the image data to print data.
  • Page 73 DFX-8500 Figure 2-16 shows the data flow through the parallel interface. Although various circuits perform data processing, the control core is the CPU, where all operations are executed. 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).

  • Page 74: Reset Circuit

    OPERATING PRINCIPLES 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 firmware 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.

  • Page 75: Sensor Circuits

    DFX-8500 SENSOR CIRCUITS Figure 2-18 shows the sensor circuits in block diagram form. The printer has the following sensors: 1. Front and rear paper end sensors (photo interrupter) 2. Top paper end sensor (photo interrupter detects the TOF position) 3. Paper jam sensor (magnetic transistor) 4.
  • Page 76 OPERATING PRINCIPLES TMP95C061 (IC2) CN10 CN14 ENCA ENCA ENCB CR Encoder ENCB PGENCA PGENCA PGENCB PGENCB PG Home PG Home TRSEL E05B36 (IC1) Tractor Select PTRCT Pull Tractor Paper Jam PJAM Front PE CN14 Rear PE Top PE RBJAM Ribbon Jam Figure 2-18.
  • Page 77 DFX-8500 Each sensor is described below. 1. Front and rear paper end sensors Detection form: Photo interrupter Output form: Open collector (pulled up to 10 kΩ resistor) Logical states: Paper present: LOW Paper out: HIGH 2. Top paper end sensor (detects the TOF position)
  • Page 78 OPERATING PRINCIPLES 8. Platen Gap home position sensor Detection form: Micro mechanical switch Logical states: Home: LOW (closed) Out of home: HIGH (open) 9. Ribbon jam sensor Detection form: Photo interrupter Function: The main board monitors signal changes during ribbon feed. 10.

  • Page 79: Carriage Motor Drive Circuit

    DFX-8500 CARRIAGE MOTOR DRIVE CIRCUIT Figure 2-19 shows the internal circuit of the carriage motor. Table 2-6 provides the carriage motor specification. Figure 2-20 shows a block diagram of the carriage motor drive circuit. An STK681-050 (IC1) bipolar driver IC drives the carriage motor. It has built-in bipolar switching transistors and a current limiter.
  • Page 80 OPERATING PRINCIPLES ENCA ENCB Main Interlock Switch Board Board STK681-050(IC1) E05B36 Carriage Encoder Sensor VCC1 CRAX Q16, IN_A Q34, VCC1 Q17, CRBX IN_B Q35, Q18, CRCX IN_C CRDX OUT1 CR A IN_D Carriage Motor CRCLK OUT2 CR B Vref AIN+ AIN- Vref A OUT...
  • Page 81 DFX-8500 Table 2-7 lists the carriage motor drive modes. Table 2-7. Carriage Motor Drive Modes Action Drive Mode Carriage Motor Acceleration / Constant Speed (rpm) Deceleration Control Speed Curve* Control Carriage moves Super Draft 2800 Acceleration and Carriage motor pulse control †...
  • Page 82 OPERATING PRINCIPLES The printer has three deceleration control modes. The degree of deceleration is determined by which carriage motor transistors are on. Table 2-8 describes how the transistors determine the mode. Table 2-8. Carriage Motor Drive Sequence Carriage Transfer Direction Driving Mode Motor Transistors (See Figure 2-19.)
  • Page 83 DFX-8500 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 deceleration driving mode 2, the control circuit measures time periods using the encoder signal,...
  • Page 84 OPERATING PRINCIPLES 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.

  • Page 85: Paper Feed Motor Drive Circuit

    DFX-8500 PAPER FEED MOTOR DRIVE CIRCUIT Stepping motor driver STK6713BMK4 (IC2) drives the paper feed motor. Figure 2-22 shows the paper feed motor drive circuit block diagram, and Table 2-9 contains motor specifications. Table 2-9. Paper Feed Motor Specifications Specification...
  • Page 86 OPERATING PRINCIPLES Main Board Board Gate Array E05B36 (IC1) Ref. Voltage PFH/R Setting Circuit (Q9) Vref 4.3 VDC CPU TMP95C061A (IC2) PG00 IN_A STK6713B PF COM (IC2) PG01 INXA OUT_A PG02 IN_B PF A OUTXA PF B PG03 INXB OUT_B PF C OUTXB PF D...

  • Page 87: Ribbon Feed Motor Drive Circuit

    DFX-8500 RIBBON FEED MOTOR DRIVE CIRCUIT Figure 2-24 shows a block diagram of the ribbon feed motor drive circuit, and Table 2-10 provides the ribbon feed motor specifications. The ribbon feed 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.

  • Page 88: Platen Gap Motor Drive Circuit

    OPERATING PRINCIPLES PLATEN GAP MOTOR DRIVE CIRCUIT Figure 2-25 shows a block diagram of the platen gap motor drive circuit, and Table 2-11 provides platen gap motor specifications. The platen gap motor is a stepping motor. The motor phase switching signals are output from the gate array ports PGA to PGD.
  • Page 89 DFX-8500 Main Board DRV Board VP 3 Gate Array E05B36 (IC1) Q10, PG H/R Q12, PG A Q13, PG B Q14. PG C PG D Plsten Gap Encoder Platen Gap Motor Figure 2-25. Platen Gap Motor Drive Circuit Block Diagram...

  • Page 90: Plunger Drive Circuit

    OPERATING PRINCIPLES 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. Three switching patterns drive the plunger. Gate array ports PLP and PLN output the plunger coil drive signals.

  • Page 91: Printhead Drive Circuit

    DFX-8500 PRINTHEAD DRIVE CIRCUIT Figure 2-27 shows the 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 send 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.
  • Page 92 OPERATING PRINCIPLES Main Board FTMP HF Motor Thermistor HFANA FANA HF Motor E05B36 (IC1) HFANB FANAX TMP95C061A (IC2) VX VP1 GP1 VX VP2 GP2 Printhead Coils 1/2 Printhead Driver Circuit DRV-B Board Printhead Driver Circuit 2/2 Printhead Coils 2/2 HTMP Printhead Thermistor HPSENS R100...
  • Page 93 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 C, the printer performs normal printing. 2. When the printhead temperature exceeds 110 C, the printer performs interval printing (carriage rest time at the sides is a little bit longer than normal).

  • Page 94: Chapter 3 Disassembly And Assembly

    CHAPTER 3 DISASSEMBLY AND ASSEMBLY OVERVIEW _________________________________________________________________ 3-1 3.1.1 Precautions ______________________________________________________________________ 3-1 3.1.2 Tools ___________________________________________________________________________ 3-3 3.1.3 Screw Specifications _______________________________________________________________ 3-5 3.1.4 Service Checks After Repair _________________________________________________________ 3-6 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...

  • Page 95: Overview

    DISASSEMBLY AND ASSEMBLY 3.1 OVERVIEW This section describes procedures for disassembling main components of the EPSON DFX-8500. Unless otherwise specified, you can assemble units or components by reversing disassembly. Therefore, no assembly procedures are included. Precautions for disassembly or assembly are described under the heading CAUTION.
  • Page 96 Foam packing for paper bail Printhead Protector Transportation Locking Brackets Foam Packing Carriage Guide Support Bar Figure 3-1. Attaching the Packing Material After attaching the packing materials, pack the printer in its container, as shown in Figure 3-2. Figure 3-2. Packing the DFX-8500...

  • Page 97: Tools

    Dial gauge master #F612 B101946800 Figure 3-5 Thickness gauge (t=0.43 mm) — Figure 3-6 Thickness gauge (t=0.80 mm) — — Motor screwdriver — — (Phillips head, torque adjustable) Chip Puller — — o: Commercially available E: EPSON exclusive A: Mandatory B: Recommended...
  • Page 98 DFX-8500 P E A C O C K P E A C O C K Figure 3-3. Dial Gauges Figure 3-4. Dial Gauge Base Figure 3-6. Thickness Gauge Set Figure 3-5. Dial Gauge Master...

  • Page 99: Screw Specifications

    DISASSEMBLY AND ASSEMBLY 3.1.3 Screw Specifications In the following sections, abbreviations are used for small parts such as screws and washers. Table 3-2 lists these abbreviations and their meanings. Table 3-3 shows screw and washer types. Table 3-2. Screw Abbreviations Abbreviation Part Name Cross-Bind head, B-tight screw...

  • Page 100: Service Checks After Repair

    DFX-8500 3.1.4 Service Checks After Repair Before returning the printer to the customer, use the check list in Table 3-4. This checklist helps make servicing and shipping more efficient. Table 3-4. Inspection Check List for the Repaired Printer Category Checkpoint...

  • Page 101: Disassembly And Assembly

    DISASSEMBLY AND ASSEMBLY 3.2 DISASSEMBLY AND ASSEMBLY WARNING Be sure to read and follow the instructions in Section 3.1, "Overview," before disassembling the printer. Be sure to turn the printer power off and unplug the AC cable before disassembling the printer. This section describes how to disassemble the printer.

  • Page 102: Rom Replacement

    DFX-8500 3.2.1 ROM Replacement CAUTION Remove the ROM carefully to avoid damaging the board. Check the INDEX mark on the chip socket to be sure the new ROM is oriented correctly before inserting it. Insert the ROM chip carefully to avoid damaging the chip pins and the board.

  • Page 103: Printhead And Ribbon Mask Assembly Removal

    3.2.2 Printhead and Ribbon Mask Assembly Removal The printhead can be changed without disassembling the entire unit. Use the printhead kit (Part # 1043489-00) to change the DFX-8500 printhead. When you receive the kit, make sure it includes the following components.
  • Page 104 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. 1. Open the top cover and remove the ribbon cartridge.
  • Page 105 DISASSEMBLY AND ASSEMBLY 6. Disconnect the narrow FPC cable from the white connector. (See Figure 3-12.) 7. Move the carriage to the 90 column (on the scale above the platen). Remove 2 screws (CP (S-P1), M4×7) securing the printhead, then remove 1 screw (CP (S-P1), M3×6) securing the ground FPC. (See Figure 3-12.) 8.
  • Page 106 DFX-8500 11. Install the new printhead, ribbon mask, and cable protection sheet by following Steps 1 to 10 in reverse. Torque the printhead screws to 12 + 1 kg cm. 12. Make sure the ribbon mask is a little loose.

  • Page 107: Housing Removal

    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 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.

  • Page 108: Left, Right, And Front Covers Removal And Fuse Replacement

    DFX-8500 3.2.3.2 Left, Right, and Front Covers Removal and Fuse Replacement 1. Remove 4 screws (CBB, M4×16) securing the left cover, then remove the left cover. 2. Remove the right cover the same way. 3. Disconnect 4 cables from the main power switch in the right cover. (See Figure 3-18.) Screws (CBB, M4×16)
  • Page 109 DISASSEMBLY AND ASSEMBLY 4. After you remove the right side cover, you may replace the C204 power supply board’s input fuse. WARNING Make sure the new fuse meets the printer's AC power specifications. Carriage Motor Ground Cable Fuse C204 PSB/PSE Board (Right Side) Figure 3-19.

  • Page 110: Front Panel Removal

    DFX-8500 3.2.3.3 Front Panel Removal 1. Remove the left and right covers. (See Section 3.2.3.2) 2. Open the top cover and disconnect control panel connector CN5. 3. Remove 2 screws (CBB, M4×16) from the control panel, then remove the control panel and control panel connector cable.

  • Page 111: Upper Case Removal

    DISASSEMBLY AND ASSEMBLY 3.2.3.4 Upper Case Removal 1. Remove the left and right covers. (See Section 3.2.3.2.) 2. Remove the front panel unit. (See Section 3.2.3.3.) 3. Remove 8 screws (6 CBB, M4×16 and 2 CBB, M3×10) from the upper case, then remove the upper case.

  • Page 112: Circuit Board Removal

    DFX-8500 3.2.4 Circuit Board Removal This section describes how to remove the circuit boards. 3.2.4.1 Bottom Panel Removal CAUTION Spread a thick, soft cloth under the printer before you follow the steps below. Make sure the parallel interface cable latch is not caught between the lower case and bottom panel when you attach the bottom panel..
  • Page 113 DISASSEMBLY AND ASSEMBLY 3. On the left side of the printer mechanism, remove 2 screws (CPB (O), M4×8) securing the green and yellow ground cables to the bottom plate of the printer mechanism and the bottom panel. 4. Disconnect connectors 1 through 6 as shown in Figure 3-24. Ground Cable Ground Cable Flat Cable Connector (50-pin): Mechanism...
  • Page 114 DFX-8500 7. Lay the printer on its back. 8. Remove 8 screws (CBB, M4×16) securing the bottom panel, then carefully remove the bottom panel. (See Figure 3-26.) Screws (CBB, M4×16) Figure 3-26. Bottom Panel Removal 3-20...

  • Page 115: Fan And C204 Power Supply Board Removal

    DISASSEMBLY AND ASSEMBLY 3.2.4.2 Fan and C204 Power Supply Board Removal 1. Remove the left and right covers. (See Section 3.2.3.2.) 2. Remove the bottom panel. (See Section 3.2.4.1.) 3. To remove the fan, disconnect CN5 on the power supply board. Remove 4 screws (CCN, M3x30) securing the fan, then remove the fan.

  • Page 116: C204 Sub Board Removal

    DFX-8500 3.2.4.3 C204 SUB Board Removal 1. Remove the left and right covers. (See Section 3.2.3.2.) 2. Remove the bottom panel. (See Section 3.2.4.1.) 3. Disconnect CN15 and CN16 on the C204 main board. 4. Remove 2 screws (1 CBB, M3×8 and 1 CBB, M3×12) securing the C204 SUB board, then remove the board.

  • Page 117: C204 Drv-B And C204 Drv Board Removal

    DISASSEMBLY AND ASSEMBLY 3.2.4.4 C204 DRV-B and C204 DRV Board Removal 1. Remove the left and right covers. (See Section 3.2.3.2.) 2. Remove the bottom panel. (See Section 3.2.4.1.) 3. Disconnect CN3 and CN14 on the C204 DRV board. 4. Disconnect CN1 and CN2 on the C204 DRV-B board. C204 DRV Board C204 DRV-B Board CN14...

  • Page 118: C204 Main Board Removal

    DFX-8500 3.2.4.5 C204 Main Board Removal 1. Remove the left and right covers. (See Section 3.2.3.2.) 2. Remove the bottom panel. (See Section 3.2.4.1.) 3. Remove the C204 SUB board. (See Section 3.2.4.3.) 4. Remove the C204 DRV-B and C204 DRV boards. (See Section 3.2.4.4.) 5.
  • Page 119 DISASSEMBLY AND ASSEMBLY Cable C204 Main Board CN8(8-pin) Figure 3-33. C204 Main Board Removal (3) 6. Remove 6 screws (4 CBB, M3×12 and 2 CBS (O), M3×8) securing the main board, then remove the main board. : Screw (CBS (O), M3×8) × 2 : Screw (CBB, M3×12) ×...

  • Page 120: Ac Inlet Removal

    DFX-8500 3.2.4.6 AC Inlet Removal 1. Remove the left and right covers. (See Section 3.2.4.2.) 2. Remove the bottom panel (See Section 3.2.4.1.) 3. Remove the C204 power supply board. (See Section 3.2.4.2.) 4. Remove the C204 main board. (See Section 3.2.4.5.) 5.

  • Page 121: C204 Pnl Board Removal

    DISASSEMBLY AND ASSEMBLY 3.2.4.7 C204 PNL Board Removal 1. Remove the left and right covers. (See Section 3.2.3.2.) 2. Remove the front panel. (See Section 3.2.3.3.) 3. Disconnect CN1 and CN2 on the C204 PNL board. 4. Remove 1 screw (CBB, M4×10) securing the C204 PNL board to the front panel unit, then remove the C204 PNL board.

  • Page 122: Interlock Switch And Cover Open Sensor Removal

    DFX-8500 3.2.5 Interlock Switch and Cover Open Sensor Removal 1. Remove the left and right covers. (See Section 3.2.3.2.) 2. Remove the front panel (See Section 3.2.3.3.) 3. Remove the upper case. (See Section 3.2.3.4.) 4. Disconnect the interlock switch cable from the connector junction board. (See Figure 3-41.) 5.

  • Page 123: Printer Mechanism Removal

    DISASSEMBLY AND ASSEMBLY 3.2.6 Printer Mechanism Removal This section describes how to disassemble the printer mechanism. Before following the steps in this section, remove the printer mechanism 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.
  • Page 124 DFX-8500 8. Remove the four screws securing the printer mechanism to the lower case. (See Figure 3-43.) Screws Screws Figure 3-43. Screw Removal 9. Insert the lift handles through the two holes in each side of the printer mechanism. Slowly lift up the printer mechanism using the handles and remove the mechanism from the lower case.

  • Page 125: Fan Removal

    DISASSEMBLY AND ASSEMBLY 3.2.6.1 Fan Removal 1. Remove the left and right covers. (See Section 3.2.3.2.) 2. Remove the front panel. (See Section 3.2.3.3.) 3. Remove the upper case. (See Section 3.2.3.4.) 4. Remove the printer mechanism. (See Section 3.2.6.) 5.

  • Page 126: Ribbon Feed Change Lever Unit Removal

    DFX-8500 3.2.6.2 Ribbon Feed Change Lever Unit Removal 1. Remove the left and right covers. (See Section 3.2.3.2.) 2. Remove the front panel. (See Section 3.2.3.3.) 3. Remove the upper case. (See Section 3.2.3.4.) 4. Remove the printer mechanism. (See Section 3.2.6.) 5.
  • Page 127 DISASSEMBLY AND ASSEMBLY Screw (CBB, M4×10) Front Panel C204 PNL Board Figure 3-47. Ribbon Feed Change Lever Unit Removal (2) To Ribbon Feed Motor To Tractor Select Sensor To Ribbon Jam Sensor Connector Junction Board Figure 3-48. Removing Connectors REMINDER When you install the ribbon feed change lever unit, make sure you correctly join the tip of the tractor select lever and the tractor select gear holder.

  • Page 128: Tractor Select Lever Disassembly

    DFX-8500 3.2.6.3 Tractor Select Lever Disassembly This section describes how to disassemble the tractor select lever and how to remove the ribbon feed motor and tractor select sensor. 1. Remove the left and right covers. (See Section 3.2.3.2.) 2. Remove the front panel. (See Section 3.2.3.3.) 3.

  • Page 129: Ribbon Jam Sensor Removal

    DISASSEMBLY AND ASSEMBLY REMINDER During assembly, attach the tractor select levers to the tractor select cam as shown in Figure 3-50. Ribbon Feed Motor Frame Tractor Select Cam Tarctor Select Gear Holder Ribbon Feed Change Lever (Upper and Lower) Figure 3-50. Tractor Select Lever Installation 3.2.6.4 Ribbon Jam Sensor Removal 1.

  • Page 130: Connector Junction Board And Fpc Board Removal

    DFX-8500 3.2.6.5 Connector Junction Board and FPC Board Removal This section describes how to remove the connector junction board and FPC board. 1. Remove the left cover. (See Section 3.2.3.2.) 2. Disconnect all the cables from the connector junction board. Remove 2 screws (CP (S-P1), M3×6) securing the connector junction board to the printer mechanism, then remove the connector junction board.

  • Page 131: Platen Gap (Pg) Sensor And Pg Motor Removal

    DISASSEMBLY AND ASSEMBLY 3.2.6.6 Platen Gap (PG) Sensor and PG Motor Removal CAUTION Be careful not to bend the PG motor encoder plate when removing or installing the PG sensor. 1. Remove the left cover. (See Section 3.2.3.2.) 2. Remove the connector junction board. (See Section 3.2.6.5.) 3.

  • Page 132: Plunger And Paper Bail Removal

    DFX-8500 3.2.6.7 Plunger and Paper Bail Removal This section describes how to remove the plunger (loading solenoid) and paper bail. 1. Remove the left and right covers. (See Section 3.2.3.2.) 2. Remove the front panel. (See Section 3.2.3.3.) 3. Remove the upper case. (See Section 3.2.3.4.) 4.
  • Page 133 DISASSEMBLY AND ASSEMBLY 8. Remove the left tension roller lever spring. (See Figure 3-55.) 9. Remove 1 e-ring securing the paper bail shaft to the left frame, then remove the platen roller shaft holder and paper bail lever. (See Figure 3-55.) E - r i n g s S h a f t H o l d e r P a p e r B a i l S h a f t...

  • Page 134: Upper Paper Guide And Top Pe Sensor Removal

    DFX-8500 3.2.6.8 Upper Paper Guide and Top PE Sensor Removal 1. Remove the left and right covers. (See Section 3.2.3.2.) 2. Remove the front panel. (See Section 3.2.3.3.) 3. Remove the upper case. (See Section 3.2.3.4.) 4. Remove the printer mechanism. (See Section 3.2.6.) 5.

  • Page 135: Tension Roller Shaft Removal

    DISASSEMBLY AND ASSEMBLY 3.2.6.9 Tension Roller Shaft Removal 1. Remove the left and right covers. (See Section 3.2.3.2.) 2. Remove the front panel. (See Section 3.2.3.3.) 3. Remove the upper case. (See Section 3.2.3.4.) 4. Remove the printer mechanism. (See Section 3.2.6.) 5.
  • Page 136 DFX-8500 11. Remove the carriage motor fan. (See Section 3.2.6.19.) 12. Remove 1 e-ring (6) from the right end of the tension roller shaft, then remove the tension roller shaft holder, 1 leaf spring and 1 washer. (See Figure 3-60.) 13.

  • Page 137: Platen Removal

    DISASSEMBLY AND ASSEMBLY 3.2.6.10 Platen Removal 1. Remove the left and right covers. (See Section 3.2.3.2.) 2. Remove the front panel. (See Section 3.2.3.3.) 3. Remove the upper case. (See Section 3.2.3.4.) 4. Remove the printer mechanism. (See Section 3.2.6.) 5.

  • Page 138: Paper Jam Sensor Removal

    DFX-8500 3.2.6.11 Paper Jam Sensor Removal 1. Remove the left and right covers. (See Section 3.2.3.2.) 2. Remove the front panel. (See Section 3.2.3.3.) 3. Remove the upper case. (See Section 3.2.3.4.) 4. Remove the printer mechanism. (See Section 3.2.6.) 5.

  • Page 139: Pull Tractor Sensor Removal

    DISASSEMBLY AND ASSEMBLY 3.2.6.12 Pull Tractor Sensor Removal 1. Remove the left and right covers. (See Section 3.2.3.2.) 2. Remove the front panel. (See Section 3.2.3.3.) 3. Remove the upper case. (See Section 3.2.3.4.) 4. Remove the printer mechanism. (See Section 3.2.6.) 5.

  • Page 140: Paper Width Sensor Removal

    DFX-8500 3.2.6.13 Paper Width Sensor Removal 1. Open the top cover. 2. Disconnect the paper width sensor connector. (See Figure 3-67.) 3. Remove 1 screw (CP (S-P1), M2.5×6) securing the paper width sensor to the ribbon mask holder, then remove the sensor. (See Figure 3-67.)

  • Page 141: Platen Gap Home Sensor Removal

    DISASSEMBLY AND ASSEMBLY 3.2.6.14 Platen Gap Home Sensor Removal 1. Remove the left and right covers. (See Section 3.2.3.2.) 2. Remove the front panel. (See Section 3.2.3.3.) 3. Remove the upper case. (See Section 3.2.3.4.) 4. Remove the interlock switch and cover open sensor. (See Section 3.2.5.) 5.
  • Page 142 DFX-8500 REMINDER When installing the carriage guide shaft gear, align the rib on the gear with the platen gap adjustment transmission gear, then rotate the carriage guide shaft gear counterclockwise for 10 mm. (See Figure 3-70.) Flat Part of Rear Carriage Guide Shaft...

  • Page 143: Paper Feed Motor Removal

    DISASSEMBLY AND ASSEMBLY 3.2.6.15 Paper Feed Motor Removal 1. Remove the left and right covers. (See Section 3.2.3.2.) 2. Remove the front panel. (See Section 3.2.3.3.) 3. Remove the upper case. (See Section 3.2.3.4.) 4. Remove the interlock switch and cover open sensor. (See Section 3.2.5.) 5.

  • Page 144: Left Gear Train Removal

    DFX-8500 3.2.6.16 Left Gear Train Removal 1. Remove the left and right covers. (See Section 3.2.3.2.) 2. Remove the front panel. (See Section 3.2.3.3.) 3. Remove the upper case. (See Section 3.2.3.4.) 4. Remove the printer mechanism. (See Section 3.2.6.) 5.

  • Page 145: Front Tractor Removal

    DISASSEMBLY AND ASSEMBLY 3.2.6.17 Front Tractor Removal 1. Remove the left and right covers. (See Section 3.2.3.2.) 2. Remove the front panel. (See Section 3.2.3.3.) 3. Remove the upper case. (See Section 3.2.3.4.) 4. Remove the printer mechanism. (See Section 3.2.6.) 5.

  • Page 146: Rear Tractor Removal

    DFX-8500 3.2.6.18 Rear Tractor Removal 1. Remove the left and right covers. (See Section 3.2.3.2.) 2. Remove the front panel. (See Section 3.2.3.3.) 3. Remove the upper case. (See Section 3.2.3.4.) 4. Remove the printer mechanism. (See Section 3.2.6.) 5. Remove the connector junction board. (See Section 3.2.6.5.) 6.

  • Page 147: Carriage Motor Fan Removal

    DISASSEMBLY AND ASSEMBLY 3.2.6.19 Carriage Motor Fan Removal 1. Remove the left and right covers. (See Section 3.2.3.2.) 2. Remove the front panel. (See Section 3.2.3.3.) 3. Remove the upper case. (See Section 3.2.3.4.) 4. Remove the printer mechanism. (See Section 3.2.6.) 5.

  • Page 148: Carriage Motor Removal

    DFX-8500 3.2.6.20 Carriage Motor Removal 1. Remove the left and right covers. (See Section 3.2.3.2.) 2. Remove the front panel. (See Section 3.2.3.3.) 3. Remove the upper case. (See Section 3.2.3.4.) 4. Remove the printer mechanism. (See Section 3.2.6.) 5. Remove the carriage motor fan. (See Section 3.2.6.19.) 6.

  • Page 149: Carriage Encoder Sensor Removal

    DISASSEMBLY AND ASSEMBLY 3.2.6.21 Carriage Encoder Sensor Removal 1. Remove the printhead. (See Section 3.2.2.) 2. Disconnect the carriage encoder sensor connector (red, 4 pins) from the carriage connector junction board. (See Figure 3-78.) 3. Remove 2 screws (CP (S-P1), M2.6×5) securing the carriage encoder sensor to the carriage, then remove the sensor.

  • Page 150: Carriage Mechanism Disassembly

    DFX-8500 3.2.6.22 Carriage Mechanism Disassembly This section describes how to disassemble the carriage mechanism, including the carriage, carriage timing belt, and front and rear carriage guide shafts. 1. Remove the left and right covers. (See Section 3.2.3.2.) 2. Remove the front panel. (See Section 3.2.3.3.) 3.
  • Page 151 DISASSEMBLY AND ASSEMBLY 10. Slide the carriage to the left side. Pull the front carriage guide shaft through the hole in the right frame and remove it. (See Figure 3-81.) 11. On the left frame, remove 1 e-ring (6) securing the carriage guide shaft gear to the rear carriage guide shaft.
  • Page 152 DFX-8500 Rear Carriage Guide Shaft Parallelism Adjustment Lever Screw (CP (S-P1), M4×6) Right Guide Shaft Holder Lever Guide Shaft Holding Spring Screw (CP (S-P1), M4×6) Screw (CBS, M4×8) Carriage Motor Holder Figure 3-83. Right Side Frame Removal REMINDER When you install the front carriage guide shaft, push the shaft toward the platen while you tighten the screws.

  • Page 153: Paper Guide Support Plate Removal

    DISASSEMBLY AND ASSEMBLY 3.2.6.23 Paper Guide Support Plate Removal 1. Remove the left and right covers. (See Section 3.2.3.2.) 2. Remove the front panel. (See Section 3.2.3.3.) 3. Remove the upper case. (See Section 3.2.3.4.) 4. Remove the printer mechanism. (See Section 3.2.6.) 5.
  • Page 154 DFX-8500 3-60...
  • Page 155 CHAPTER 4 ADJUSTMENT OVERVIEW ___________________________________________________________________1 Platen Gap Motor Placement Adjustment ____________________________________________1 Carriage Timing Belt Tension Adjustment ___________________________________________2 Tractor Wire Spring Tension Adjustment ____________________________________________3 Pull Tractor Sensor Position Adjustment_____________________________________________4 Carriage Guide Shaft Parallelism Adjustment ________________________________________5 Platen Angle Adjustment__________________________________________________________9 Platen Gap Adjustment __________________________________________________________ 11 Resetting the Platen Gap Values _______________________________________________________________ 12 Measuring the Platen Gap Values______________________________________________________________ 13 Bi-directional Printing Adjustment ________________________________________________15...

  • Page 156: Overview

    ADJUSTMENT 4.1 OVERVIEW This chapter describes the printer mechanism adjustments required after any part is replaced or repaired. Perform the appropriate adjustments before assembling the printer. 4.2 PLATEN GAP MOTOR PLACEMENT ADJUSTMENT In this adjustment, the platen gap motor pinion gear must mesh smoothly with the platen gap transmission gear.

  • Page 157: Carriage Timing Belt Tension Adjustment

    DFX-8500 4.3 CARRIAGE TIMING BELT TENSION ADJUSTMENT Adjust the carriage timing belt tension when you disassemble any carriage mechanism part (such as the carriage motor, belt pulley, or carriage timing belt). Remove the printer mechanism before performing this adjustment. (See Section 3.2.6.) CAUTION Before performing this adjustment, carefully secure the printer mechanism;...

  • Page 158: Tractor Wire Spring Tension Adjustment

    ADJUSTMENT 4.4 TRACTOR WIRE SPRING TENSION ADJUSTMENT Perform this adjustment when you remove the front or rear tractor assembly. If the spring is not adjusted properly, incorrect paper tension may cause paper jams. 1. Remove the printer mechanism. (See Section 3.2.6.) 2.

  • Page 159: Pull Tractor Sensor Position Adjustment

    DFX-8500 4.5 PULL TRACTOR SENSOR POSITION ADJUSTMENT Perform this adjustment when you replace or disassemble the platen, rear paper guide, platen roller shaft, tension roller shaft, or pull tractor sensor. If the sensor position is incorrect, the sensor is always on. Figure 4-4 illustrates the pull tractor sensor position adjustment.

  • Page 160: Carriage Guide Shaft Parallelism Adjustment

    + 0.015 mm. Since this value is extremely small, you must use the two dial gauges, a dial gauge base, and a dial gauge master supplied by EPSON to measure it. Do not adjust the parallelism using any other method.
  • Page 161 DFX-8500 Hex screw Gauge needle Figure 4-6. Dial Gauge Setup 3. Tighten the hexagonal screw securing the dial gauge to the base. 4. Install the second gauge the same way. Set both gauges to exactly the same reading, then tighten the hexagonal screw.
  • Page 162 ADJUSTMENT 6. Remove 1 screw (CP (PS), M3×6) securing the timing belt holder to the timing belt, then remove the timing belt holder. (See Figure 4-9.) Rear Carriage Guide Shaft Screw (CP (PS), M3×6) Timing Belt Holder Carriage Figure 4-9. Timing Belt Holder Removal 7.
  • Page 163 DFX-8500 Carriage Guide Shaft Gear Stopper Platen Gap Transmission Gear Figure 10a. Carriage Guide Shaft Gear Positioning 12. Measure the distance between the platen and the carriage guide shaft on the left end of the platen. Then measure the distance between the platen and the carriage guide shaft on the right end of the platen, and compare the two values.

  • Page 164: Platen Angle Adjustment

    ADJUSTMENT 4.7 PLATEN ANGLE ADJUSTMENT The platen must make a right angle with the carriage. Perform this adjustment after you remove or replace the platen or loosen the two hexagonal screws securing the platen to the frame. Do not remove the printer mechanism, or the adjustment will be undone when you install it.
  • Page 165 DFX-8500 2.8 inches 2.8 inches Center Position (70 mm) (70 mm) Platen Figure 4-14. Measuring the Platen Angle (not to scale) Platen Down (Angle Adjustment Method) Figure 4-15. Adjusting the Platen Angle 6. If the difference between the two gauge values is more than 0.015 mm at any point, loosen (but do not remove) the 2 hexagonal screws securing the platen stay to the frame, then slowly adjust the platen angle.

  • Page 166: Platen Gap Adjustment

    This measurement is important because it determines the platen gap, so be sure to use the EPSON exclusive thickness gauge set and tension gauge. Thickness gauge (0.43 mm) : #F616 (EPSON Part No. B102047100) Thickness gauge (0.80 mm) Tension gauge (200 g) : #F545 (EPSON Part No. B765114601) The printer must be on during adjustment.

  • Page 167: Resetting The Platen Gap Values

    DFX-8500 RESETTING THE PLATEN GAP VALUES To reset the Alpha and Beta values: 1. Remove the paper, ribbon cartridge, and ribbon mask holder from the printer. 2. Write down the Alpha value written on the side of the printhead. 3. Write down the Beta values written on the label on the inside bottom right corner of the printer mechanism, under the ribbon cartridge.

  • Page 168: Measuring The Platen Gap Values

    ADJUSTMENT MEASURING THE PLATEN GAP VALUES To measure and enter new Beta values: 1. Remove the paper, ribbon cartridge, and ribbon mask holder from the printer. 2. Write down the Alpha value written on the side of the printhead. 3. Write down the Beta values written on the label on the inside bottom right corner of the printer mechanism, under the ribbon cartridge.
  • Page 169 DFX-8500 17. Gradually bring the printhead to the surface of the thickness gauge using the Micro Feed buttons: Press the Micro Feed ↓ button to increase the value by 1. Press the Micro Feed ↑ button to decrease the value by 1.

  • Page 170: Bi-Directional Printing Adjustment

    ADJUSTMENT 4.9 BI-DIRECTIONAL PRINTING ADJUSTMENT The purpose of this adjustment is to correct the printer mechanism parameters that control bi-directional printing. If the adjustment is not performed correctly, bi-directional printing may be misaligned, or the carriage might operate incorrectly. Before performing this procedure, be sure that the following adjustments have been completed correctly: Carriage Timing Belt Tension Adjustment Carriage Guide Shaft Parallelism Adjustment...
  • Page 171 DFX-8500 START Mount the ribbon cartridge. Turn the power on while pressing the Tear Off, Micro Feed ↑ , and Front/Rear buttons. Put 15-inch fanfold paper in the Front or Rear tractor, then load the paper by pressing LF/FF Load or Front/Rear.
  • Page 172 ADJUSTMENT Decrease flight time Increase flight time TTTTTTTTTTTTTTTTTTTTT TTTTTTTTTTTTTTTTTTTTT TTTTTTTTTTTTTTTTTTTTT TTTTTTTTTTTTTTTTTTTTT 40 COLUMNS 40 COLUMNS 56 COLUMNS Figure 4-20. Flight Time Pattern 4-17...
  • Page 173 DFX-8500 Bi-D. Adjustment Mode Adjustment Super Draft Print Mode The control panel diplays the current Bi-D value. Adjustment The printer prints "Speed = AAA Bid adjust = BBB". BBB* is the current Bi-D value. Draft Print Mode The printer prints the test print pattern using the current value.

  • Page 174: Chapter 5 Troubleshooting

    CHAPTER 5 TROUBLESHOOTING TROUBLESHOOTING INFORMATION ___________________________________________ 1 Error Messages _____________________________________________________________________________ 1 Bypassing the Interlock Switch and Cover Open Sensor _____________________________________________ 3 Coil Resistance and Printhead Cable Signals ______________________________________________________ 4 Unit Replacement ___________________________________________________________________________ 6 CIRCUIT BOARD REPAIR _____________________________________________________ 14 C204 PSB/PSE Board Repair _________________________________________________________________ 14 C204 Main/DRV/DRV-B Boards Repair_________________________________________________________ 16 Printer Mechanism Repair____________________________________________________________________ 19...

  • Page 175: Troubleshooting Information

    TROUBLESHOOTING 5.1 TROUBLESHOOTING INFORMATION This chapter lists various problems that can occur with the DFX-8500 and provides possible solutions. No special tools, other than a digital multi-meter, are necessary to troubleshoot at the unit level. Some component-level troubleshooting may require an oscilloscope.
  • Page 176 DFX-8500 Table 5-2. Fatal Error Information † ‡ Fatal Error 7-segment Beeper Description Note LED * Carriage motor The isolation resistance in the carriage Auto power off circuit short motor is too low. after 12 seconds • The optional cutter cable is not...

  • Page 177: Bypassing The Interlock Switch And Cover Open Sensor

    TROUBLESHOOTING BYPASSING THE 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. These sensors automatically disable printing when the top cover is open. Interlock Switch Connector Cover Open...

  • Page 178: Coil Resistance And Printhead Cable Signals

    DFX-8500 COIL RESISTANCE AND PRINTHEAD CABLE SIGNALS The following table provides the coil resistance for the motor, head fan, plunger, and printhead. Table 5-3. Motor, Fan, Plunger, and Printhead Coil Resistance Part Coil Resistance 1.66 Ω + 10 % Carriage (CR) motor 2.80 Ω...
  • Page 179 TROUBLESHOOTING FPC A FPC B FPC C Load Pattern MA : Fan motor phase A : Printhead coil GND side MB : Fan motor phase B : Printhead coil P/S side MC : Fan motor common : Printhead thermistor MT : Fan motor thermistor PWD : Paper width sensor +5V : +5 VDC P/S : Power supply (+37 VDC)

  • Page 180: Unit Replacement

    DFX-8500 UNIT REPLACEMENT 1. The printer does not operate when power is turned on. START Does the Check Table 5-1, Error printer beep Codes. before it dies? Is the Use the correct AC voltage. AC input voltage normal? Replace the fuse F1 and...
  • Page 181 TROUBLESHOOTING 2. Carriage operation is abnormal. START Are the connectors listed in the note below Reinsert the connectors. inserted securely? Is the problem fixed? Manually move the Not smooth carriage to see if movement is smooth or not. Check the CR encoder belt and Smooth encoder sensor.
  • Page 182 DFX-8500 3. Carriage operation is normal, but the self-test is printed incorrectly (1/3). START Perform the self-test. Does the printer perform the self-test? Are the connectors listed in the note below inserted securely? Are any R e in s e rt c o rre ctly .
  • Page 183 TROUBLESHOOTING 4. Carriage operation is normal, but the self-test is printed incorrectly (2/3). Check the printhead coil resistance. Is the printhead resistance correct? Check the printhead drivers. Check the printhead drivers. Replace the DRV Are the board and the drivers OK? printhead.
  • Page 184 DFX-8500 5. Carriage operation is normal, but the self-test is printed incorrectly (3/3). Is the print correct? Perform bidirectional adjustment. Go back to Section 5.3, Repair of the Printer Mechanism, and check for other problems. Perform bidirectional adjustment. 5-10...
  • Page 185 TROUBLESHOOTING 5. Printing is normal, but paper feeding is abnormal. START Is the paper loaded correctly? Load the paper correctly. Is there anything stuck in the Clear the paper path. path of the paper? Is PF motor coil Check the resistance of the PF motor resistance coils and check the PF motor drivers.
  • Page 186 DFX-8500 7. Control panel operation is abnormal. START Is CN5 between the C204 Main and C204 PNL board connected correctly? Reinsert connector CN correctly. Is the problem fixed? Using a multimeter, check the switches on the PNL board. Do the...

  • Page 187: Troubleshooting

    TROUBLESHOOTING 8. Data sent by the host computer is printed incorrectly. Note : The flowchart below assumes the host computer is operating normally. START Run the self-test. Is the self-test printed correctly? Troubleshoot printer using the previous flowcharts. Can you print from DOS? Check the software application setup...

  • Page 188: Circuit Board Repair

    DFX-8500 5.2 CIRCUIT BOARD REPAIR This section describes troubleshooting and repair procedures for the DFX-8500 circuit boards. By referring to the checkpoints below, you can determine which component is defective and perform the proper repair procedure. The tables have four columns:...
  • Page 189 TROUBLESHOOTING Table 5-5. C204 PSB/PSE Board Component Repair Symptom Cause Checkpoint Solution No DC voltage at the PD signal is HIGH Measure the PD signal Wait until the printer output. (The fan on the (signal from the main level at CN4. prints again.

  • Page 190: C204 Main/Drv/Drv-B Boards Repair

    DFX-8500 C204 MAIN/DRV/DRV-B BOARDS REPAIR Table 5-6 includes troubleshooting procedures. Table 5-6. C204 Main/DRV/DRV-B Boards Component Repair Symptom Cause Checkpoint Solution The printer does The DRERR signal Check the level of the DRERR signal Replace the not operate at all.
  • Page 191 TROUBLESHOOTING Table 5-6. C204 Main/DRV/DRV-B Boards Component Repair (continued) Symptom Cause Checkpoint Solution The carriage The carriage encoder Observe the carriage encoder sensor Replace the operates sensor is defective. output signal at pins 4 (ENCA) and 3 carriage encoder abnormally. (ENCB) of CN4 on the main board.
  • Page 192 DFX-8500 Table 5-6. C204 Main/DRV/DRV-B Boards Component Repair (continued) Symptom Cause Checkpoint Solution The PG home Check the PG HP sensor signal level Replace the PG position sensor is at pin 36 (PGHOME) of CN14. (PG home position defective. home = LOW; other = HIGH) sensor.

  • Page 193: Printer Mechanism Repair

    TROUBLESHOOTING PRINTER MECHANISM REPAIR The table below describes how to isolate problems with the printer mechanism. To replace or adjust printer mechanism parts, see Chapters 3 and 4. If a symptom recurs following a repair, look for other possible causes and solutions in the table below. Table 5-7.
  • Page 194 DFX-8500 Table 5-7. Printer Mechanism Repair (continued) Symptom Cause Checkpoint Solution The parallelism Print density differs at the right and Perform the value is incorrect. left sides of the page (darker on one parallelism side). adjustment, as described in Section 4.6.
  • Page 195 TROUBLESHOOTING Table 5-7. Printer Mechanism Repair (continued) Symptom Cause Checkpoint Solution The PG home sensor Check the continuity of the sensor. Replace the PG is defective. (Check the status of the two micro home sensor (micro switches.) switch type). The PG motor is Check the coil resistance of the PG Replace the PG motor.
  • Page 196 DFX-8500 5-22...
  • Page 197 CHAPTER 6 MAINTENENCE PREVENTIVE MAINTENANCE ___________________________________________________1 LUBRICATION AND ADHESIVE APPLICATION ____________________________________1...

  • Page 198: Preventive Maintenance

    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 the needs of the printer.
  • Page 199 DFX-8500 Table 6-2. Lubrication Points Lubrication See Figure: Description Lubricant Point Carriage oil pad ring (on both left and right sides of carriage) Carriage oil pad (under the carriage head cable holder), Hole holding the tip of the rear carriage guide shaft (in both...
  • Page 200 MAINTENANCE Figure 6-2. Lubrication and Adhesion Points (1/3)
  • Page 201 DFX-8500 Figure 6-3. Lubrication and Adhesion Points (2/3)
  • Page 202 MAINTENANCE Figure 6-4. Lubrication and Adhesion Points (3/3)
  • Page 203 DFX-8500...
  • Page 204 APPENDIX CONNECTOR PIN ASSIGNMENTS ____________________________________________A-1 COMPONENT LAYOUT DIAGRAMS __________________________________________A-10 CONNECTORS ON THE CONNECTOR JUNCTION BOARD _____________________A-16 PARTS LIST ________________________________________________________________A-17 EXPLODED DIAGRAMS _____________________________________________________A-20 CIRCUIT DIAGRAMS _______________________________________________________A-28...

  • Page 205: Connector Pin Assignments

    APPENDIX A.1 CONNECTOR PIN ASSIGNMENTS Figure A-1 illustrates the connections between the primary components. Table A-1 lists the connectors and pin assignments. 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 TYPE-B Printer Mechanism CN11(36) CR Encoder...
  • Page 206 DFX-8500 Table A-1. Board Connector Summary Connector Connected to: No. of Pins Details C204 Main Board Mechanism (Printhead) 30 pins Table A-2 C204 DRV-B board 20 pins Table A-3 Cover Open 2 pins Table A-4 Mechanism (Carriage encoder) 4 pins...
  • Page 207 APPENDIX Table A-2. C204 Main Board Connector CN1 Signal Name Function P+10 Printhead pin #10 P-10 P+12 Printhead pin #12 P-12 P+16 Printhead pin #16 P-16 P-17 P+17 Printhead pin #17 P-11 P+11 Printhead pin #11 Printhead pin #9 Printhead pin #2 Printhead pin #1 HFANB HF motor phase B...
  • Page 208 DFX-8500 Table A-4. C204 Main Board Connector CN3 Signal Name Function COPEN Cover open status — — Table A-5. C204 Main Board Connector CN4 Signal Name Function — — ENCB CR encoder B phase pulse ENCA CR encoder A phase pulse Table A-6.
  • Page 209 APPENDIX CUTHPI Cutter home position — — Reverse point signal Table A-11. C204 Main Board Connector CN10 Signal Name Function 1, 2 3, 4 DRERR Printhead driver error signal Power down signal Current limit signal Power shutdown signal Table A-12. C204 Main Board Connector CN11 Signal Name Function 1, 2, 3, 4, 5, 6...
  • Page 210 DFX-8500 Table A-13. C204 Main Board Connector CN14 Signal Name Function — +37 VDC 2, 3, 4 — 5, 6, 7, 8 — 9, 10 — +5 VDC switched by reset status HF control signal Plunger negative channel RFH/R RF motor common...
  • Page 211 APPENDIX Table A-14. C204 Main Board Connector CN15 Signal Name Function DIP1 DIP switch bank 1 status DIP2 DIP switch bank 2 status DIP3 DIP switch bank3 status DIP4 DIP switch bank 4 status DIP5 DIP switch bank 5 status DIPCNT1 DIP switch select port 1 Table A-15.
  • Page 212 DFX-8500 Table A-16. C204 DRV Board Connector CN2 Signal Name Function 1, 3, 5, 8 — +37 VDC — — RBJAM Ribbon jam INTLOC — FANDRV CR fan drive INTLOC — INTLOC — — — GND for VP3 TR_SEL Tractor select signal...
  • Page 213 APPENDIX Table A-17. C204 DRV Board Connector CN3 Signal Name Function 1, 2, 3 — +37 VDC 4, 5, 6 GND for VP3 Table A-18. C204 DRV-B Board Connector CN1 Signal Name Function Printhead pin #6 Printhead pin #4 P-18 P+14 Printhead pin #14 P-14...

  • Page 214: Component Layout Diagrams

    DFX-8500 A.2 COMPONENT LAYOUT DIAGRAMS Figure A-2. C204 Main Board Component Layout (1) A-10...
  • Page 215 APPENDIX Figure A-3. C204 Main Board Component Layout (2) A-11...
  • Page 216 DFX-8500 Figure A-4. C204 DRV Board Component Layout (1) Figure A-5. C204 DRV Board Component Layout (2) A-12...
  • Page 217 APPENDIX Figure A-6. C204 DRV-B Board Component Layout (1) Figure A-7. C204 DRV-B Board Component Layout (2) A-13...
  • Page 218 DFX-8500 Figure A-8. C204 PSB Board Component Layout A-14...
  • Page 219 APPENDIX Figure A-9. C204 PSE Board Component Layout A-15...

  • Page 220: Connectors On The Connector Junction Board

    DFX-8500 A.3 CONNECTORS ON THE CONNECTOR JUNCTION BOARD The figure below illustrates the arrangement of connectors on the connector junction board. C o n n e c t o r C o l o r s : B l a c k...

  • Page 221: Parts List

    APPENDIX A.4 PARTS LIST Table A-20. Parts List Part Names Part Names HOUSING ASSY.,LOWER SPACER,PS UNIT FRAME ASSY.,BOTTOM LEAF SPRING,BASE FRAME COVER ASSY.,FRONT COVER, DIP SWITCH HOUSING ASSY.,UPPER COVER,CONNECTOR,UPPER ECW HOUSING ASSY.,TOP C.B.(O)SCREW M3X8 F/ZN LOGO PLATE CONNECTOR LOCK NUT for USA COVER,PAPER SUPPORT CONNECTOR LOCK NUT for others CAP,LOWER...
  • Page 222 DFX-8500 Table A-20. Parts List (continued) Part Names Part Names C.B.S.(O) SCREW M3X6 PAPER THICKNESS DETECTOR +.ONEWAY PLA- LOCK,3X12,F/ZN DETECTOR ASSY.,PGHP DAMPER SHEET DETECTOR ASSY.,PULL TRACTOR DAMPER SHEET;B PAPER GUIDE,UPPER SHAFT,FRONT,LOWER,RIGHT ECW CARRIAGE ASSY. SHAFT,FRONT,LOWER,LEFT LEAD WIRE LEVER ASSY.,LOCK,LEFT BELT PULLEY HOLDER LEVER ASSY.,LOCK RIGHT...
  • Page 223 APPENDIX Table A-20. Parts List (continued) Part Names Part Names OIL PAD COVER C.P.(PS).SCREW M4X8 OIL PAD RING C.P.S.SCREW M2X10 FLAME,CABLE,HEAD C.P.S.(O) SCREW M3X6 COVER,HEAD CABLE C.P.S(P.S) SCREW,3X10,F/ZN SHAFT,FASTEN,HOLDER METAL FITTINGS,FASTEN,SHAFT TIMING BELT,CR C.P.O SCREW M4X5 HOLDER,BELT FASTEN PLAIN WASHER 2.5X0.5X7.5 FRAME,PAPER GUIDE MOUNT SHEET,DUST PROOF EXTENSION SPRING,1000...

  • Page 224: Exploded Diagrams

    DFX-8500 A.5 EXPLODED DIAGRAMS See the following pages for exploded diagrams. Figure A-11. Exploded Diagrams (1) A-20...
  • Page 225 APPENDIX Figure A-12. Exploded Diagrams (2) A-21...
  • Page 226 DFX-8500 Figure A-13. Exploded Diagrams (3) A-22...
  • Page 227 APPENDIX Figure A-14. Exploded Diagrams (4) A-23...
  • Page 228 DFX-8500 Figure A-15. Exploded Diagrams (5) A-24...
  • Page 229 APPENDIX Figure A-16. Exploded Diagrams (6) A-25...
  • Page 230 DFX-8500 Figure A-17. Exploded Diagrams (7) A-26...
  • Page 231 APPENDIX Figure A-18. Exploded Diagrams (8) A-27...

  • Page 232: Circuit Diagrams

    DFX-8500 A.6 CIRCUIT DIAGRAMS See the following pages for these circuit diagrams: C204 Main Board C204 DRV Board C204 DRV-B Board C204 PSB Board C204 PSE Board A-28...

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