Chapter Troubleshooting

5.1 PROBLEM ISOLATION

5.2 SELF DIAGNOSTIC FUNCTION

5.3 TROUBLESHOOTING

5.1 troubleshooting information

The information in this chapter makes troubleshooting easier to perform by listing various problems that can occur and providing possible solutions.

Note: For this printer, no special tools are necessary for troubleshooting to the unit level, with the exception of a digital multi-meter. Some component-level troubleshooting may require an oscilloscope.

5.1.1 Error Messages

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

Table 5-1. Fatal Error Information

Fatal Error

7-segment LED *1)

Beeper*2)

Description

Note*3)

CR motor circuit shortage error

1

• The isolation resistance in the CR motor is too low.

Auto power off after 12 seconds

Cutter error

2

• Optional cutter cable is not connected firmly.

• Optional cutter is defective.

Auto power off after 12 seconds

Platen gap error

3

• The parallelism adjustment is incorrect.

• PG adjustment values are incorrect.

• PG backlash is too tight.

Auto power off after 12 seconds

Carriage lock error

4

• The interlock switch doesn't close exactly.

• The parallelism adjustment is incorrect.

• PG adjustment values are incorrect.

Auto power off after 12 seconds

Carriage load measurement error

6

• The CR motor is defective.

• The CR encoder sensor is defective.

Auto power off after 12 seconds

Head fan error

7

• The head fan driver IC is shorted.

• The head fan of the print head is defective.

Head power off immediately

Head circuit shortage error

8

• The print head driver IC is shorted.

• The coil of the print head is defective.

Head power off immediately

RAM check error

9

• DRAM of C204 MAIN board is defective.

Auto power off after 12 seconds

Paper memory setting error

a

-

-

EEPROM data compare error

b

• EEPROM on the C204 MAIN board is defective.

Tractor change error

c

-

• Tractor select mechanism is defective.

Auto power off after 12 seconds

Watch dog error

d

• C205 MAIN board has trouble.

Auto power off after 12 seconds

Note 1: The 7 segment LED indicates error No. and "E" alternately. Note 2: The descriptions "."and "-" show how the beeper sounds.

Note 1: The 7 segment LED indicates error No. and "E" alternately. Note 2: The descriptions "."and "-" show how the beeper sounds.

".": Beeper sounds 100 ms and interval is 100 ms. "-": Beeper sounds 500 ms and interval is 100 ms. Note 3: Turn the printer power off while the 7 segment LED are on, or the printer shuts power down automatically. You can't turn the printer back on for 5 minutes after the printer shuts power down automatically

5.1.2 Bypassing Interlock Switch and Cover Open Sensor

To print with the top cover open or removed, you need to bypass the interlock switch and cover open sensor because these sensors automatically disable printing when the top cover is open.

Cover Open Sensor

Interlock SW.

Cover Open Sensor

Interlock SW.

Connecteur Interlock

Red: 3j-pin White:j2-pin

Connector Junction IBoard

C204/MAIN Board

Figure 5-1. Interlock Switch Assembly Location

Red: 3j-pin White:j2-pin

Connector Junction IBoard

C204/MAIN Board

Figure 5-1. Interlock Switch Assembly Location

The interlock switch and cover open sensor consists of an assembly. To bypass the interlock switch and the cover open sensor,

1. remove the left side cover,

2. make the short circuit connectors for the interlock switch and cover open sensor connectors,

3. insert the short circuit connectors for the interlock switch and cover open sensor connectors.

Short Circuit J Connector

' |il|á ^_ConnectOr

White:|2-pin onnectOr Junction IBoard

C204/MAIN Board

Figure 5-2. Bypassing Interlock Switch and Cover Open Sensor

5.1.3 Coil Resistance

The following table provides the coil resistance for the motor, head fan, plunger, and printhead.

Table 5-2. Motor, Fan, Plunger, and Printhead Coil Resistance

Part

Coil Resistance

CR motor

1.66 ohms + 10 %

PF motor

2.80 ohms + 10 % at 25oC

RF motor

150 ohms + 10 % at 25oC

PG motor

250 ohms + 18 ohms at 25oC

Head fan

61 ohms + 4.3 ohms at 25oC

Plunger

9 ohms + 5 % at 25oC

Printhead

2.93 ohms + 0.2 ohms at 25oC

Epson Printheads Artisan
Figure 5-3. Disconnect Printhead FPC

FPCA

FPC B

10 12

10 12

FPC C

Head coil GND side Head coil P/S side Head thermistor

PWD : Paperwidth sensor +5V : +5 VDC ENCA: EncoderA GND : GND HT : Head thermistor

MA : Fan motor phase A MB : Fan motor phase B MC : Fan motor common MT : Fan motorthermistor

Figure 5-4. Printhead Coil Resistance

Check all motors, solenoid, printhead and drivers using a multimeter

See Section 5.3 to repair the printer mechanism._

Nn

Replace bad motor, solenoid, or printhead. If driver also is bad, replace at the same time.

> ii" p>

See Section 5.3 to repair the printer mechanism._

Epson Dfx 8500 Error

Is the fault

NOTE 1: Check the following connectors:

Three head junction board connectors to printhead CN1 of C204 MAIN board to head junction board CN2 of C204 MAIN board to C204 DRV-B board CN1 of C204 DRV-B board to printermechanism

Flowchart Seleksi Siswa Baru

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

Flowchart Repair Computer

5.2 circuit board repair

This section provides detailed troubleshooting methods to isolate components in the power supply or on the main board. This information is for use by service personnel who repair to the component level.

The table below provides causes, checkpoints, and solutions for different power supply circuit problems. The checkpoints include waveforms for normal operation. By referring to the checkpoints, determine the defective component. Then perform the proper repair. The table provides the following four columns:

□ Symptom: Check this column for a list of common printer problems.

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

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

□ Solution: Repair the printer using the instructions in this column.

5.2.1 C204 PSB/PSE Board Repair

Table 5-4 indicates majour components which is used for the C204 PSB/PSE board and Table 5-4 shows the C204 PSB/PSE board component level troubleshooting.

Table 5-4. C204 PSB/PSE Board Main Parts List

Location

Description

DB1

Diode bridge

TY1

TRIAC

QF101

Switching FET for VP1 and VP2

QF201

Switching FET for VP3 and +5 VDC

IC101

PWM switching controller

IC204

+5 V regulator IC

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

Symptom

Cause

Checkpoint

Solution

No DC voltage is present at the output . (Fan on the power supply board doesn't rotate at all.)

PD signal is HIGH (sent from the main board).

Measure the signal level of the PD signal at CN4.

Wait until the printer prints again.

Replace the E05B36 on the C204 MAIN board.

The DRERR signal is HIGH.

Measure the signal level of the DRERR signal at CN4.

Replace the printhead driver on the C204 MAIN board and/or C204 DRV-B board.

CL signal is HIGH.

Measure the signal level of the CL signal at CN4.

Wait until the printer prints again.

Replace the E05B36 on the C204 MAIN board.

Fuse F1 blows immediately after replacement.

The line filter circuit is defective.

Check if any of pins C1-C5 or R1 is shorting the AC line.

Replace the abnormal element.

Symptom

Cause

Checkpoint

Solution

The +37 VDC (VP1 / VP2) line is dead.

The main switching FETs QF101 is defective.

Observe the voltage waveform between the drain side and GND.

Replace QF101.

IC101 is defective.

Pin 5 (FB) must be HIGH then observe the voltage waveform between pin 2 (VOUT) and pin 12 (GND) of IC101.

Replace IC101.

The +37 VDC (VP3) line is dead.

The main switching FETs QF201 is defective.

Observe the voltage waveform between the drain side and GND.

Replace QF201.

Q201 is defective.

Observe the voltage waveform between the collector side and GND.

Replace Q201.

Q202 is defective.

Observe the voltage waveform between the collector side and GND.

Replace Q202.

TROUBLESHOOTING

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

TROUBLESHOOTING

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

Symptom

Cause

Checkpoint

Solution

The 5 VDC line is defective.

IC204 is defective.

Check the voltage level at pin 10 (V1) and pin5 (GP).

Replace IC204.

Observe the drive waveform at pin 8 (VO) and pin 5 (GP).

Replace IC204 or ZD211.

37 VDC line (VP1/VP2) is abnormal.

IC102 is defective. (If this IC is defective, it cannot monitor the 37 VDC lines, and printing operation becomes abnormal.),

When the input voltage of the minus port (pin 6 for VP1 and pin2 for VP2) is less than 13 VDC, the comparator outputs a HIGH signal.

Replace IC203.

37 VDC line (VP3) is abnormal.

IC203 is defective. (If this IC is defective, it cannot monitor the 37 VDC lines, and motor operations become abnormal.),

When the input voltage of the plus port is bigger than 13 VDC, the comparator outputs a HIGH signal.

Replace IC203.

5.2.2 C204 MAIN/DRV/DRV-B Boards Repair

Table 5-6 indicates major components which is used for the C204 MAIN/DRV/DRV-B boards and Table 5-7 shows the C204 MAIN/DRV/DRV-B boards component level troubleshooting.

Table 5-6. C204 MAIN/DRV/DRV-B boards Component Repair 1/7

Symptom

Cause

Checkpoint

Solution

The printer does not operate at all.

The DRERR signal was sent to the C204 power supply board (HIGH level turns off the power supply).

Check the logic level of the DRERR signal at CN10 or check the VP1 and VP2 voltage.

Replace the head driver on the C204 MAIN board (VP1) or C204 DRV-B board (VP2).

The PD signal was sent to the C204 power supply board. (HIGH level turns off the power supply)

Check the logic level of the PD signal during power on and verify the voltage waveform for the head driver. (Refer to the head driver waveform figure, above.)

Replace the head driver or gate array.

The reset circuit is not operational (for logic).

Check the logic level at pin1 (VOUT) of IC13.

Replace IC13.

The driver circuits don't operate at all.

The pull up voltage VX is not generated.

When the collector of Q15 is high Check the logic level at collector of Q14 (VX) (When the collector of Q15 is high, VX is HIGH..

Replace Q15.

Serial interface is dead.

The level converter IC is defective.

Check the signal level change between in and out port of the IC9.

Replace IC9.

TROUBLESHOOTING

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

TROUBLESHOOTING

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

Symptom

Cause

Checkpoint

Solution

The printer does not operate at all.

The control ROM is defective.

Confirm that the PROM is inserted the socket correctly.

Replace IC5.

The gate array (IC1) is defective.

Check pin 86 (D0)of IC1 for a change in the signal (HIGH or LOW).

Replace IC1.

The CPU (IC2) is defective

Look at the oscillator at either pin 27 (x1) or pin 28 of the CPU.

Replace CRU1 or IC1

The DRAM (IC14) is defective

Observe pin 2 (D0) of IC14 for a change in the signal (HIGH or LOW).

Replace IC14.

Symptom

Cause

Checkpoint

Solution

The carriage operates abnormally.

IC1 on the C204 MAIN board is defective.

Check the signals for the carriage motor phases at pins 204 (CRA), 205 (CRB), 206 (CRC), and 5 (CRD) of IC1

Replace IC1.

Q16, Q17, Q18, or Q19 on the C204 MAIN board is defective.

Check the signals for the carriage motor phases at collectors Q16 (CRA), Q17 (CRB), Q18 (CRC), and Q19 (CRD).

Replace Q16, Q17, Q18, or Q19.

IC1 is doesn't work.

Check the voltage level between Anode and Kathode of ZD2 is APPROX. 6.2 V.

Replace ZD2, Q34, or Q35.

IC1 on the C204 DRV board is defective.

Check the signals for the carriage motor phases at pins 14 (IN A) and 10 (OUT1) of IC1..

Replace IC1.

Measure the voltage level at pins 10 (OUT1) and 5 (GP) of IC1 when the carriage is operating. (The normal voltage level is approximately 37 VDC.),

Replace IC1.

IC3 on the C204 DRV board is defective.

Observe the waveform at pin 1 of IC3.

Replace IC3.

TROUBLESHOOTING

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

TROUBLESHOOTING

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

Symptom

Cause

Checkpoint

Solution

The carriage operates abnormally.

The carriage encoder sensor is defective.

Observe the carriage encoder sensor output signal at pins 4 (ENCA) and 3 (ENCB) of CN4 on the C204 MAIN board.

Replace the carriage encoder sensor.

Carriage operation is unstable (due to a lack of motor torque).

Check the switching waveform for Q5, Q6, and Q7.

Replace the abnormal transistor.

Symptom

Cause

Checkpoint

Solution

Paper feeding is abnormal.

The CPU IC2) on the C204 MAIN board is defective.

Check the PF motor phase drive signals at pins 2 - 5 of IC2.

Replace IC2.

IC2 on the C204 DRV board is defective.

At IC2, check the output signals for pins 2 (OUT A), 3 (OUTXA), 6 (OUT B), and 7 (OUTXB).

Replace IC2.

Ribbon feeding is abnormal.

The CPU IC2) on the C204 MAIN board is defective.

Check the RF motor phase drive signals at pins 6 - 9 of IC2.

Replace IC2.

The common switching transistor on the C204 DRV board is defective.

Check the collector voltage of Q21.

Replace Q20 or Q21.

The phase switching transistor on the C204 DRV board is defective.

For transistors Q22 - Q25, observe the input signal from the CPU (base) and the output signal (collector).

if there is no output signal, replace the abnormal transistor.

Fuse F1 on the C204 DRV board is defective.

Check if fuse F1 is defective.

Replace F1.

Symptom

Cause

Checkpoint

Solution

The head fan operation is abnormal.

IC1 on the C204 MAIN board is defective.

Observe the PG motor phase signal at pins 163 (FANA) and 164 (FANAX) of IC1.

Replace IC1.

Q10 or Q11 on the C204 MAIN board is defective.

Observe the head fan phase drive voltage level for pins 25 (HFANA) and 17 (HFANB) of CN1. (The normal voltage is approximately 37 VDC.)

Replace Q10 or Q11.

The PG motor operates abnormally.

IC1 on the C204 MAIN board is defective.

Observe the PG motor phase signal at pins 10 (PGA), 12 (PGB), 14 (PGAX), and 13 (PGBX) of IC1.

Replace IC1.

The common switching transistor on the C204 DRV board is defective.

Check the collector voltage of Q11.

Replace Q10 or Q11.

The phase switching transistor on the C204 DRV board is defective.

For transistors Q12 - Q15, observe the output signal (collector).

if there is no output signal, replace the abnormal transistor.

Fuse F2 on the C204 DRV board is defective.

Check if fuse F2 is defective.

Replace F2.

The PG sensor is defective.

Observe the PG sensor output signal at pins 35 (PGENCA) and 34 (PGENCB) of CN14.

Replace the PG sensor.

The PG home position sensor is defective.

Observe the PG HP sensor signal level for pin 36 (PGHOME) of CN14. (PG home = LOW level; other = HIGH level.)

Replace the PG home position sensor.

The plunger is defective.

Fuse F3 is defective

Check if fuse F3 is defective.

Replace F3.

IC1 on the C204 MAIN board is defective.

When paper is loaded into the printer, look at the switching signal at pins 16 (PLP) and 17 (PLN)of IC1.

Replace IC1.

Plunger drive transistor on the C204 DRV board is defective.

Observe the Q31 collector voltage at paper loading.

Replace Q31, Q30, or Q32.

Symptom

Cause

Checkpoint

Solution

The self-test is printed incorrectly

IC1 on the C204 MAIN board is defective.

Observe the output signal at pins 136181 of IC1.

Replace IC1.

The head driver FETs on the C204 MAIN and/or C204 DRV-B boards are defective.

Observe the voltage waveform at the each FET drain side.

Replace the abnormal FET.

The CPU (IC2) on the C204 MAIN board is defective.

Observe the signals at pins 38 (PTS1) and 42 (PTS2) of the IC2

Replace the IC2.

5.2.3 Printer Mechanism Repair

The table below describes how to isolate problems with the printer mechanism. To replace or adjust printer mechanism parts, refer to Chapter 3, Disassembly and Assembly, and Chapter 4, Adjustments. If a symptom recurs following a repair attempt, look for other possible causes and solutions in the table below.

Table 5-7. Printer Mechanism Repair 1/4

Symptom

Cause

Checkpoint

Solution

The CR motor does not operate.

The transport locking bracket (used to hold the carriage in place when the printer is moved) has not been removed.

Verify that the transport locking bracket has been removed.

Remove bracket. (Refer to Section 3.1.)

Foreign objects are lodged in the gears or elsewhere (e.g. paper dust on the carriage encoder belt) in the mechanism.

Manually move the carriage to see if the motor rotates.

Remove any foreign objects.

The CR motor is defective.

Measure the coil resistance of the CR motor. It should be approximately 1.66 ohms + 10 %.

Replace the CR motor.

The carriage timing belt is defective.

Manually check the carriage timing belt tension.

Perform the carriage timing belt tension adjustment, as described in Section 4.1.2.

The carriage guide shaft parallelism value is incorrect.

Check whether the carriage moves smoothly when moved manually. (Check that foreign objects are not lodged in the printer mechanism.),

Perform the carriage guide shaft parallelism adjustment, as described in Section 4.1.5.

The CR encoder sensor is defective.

Check the waveform for the carriage encoder signal. (Refer to Table 5-6.),

Replace the CR encoder sensor.

The carriage encoder belt is damaged or covered with dust.

Check the encoder belt (below the carriage timing belt).

Replace or clean the carriage encoder belt.

The carriage moves, but no printing is performed.

The printhead FPC common wires are broken.

Check the continuity of the common wires for the printhead FPC.

Replace the FPC.

Symptom

Cause

Checkpoint

Solution

A particular dot does not print.

The printhead is defective.

Measure the printhead coil resistance. (Refer to Figure 5-4 for details.)

Replace the printhead.

Check whether a dot wire is worn.

Replace the printhead.

The print is too light or print density is not uniform.

The printhead is defective.

Check if the tip of a dot wire is worn.

Replace the printhead.

The parallelism value is incorrect.

Print density differs at the right and left sides of the page (darker on one side than the other).

Perform the parallelism adjustment, as described in Section 4.1.5.

The platen gap value is incorrect.

Print density is too light even the new ribbon cartridge is mounted.

Perform the parallelism adjustment, as described in Section 4.1.5.

Printing is performed, but the printer does not feed paper or does not feed it correctly.

Foreign objects are lodged in the paper path.

Visually check the paper path.

Remove any foreign substances.

The PF motor is not driving the gear properly.

Check whether the PF motor pinion gear rotates smoothly when rotated manually

Check backlash between PF motor pinion gear and paper feed reduction gear.

The PF motor is defective.

Measure coil resistance for the PF motor. (The correct resistance is approximately 2.8 ohms + 10%.) Also check the PF motor drivers.

Replace the PF motor, and if drivers are bad, replace main board at the same time

The ribbon feed (RF) motor does not operate.

The ribbon cartridge is defective.

Remove the ribbon cartridge, rotate it, and check whether it feeds the ribbon normally.

Replace the ribbon cartridge.

Foreign objects are caught in the gears.

Check whether the ribbon driving gear rotates when the cartridge is moved manually.

Remove any foreign objects or replace damaged ribbon feed mechanism part (the ribbon feed select gear, ribbon feed transmission gear, or ribbon feed gear).

TROUBLESHOOTING

Table 5-7. Printer Mechanism Repair 3/4_

TROUBLESHOOTING

Table 5-7. Printer Mechanism Repair 3/4_

Symptom

Cause

Checkpoint

Solution

The RF motor does not operate.

The parallelism value is incorrect.

Check whether the carriage moves smoothly when moved manually. (Check that foreign objects are not lodged in the printer mechanism.)

Perform the parallelism adjustment, as described in Section 4.1.5.

The RF motor does not operate.

The RF motor is defective.

Check the coil resistance of the RF motor. (It should be about 150 ohms + 10 %.)

Replace the RF motor.

The PG motor does not operate.

The backlash value is incorrect.

Check whether the carriage guide shaft rotates smoothly when rotated manually.

Loosen the 2 screws securing the PG motor to the left side frame. Then adjust the backlash between the PG motor pinion gear and the carriage guide shaft gear, as described in Chapter 4, Adjustments.

The PG encoder sensor is defective

Check the output signal of the PG encoder sensor. (Refer to Table 5-6.)

Replace the PG encoder sensor.

The encoder plate is defective.

Check whether the encoder plate is broken or stained.

Replace the PG motor or clean the encoder plate.

The PG home sensor is defective

Check the continuity of the sensor. (Check the status of the two micro switches.),

Replace the PG home sensor (micro switch type).

The PG motor is defective.

Check the coil resistance of the PG motor. (It should be about 250 ohms + 18 ohms.)

Replace the PG motor.

Printing continues past the end of the paper.

The front, rear, or top PE sensor is defective.

Check the PE sensor.

Replace the PE sensor.

When paper jams, the printer does not beep.

The paper jam sensor is defective.

Check the paper jam sensor.

Replace the paper jam sensor.

Ribbon Jam error occurs even the ribbon is fed correctly.

Ribbon jam sensor is defective.

Check the ribbon jam sensor.

Replace the ribbon jam sensor.

Symptom

Cause

Checkpoint

Solution

Printing occurs outside the paper width.

The PW sensor is defective.

Check the PW sensor.

Replace the PW sensor.

The paper bail assembly does not work.

The plunger is defective.

Check the coil resistance of the plunger. (It should be about 9 ohms.)

Replace the plunger.

Continuous paper becomes crumpled at the front or rear tractor assembly.

The tension value of the tractor wire spring is incorrect.

The distance between the frame and the seal securing the white line should be about 3 mm (0.12 inches).

Perform the tractor wire spring tension adjustment, as described in Section 4.1.3.

The tractor select (front or rear) function is not working.

The tractor select sensor is defective.

Check the continuity of the tractor select sensor.

Replace the tractor select sensor.

The tractor select gear is disconnected from the tractor select cam.

Visually check the tractor select gear holder.

Join the tip of the tractor select lever to the tractor select gear holder.

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