Epson DFX-5000+ User manual

EPSON
®
Service Manual
Epson America, Inc.
TM-DFX5K+

Service Manual
Revision Level
~
Revision
~
Date
~
1st printing 4129194
I
EPSON
®
@
Printed on Recycled Paper.

FCC Compliance Statement
For American Users
This equipment has been tested and found to comply with limits for a Class B digital device
pursuant to Part 15 of FCC Rules. These limits are designed to provide reasonable protection
against harmful interference in a residential installation. This equipment generates, uses, and can
radiate radio frequency energy and, if not installed and used in accordance with the instructions,
may cause harmful interference to radio or television reception. However, there is no guarantee that
interference will not occur in a particular installation. If this equipment does cause interference to
radio or television reception, which can be determined by turning the equipment on and off, the user
is encouraged to try to correct the interference by one or more of the following measures:
0Reorient or relocate the receiving antenna.
0Increase the separation between the equipment and the receiver.
0Connect the equipment into an outlet on a circuit different from the one connected to the receiver
For Canadian Users
This digital apparatus does not exceed the Class B limits for radio noise emissions from digital
apparatus as set out in the radio interference regulations of the Canadian Department of
Communications.
Le present appareil numerique n’emet pas de bruits radioelectrique depassant les limites applicables
aux appareils numeriques de Classe B prescrites dans le reglement sur le brouillage radioelectriques
Cdicte par le Minister-e des Communications du Canada.
Caution
The connection of a non-shielded equipment interface cable to this equipment will invalidate the
FCC Certification of this device and may cause interference levels which exceed the limits
established by the FCC for this equipment. It is the responsibility of the user to obtain and use a
shielded equipment interface cable with this device. If this equipment has more than one interface
connector, do not leave the cables connected to unused interfaces.
Changes or modifications not expressly approved by the manufacturer could void the user’s
authority to operate the equipment.
EPSON DFX-5000+ Service Manual

Copyright Notice
All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or
transmitted in any form or by any means, electric, mechanical, photocopying, recording, or
otherwise, without the written permission ofEpson America, Inc. No patent liability is assumed
with respect to use ofthe information contained herein. Neither is any liability assumed for
damages resulting from the use of the information contained herein. While every precaution has
been taken in the preparation ofthis book, Epson America, Inc., assumes no responsibility for errors
and omissions.
Neither Epson America, Inc., nor its affiliates shall be liable to the purchaser of this product or third
parties for damages, losses, costs, or expenses incurred by purchaser or third parties as a result of
accident, misuse, or abuse of this product or unauthorized modifications, repairs, or alterations to
this product.
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.
Trademarks
EPSON@ and ESC/P@ are registered trademarks and ESC/P 2 is a trademark of Seiko Epson
Corporation.
General Notice: Other product names used herein are for identification purposes only and may be
trademarks of their respective companies.
Copyright 1994 Epson America, Inc
Epson America, Inc.
20770 Madrona Avenue, Torrance, CA 90509
EPSON DFX-5000+ Service Manual
III

Precautions
Precautionary notations throughout the text are categorized relative to
1. personal injury
2. damage to equipment.
Warning
Signals a precaution which, if ignored, could result in serious orfutulpersonul injury.
Great caution should be exercised in performingprocedures preceded by a WARNING
heading.
Caution
Signals a precaution which, if ignored, could result in damage to equipment.
The precautionary measures itemized below should always be observed when
performing repair/maintenance procedures.
Warning
II II
1. Alw uys disconnect the product from both the power source and host computer before
performing any maintenance or repair procedure.
2. No work should beperformed on the unit by persons unfamiliar with basic sufdy
measures dictatedfor all electronics technicians in their line of work.
3. In performing testing described in this manual, do not connect the unit to a power source
until instructed to do so. When thepower supply cable must be connected, use
extreme caution in working on thepower supply and other electronic components.
Caution
1. Repairs on EPSONproducts should beperformed only by an EPSON-certified repair
technician.
2. Make certain that the source voltage is the same us the rated voltage listed on the serial
numbedrutingplute. If the EPSONproduct has a primary AC rating different
from the availablepower source, do not connect it to thepower source.
3. Always verify that the EPSONproduct has been disconnectedfrom thepower source
before removing or replacingprinted circuit boards and/or individual chips.
4. To protect sensitive r-lp chip and circuitry, use static discharge equipment,
such us anti-static wrist straps, when accessing internal components.
5. Replace malfunctioning components only with those components recommended by
the manufacturer; introduction of second-source ICs or other nonapproved
components may damage theproduct and void any applicable EPSON warranty.
iv EPSON DFX-5000+ Service Manual

Handy Numbers for U.S. Dealers
The EPSON Connection (800) 922-89 11
EPSON Faxback System [phone]
EPSON Bulletin Board System (3 10) 782-453 1
Numbers and Locations for Dealers Outside the U.S.
Epson Canada, Ltd. Epson Latin America, Inc.
Willowdale, Ontario Miami, FL
Phone: (800) GO-EPSON Phone: [phone]
Fax: [phone] Fax: [phone]
Epson Do Brazil
Sao Paulo, Brazil
Phone: (55) (11) 813-3044
Fax: (55) (11) 210-9290
Epson Chile S.A.
Providencia, Santiago, Chile
Phone: [phone]
Fax: [phone]
Epson Argentina S.A.
Buenos Aires, Argentina
Phone: [phone]
Fax: [phone]
Epson Costa Rica
San Jose, Costa Rica
Phone: [phone]
Fax: [phone]
Epson Mexico S.A. De C.V.
Mexico, D.F.
Phone: [phone]
Fax: [phone]
Epson Venezuela S.A.
Caracas, Venezuela
Phone: [phone]
Fax: [phone]
EPSON DFX-5000+ Service Manual

Contents
Chapter 1
Product Description
General Features ..................................
1-1
Specifications .....................................
1-3
Printer Capabilities. ..........................
1-3
Paper Handling Specifications ..................
1-5
Paper Specifications ..........................
1-5
Ribbon Specifications. .........................
1-17
Environmental Conditions .....................
1-17
Electrical Specifications .......................
1-18
Reliability. ..................................
1-18
Safety Approvals .............................
1-18
Physical Specifications ........................
1-18
Interface Specifications. .......................
1-19
Parallel Interface. ............................
1-19
RS-232C Serial Interface. ......................
1-21
Printer Operation. .................................
1-22
Control Panel. ...............................
1-22
Self-test. ....................................
1-23
Hexadecimal Dump Function ...................
1-24
Paper Out Detection Function ..................
1-24
Cover Open Detection .........................
1-24
Paper Width Detection ........................
1-24
Automatic Paper Thickness Adjustment ..........
1-24
Paper Memory Function .......................
1-25
Automatic Tear Off Function ...................
1-28
Paper Jam Detection. .........................
1-28
Automatic Interface Selection. ..................
1-28
Thermal Protection ...........................
1-28
Skip Binding Function ........................
1-28
Printer Initialization ..........................
1-29
Buzzer Operation. ............................
1-29
DIP Switch Settings ..........................
1-31
Main Components. .................................
1-34
M-3C11 Printer Mechanism ....................
1-35
Main Control Board (C117 MAIN Board Assembly).
1-36
Power Supply Circuit (C117 PSB Board Assembly)
1-37
Control Panel Board (C117 PNL Board Assembly).
1-37
Housing.....................................
1-38
List of Figures
Figure 1-1. Exterior View of the DFX-5000+. .......................
1-2
Figure 1-2. Pin Configuration. ...................................
1-3
Figure 1-3. Printable Area for Fanfold Paper .......................
1-6
EPSON DFX-5000+ Service Manual
vii

Contents
Figure 1-4. Unsuitable Paper .........................
1-7
Figure 1-5. Form Override Area .......................
1-7
Figure 1-6. Perforation Pitch .........................
1-8
Figure 1-7. Paper Edge at a Horizontal Perforation. ......
1-8
Figure 1-8. Perforation Intersections. ..................
1-8
Figure 1-9. Raised Portion at a Perforation. .............
1-9
Figure 1-10. Sprocket Holes ..........................
1-9
Figure 1-11. Aligned Sprocket Holes ...................
1-9
Figure 1-12. Incorrectly Folded Paper ..................
1-10
Figure 1-13. Printable Area, Overlapping Multi-part Forms
1-11
Figure 1-14. Dotted Paste Positions. ...................
1-12
Figure 1-15. Stapled Area 1 ..........................
1-12
Figure 1-16. Stapled Area 2 ..........................
1-13
Figure 1-17. Stapled Area 3 ..........................
1-13
Figure 1-18. Correct Multi-part Form Binding ...........
1-13
Figure 1-19. Printable Area for Fanfold Paper with a Label
1-14
Figure 1-20. Printable Area for Labels. .................
1-15
Figure 1-21. Label and Carrier. .......................
1-16
Figure 1-22. Data Transmission Timing ................
1-19
Figure 1-23. Control Panel ...........................
1-22
Figure 1-24. Multi-part Forms with a Label .............
1-25
Figure 1-25. Overlapping Multi-part Forms .............
1-25
Figure 1-26. Main Components .......................
1-34
Figure 1-27. M-3C11 Printer Mechanism ...............
1-35
Figure 1-28. C117 MAIN Board Assembly. ..............
1-36
Figure 1-29. C117 PSB Board Assembly ................
1-37
Figure 1-30. C117 PNL Board Assembly. ...............
1-37
Figure 1-31. Housing. ...............................
1-38
List of Tables
Table 1-1. Options and Consumables. ..........................
Table l-2. Character Size and Pitch. ...........................
Table 1-3. Printing Speeds ...................................
Table 1-4. Character Tables ..................................
Table 1-5. Acceptable Environmental Conditions. ................
Table 1-6. Rated Electrical Ranges ............................
Table 1-7. Parallel Interface Signals and Connector Pin Assignments
Table 1-8. Serial Interface Signals and Connector Pin Assignments
Table 1-9. Selecting the Paper Memory Area ....................
Table 1-10. Setting the Page Length. ...........................
Table 1-11. Setting the Paper Type. ............................
Table 1-12. DIP Switch Settings ...............................
Table 1-13. IBM Mode Selection ...............................
Table 1-14. ESC/P Mode Selection .............................
Table 1-15. Interface Selection ................................
1-2
1-4
1-4
1-4
1-17
1-18
1-20
1-21
1-26
1-27
1-27
1-31
1-32
1-32
1-33
VIII
EPSON DFX-5000+ Service Manual

Contents
Table 1-16. Baud Rate Selection. ................................
1-33
Table 1-17. Page Length Selection. ..............................
1-33
Chapter 2
Product Description
Overview of Printer Mechanism Operation ..........
Printhead Mechanism ......................
Carriage Mechanism .......................
Platen Gap Adjustment Mechanism. ..........
Paper Feed Mechanism. ....................
Ribbon Feed and Tractor Select Mechanisms ...
Plunger Mechanism. .......................
Power Supply Operation .........................
Power Supply Overview ....................
+5 VDC Line Regulator Circuit ..............
+35 VDC Line Regulator Circuit .............
f12 VDC Half-wave Rectifier Smoothing Circuit
Control Circuits ................................
Control Circuit Operation Overview ..........
Reset Circuit .............................
Sensor Circuits. ...........................
CR Motor Driver Circuit ....................
PF Motor Driver Circuit ....................
RF Motor Driver Circuit ....................
PG Motor Driver Circuit ....................
Plunger Driver Circuit. .....................
Printhead Driver Circuit. ...................
List of Figures
2-1
2-4
2-4
2-5
2-6
2-9
2-12
2-13
2-13
2-16
2-17
2-20
2-2 1
2-2 1
2-25
2-27
2-30
2-3 8
2-39
2-40
2-42
2-43
Figure 2-1. Model 3C11 Printer Mechanism .......
2-1
Figure 2-2. Printer Mechanism Operation 1 ....... 2-2
Figure 2-3. Printer Mechanism Operation 2 .......
2-3
Figure 2-4. Printhead Operation ................ 2-4
Figure 2-5. Carriage Mechanism ................
2-5
Figure 2-6. Platen Gap Adjustment Mechanism. ... 2-6
Figure 2-7. Tension Roller and PF Roller Operation 2-7
Figure 2-8. Front Tractor Assembly Operation. .... 2-7
Figure 2-9. Rear Tractor Assembly Operation. ..... 2-8
Figure 2-10. Tractor Wire Operation ............. 2-9
Figure 2-11. Ribbon Feed Mechanism ............ 2-10
Figure 2-12. Tractor Select Mechanism. ..........
2-11
Figure 2-13. Plunger Mechanism ................ 2-12
EPSON DFX-5000+ Service Manual ix

Contents
Figure 2-14. Power Supply Board Block Diagram. 2-13
Figure 2-15. +5 VDC Line Regulator Circuit. ..... 2-16
Figure 2-16. +35 VDC Line Regulator Circuit. .... 2-18
Figure 2-17. Half-wave Rectifier Circuit ......... 2-20
Figure 2-18. Control Circuit Block Diagram ...... 2-22
Figure 2-19. Data Flow from the Parallel Interface 2-23
Figure 2-20. Reset Circuit Block Diagram. ....... 2-26
Figure 2-21. Sensor Circuit Block Diagram. ...... 2-28
Figure 2-22. CR Motor Internal Circuit. .........
2-31
Figure 2-23. CR Motor Driver Block Diagram. ....
2-31
Figure 2-24. Acceleration Control Curve ......... 2-34
Figure 2-25. Deceleration Control Curve. ........ 2-35
Figure 2-26. Measurement Sequence. ........... 2-37
Figure 2-27. PF Motor Driver Circuit. ........... 2-38
Figure 2-28. RF Motor Driver Circuit ........... 2-39
Figure 2-29. PG Motor Driver Circuit ..........
2-41
Figure 2-30. Plunger Driver Circuit. ............ 2-42
Figure 2-31. Printhead Driver Circuit ........... 2-43
List of Tables
Table 2-1. Power Supply Board 2-13
Table 2-2. DC Voltages 2-15
Table 2-3. Main IC Functions. 2-25
Table 2-4. CR Motor Drive Modes 2-32
Table 2-5. CR Motor Drive Sequence 2-33
Table 2-6. PF Motor Specifications. 2-39
Table 2-7. RF Motor Specifications. 2-40
Table 2-9. PG Motor Specifications
2-41
Table 2-10. Plunger Switching Pattern 2-42
Chapter 3
Disassembly and Assembly
Before Starting. ..........................
Tools ...................................
Small Parts ..............................
Disassembly and Assembly .................
Replacing the Printhead ..............
Replacing the ROM ..................
Removing the Housing ...............
Removing the Circuit Boards ..........
Removing the Interlock Switch Assembly
3-1
3-3
3-5
3-7
3-7
3-10
3-11
3-17
3-25
EPSON DFX-5000+ Service Manual