TSC CPX4P Series User manual

CPX4P
Service Manual
COLOR INKJET LABEL PRINTER

Application
This manual has been issued for qualified persons to learn technical theory, installation,
maintenance, and repair of products. This manual covers all localities where the products
are sold. For this reason, there may be information in this manual that does not apply to
your locality.
Corrections
This manual may contain technical inaccuracies or typographical errors due to
improvements or changes in products. When changes occur in applicable products or in
the contents of this manual, technical information will be released as the need arises.
The following paragraph does not apply to any countries where such provisions are
inconsistent with local law.
Trademarks
The product names and company names used in this manual are the registered
trademarks or the trademarks of the individual companies.
Caution
Use of this manual should be strictly supervised to avoid disclosure of confidential
information.

Explanation of Symbols
The following symbols are used throughout this Service Manual.
Symbols
Explanation
Symbols
Explanation
Check.
Remove the claw.
Check visually.
Insert the claw.
Check the noise.
Use the bundled part.
Disconnect the
connector.
Push the part.
Connect the
connector.
Plug the power cable.
Remove the cable/wire
from the cable guide or
wire saddle.
Turn on the power.
Set the cable/wire to
the cable guide or wire
saddle.
Remove the screw.
Tighten the screw.
The following rules apply throughout this Service Manual:
1.Each chapter contains sections explaining the purpose of specific functions and the
relationship between electrical and mechanical systems with reference to the timing of
operation.
In the diagrams, represents the path of mechanical drive; where a signal name
accompanies the symbol, the arrow indicates the direction of the electric signal.
The expression "turn on the power" means flipping on the power switch, closing the front
door, and closing the delivery unit door, which results in supplying the machine with power.
2.In the digital circuits, '1' is used to indicate that the voltage level of a given signal is "High",
while '0' is used to indicate "Low". (The voltage value, however, differs from circuit to circuit.)
In addition, the asterisk (*) as in "DRMD*" indicates that the DRMD signal goes on when '0'.
In practically all cases, the internal mechanisms of a microprocessor cannot be checked in the
field. Therefore, the operations of the microprocessors used in the machines are not discussed:
they are explained in terms of from sensors to the input of the DC controller PCB and from the
output of the DC controller PCB to the loads.
The descriptions in this Service Manual are subject to change without notice for product improvement
or other purposes, and major changes will be communicated in the form of Service Information
bulletins.
All service persons are expected to have a good understanding of the contents of this Service Manual
and all relevant Service Information bulletins and be able to identify and isolate faults in the machine.

0
Table of Contents
Safety Precautions ............................................................................................4
Notes When Handling the Lithium Battery............................................... 4
Notes before Servicing.............................................................................. 4
Note at Cleaning........................................................................................ 4
Notes on Assembly/ Disassembly ............................................................. 4
1. Product Overview.........................................................................................5
Features..................................................................................................... 5
Pigment Ink..............................................................................................................5
High Speed and Fine Quality Printing ..................................................................... 5
Compact / Space Saving / Light Weight ..................................................................5
AIS (Auto Image Shifter)..........................................................................................5
Non-Ink Recycling ....................................................................................................5
Specifications List...................................................................................... 6
Specifications...........................................................................................................6
Media .......................................................................................................................6
Printhead ................................................................................................................. 7
Ink Tank....................................................................................................................7
Maintenance Cartridge............................................................................................7
Power Supply...........................................................................................................7
Cleaning.................................................................................................................... 7
Additional Function .................................................................................................7
Others ...................................................................................................................... 7
Component Names ................................................................................... 8
Front View................................................................................................................ 8
Rear View.................................................................................................................8
Internal View (Front) ...............................................................................................9
Internal View (Rear) ................................................................................................9
Front Cross-sectional View.................................................................................... 10
Horizontal Cross-sectional View............................................................................10
Operation Panel.....................................................................................................11
2. Technology .................................................................................................12
Basic Configuration.................................................................................. 12
Functional Configuration.......................................................................................12
Outline of Electrical Circuits ..................................................................................14
Drive Configuration ...............................................................................................15
Basic Sequence ......................................................................................................16
Power Supply.........................................................................................................19
Image Formation System ........................................................................ 20
Image Formation System.......................................................................................20
Control ................................................................................................................... 21
Ink Supply System.................................................................................... 29
Overview................................................................................................................29
Control ................................................................................................................... 30
Feeder/Transport System........................................................................ 45
Overview................................................................................................................45
Control ................................................................................................................... 47
External Auxiliary System........................................................................ 53
Operating Panel .....................................................................................................53
External Interface ..................................................................................................54
3. Periodical Service .......................................................................................55
Periodical Service Operation Item........................................................... 55
4. Parts Replacement and Cleaning ...............................................................56
Adjustment at Part Replacement............................................................ 56

1
List of Parts.............................................................................................. 57
List of External Covers ...........................................................................................57
List of Main Units / Parts.......................................................................................58
Periodic Replacing Parts, Durable Parts................................................................59
List of Motors.........................................................................................................60
List of Solenoids and Clutches...............................................................................61
List of Fans .............................................................................................................61
List of Sensors _1 ...................................................................................................62
List of Sensors _2 ...................................................................................................63
List of Switches and Others ................................................................................... 63
List of PCBs............................................................................................................. 64
External Covers........................................................................................ 65
Removing Upper Cover Unit..................................................................................65
Removing Right Cover ........................................................................................... 66
Removing Left Cover..............................................................................................66
Removing Rear Cover ............................................................................................67
Removing Maintenance Cover ..............................................................................67
Main Units and Parts............................................................................... 68
Removing Roll Drive Unit ......................................................................................68
Removing Paper Guide Unit .................................................................................. 69
Removing Ink Tank Holder Unit ............................................................................ 71
Removing Valve Unit ............................................................................................. 76
Removing Print Module.........................................................................................81
Periodic Replacing Parts, Durable Parts.................................................. 87
Removing Blade Cleaner........................................................................................87
Replacing Printhead Unit.......................................................................................88
Replacing Printhead...............................................................................................93
Removing Purge Unit.............................................................................................97
Removing Tube ......................................................................................................98
Removing Transport Unit ......................................................................................99
PCB......................................................................................................... 102
Removing Needle Unit (Ink Tank Relay PCB) ......................................................102
Removing Operation Panel PCB ..........................................................................103
Removing Printer Controller PCB ........................................................................104
Removing DC Power Supply PCB.........................................................................106
Removing Maintenance Cartridge Relay PCB .....................................................109
Removing Printhead Relay PCB...........................................................................110
Motors................................................................................................... 111
Removing Roll Motor...........................................................................................111
Removing Transport Motor.................................................................................112
Removing Valve Motor........................................................................................113
Fans ....................................................................................................... 114
Removing Paper Suction Fan...............................................................................114
Removing Power Supply Fan...............................................................................114
Sensors .................................................................................................. 115
Removing Lower Cover Unit................................................................................115
Removing Trailing Edge Sensor ...........................................................................116
Removing Upper TOF Sensor PCB .......................................................................118
Removing Paper Sensor.......................................................................................119
Removing Encoder Sensor...................................................................................120
Removing Lower TOF Sensor PCB .......................................................................121
Removing Remaining Ink Sensor.........................................................................122
Removing Valve Sensor .......................................................................................123
Removing Electrode Plate ...................................................................................124
Switches and Others.............................................................................. 125
Removing Upper Unit Safety Switch ...................................................................125
Removing Ink Tank Lever.....................................................................................125
Cleaning Procedure ............................................................................... 126

2
Cleaning Procedure of Printhead Face................................................................126
Cleaning Procedure of TOF Sensor ......................................................................128
5. Troubleshooting .......................................................................................129
Initial Check........................................................................................... 129
Initial Check Items ...............................................................................................129
Image Defect Recovery ......................................................................... 130
Image Defect Samples .........................................................................................130
Defect Recovery Procedures ...............................................................................137
Adjustment............................................................................................ 142
Adjustment at Part Replacement........................................................................142
Adjustment and Setup.........................................................................................143
Error Code ............................................................................................. 152
Overview..............................................................................................................152
Service Call Error..................................................................................................153
Operator Call Error ..............................................................................................166
Warning................................................................................................................172
Correspondence Table of Error Code.................................................... 174
Service Modes....................................................................................... 176
Overview..............................................................................................................176
Download Mode ..................................................................................................176
Standalone Mode ................................................................................................177
Service Tool ........................................................................................... 181
Overview..............................................................................................................181
Menu Options......................................................................................................181
Service Utility.......................................................................................................182
6. Installation................................................................................................196
How to Utilize This Installation Procedure Symbols in the Illustration .............196
Checking Before Installation ................................................................. 196
Checking the Power Supply.................................................................................196
Checking the Installation Environment...............................................................196
Checking the Installation Space ..........................................................................197
Installation Precautions......................................................................... 197
Checking the Contents .......................................................................... 198
Unpacking Procedure............................................................................ 199
Installation Procedure........................................................................... 202
Mounting Printhead Unit ....................................................................................202
Loading Ink Tanks ................................................................................................208
Installing Cutter Unit ...........................................................................................210
Initial Ink Loading ................................................................................................210
Checking after Installation .................................................................... 211
Setting of Test Label ............................................................................................211
Printing and Checking a Nozzle Check Pattern ...................................................213
Cleaning Procedure of Printhead Face................................................................216
Confirmation of Printhead Position ....................................................................219
Printer Transport Work ......................................................................... 220
Overview..............................................................................................................220
Relocating on Same Floor or in Same Building ...................................................220
Long Distance Relocation ....................................................................................220
7. Appendix...................................................................................................223
Exclusive Service Tools .......................................................................... 223
Service Exclusive Tool List ...................................................................................223
General Circuit Diagram ........................................................................ 224
General Circuit Diagram (1/3) .............................................................................224
General Circuit Diagram (2/3) .............................................................................225
General Circuit Diagram (3/3) .............................................................................226
Update History..............................................................................................227

3

4
Safety Precautions
Notes When Handling the Lithium Battery
The following warning in the local languages is given to comply with the safety regulations in respective
countries and regions.
Notes before Servicing
Note at Cleaning
Notes on Assembly/ Disassembly
Follow the items below to assemble/ disassemble the printer.
1. Disconnect the power plug to avoid any potential dangers during assembling/disassembling works.
2. Be sure to wear a grounding wrist strap prior to the service work to prevent electrostatic destruction
of the printheads, PCB's, etc.
3. Ensure to use the right screw type (length, diameter, etc.) at the right position when assembling.
4. Tokeep electric conduction, binding screws with washers are used to attach the grounding wire and
the varistor. Ensure to use the right screw type when assembling.
5. Unless it is specially needed, do not operate the device with some parts removed.
6. Never remove the paint-locked screws when disassembling.
7. If not specially instructed, reverse the order of disassembly to reinstall.
English
CAUTION
The fuse may be in the neutral, and that the mains shall be disconnected to de-energize the
phase conductors.
German
VORSICHT
Die Sicherung kann sich im Nullleiter befinden und das Hauptnetz muss abgetrennt werden,
um die Phasenleiter stromlos zu machen.
Wenn mit dem falschen Typ ausgewechselt, besteht Explosionsgefahr. Gebrauchte Batterien
gemäß der Anleitung beseitigen.
如果更換不正確之電池型式會有爆炸的風險，請依製造商說明處理用過的電池。
For CA, USA Only
Included battery contains Perchlorate Material ---- special handling may apply.
See
http://www.dtsc.ca.gov/hazardouswaste/perchlorate/
for detail.
•At servicing, be sure to turn OFF the power source according to the specified steps and
disconnect the power plug.
When performing cleaning using organic solvent such as alcohol, be sure to check that the
component of solvent is completely dried up before assembling.
RISK OF EXPLOSION IF BATTERY IS REPLACED BY AN INCORRECT TYPE.
DISPOSE OF USED BATTERIES ACCORDING TO THE INSTRUCTIONS.
•If the power plug is exposed to dust, humidity, or oily smoke, the resulting buildup can prove to
be a fire hazard. (The buildup of dust, for instance, can absorb moisture and suffer insulating
failure.) Be sure to disconnect the power plug on a periodical basis, and remove any buildup of
dust and dirt with a dry cloth.
•Do not incline Printer more than 15°degrees during installation or relocation of Printer.

5
1. Product Overview
Features
Pigment Ink
Pigment Ink is superior in weather resistance and water resistance, so it's possible to print on logistic
label and display advertising which is required to keep color stability for a long time.
High Speed and Fine Quality Printing
Fine-quality printing at maximum printing speed of 150 mm/sec, at 1200 dpi for vertical scanning by
1200 dpi for horizontal scanning.
Compact / Space Saving / Light Weight
Compact, space-saving design makes for printer weight of Approx. 24Kg (53 lbs)*.
*When packed : approx. 31Kg (69 Ibs)
AIS (Auto Image Shifter)
AIS function (which shifts printed images for each set of 10,000 sheets) realizes longer lives of
Printheads.
Non-Ink Recycling
Non-ink recycling keeps ink fresh at all times, offering consistent print images with little density change.

6
Specifications List
Specifications
Item
Specifications
Type
Desktop color label printer
Printing method
Inkjet recording / Fixed Carriage system
Feeding method
Inner drive unit (Roll paper/fanfold paper-ready)
Paper reference position
Left reference
Feeding capacity
Roll paper
Outside diameter : φ200 mm (7.87 in) or less
Core diameter : φ76.2 ±1.0 mm (φ3.0 ± 0.04 in)
Fanfold paper
Paper feed height: 40 mm (Feeder Slot) or less to 850 mm (33.46 in)
Paper feed position (front/rear): 150mm or more
Fusing method
Natural drying
Printing speed
Preset printing speed : 300, 200, 150, 120, 100, 90, 80, 70, 60, 50mm/sec
Auto mode: 150, 120, 90mm/sec
AIS(Auto Image Shift)
function
Yes (default: ON(*1))
(*1) Shifts images about 0.32 mm for each set of 10,000 sheets printed.
Minimum margins
Leading and trailing edges : 1.5 mm (0.06 in)
Left and right:
AIS Mode ON : 2.7 mm (0.11 in) (Default )
AIS Mode OFF : 2.5 mm (0.10 in) (Including separator)
Printable area
AIS mode ON: 105.9 mm x 397.0 mm (4.17
inch x 15.6 inch)
AIS mode OFF: 106.3 mm x 397.0 mm (4.19
inch x 15.6 inch)
Waste ink
Collection to Maintenance Cartridge
Display panel
LCD : No
SWs : 4 pcs
LEDs : 8
pcs
Power ON waits time
Soft SW ON Ready: 15 sec
Fast printout time (period of
time to complete printing of
first page after pressing
print button)
10 seconds or less (*3) (*4)
(*3) 4×3 in label
(*4) CPU: Intel Core 2 Quad Q6700 2.66 GHz,
Memory:3 GB,
HDD : 80 GB,
OS : Windows XP + SP2
I/F : Hi-Speed USB
External dimensions
(W×D×H)
386 x 570 x 394 mm (15.2 x 22.4 x 15.5 in)
When Cutter is installed: 386 x 687 x 394 mm (15.2 x 27.0 x 15.5 in)
Weight
Approx. 24 kg (Approx. 53 lbs) (*5) (*6) (*5)
Excluding Printheads and Ink Tanks. (*6)
Packed state : Approx. 31 kg (69 Ibs)
Working temperature and
humidity ranges
Operation guaranteed environment:
5 to 35 degrees Celsius (59 to 86 degrees Fahrenheit), 10 to 90 % RH
Performance guaranteed environment:
15 to 30 degrees Celsius (59 to 86 degrees Fahrenheit) , 10 to 80 % RH
Acoustic noise
Sound pressure level (Fast mode)/Bystander position
40 dB or less (On standby)
60 dB or less
(printing) Sound power
level:
6.8 Bels or less (printing)
Media
Item
Specifications
Media form
Dedicated roll paper (Label paper, Tag paper)
Dedicated fanfold paper (Label paper)
Media type
Dedicated coated paper (matte coated paper, glossy paper)
Media size
Width : 25.4 to 120.0 mm (*6)
Length : 6.0 to 400.0 mm (*7)
(*6) Tag/label (roll paper form) perforation interval specification
•Paper width 2 inches or more : 25mm or more
•Paper width less than 2 inches: 130mm or more
Fanfold paper is 25mm or more without restricted by paper width.
(*7) Restricted
Media thickness
145 to 255 μm (5.7 to 10.0 mil) (Label paper,Tag paper)

7
Printhead
Item
Specifications
Printheads
4.32 inch Monolithic Printhead
4 Printheads for Bk/C/M/Y
Print resolution
1200dpi
Amount of discharge
8+0-2ng
Number of nozzle
Number of nozzles used for printing at same time: 5,030
Number of available nozzles to discharge: 5,184 x 4 Printhead
Nozzle pitch
0.0211mm
Ink Tank
Item
Specifications
Ink Tanks
Independent dedicated Ink Tank for BK, C, M and Y each.
Ink type : Water-based pigment ink
Ink Tank capacity
240 ml for each color
(available ink volume: 230 ml) (*8)
(*8) Volume of ink that come supplied with Printer : 105ml for each color
General number of
printable sheets
34,000 sheets per Ink Tank ( 7.5%duty per color, 4×3 inches label)
Ink Tank size (W×D×H)
31 x 220 x 85 mm (1.22 x 8.66 x 3.36 in)
Maintenance Cartridge
Item
Specifications
Collection method
Waste ink is absorbed by ink absorber.
Maintenance Cartridge
capacity
Near full: 360 ml (80% of full capacity)
Full:450 ml
Maintenance Cartridge
dimensions (W×D×H)
133.8mm (W) x 278.9mm (D) x 54.4mm (H)
Replacement frequency
Approx. 100,000 sheets
(7.5% duty/color, 4 x 3 in sheets, 100 sheets × 50 jobs/day)
Power Supply
Item
Specifications
Rated input voltage
AC 100V-240V 50Hz/60Hz
Maximum power
consumption
250W (Printer only)
265W (Reference value: with optional cutter)
Average power
consumption
Power ON: 25 W or less
Sleep mode: 9 W or less
Cleaning
Item
Specifications
Cleaning types
Maintenance jet cleaning, wipe cleaning, and tube pump type suction
cleaning
Cleaning mode
Automatic cleaning
At power ON, when Printer backs from sleep mode, before
printing, during printing, after printing etc.
Manual cleaning
Execute from Printer Driver, etc.
Additional Function
Item
Specifications
Self-diagnosis function
Yes
Ink detection
Yes
Ink Tanks detection
Yes (Ink Tank ROM PCB mounted)
Maintenance Cartridge
detection
Yes (Maintenance Cartridge ROM PCB mounted)
Door open detection
Yes(Ink Tank Door, Upper Unit, Maintenance Cartridge Door, Roll Cover)
Feed area paper
detection
Yes
Transport area paper
Detection
Yes
Jam detection
Yes (Transport Unit only)
Paper width detection
Yes
Paper length detection
Yes
Sleep mode
Yes
Mechanical counter
No
Back feed
Yes (Auto/ Manual)
Others
Item
Specifications
Interface
USB2.0 HighSpeed
10Base-T/ 100Base-TX/ 1000Base-T
RS-232C upper :Barcode reader connection (*9)
RS-232C lower: External device control connection
Cutter connection I/F
(*9) RS-232C Connector is provided for future expansion. Currently, it is not
provided with any function.
Supported OS
Windows 7 SP1 / 8.1/ 10 (32bit/ 64bit)
Supported hardware
Computers recommended by the above OSs
Options
Auto Cutter

8
Component Names
Front View
[1]
Upper Cover
[6]
Right Cover
[2]
Operation Panel
[7]
Roll Cover
[3]
Ink Tank Door
[8]
Rear Cover
[4]
Cutter Cover
[9]
Maintenance Cartridge Door
[5]
Maintenance Cover
Rear View
[1]
Rear Feeder Slot
[5]
USB Connector
[2]
Power Socket
[6]
LAN Connector
[3]
RS-232C Connector
[7]
Left Cover
[4]
RS-232C Connector

9
Internal View (Front)
[1]
Ink Tank Lever
[2]
Transport Unit
[3]
Roll Holder
Internal View (Rear)
[1]
Pinch Roller Release Lever
[4]
Paper Guide
[2]
Maintenance Cartridge
[5]
Upper Unit Open Lever
[3]
Transport Guide

10
Front Cross-sectional View
[1]
Print Module
[6]
Yellow Ink Tank
[2]
Pump Unit
[7]
Magenta Ink Tan
[3]
Printhead Lifter Part
[8]
Cyan Ink Tan
[4]
Printhead
[9]
Black Ink Tan
[5]
Purge Unit
Horizontal Cross-sectional View
[1]
Transport Sensor
[7]
DC Power Supply PCB Unit
[2]
Printhead
[8]
Paper Suction Fan
[3]
Upper TOF Sensor PCB
[9]
Lower TOF Sensor PCB
[4]
Roll Holder
[10]
Transport Belt
[5]
Printer Controller PCB
[11]
Purge Unit
[6]
Maintenance Cartridge
[12]
Transport Sensor Flag

11
Operation Panel
[1]
Power Key
[2]
[PAUSE] Key
[3]
[FEED] Key
[4]
[BACK FEED] Key
[5]
Ink Warning Lamp
[6]
Maintenance Cartridge Lamp
[7]
[ERROR] Lamp
[8]
[STATUS] Lamp

12
2. Technology
Basic Configuration
Functional Configuration
This Printer mainly consists of 3 systems: Image Formation System, Ink Supply System, and
Feeder/Transport System.
Image Formation System
Image Formation System discharges ink from Printheads based on the print data to form a print image
on paper. It consists of Printheads, Printhead Lifter Part, and Purge Unit in Print Module.
[1]
Printhead Lifter Part
[2]
Purge Unit
Ink Supply System
Ink Supply System supplies ink from Ink Tank to Printheads, suctions ink from Printheads, and collects
waste ink from Purge Unit to Maintenance Cartridge. It consists of Ink Tank Holder Unit, Valve Unit, and
Pump Unit in Print Module.
[1]
Pump Unit
[2]
Valve Unit
[3]
Ink Tank Holder Unit

13
Feeder/Transport System
Feeder/Transport System feeds paper. It consists of Roll Drive Unit, Paper Guide Unit and Transport
Unit.
[1]
Roll Drive Unit
[2]
Transport Unit
[3]
Paper Guide Unit

14
Outline of Electrical Circuits
Main electric circuits of this Printer include Printer Controller PCB and DC Power Supply PCB.
Main control of this Printer is performed by the microcomputer installed on Printer Controller PCB.
Printer Controller PCB performs image processing for the print data spooled from the host computer,
and controls Printheads to print an image on a paper according to the processed print data.
Main functions of these PCBs are as follows:
1. Printer Controller PCB
Printer Controller PCB performs communication with the host computer to manage printing. It
controls printing and cleaning operation using a microcomputer and ASIC.
It performs image processing for print data and performs all kinds of control related to
Printheads.
It has Flash ROM to allow to rewrite software using a PC.
• Image data management
• Control of motors, solenoids, clutches, sensors, fans, and switches
• Management of temperature and humidity data
• Control of DC Power Supply PCB output
• Command data analysis
• Overlay data retention
• Communication with host computer (3 types of interfaces)
• Print data transfer to image memory
• Control of operation on Operation Panel
• Power supply to Operation Panel
• Control of transfer of image data to Printhead
2. DC Power Supply PCB
Printer is equipped with universal-type DC Power Supply PCB to generate +24 V and +5 V from
100-240 VAC, and supplies them to Printheads, motors, and solenoids.
Block diagrams of main circuits of Printer are shown below.

15
Drive Configuration
M103:
Purge Motor
CL101:
Valve Clutch
M104:
Printhead Lift Motor
CL102:
Pump Clutch
M105:
Pump Motor
SL101:
Buffer Solenoid
M101:
Roll Motor
M102:
Transport Motor
M106:
Valve Motor

16
Basic Sequence
Outline
Initialization processing that must be performed at power-on to allow Printer to perform printing
properly is broadly classified into hardware start and initialization sequences.
On the other hand, shutdown processing is performed at power-off to retain Printer condition normally
until Printer is used next time.
Hardware Start Sequence
This is electrical initialization performed when Printer is turned on.