Epson DFX 8000 User manual

DFX-8000
Dot Matrix Printer
TM-DFX8000

EPSON
®
DFX-8000
Service Manual
Revision Level
11

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 16 of the FCC Rules. These limits are designed to provide reasonable protections
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, which can be determined by turning
the equipment off and on. The user is encouraged to try to correct the interference by one or more of
the following measures:
l Reorient or relocate the receiving antenna
l Increase the separation between the equipment and the receiver
l Connect the equipment to an outlet on a circuit different from that to which the receiver is
connected
l Consult the dealer or an experienced radiofI’V technician for help.
WARNING: The connection of a nonshielded interface cable to this equipment will
invalidate the FCC Certification of this device and may cause interference levels that
exceed the limits established by the FCC for this equipment. If this equipment has more
than one interface connector, do not leave cables connected to unused interfaces.
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 radioelectriques depassant les limites
applicable8 aux appareils numeriques de Classe B prescrites dans le reglement sur le brouillage
radio&ctriques &licte par le Mini&&e des Communications du Canada.
Subsequent product modifications will be brought to your attention via service bulletins. Please
revise the text when you receive these bulletins.
This document is subject to change without 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, mechanical, photocopying, recording, or otherwise,
without the prior written permission of Epson America, Inc. No patent liability is assumed with
respect to use of the information contained herein. While every precaution has been taken in the
preparation of this book, Epson America, Inc., assumes no responsibility for errors or omissions.
Neither is any liability assumed for damages resulting from the use of the information contained
herein.
Epson is a registered trademark of Seiko Epson Corporation.
IBM is a registered trademark of International Business Machines Corporation.
© 1990 Epson America, Inc.
Epson America, Inc.
23610 Telo Avenue
Torrance, California 90505
ii
DFX-8000

Precautionary notations throughout the text are categorized relative to 1) personal
injury and 2) damage to the equipment.
WARNING Signals a precaution which, if ignored, could result in
serious or fatal personal injury. Great caution should
be exercised in performing a procedure preceded by a
WARNING heading.
CAUTION Signals a precaution which, if ignored, could result in
damage to the equipment.
The precautionary measures itemized below should be observed when performing
repair/maintenance procedures.
WARNING
1. Always disconnect the product from both the power source and
peripheral equipment before performing any maintenance or
repair procedure.
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 the power supply and other electronic
components.
CAUTION
1. Repairs on Epson products should be performed only by an
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 the 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 componen
recommended by the manufacturer; introduction of second-
source ICs or other nonapproved components may damage the
product and void any applicable Epson warranty.
ts
DFX-8000
III

iv

Contents
Chapter 1 General Description
Features...........................................................................................
1-1
Specifications ..................................................................................
1-3
Printing Specifications ..............................................................
1-3
Paper Specifications...................................................................
1-5
Ribbon Specifications.................................................................
1-18
Electrical Specifications ............................................................
1-19
Environmental Specifications ...................................................
1-19
Physical Specifications ..............................................................
1-19
Reliability
..................................................................................
1-20
Safety Approvals........................................................................
1-20
Interface Specifications..............................................................
1-20
Operating Controls..........................................................................
1-28
Control Panel.............................................................................
1-28
Self Test Function......................................................................
1-32
Hexadecimal Dump Function....................................................
1-33
DIP Switch Settings...................................................................
1-34
Jumper Settings.........................................................................
1-38
Buffer Full Printing...................................................................
1-38
Buzzer
........................................................................................
1-38
Error Detection..........................................................................
1-39
Paper End Detection..................................................................
1-40
Cover Open Detection................................................................
1-40
Paper Thickness Detection........................................................
1-41
Paper Width Detection ..............................................................
1-41
Non-volatile User-defined Characters.......................................
1-41
Paper Memory Function............................................................
1-41
Paper Cutter ..............................................................................
1-48
Copy Mode..................................................................................
1-48
Printer Initialization .................................................................
1-49
Major Units......................................................................................
1-50
Printer Mechanism....................................................................
1-50
Power Supply Board ..................................................................
1-52
Main Board ................................................................................
1-54
Driver Board ..............................................................................
1-56
Control Panel.............................................................................
1-57
Housing......................................................................................
1-58
DFX-8000
V

Chapter 2 Principles of Operation
Printer Mechanism.......................................................................... 2-1
Print Head Mechanism..............................................................
2-1
Carriage Mechanism .................................................................
2-3
Platen Gap Adjustment Mechanism .........................................
2-7
Ribbon Feed Mechanism............................................................ 2-8
Paper Feed Mechanism.............................................................. 2-10
Paper Width Detection Mechanism........................................... 2-18
Power Supply Circuit....................................................................... 2-19
DC Voltages and Applications...................................................
2-20
Power Supply Circuit Operation ...............................................
2-21
Control Circuit.................................................................................
2-24
Main CPU pPD70322 (5E)
.........................................................
2-25
Gate Array E05A38NA (6A)......................................................
2-26
Gate Array E05A16GA (2E) ......................................................
2-26
Interface Circuit ........................................................................
2-27
Reset Circuit..............................................................................
2-29
Memory Backup Circuit ............................................................ 2-30
A-D Converter Detection Circuit............................................... 2-33
Interrupt Port Detection Circuit............................................... 2-35
Detection Circuits Connected to the General Purpose Ports
....
2-37
Ribbon Feed Motor/External Fan Control/Drive Circuit
.......... 2-39
Paper Feed Motor Control/Drive Circuit...................................
2-40
Platen Gap Motor Control/Drive Circuit...................................
2-42
Carriage Motor Control/Drive Circuit.......................................
2-46
Print Head Control/Drive Circuit..............................................
2-49
Chapter 3 Disassembly and Assembly
Before Starting................................................................................ 3-1
Tools...........................................................................................
3-5
Service Delivery Standard Checklist ........................................
3-8
Disassembly and Assembly .............................................................
3-9
Replacing the Print Head..........................................................
3-11
Replacing the ROM....................................................................
3-20
Removing the Housing..............................................................
3-21
Removing
the Circuit Boards....................................................
3-30
Removing the Interlock Switch.................................................
3-35
Removing the Printer Mechanism ............................................
3-36
Removing Printer Mechanism Components
Without Removing the Printer Mechanism........................
3-40
Removing Printer Mechanism Components
After Removing The Printer Mechanism............................
3-57
DFX-8000

Chapter 4 Adjustment
Adjustment Overview......................................................................
4-1
Writing the Print Head Adjustment Value ....................................
4-3
Bidirectional Printing Adjustment .................................................
Parallelism Adjustment ..................................................................
EO
Timing Belt Tension Adjustment....................................................
4-13
Mechanism Adjustment Value Measurement ................................
4-15
Chapter 5 Troubleshooting
General ............................................................................................
5-1
Error Message Function ............................................................
5-2
Bypass of the Interlock Switch and the Cover-open Sensor
......
5-3
Unit Replacement............................................................................
5-6
Power Supply Board Unit Component Repair ................................
5-14
Driver Board Unit Component Repair............................................
5-20
Main Board Unit Component Repair..............................................
5-25
Chapter 6 Maintenance
Preventive Maintenance .................................................................
6-1
Lubrication and Adhesive Application............................................
6-1
Appendix A Technical Specifications
Component Connections..................................................................
A-1
The Terminal Board .................................................................. A-19
The Head Board......................................................................... A-22
Circuit Diagrams, Schematics, and Lubrication
and Adhesive Diagrams............................................................. A-25
DFX-8000
vii

Chapter 1
General Description
Features...........................................................................................
1-1
Specifications ..................................................................................
1-3
Printing Specifcations
..............................................................
Paper Specifications...................................................................
;:;
Single-part forms .................................................................
1-10
Multi-part forms...................................................................
1-10
Labels ...................................................................................
1-14
Overlapping multi-part forms
..............................................
1-17
Ribbon Specifications.................................................................
1-18
Electrical Specifications ............................................................
1-19
Environmental Specifications ...................................................
1-19
Physical Specifications ..............................................................
1-19
Reliability
..................................................................................
1-20
Safety Approvals........................................................................
1-20
Interface Specifications..............................................................
1-20
Parallel interface .................................................................
1-20
Serial interface.....................................................................
1-24
Operating Controls..........................................................................
1-28
Control Panel.............................................................................
1-28
Control panel buttons ..........................................................
1-28
Control panel indicators ......................................................
1-31
Self Test Function......................................................................
1-32
Hexadecimal Dump Function....................................................
1-33
DIP Switch Settings...................................................................
1-34
Jumper Settings.........................................................................
1-38
Buffer Full Printing...................................................................
1-38
Buzzer
........................................................................................
1-38
Error Detection..........................................................................
1-39
Paper End Detection..................................................................
1-40
Cover Open Detection................................................................
1-40
Paper Thickness Detection........................................................
1-41
Paper Width Detection ..............................................................
1-41
Non-volatile User-defined Characters.......................................
1-41
Paper Memory Function............................................................
1-41
Saving paper format and thickness information..
............... 1-43
Loading paper format information from memory ...............
1-48
Paper Cutter ..............................................................................
1-48
Copy Mode..................................................................................
1-48
Printer Initialization .................................................................
1-49
Hardware initialization .......................................................
1-49
Software initialization .........................................................
1-50
Major Units......................................................................................
1-50
Printer Mechanism....................................................................
1-50
Power Supply Board ..................................................................
1-52
Main Board ................................................................................
1-54
Driver Board ..............................................................................
1-56
Control Panel.............................................................................
1-57
Housing......................................................................................
1-58
DFX-8000
1-i

General Description
List of Figures
Figure 1-1
Figure 1-2
Figure 1-3
Figure 1-4
Figure 1-5
Figure 1-6
Figure 1-7
Figure 1-8
Figure 1-9
Figure 1-10
Figure 1-11
Figure 1-12
Figure 1-13
Figure 1-14
Figure 1-15
Figure 1-16
Figure 1-17
Figure 1-18
Figure 1-19
Figure 1-20
Figure 1-21
Figure 1-22
Figure 1-23
Figure 1-24
Figure 1-25
Figure 1-26
Figure 1-27
Figure 1-28
Figure 1-29
Figure 1-30
Figure 1-31
Figure 1-32
Figure 1-33
Figure 1-34
Figure 1-35
Figure 1-36
Figure 1-37
Figure 1-38
Figure 1-39
Figure 1-40
DFX-8000.. ................................................................
1-2
Print Head Pin Configuration..................................
1-3
Unsuitable Paper......................................................
1-6
Form Override Area.................................................
1-7
Perforation Pitch ......................................................
1-7
Perforation at the Edge of the Paper.......................
1-8
Perforation Intersections..........................................
1-8
Raised Portion at a Perforation................................
1-9
Sprocket Holes..........................................................
l-9
Incorrectly Folded Paper ..........................................
1-9
Printable Area for Single-part Forms......................
1-10
Dotted Paste
Positions..............................................
1-12
Stapled Area A .........................................................
1-12
Stapled Area
B .........................................................
1-13
Stapled Area C .........................................................
1-13
Sprocket Holes..........................................................
1-14
Printable Area for Labels A.....................................
1-14
Printable Area for Labels B .....................................
1-15
Label and Carrier.....................................................
1-16
Printable Area for Overlapping Multi-part
Forms with Labels .............................................
1-17
Multi-part Form Binding .........................................
1-18
Handshake Timing...................................................
1-21
36-pin 57-30360 Connector.......................................
1-21
DTR Control Handshake Timing.............................
1-25
X-ON/X-OFF Control Handshake Timing..
.............
1-26
EIA Standard 25-Pin
Connector..
.............................
1-26
Control Panel............................................................
1-28
Self Test Printout.....................................................
1-33
Hexadecimal Dump List...........................................
1-33
Forms with Labels....................................................
1-42
Overlapping Multi-part Forms.................................
1-42
Aligning the Label’s Top Edge with
the Horizontal Line............................................
1-45
Aligning the Vertical Line with the
Label’s Left Edge ...............................................
1-45
Aligning the Label’s Bottom Edge with
the Horizontal Line............................................
1-46
Aligning the Vertical Line with the
Label’s Right Edge.............................................
1-46
Model 3C65 Printer Mechanism ..............................
1-52
BOPS Power
Supply Board ......................................
1-53
C030MAIN Board.....................................................
1-55
C030DRV Driver Board............................................
1-57
Control Panel............................................................
1-57
l-ii DFX-8000
Figure 1-41 Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-58

General Description
List of Tables
Table 1-1
Table 1-2
Table 1-3
Table 1-4
Table 1-5
Table 1-6
Table 1-7
Table 1-8
Table 1-9
Table 1-10
Table 1-11
Table 1-12
Table 1-13
Table 1-14
Table 1-15
Table 1-16
Table 1-17
Table 1-18
Table 1-19
Table 1-20
Table 1-21
Table 1-22
Table 1-23
Table 1-24
Table 1-25
Options and Expendables .........................................
1-2
Character Size and Pitch..........................................
1-4
Printing Column Width ...........................................
Printing Speed.......................................................... ‘1::
Weights of Parts of Multi-part Forms......................
1-11
Pin Assignments for the Parallel Interface
............. 1-22
DC1/DC3 Control......................................................
1-24
DTR and X-ON/X-OFF Control................................
1-25
Pin Assignments for the Serial Interface
................
1-27
DIP Switch Set 1 ......................................................
1-34
DIP Switch Set 2 ......................................................
1-35
DIP Switch Set 3 ......................................................
1-36
Character Set Selection............................................
1-37
Interface Settings.....................................................
1-37
Baud Rate.................................................................
1-37
Jumper Settings .......................................................
1-38
Selecting a Paper Memory
Area
.............................. 1-43
Setting the Page Length ..........................................
1-43
Selecting Overlapping Multi-part Forms.................
1-44
Selecting Multi-part Forms with Labels..................
1-44
Selecting Overlapping Multi-part Forms
with Labels.........................................................
1-47
Model 3C65 Printer Mechanism
Components........................................................
1-51
BOPS Power Supply Board Components
................. 1-52
C030 MAIN Board Components................................
1-54
C030 DRV
Driver Board Components ......................
1-56
DFX-8000
l-iii

General Description 1
Features
The DFX-8000 is an 18-pin serial dot matrix printer with a maximum printing
speed of 1066 cps.
The DFX-8000 is designed for business use and provides high-
speed printing, heavy duty specifications, and continuous paper handling.
The DFX-8000’s main features are:
Maximum printing speed:
1066 cps; high speed draft mode
960 cps; draft elite mode
800 cps; draft pica mode
Bidirectional two-way push tractor
Advanced paper handling
Automatic tractor select function
Automatic paper back out and loading
Automatic paper thickness measurement
Automatic platen-print head gap adjustment
Automatic paper width detection
Paper memory function
Copy mode for printing clear multi-part forms
Optional paper cutter
8-bit parallel interface and RS-232C serial interface
Epson ESC/P-83 printer driver (compatible with the FX-850/1050 and the
DFX-5000)
IBM
®
Proprinter emulation mode
3KB input data buffer
Compatibility with Epson optional interface board series #81XX
DFX-8000
1-1

General Description
Figure 1-1 shows the DFX-8000 and Table 1-1 lists the options and expendables
available for the DFX-8000.
Group
Options
Expendables
[email protected] l-l. DFX-tUW
Table l-l. Options wtd ExpertdaMes
Code Number
I
Name
#8309 Pull tractor
#c815001 Paper cutter
#8xXx
Optional interface board series
#c823021 32KB serial buffer
#c823032
32KB parallel buffer
#8766
#8767 Ribbon cartridge
Ribbon pack
1-2
DFX-8000

General Description
Specifications
This section provides the specifications for the DFX-8000.
Printing Specifications
Printing method: Serial impact dot matrix
Pin configuration: 18 wires (two columns of nine wires, as shown in Figure 1-2)
1/15’(1.68mm)
I
Figure l-2. Print Head Pin Configuration
Dot matrix:
9 X 9; draft mode
9 X 7; high speed draft mode
18 X 20; near letter quality (NLQ) mode
Printing direction:
Text mode:
Bidirectional with logic seeking (unidirectional printing can
be selected with a printer command)
Bit image
mode:
Unidirectional
Built in
character sets:
ASCII characters
International characters for 13 countries
Graphics
Built-in fonts:
Draft
NLQ Roman
NLQ Sans Serif
DFX-8000
1-3

General Description
Printing pitch:
-102 inches (2.54 mm); 10 cpi
,017 inches (.42 mm); 60 dpi
Paper feeding: Bidirectional
variable-width push tractor feeding
Note: Pull tractor feeding is available with the optional pull
tractor,
Line spacing:
l/6 or l/8 inch (can be set with a DIP switch or with a printer
command)
n/216 inch (set with a printer command)
Paper feed speed:
Line feed
gl$;Lieed):
26 ms (6 incheakecond)
(continuous): 17 ms (10 inches/second)
Character size
and pitch:
See the table below.
Table 1-2. Character Size ad Pitch
Printing Mode
Pica
Emphasized pica
Condensed pica
Elite
Condensed elite
Notes:
Width Height
(mm) (mm)
2.1 3.1
2.1 3.1
1.05 3.1
1.7 3.1
0.85 3.1
Total Character
Pitch
Width (mm) (cpi)
2.54
10
2.54
10
1.48 17
2.11
12
1.27
20
l The total character width is the total of the character width and the character spacing (in dots).
l In proportional mode, the total character width varies because character spacing varies.
DFX-8000

General Description
printing column
width: See
the table below.
Quality:
Width:
Length:
Table 13. Printing Column Width
Printing Mode
Maximum Printable Column Width (cpi)
Pica
136
Condensed pica 233
Elite
163
Condensed elite
272
Note: cpl...characters per line
Printing speed:
See the table below.
Table 14. Printing Speed
Printing Mode
High speed draft (pica)
Draft (pica)
Draft (elite)
Condensed drafl (pica)
Emphasized draft (pica)
NLQ (pica)
NLQ (elite)
Printing Speed (cps)
1066
800
960
660
400
160
192
Input data
buffer size:
3KB
Paper Specifications
Feeding method: Tractor feed
Type:
Continuous fan-fold paper
Single-part forms
Multi-part forms
Forms with labels
Overlapping multi-part forms
High quality paper
4 to 16 inches (101 to 406 mm)
3.5 inches (88.9 mm) minimum for forms with labels
DFX-8000 1-5

Total thickness:
Front tractor:
I,~XSS than .018 inches t.46 mm)
Rear tractor:
LOSS than .012 inches C.30 mm)
Notes:
l
Horizontal alignment may be irregular in the top 3 inches (75 mm) of the first
page.
l
When using the optional pull tractor, do not print on the top 4.8 inches
(120 mm) of the first page.
l
Use only clean paper with no folds, creases, or tears. The figure below shows
paper you should not use.
Figure 13. Unsuitable Paper
1-6
DFX-8000

General Description
l
Form override printing is available 20 lines after paper end.
The paper
feeding pitch is not guaranteed. The end of the printable area is .60 inches
(15 mm) above the bottom edge of the paper. The figure below shows the form
override area.
A
A
0
0
ASCD-
Ol r
- -
- -
WXYZ
1
0
00
00
0’
0
!z
a
0
0
ID
0’
z
L
‘0
-I
t
o AOcD- xOF pApER_wyz o
+I
E
2
Figure 14. Form Override Area
l
Weak horizontal and vertical perforations cause paper jams.
l
The pitch ratio of perforations (the ratio of the pitch of the cut part to the
pitch of the uncut part) must be less than 3:l. The figure below shows the
perforation pitch.
cut
+.-~fl!L
Uncut
Figure 15. Perforation Pitch
DFXgOOO 1-7

General Description
0
Perforations must have uncut parts on both edges of the paper. The figure
below shows the perforation at the edge of the paper.
Rgure 14. Perforation at the Edge of the Paper
l
At the intersection of horizontal and vertical perforations, the perforation cuts
must not cross each other as shown below.
I
I
---
l
I
Figure 1-7. Perforation Intersections
1-8
DFX-8000

General Description
0
The raised portion at the fold perforation must be less than .04 inches (1 mm)
f?om the flat part and the bottom layer must be kept flat by force. The figure
below shows the raised portion at a perforation.
Perforations
Printable
figure 18. Raised Portion at a Perforation
l
Sprocket holes must be circular and may have teeth. The figure below shows
some sample sprocket holes.
OU
Figure 19. Sprocket Holes
l
Remove any pieces of paper remaining in the sprocket holes.
l
Paper should be fan-folded at the horizontal perforations. Never use
improperly folded paper, such as the paper shown below.
NG
Figuse l-10. Incorrectly Folded Paper
DFX-8000 1-9