800 ch2

Chapter 2 Operating Principles
2.1 Overview ............................................................................................................................ 2-1 2.2 Printer Mechanism Operating Principles ............................................................................. 2-1 2.2.1 Printing Mechanism ........................................................................................... 2-2 2.2.1.1 Printing Process ................................................................................ 2-3 2.2.1.2 Printing Methods ............................................................................... 2-3 2.2.2 Carriage (CR) Mechanism.................................................................................. 2-4 2.2.3 Paper Feed Mechanism ..................................................................................... 2-6 2.2.4 Platen Gap (PG) Adjust Mechanism ................................................................... 2-7 2.2.5 CR Lock Mechanism .......................................................................................... 2-8 2.2.6 ASF Mechanism................................................................................................. 2-8 2.2.7 Ink System....................................................................................................... 2-11 2.2.7.1 Pump Mechanism............................................................................ 2-12 2.2.7.2 Capping Mechanism........................................................................ 2-14 2.3 Circuit Operating Principles .............................................................................................. 2-15 2.3.1 C202 PSB/PSE Board...................................................................................... 2-15 2.3.2 C202 MAIN Control Board................................................................................ 2-18 2.3.2.1 Printhead Driver Circuit ................................................................... 2-20 2.3.2.2 Reset Circuits.................................................................................. 2-22 2.3.2.3 Motor Driver Circuits........................................................................ 2-24 2.3.2.4 Sensor Circuits................................................................................ 2-25 2.4 Ink System Management .................................................................................................. 2-26 2.4.1 Ink System Operations..................................................................................... 2-26 2.4.2 Timers and Counters........................................................................................ 2-27 2.4.3 Ink System Sequences..................................................................................... 2-28
EPSON Stylus COLOR 800 Service Manual
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Principles of Operation
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2.1 Overview
This chapter provides information on the printer mechanism, electrical circuits, and ink system. The operating principles for each device in the printer mechanism are described individually. The description of circuits covers the C202 PSB/PSE board and C202 MAIN board.
2.2 Printer Mechanism Operating Principles

This printer is composed mainly of the printing mechanism, paper feed mechanism, carriage mechanism, pump mechanism, and ASF mechanism. There are three motors: the carriage motor (CR motor), paper feed motor, (PF motor) and pump motor. Table 2-1 shows each motor and corresponding units driven. Table 2-1. Motor and the Assembly it Drives Motor PF motor CR motor Pump motor Unit Driven PF roller assembly, CR lock lever CR unit, capping unit Pump unit, capping unit, wiper, ASF unit
When the PF motor rotates clockwise, its torque drives the PF roller assembly and releases the CR lock lever. When the PF motor rotates counterclockwise, the torque locks the CR lock lever. The CR motor transmits torque via the timing belt to move the carriage in both right and left directions in parallel with the platen. The torque from the pump motor, switched by the disengage mechanism, is transmitted to the ASF and the pump. The figure below shows the block structure of the printer mechanism.
Carriage Mechanism Print Mechanism
CR Motor
Slider Mechanism
Black
Color
Pump Mechanism
ASF Mechanism Pump Motor Disengage Mechanism Paper Feed Mechanism
CR Lock Mechanism PF Motor
Figure 2-1. Printer Mechanism Block Diagram
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2.2.1 Printing Mechanism

The printer uses an on-demand ink jet system to print, just as with other EPSON ink jet printers. This printer, however, has a newly designed MACH head, which ensures high printing quality at a higher speed. The printer is equipped with separate printheads of the same type: one for black and one for each of the three colors (magenta, cyan, and yellow). The quick penetration-type of black and color ink is also improved for this printer, which enables users to print images at a high quality on normal paper.
Y Printhead
The black and color printheads for this printer use the newly designed MACH head (E-CHIPS head). The printhead structure is the same as for the previous CHIPS head, except for the nozzle configuration. The black head for this printer has 128 nozzles (32 nozzles in each of 4 rows), which is as twice as many as previous EPSON ink jet printers. The color head has 192 nozzles (32 nozzles for each of 6 rows), which is 3 times as many as previous EPSON ink jet printers. Therefore, print quality as well as speed for this printer is higher than ever. Nozzle structure for this printhead is shown in the figure below.
Printhead Driver Board
Ink Cartridge Sensor Lever Cartridge Needle
(Ink Cartridge)
PZT Cavity Nozzle Plate
Filter Ink Tube
Figure 2-2. Printhead Structure
YPZT PZT is an abbreviation for piezo electric element. The print signal from the C202 MAIN board is sent YCavity Set Ink absorbed from the ink cartridge goes through the filter and is stored temporarily in this tank (called a cavity), which is driven by the PZT. YNozzle Plate The board with nozzle holes on the printhead surface is called the nozzle plate.
through the driver board on the printhead unit and to the PZT. Then, the PZT pushes the top of the cavity, which contains stored ink, and discharges the ink from each nozzle on the nozzle plate.
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YFilter
When the ink cartridge is installed, if any dirt or dust around the cartridge needles is absorbed into the head internally, there is a great possibility of nozzles clogging and disturbance of ink flow, which will finally cause alignment failure and missing dots. To prevent this, a filter is installed below the cartridge needle, and ink is once filtered here.
2.2.1.1 Printing Process

The stages below describe how the on-demand ink jet system ejects the ink from each printhead nozzle. Stage 1 Normal state When no print signal is output, the PZT does not move and is in the waiting state (normal state). Stage 2 Ejecting state When a print signal is output from the C202 MAIN board, the nozzle selector IC mounted on the head driver board latches data in 1-byte units. The appropriate PZT latched by nozzle selector is pushed into the cavity by applying a common voltage from the C202 MAIN board. By this operation, ink stored in the cavity spurts out from the nozzle.
Normal State Piezo Nozzle Cavity Ejecting State
Ejected ink
Figure 2-3. Print Process During ink charging or cleaning, ink left in the cavity is vacuumed out by the pump mechanism via the capping unit. Then it is ejected to the waste ink drain tank. The cavity is refilled with ink from the ink cartridge during printing or other operations. Ink viscosity tends to change with the temperature around the heads, and this change in viscosity could result in low printing quality. This, however, is avoided by attaching a thermistor directly to the driver circuit board. It is used to determine the proper drive pulse automatically based on the detected temperature.
2.2.1.2 Printing Methods

This printer uses three kinds of dot to compose the print image: the normal dot, the double-firing normal dot, and the micro dot. Each dot is selected to control printing depending on conditions, such as the paper type and the print resolution set through the printer driver.
YNormal Dot / Double-Firing Normal Dot Print Modes Normal dot/double-firing normal dot print modes are available for both black and color printing. The
normal dot print mode forms single dot with two head drive pulses. In this mode, the dot diameter is expanded to solve the white banding problem that occurs in solid printing at 360 dpi. This printer is, however, designed to use less ink than other printers to print at 1440 dpi, the maximum resolution on a horizontal line. Therefore, the double-firing normal dot and normal dot modes used in this printer are considered equivalent, respectively, to the normal dot and micro dot modes used in previous ink jet printers. Double-firing normal dot mode is usually selected for printing 360 dpi, and the normal dot mode is used for printing in 720 x 360 dpi or 720 dpi x 720 dpi, depending on the paper type.
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YEPSON Micro Dot Printing Both black and color printing can be performed in micro dot print mode. In normal dot printing, one dot is YMicroweave Printing This function enhances graphic image quality by eliminating white banding on each line. The printer is
equipped with a new Microweave print mode and controlled to form a horizontal line using two types of nozzle. In this mode, the printer can prevent color inks from mixing with each other before drying and can provide clearer colors in output. Microweave printing can be selected through the printer driver. formed by two pulses. On the other hand, EPSON micro dot printing forms one dot with a single pulse, using less ink. As mentioned above, micro dot printing for this printer is controlled to use less ink to create 1440 dpi images, the maximum resolution in a horizontal line. This mode is used for printing in 720 or 1440 dpi by controlling the ink firing duty.
2.2.2 Carriage (CR) Mechanism

The CR mechanism is composed of the CR motor, timing belt, CR guide shaft, top frame, and home position (HP) sensor. Torque from the CR motor is transmitted to the CR unit via the timing belt to move the CR unit right and left along the CR guide shaft, depending on the direction the CR motor rotates. When the CR unit returns to HP position, it is detected by the HP sensor mounted on the right end of the top frame, and the information is fed back to gate array IC2 (E05B33CB). Figure 2-4 illustrates the CR mechanism.
CR Motor HP Sensor
Timing Belt
Driven Pulley CR Guide Shaft
CR Unit
CR Motor Pinion Gear
Figure 2-4. Carriage Mechanism The CR motor, which drives the CR mechanism, is a 4-phase/200-pole/HB-type stepping motor controlled by a constant-current bipolar control system. The current control signal for each phase and the phase control signal output from gate array IC2 E05B33CB are converted into CR motor control signals by IC13 bipolar driver UDN2917EB to control the CR motor. See Table 2-2 and Table 2-3, which show CR specifications and drive frequencies.
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Table 2-2. CR Motor Specifications Item Motor type Drive voltage Coil resistance Inductance Drive frequency Excitation mode Minimum step Description 4-phase / 200-pole / HB-type stepping motor 42 VDC 5% 7.8 10% at 77 F (25 C) per phase 14 mH 20% (1 KHz, 1 V rms) 240 ~ 4080 Hz Bipolar drive 1/120 inch / pulse (2-2 phase drive), 1/240 inch / pulse (1-2 phase drive) 1-480 inch / pulse (W1-2 phase drive) Table 2-3. CR Motor Driver Terms CR Speed Drive Drive System and Acceleration/ (CPS) Frequency Deceleration Steps 2 3 (Hz) A* : 1, D* : 2 A: 2, D: 2 Constant Fast skip 340 4080 64 (W1-2) 164 (2-2) (2-2) Draft 266.7 3200 88 (W1-2) 86 (2-2) (2-2) LQ 200 2400 432 (W1-2) (W1-2) Text LQ 200 2400 240 (W1-2) (W1-2) SLQ 100 1200 432 (W1-2) (W1-2) Capping 90 1080 64 (W1-2) (W1-2) Wiping 2 80 960 64 (W1-2) (W1-2) Wiping 40 480 16 (W1-2) (W1-2) Capping 20 240 8 (W1-2) (W1-2) (open) Constant 20 240 (W1-2) value Note: *1: Steps: reduced to 2-2 phase *2: Acceleration *3: Deceleration Modes Acceleration/ Deceleration 1 Pulses* 180 108 108 60 108 16 16 4 2
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2.2.3 Paper Feed Mechanism

To improve feeding speed, this printer is equipped with a PF motor that is used only to feed paper. The drive from the pump motor is used to load paper from the ASF and the drive from the PF roller is independently used only to feed paper. The paper feed mechanism is separated into two parts: the paper feed part, including the PF roller in the main assembly; and the paper eject part, including the paper eject roller in the main assembly. The PF roller is coated with a powdery material to improve paper feed accuracy. The PF motor in the rear left part of the printer mechanism transmits torque via the combination gear (14 mm, 31.5 mm) and gear (70 mm) to the PF roller assembly to feed loaded paper. The torque is then transmitted from the gear (17 mm) on the paper feed roller assembly to the paper eject roller via the gear (19 mm) to eject paper. Torque is transmitted in the following order:
YPaper feed part
YPaper eject part
1. PF motor pinion gear 2. Combination gear (14 mm, 31.5 mm) 3. Gear (70 mm) 4. PF roller assembly 1. PF motor pinion gear 2. Combination gear (14 mm, 31.5 mm) 3. Gear (70 mm) 4. Gear (17 mm), PF roller assembly 5. Gear (19 mm), front paper guide assembly 6. Paper eject roller assembly, front paper eject assembly
PF Motor Pinion Gear PF Motor Combination Gear (14 mm, 31.5 mm) PF Roller Assembly Timing Belt HP Sensor
CR Motor
Gear (70 mm)
Gear (19 mm)
Gear (17 mm)
Paper Eject Roller
Front Paper Guide Assembly
CR Unit
Figure 2-5. Paper Feed Mechanism
This printer uses a 4-phase/96-pole/HB-type pulse motor controlled by a bipolar constant-voltage system as the PF motor. The current control signal for each phase and phase control signal output from gate array IC2 E05B33CB are converted into PF motor control signals by the IC16 bipolar driver UDN2917EB to control the PF motor. Since the power switch for this printer is wired in the secondary circuit, voltage remains constant until the loaded paper is ejected after printer power is turned off. Table 2-4 and Table 2-5 show PF motor specifications and PF motor drive frequencies, respectively.
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Table 2-4. PF Motor Specifications Item Motor type Drive voltage Coil resistance Inductance Drive frequency Excitation mode Minimum step Description 4-phase / 96-pole / HB-type pulse motor 42 VDC 5% (The voltage applied to the driver) 7.8 10%, at 77 F (25 C) per phase 14 mH 20% (1 KHz, 1 V rms) 400 ~ 4320 Hz Bipolar drive 1/120 inch / pulse (2-2 phase drive) Table 2-5. PF Motor Drive Terms Feeding Drive Speed Frequency (inch/sec) (Hz) Normal feed 5 3600 Fast feed 6 4320 Slow feed 2.5 1800 At loading 3 22160 Micro adjust 1 1.25 900 Micro adjust 2 0.55 400 Mode Acceleration Steps for Each Phase W1-2 2-2 1-2 50 60 20 30 2 Note: Drive frequency and pulse intervals are reduced to 2-2 phase. Pulse Intervals (s) 278 231 556 463 1111 2500 Deceleration Steps for Each Phase W1-2 2-2 1-2 50 60 20 30 2
2.2.4 Platen Gap (PG) Adjust Mechanism

The PG adjust mechanism, at the left of the printer mechanism, consists of the PG lever, PF sub lever, right/left parallelism adjustment bushings, and CR guide shaft. The PG adjust mechanism is designed to keep the platen gap correct for the paper thickness to prevent ink from smearing. The PG lever joins the CR guide shaft, which has an eccentricity via PG sub lever. Switching the lever from 0 to + rotates the CR shaft and changes the platen gap from narrow to wide. Figure 2-6 shows the PG adjust mechanism.
PG Lever Position + PG Lever Position 0
PG Lever
PG Sub Lever
CR Guide Shaft
Figure 2-6. PG Adjust Mechanism
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2.2.5 CR Lock Mechanism

The CR lock lever, on the right side of the printer mechanism, is composed of the PF motor, PF roller assembly, CR lock lever (stopper lever), and so on. When no paper is loaded and no data stored, the CR lock mechanism fixes the CR unit in the capping position. This is done by rotating the PF motor clockwise in the specified steps to move the lock lever at the right end of the PF roller to the left of the CR unit. The lock lever is released from the lock position when the PF motor rotates counterclockwise in the specified steps. The PF motor drive is transmitted in the following order: 1. PF motor pinion gear 2. Combination gear (14 mm, 31.5 mm) 3. Gear (70 mm) 4. PF roller assembly 5. Lock lever The figure below shows the CR lock mechanism.
PF Motor Pinion Gear CR Motor PF Motor Combination Gear (14 mm, 31.5 mm) PF Roller Assembly Timing Belt HP Sensor
Gear (70 mm)
Gear (19 mm)
Paper Eject Roller Gear (17 mm)
Front Paper Guide
Compression Spring (5.85 g)
Lock Lever
Figure 2-7. CR Lock Mechanism
2.2.6 ASF Mechanism

The ASF mechanism, which consists of the pump motor, slider mechanism, disengage mechanism, and ASF unit, loads paper into the paper feed mechanism. When the CR unit returns to the home position, it pushes the slider in the slider mechanism to the right, and the gear (16 mm) in the slider mechanism then engages the change cam in the disengage mechanism. With this motion, the pump motor rotates in the specified steps counterclockwise, which switches the change cam to the ASF unit side. Then torque from the pump motor is transmitted to the ASF unit. The process in which drive from the pump unit is switched to the ASF unit side is described below. Figure 2-8 illustrates the process for the switching operation.
YDisengage Mechanism Switch Process

1. 2. 3. 4. 5.
CR moves to home position. Slider moves to the right end (slider mechanism). The gear (16 mm) engages the change cam in the disengage mechanism (slider mechanism). The change cam switches to the ASF side (disengage mechanism). The combination gear (14.4 mm, 21.6 mm) moves to the left.
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The figure below shows movements in steps 3 to 5.

Combination Gear (12 mm, 20.8 mm) Combination Gears (12 mm, 26 mm) Pump Motor Pinion Gear
Pump Motor
4
Gear (27.2 mm)
Gear (11.5 mm) Slider Shaft
5 3
Gear (16.8 mm) Combination Gears (14.4 mm, 21.6 mm) Change Cam
Gear (16 mm) (Slider Mechanism)
Combination Gear (12 mm, 15 mm)
Figure 2-8. ASF Mechanism
YTransmission Process for Pump Motor Torque
1. Pump motor pinion gear 2. Combination gear (12 mm, 26 mm) 3. Combination gear (14.4 mm, 21.6 mm) 4. Gear (16.8 mm) 5. Combination gear (12 mm, 20.8 mm) 6. Gear (27.2 mm), ASF unit 7. LD roller shaft, ASF unit Note: This order has no relevance to the order in the figure above.
ASF home position is sensed by the detection wheel attached to the right end of the LD (load) roller shaft and the ASF HP sensor. The detected condition is fed back to IC2 E05B33CB. The ASF motor is controlled based on the home position detected by the ASF HP sensor. A 4-phase/48-pole PM-type pulse motor is used for the pump motor, which is controlled by a constant-current bipolar drive. The current control signal for each phase and phase control signal output from the IC2 gate array E05B33CB are converted into pump motor control signals by the IC6 bipolar driver UDN2917EB to control the PF motor. Table 2-6 and Table 2-7 show pump motor specifications and pump motor drive frequency, respectively. Table 2-6. Pump Motor Specifications Item Motor type Drive voltage Coil resistance Drive frequency Excitation mode Minimum step Description 4-phase / 48-pole / PM-type pulse motor 42 VDC 5% (Voltage applied to the driver) 9.3 10%, at 77 F (25 C) per phase 272 ~ 654 Hz Bipolar drive 1/218 inch / pulse (2-2 phase drive)
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Table 2-7. Pump Motor Drive Terms Mode Paper feedback Frequency 436 Pulse Intervals 2294 Feeding Speed 2/sec. Acceleration Steps Deceleration Steps W1-Phase 1-2 Phase W1-Phase 1-2 Phase 5 5
YASF Multi Feed Prevention Mechanism
The paper loading assembly in the ASF is composed of a D-cut paper loading roller, a C-cut cam, a paper feedback lever, and a pinch roller. The C-cut cam and the D-cut roller move synchronously, because they are on the same shaft. When they rotate counterclockwise (viewed from the right), the paper feedback lever moves along with the notch in the C-cut cam to push dislocated paper back up to the standby position. It is called dislocation when multiple sheets, including the paper to be loaded in the next rotation, slip out of standby position and fall into the paper path.
Pinch Roller D-Cut Paper Loading Roller Hopper C-Cut Cam Hopper Spring
Pad Spring Paper Feedback Lever
Figure 2-9. ASF Multi Feed Prevention Mechanism
YASF Multi Feed Prevention Mechanism Operating Principles

1. When you press LOAD/EJECT or input a print order at the PC, the PF motor rotates counterclockwise and makes the C-cut cam rotate in the same direction. 2. The paper feedback lever clutched to the C-cut cam rises with the counterclockwise rotation to catch slipped paper. With this motion, the pad is pushed back, and the pinch roller and D-cut paper loading roller move to a position where there is no friction. 3. When dislocated paper is pushed back up to standby position by the paper feedback lever, counterclockwise rotation of the pump motor releases the hopper release lever and the D-cut paper feed roller begins to load the paper. 4. When the ASF finishes feeding the paper to the specified position, the flat part of the D-cut paper loading roller turns around to the paper path side, where the D-cut paper loading roller loses contact with the paper and the pinch roller supports the paper instead. The paper pinch roller continues to support the paper until it is completely ejected from the ASF by rotation of the PF roller. The paper feedback lever, during this movement, is in the standby position, as shown in the above left figure.
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2.2.7 Ink System

The ink system for this printer absorbs and ejects ink, cleans the printhead surface, and caps the printheads. It is composed of the following:
VInk cartridge VPump mechanism VWiping mechanism VCapping mechanism VWaste ink drain pads
This section describes operational principles of the pump mechanism and capping mechanism. The figure below shows the structure of the ink system.
Capping Mechanism Black Ink Cartridge Color Ink Cartridge
Pump Motor
Combination Gear (12 mm, 26 mm) Air Valves Head Cleaner Combination Gear (14.4 mm, 21.8 mm)
Pump Drive Shaft Gear (21.6 mm)
Pump 1
Pump 2 Pump Reduction Shaft
Clutch
Wiping Mechanism
Pump Mechanism Waste Ink Drain Pads
Figure 2-10. Ink System
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2.2.7.1 Pump Mechanism

The functions of the pump mechanism, which is composed of the pump motor, slider mechanism, and disengage mechanism, are absorbing black/color ink from the capping unit, false absorption, and setting and resetting the wiper. When the CR returns to CR home position, it pushes the slider in the slider mechanism to the right end. That movement engages the gear (16 mm) in the slider mechanism with the change cam in the disengage mechanism. Then the change cam switches to the pump mechanism side when the pump motor rotates clockwise in the specified steps, and the drive from the pump motor is transmitted to the pump mechanism. Torque is transmitted to the pump side via the disengage mechanism in the following order: 1. 2. 3. 4. 5. 6. Disengage mechanism switch process. CR moves to home position. Slider moves the right end (slider mechanism). The gear (16 mm) engages the change cam (slider mechanism). The change cam switches to the pump side (disengage mechanism). The combination gear (14.4 mm, 21.6 mm) shifts to the right (disengage mechanism).
The following figure shows how the gears are engaged.

Combination Gear (12 mm, 20.8 mm) Combination Gear (14.4 mm, 21.6 mm) Combination Gear (12 mm, 26 mm)
Pump Motor Pinion Gear Pump Motor Gear (11.5 mm)
4
Gear (27.2 mm)
Slider Shaft Pump Drive Shaft
5 3
Gear (16.8 mm)
Cam
Gear (16 mm) (Slider Mechanism)
Combination Gear (12 mm, 15 mm)
Gear (21.6 mm)
Pump Reduction Gear
Pump Unit
Figure 2-11. Pump Mechanism
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YTransmission Process for Pump Motor Torque
1. Pump motor pinion gear 2. Combination gear (12 mm, 26 mm) 3. Combination gear (14.4 mm, 21.6 mm) 4. Pump drive shaft 5. Gear 21.6 6. Pump reduction shaft 7. Pump unit
Note: This order is irrelevant to the order indicated with arrows in Figure 2-11.
The pump unit switches functions, depending on the direction the pump motor rotates, as show in Table 2-8. Table 2-8. Pump Motor Rotation and Function Motor Rotation Direction Function Clockwise direction Absorption of color ink, false absorption of color ink, (Forward) Micro absorption of color ink, resetting the wiper Counterclockwise direction Absorption of black ink, False absorption black ink, (Reverse) Micro absorption of black ink, setting the wiper Note: The rotation direction is described when the motor is viewed from the pinion gear side.
Pump Motor (Clockwise Direction)
Black Capping Color Capping
Wiper
Color Pump Side Color Ink Absorbed
Waste Ink Drain Pads
Black Pump Side No Black Ink Absorbed
Black Pump Side Wiper Reset
Pump Motor (Counterclockwise Direction)

Color Capping Black Capping Wiper
Color Pump Side No Color Ink Absorbed
Waste Ink Drain Pads
Black Pump Side Black Ink Absorbed
Black Pump Side Wiper Set
Figure 2-12. Pump Mechanism
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The pump motor for this printer also drives the ASF mechanism. See Table 2-6 for its specifications. The drive terms for the pump motor in pump mode are shown in Table 2-9. Table 2-9. Pump Motor Drive Terms in the Pump Mode Absorption Mode Frequency High speed Normal speed Low speed Disengage 1350 675 281 141 Pulse Intervals 741 1481 3559 7092 Acceleration Steps W1-2 2-2 1-2 Phase Phase Phase 30 18 0 0 Deceleration Steps W1-2 2-2 1-2 Phase Phase Phase 30 18 0 0
2.2.7.2 Capping Mechanism

The capping mechanism caps printheads with the cap holder to prevent ink around the nozzles from thickening while the printer is in standby or when printer power is off. There are two separate holders: one for color ink and the other for black ink. When the CR moves from home position to the right side of the printer (motion 1 in Figure 2-13), the holders move up to capping position (motion 2 in Figure 2-13) to cap the printheads. Also, when the CR unit moves to the right end of the CR shaft, the air valve shuts off completely (motion 3 in Figure 2-13). The air valve is released and shut alternately for false absorption or absorption mode. (See Section 2.4.1 for the details.) Since this printers power switch is in the secondary circuit, the capping operation is completely carried out by constant voltage if printer power is turned off during the capping operation. The figure below shows the capping mechanism. Black Ink Cartridge Color Ink Cartridge
1 Cap 1 2 Cap 2 2 3
To the Drain Pads 2 Air Valve
Air Tubes Figure 2-13. Capping Mechanism
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2.3 Circuit Operating Principles

This printer consists of the following circuit boards:
VC202 MAIN board VC202 PSB/PSE board VC202 panel board
In addition to the circuit boards above, printhead driver circuits are directly attached to the black head and the color head in the CR unit. This section describes the operational principles of the C202 PSB/PSE board and C202 MAIN board. Table 2-10 shows input voltages and applications.
Printer Mechanism CR Motor PF Motor C202 PNL Board Pump Motor
C202 PSB/PSE Board
+42 VDC C202 MAIN Control Board +5 VDC
Color Head Black Head Driver Circuit Driver Circuit
Sensors
Figure 2-14. Circuit Block Diagram
2.3.1 C202 PSB/PSE Board

The power circuitry of this printer uses an RCC (ringing choke converter), which outputs two types of VDC necessary to operate the printer. Table 2-10. DC Voltage Distribution VDC +42 V +5 V
Y Motors Y Printhead common voltage Y C202 MAIN control board (logic) Y C202 panel board Y Sensors (HP sensor, ASF HP sensor, PE sensor)
Application
The power switch for this printer is in the secondary circuit, allowing the PSB/PSE board to continue to supply voltage for the power and logic lines for a minimum of 20 seconds, until the printhead returns to the capping position, even if the printer is turned off during printing. This extra time prevents ink leakage and drying in the printhead that could be caused by leaving the printhead uncapped. AC voltage from the AC inlet is first input to a filter circuit for higher harmonics absorption and is then input to a rectification and smoothing circuit, converting it into DC voltage. This DC voltage is then input to the switching circuit. An FET on the primary side performs this switching operation and generates a +42 voltage that is stabilized on the secondary side and then converted into a stable +5 VDC by a chopping regulator IC. Figure 2-15 shows a block diagram for the electrical circuitry.
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Primary Circuit
Smoothing Circuit Switching Circuit Smoothing Circuit
Secondary Circuit
Full Wave Rectifier Circuit
+42V
Filter Circuit Photo Coupler AC Input Photo Coupler
+5V Switching Regulator +5V Constant Voltage Control Circuit +5V Over Current Protection Circuit +42V Constant Current Control Circuit
+5V Power Switch
+5V Over Voltage Protecion Circuit +42V Over Voltage Protection Circuit +42V Over Current Protection Circuit Power Off Delay Circuit
Figure 2-15. VDC Circuit Block Diagram
The operating principles for the various protection and controller circuits shown above are described below.
Y+5 VDC line over voltage protection circuit The output voltage level of +5 V is monitored by a Zener diode (ZD53) in the secondary circuit. If the
Y+5 VDC line constant voltage control circuit / +5 VDC line over current protection circuit Voltage and current on the +5 VDC line are monitored by regulator IC51. Abnormal voltage or current on Y+42 VDC line over voltage protection circuit The output level of the +42 VDC line is monitored by two Zener diodes: ZD52 and ZD87. When the
output level of the +42 VDC line exceeds +48 V, switching FET Q1 goes OFF in the following sequence: Q Zener diodes (ZD52, ZD87) detect a voltage over 48 V on the +42 V line. Q Transistor Q81 goes ON. Q Photo coupler PC1 goes ON. Q FET Q31 goes ON, and the gate current for the switching FET Q1 is cut OFF. Q Switching FET Q1 goes OFF. the +5 VDC line are detected, and the information is fed back to the +5 V comparator in the IC. Then the +5 VDC is controlled or cut off.
voltage level exceeds 9 V, switching FET Q1 goes OFF, no induced voltage is generated, and production of the +5 VDC and +42 VDC stops as a result. The circuit operates as follows: Q Zener diode (ZD53) detects a voltage exceeding +9 V on the +5 V line. Q Transistor Q81 goes ON. Q Photo coupler PC1 goes ON. Q FET Q31 goes ON, and the gate current for switching FET Q1 is cut OFF. Q Switching FET Q1 goes OFF.
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Y+42 VDC line constant voltage control circuit Voltage on the +42 VDC line is monitored by Zener diodes ZD51 and ZD81 to ZD86. When the voltage
on the +42 VDC line exceeds 38 V, switching FET Q1 is controlled in the following sequence: Q Zener diodes (ZD52 and ZD81 to ZD86) detect the voltage over 38 V on the +42 VDC line. Q Transistor Q81 goes ON. Q Photo coupler PC1 goes ON. Q Transistors Q3 and Q2 go OFF, and gate current for the switching FET Q1 is cut OFF. Q Switching FET Q1 goes OFF. Q When the voltage level drops under +38 V, photo coupler PC1 and transistors Q3 and Q2 go OFF and switching FET Q1 goes back ON.
Y+42 VDC line overcurrent protection circuit
The output current is monitored by transistors Q81 and Q82. When the output voltage is abnormally low, this information is fed back to the primary circuit via the photo coupler PC1 to stop the switching operation.
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2.3.2 C202 MAIN Control Board

C202 MAIN control board consists of the following:
YLogic circuits for the PROM, DRAM, CPU, ASIC, and EEPROM YMotor control and driver circuits for the CR motor, PF motor, and pump motor YHead control/ driver circuits for the black and color heads YOther circuits for the I/F (parallel I/F, Mac serial, Type B I/F), sensors, RTC timers, and reset
C202 MAIN Control Board C202 PNL Board IC3 P-ROM (4M) IC7 CG-ROM (16M) IC5 DRAM (4M) C202 PSB/PSE Board
Figure 2-16 shows the circuit block diagram for the main control board.
+42 V +5 V IC11 EEPROM IC20 Timer IC
IC1 CPU
IC2 Gate Array

Black Ink Cartridge Black Ink Driver Circuit Color Ink Cartridge Color Head Driver Circuit Common Driver
IC16 PF Motor Driver IC13 CR Motor Driver IC6 Pump Motor Driver
Common Driver
IC15 Mac Serial I/F Tranceiver IC IC12 Parallel I/F IC Type B I/F
CR Unit
IC9 5 V Line Reset IC IC8 +42 V Line Reset IC HP Sensor PE Sensor HP Sensor
Data Bus
Address Bus
Figure 2-16. C202 MAIN Board Block Diagram
2-18
Table 2-11 shows the functions allocated for the CPU and gate array. Table 2-11. Functions Allocated for the CPU and the Gate Array IC Location
CPU
IC1
Gate Array
IC2
YSets the current value for each motor. YOutputs the driving trigger pulse for each motor. YOutputs the driving trigger pulse for each head. YOutputs the system clock. YInputs the resistance value for the thermistor. YInputs an ON/OFF signal indicating the installation status for each cartridge. YTransfers data received from the I/F to the DRAM. YControls interruption signals. YControls motor drivers. YControls print data for each head. YControls data from I/F and transfers it to the CPU. YOutputs head driver control pulses. YCounts the dot numbers used for printing. YControls voltages for EEPROM, control panel,
timers, and heads.
Function
2-19
2.3.2.1 Printhead Driver Circuit

The printhead driver circuits, built in separately on the black and color heads, consist of the common drivers (black head, IC17; color head, IC18) on the C202 MAIN board and nozzle selectors (black head, IR2C72C; color head, IR2C73C) on the head driver boards. Each common driver produces trapezoidal pulses according to signals sent from gate array IC2, and transfers them to the nozzle selector on the head driver board. Print data is converted into serial data in the gate array and is then transferred to the nozzle selector on the head driver board to select the nozzles to activate. The PZT common lines are selectively driven simultaneously, based on the driver waveform produced by the common driver to activate nozzles selected by the print data.
C202 MAIN Board
BCHG BKC BND1 BND2 BMD1 BMD2 SBDATA SCLK BHCLK BHLAT BBHDATA BAHDATA Gate Array VHPR 68 61 67 66 63 62 75 79 87 86 89 90 82
+5 V +42 V
Black Printhead Driver Board

IR2C72C
Common Signal
IC 17 HBD2813C
Common Driver (Black Head)
CN9
Nozzle Selector
VDD (+5 V)
Black Head Driver Waveform
BCLK BLAT BSI2 BSI1 VH
IC 2 E05B33CB
CCHG 74 CKC 69 CND1 73 CND2 72 CMD1 71 CMD2 70 SCDATA 76 CHCLK CHLAT YHDATA MHDATA CHDATA 95 94 99 98 97
IC 18 HBD2813C
Common Driver (Color Head)
CN10
IR2C72C
Common Signal
Nozzle Selector
VDD (+5 V)
Color Head Driver Waveform

CCLK CLAT CSI3 CSI1 VH VDD CCLK CLAT VH CSI2
IR2C73C
Nozzle Selector
Color Printhead Driver Board
Figure 2-17. Printhead Driver Circuit Diagram
YCommon Driver Circuit for the Black Head

Common driver IC17 HBD2813C produces trapezoidal waveforms by combining six signals (BCHG, BND1, BND2, BMD1, BMD2, and BKC) output from gate array IC2 E05B33CB, using the VM voltage as a basis. There are seven different types of trapezoidal waveforms produced for normal dot mode, Micro dot mode, and so on, and each form varies, depending on the width of the combined signals. The rising form is determined by the BCHG and BKC signals, regardless of the print mode. The falling form is determined by two different pairs of signals: BND1 and BND2 in normal dot mode; and BMD1 and BMD2 in Micro dot mode. The VH voltage adjustment value stored in the EEPROM, which is unique to each head, is read into the gate array, and then transferred as 8-bit serial data via the CBDATA signal to be set in the common driver. By this procedure, internal resistance is determined, and the driver waveform is adjusted as a result.
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Head Drive Waveform
LAT NCHG BCHG BND1 BND2 BMD1 BMD2 BKC
Figure 2-18. Waveform Producing Process for Black Nozzles
YBlack Head Nozzle Selector Circuit

Print data is input from data input ports D0 to D15 in gate array IC2 E05B33CB into the gate array to be converted into serial data and output to the nozzle selector from ports BBHDATA and BAHDATA. Data is then separated into two sides through ports BBHDATA and BAHDATA, which are allocated with two lines of black nozzles; the lines #1, #3 and #2, #4, respectively. The smaller-numbered nozzle on each line receives data faster. Data is transferred from IC2 gate array to nozzle selector IC IR2C72C at 64-bit / 2.5 MHz, synchronizing with the BHCLK (clock signal) and BHLAT (latch signal). The ON/OFF status of each nozzle in the nozzle selector is determined based on the data transferred.
YCommon Driver Circuit for the Color Head
The circuit structure for the color head is basically the same as for the black head. Common driver IC18 HBD2813C produces trapezoidal waveforms by combining six signals (CCHG, CND1, CND2, CMD1, CMD2, and CKC) output from gate array IC2 E05B33CB. There are seven different types of trapezoidal waveforms produced for normal dot mode, Micro dot mode, and so on, and each form varies, depending on the width of the combined signals. The rising form is determined by CCHG and CKC, regardless of the print mode. The falling form is determined by two different pairs of signals: CND1 and CND2 in normal dot mode; and CMD1 and CMD2 in micro dot mode. The VH voltage adjustment value stored in the EEPROM, which is unique to each head, is read into the gate array, and then transferred as 8-bit serial data via the SBDATA signal to be set in the common driver. By this procedure, internal resistance is determined and the driver waveform is adjusted as the result.
Head Drive Waveform
LAT NCHG CCHG CND1 CND2 CMD1 CMD2 CKC
Figure 2-19. Waveform Producing Process for Color Nozzles
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YColor Head Nozzle Selector Circuit

Print data is input from data input ports D0 to D15 in gate array IC2 E05B33CB into the gate array to be converted into serial data, and output to the nozzle selector from ports YHDATA, MHDATA, and CHDATA, depending on the color. Data is then allocated to the corresponding nozzle lines, alternating two lines: from #1 to #2. Data is transferred from gate array IC2 to nozzle selector IC IR2C72C at 64-bit / 2.5 MHz, synchronizing with the CHCLK (clock signal) and CHLAT (latch signal). The ON/OFF status of each nozzle in the nozzle selector is determined based on the data transferred.
2.3.2.2 Reset Circuits

The C202 MAIN board contains two reset circuits; for logic line (+5 V) and power line (+42 V). The voltages for +5 V and +42 V in each reset circuit are monitored to prevent printer malfunctions caused by abnormal voltage levels. When an abnormal condition is detected, a reset signal is sent to the CPU to reset the CPU and the gate array. The function of the reset circuit is described below.
YReset Circuit for the +5 V Line The +5 V reset circuit monitors the voltage level for the +5 V line at the 3 VCC port of IC9 PST592D,
Q When the printer is turned ON, a reset signal is output for 100 ms after the +5 V line voltage level rises to 4.2 V. Q During printing, when the 5 V line voltage level drops under 4.2 V, a reset signal is output. The reset signal does not go OFF until 100 ms passes after the +5 V line voltage level recovers to 4.2 V, as described above.
+5V
Reset IC for +5V line
and outputs a reset signal from port 1 VOUT to the CPU gate array when it detects an abnormal voltage level. IC9 is energized under the conditions below.
+5V
IC9
VOUT MRES VCC GND
1 2 3 4
R29 1K
27 MRES IC1 CPU RES 81 23 RESET IC2 Gate array
Figure 2-20. Reset Circuit for the +5 VDC Line
2-22
YReset Circuit for the +42 V Line

The +42 V reset circuit monitors the voltage level of 42 V line at the 3 VCC port of IC8 M51955D, and feeds back the information on power ON/OFF status to the CPU based on the detected voltage. When the +42 V line drops under +33.2 V, IC8 detects the power off status and outputs a reset signal from port 6 to CPU port 82 NMI via the OR circuit of IC19. When the voltage level recovers to 32.2 V, port 6 of IC8 stops outputting the signal, which is detected by port 78 of the CPU.
+42V +5V R78 10K
R11 120K 1% R12 4.65K 1%
Reset IC for +42V line NC8 8 1 NC1 VCC 7 2 IN IC8 OUT 6 3 NC3 NC5 5 4 GND
C15 0.1U
+5V IC19 1 4 2 TC7S32F
82 NMI 78 P21 IC1 RES 81 CPU
27 MRES
IC2 23 RESET Gate Array LED4 113
Figure 2-21. Reset Circuit for the +42 VDC Line
2-23
2.3.2.3 Motor Driver Circuits

This printer has three motors: the CR motor, PF motor, and pump motor. Since they are all driven by IC13 (UDN2917EB), they use the same control system.
YCR Motor Driver Circuit The phase control signal for the CR motor is converted into the UDN2917EB micro-step bipolar driver YPF Motor Driver Circuit The motor driver circuit for the PF motor is the same as for the CR motor. YPump Motor Driver Circuit
CRA0 51 CRA1 52 IC2 CRB0 53 Gate Array CRB1 54 CRAPH 55 CRBPH 56 198 CRTRG
Data Bus
system by gate array IC2. Then it is output from port 55 to ports 43 and 26 on IC13 UDN2917EB. IC13 determines the phase mode based on the signal sent. The current control signal is also produced in gate array IC2 and output from ports 51 to 54 to ports 1, 2, 23, and 24 on IC13 UDN2917EB.
The motor driver circuit for the pump motor is the same as for the CR motor.
2
1
I10 I11 I20 I21
23 24
A A B B
6 3 18 21
1 CR A 3 CR-A 2 CR B 4 CR-B
CR Motor
43 PH1 26 PH2 IC13 UDN2917EB
112 DA1
IC1 CPU
44 VREF1 25 VREF2
Figure 2-22. CR Motor Driver Circuit
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2.3.2.4 Sensor Circuits
Y photodiode sensors: 3 HP sensor, ASF HP sensor, PE sensor Y mechanism switch sensors: 2 Black and color cartridge sensors Y thermistor for the color head 1 YHP Sensor The HP sensor, mounted on the upper right end of the top frame, determines the CR home position. YASF HP Sensor This sensor is mounted on the left end of the ASF to detect ASF home position. While the printer is in
The sensors for this printer are:
When the CR returns to the home position, the detector plate attached to the back of the CR unit cuts in between sensor terminals, and a HIGH signal is output to the CPU. A LOW signal is then output to the CPU when the CR leaves the home position.
YPE Sensor The PE sensor, mounted on the bottom right end of the top frame in the printer mechanism, detects a
standby after printer power is turned on, the ASF is controlled to be located in ASF home position, which means the ASF is ready to load paper. ASF HP position is detected by the ASF HP sensor and the ASF detector wheel attached to the left end of the LD roller. A small portion of the ASF HP detector wheel has a cutout, and when the cutout comes into position between the photo diode terminals, ASF home position is detected. Then, a LOW signal is output to the CPU. When the cutout leaves home position, the ASF detector wheel cuts in between photo diode terminals, and a HIGH signal is output.
YInk Cartridge Sensor An ink cartridge sensor built into each printhead determines whether a black or color ink cartridge is YPrinthead Thermistor
installed. An installed cartridge presses the sensor plate down, connecting two terminals on the printhead driver board. Then a LOW signal is output to the CPU. If no cartridge is installed, the sensor plate loses contact with the terminals on the head driver board, and a HIGH signal is output to the CPU.
paper end. A paper end is detected when the detector plate on the PE sensor lever cuts in between the photodiode terminals, and a HIGH signal is output to the CPU. When paper is loaded, it pushes up the PE sensor lever. With this motion, the detector plate, along with the PE sensor lever, is held up so that it does not fall between diode terminals, and a LOW signal is output to the CPU.
A printhead thermistor is attached directly to the color printhead driver board. The printer refers to the thermistor signal, which indicates the temperature around the printhead and feeds back the information to CPU analog port 105. This information lets the printer control the head drive discharge voltage pulse, based on the ink viscosity. The normal resistance for this thermistor is 10K 10% at 77 F (25 C).
Head Thermistor
105
AN0
SWA0
57
+5V
+5V HP Sensor
Black Ink Cartridge Sensor Color Ink Cartridge Sensor
106 107
P41 P42
IC1 CPU
Data Bus
IC2 SWC0 Gate Array
59
+5V
+5V ASF HP Sensor
+5V SWC1 60 +5V PE Sensor
Figure 2-23. Sensor Circuits
2-25
2.4 Ink System Management

This section explains how the ink system is controlled to protect the printheads and ink supply and ensure high-quality output. This printer has several ink system control sequences, which vary for combinations of basic ink system operations. The printer selects the most suitable sequence by referring to printer information, such as values for the timers and counters stored in the EEPROM, flags, and numbers of sensor signals. This section describes basic ink operations, timers counters, and ink sequences.
2.4.1 Ink System Operations

The basic ink system operations are as described below.
YRubbing This operation rubs the printhead surface against the felt part of the head cleaner (left half of the blade)
YWiping This operation moves the CR from right to left to rub the printheads against the rubber part of the head
in the pump unit by moving the CR from left to right. The printer does this to eliminate ink and dust on the printhead surface to regain normal ink ejection and ensure firm head capping. A small amount of ink is sent to the nozzle surface before the rubbing operation to make adhering objects come off easily.
YInk Absorbing This operation draws ink out of the ink cavities by rotating the pump for both black and color heads using
cleaner (right half of the blade) in the pump unit. The printer does this prior to ink absorption to eliminate ink and dust on the printheads to regain normal ink ejection and ensure firm head capping.
YFalse Absorbing This operation removes ink remaining inside the caps by rotating the pump for black and color heads YMicro Absorbing This operation absorbs ink from the ink cavity by rotating the pump for black and color using the YFlushing
using the specified steps while the head surfaces are capped and the air valves open. This removes ink from the nozzle plate by vacuuming and ejecting ink remaining after the Ink absorbing and flushing operations.
the specified steps while the head surfaces are capped and the air valves closed. The printer does this to eliminate the ink that has increased viscosity and bubbles around the nozzles.
specified steps while the head surfaces are capped and the air valves open. This sensitive operation eliminates bubbles formed in the ink cavities during the Ink absorbing operation.
This operation ejects a specific amount of ink from the head when the CR moves to the false absorbing position. This is done to prevent increases in ink viscosity. There are three types of flushing, as listed below. Table 2-12. Flushing Specifications Power flushing Periodic flushing Cleaning flushing Numbers of Shots Driver Waveform 4000 shots + 2 V, maximum 36 V for the correct voltage of the normal dot 36 shots Waveform for the normal dot 1400 shots Waveform for the normal dot
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YMicro Vibration
Micro vibration is done to prevent ink from increasing in viscosity. The printer micro vibrates the ink in the cavity by applying a driver voltage and pulse that vibrates the piezo elements. The printer only does this while the CR motor is accelerating to move the CR for printing.
2.4.2 Timers and Counters
YCL Timer (set individually for black and color ink) The CL timer manages auto cleaning. It remains active while printer power is off and is reset when cleaning done. YAccumulated Printing Timer (set individually for black and color ink) This timer adds up the amount of time spent printing. The value of this timer is not cleared after printer
This printer has a number of timer counters, soft counters, and flags. Their values, usually stored in the EEPROM, are the basis for selecting the ink sequence to be performed.
YPower Off Timer This timer monitors how long printer power is off. YInk Counter RB, Ry (set individually for black and color ink) This counter monitors the amount of ink used in the cap during flushing. The value is stored after printer
power off. The timer is activated when the head is uncapped and pauses its adding when the printer goes into the wait state. The value of this counter is reset when an ink absorbing operation is done.
YCL2 Counter KKb, Kky (set individually for black and color ink) The printer uses this counter value to determine the order of manual cleaning cycles run through the YProtect Counter A This counter monitors the total amount of ink drained to the waste ink drain pads. When the value YInk Consumption Counter Cb, Cy, Cm, Cc (set individually for black and color ink)
control panel. Cleaning is usually performed in the order CL1, CL1, and CL2. This printer, however, does not necessarily follow this order, depending on the number of pages printed since the last cleaning. (See the description of the cleaning cycles in Section 2.4.3 on the next page.)
power is turned off. When the value exceeds a specified value, the printer performs false absorbing and then resets the counter.
exceeds a specified amount (the counter value = 49000), a maintenance error occurs. The counter is reset by the EEPROM reset operation.
Each counter measures the ink consumed through printing, cleaning, and flushing after an ink cartridge is installed. The printer or the EPW indicates an INK LOW or INK END based on the counter value. Even if the printer is turned off before a cleaning sequence completes, the printer regards the job as a full cleaning and adds the specified value for the cleaning to the consumption counter. The counter is reset only when a cartridge is removed in cartridge replacement mode, which is selected on the control panel. Table 2-13. Ink Consumption Counter INK LOW counter INK END counter Black Ink Cartridge 7 37.6 10 dots 7 41.6 10 dots Color Ink Cartridge 7 17.2 10 dots 7 19.2 10 dots
2-27
2.4.3 Ink System Sequences

The ink system sequences in this printer are combinations of basic ink system operations described in Section 2.4.1. The printer selects the most suitable ink sequence based on information provided by various counters, timers, and flags. The major ink system sequences are described in this section.
YManual Cleaning Manual cleaning is performed by pressing the CLEANING button on the control panel. The cleaning
mode to be used is selected from the following 5 modes based on the CL2 counter value for KKB, Kky (cleaning selection counter) and the number of the pages printed after the last cleaning.
Y (normal cleaning mode): CL1 Y (powerful cleaning mode): CL1 Y (powerful cleaning mode): CL2 Y (false cleaning mode): CL3 Y One-time CL:
wiping, ink absorbing, micro absorbing, false absorbing. wiping, ink absorbing, micro absorbing, false absorbing. The combined operations are same as in CL1, except for the amount of ink consumed. wiping, rubbing, ink absorbing, micro absorbing, false absorbing. Every operation except rubbing is the same as in CL1. However, the amount of ink consumed is larger than in CL1. wiping, micro absorbing, false absorbing. The amount of ink consumed is very little, since ink is not absorbed. wiping, ink absorbing, micro absorbing, false absorbing. The combined operations are same as in CL1, but the amount of ink consumed in this cleaning mode is the largest amount of ink.
The CL2 counter is used to determine the cleaning mode to be performed when the manual cleaning is repeated. The counter resets if the printer is turned off. The printer normally follows the order CL1 CL1 CL2. However, this can vary, depending on the conditions described below:
VCL3 is selected if no image has been printed since the latest cleaning. VCL1 is selected if more than 5 pages have been printed since the latest cleaning. VCL1, CL1, or CL2 selection is based on the CL2 counter value for Kkb, Kky under the following V
conditions: 5 or fewer pages have been printed since the latest cleaning, and the current ink cartridge is a replacement for an old one that was removed after an INK END or INK LOW error. One time CL is performed under the following conditions: 5 or fewer pages have been printed since the latest cleaning, but the current cartridge is a replacement for one that was removed without an INK END or INK LOW error.
YTimer Cleaning This cleaning is done automatically, based on the value of the CL timer counter while printer power is
on. The sequence, which has four separate modes (Timer CL1, Timer CL2, Timer CL3, and Timer CL4) for black and color ink, differs from manual cleaning modes. It does not include ink absorbing, but only uses wiping and micro absorbing operations. Therefore, little ink is consumed compared to manual cleaning.
2-28
YPower ON Sequence During this sequence, the printer does the following: VRefers to protect counter A. VResets CL2 counter Kkb, Kky. VChecks if ink cartridges are installed. VChecks consumed ink amount. VPerforms necessary cleaning, based on the conditions such as initial charging, HP status, the power off timer, and CL timers. VResets the power off timer. YCartridge Replacement Sequence The printer determines which ink cartridge (black or color) needs replacing during the cartridge
replacement CL sequence, based on conditions such as cartridge installation, INK LOW, and INK END. The cartridge replacement CL sequence consists of wiping, ink absorbing, micro absorbing, and false absorbing. It consumes less ink than the manual cleaning sequence. (If the initial charge flag is not detected during this operation because the printer is new, the printer enters initial ink charge sequence, instead.) During the cartridge replacement sequence, the one-time flag is reset or set in the EEPROM, depending on the amount of ink consumed in the removed cartridge. (If 50% was used or not.) This flag indicates whether the cartridge was removed because of an INK END error or by accident. The printer stores this information in the EEPROM to refer to when selecting the manual cleaning mode to carry out. If less than 50% ink was consumed in the ink cartridge that was removed from the CR unit, the one-time flag is set in the EEPROM, and one-time cleaning is carried out as the first manual cleaning operation after completion of the cartridge replacement sequence.
YInitial Charge Sequence
The printer performs wiping, rubbing, ink absorbing, micro absorbing, and false absorbing during the initial charge sequence. This sequence is performed according to the status of the initial charge flag. This sequence consumes a large amount of ink (about 20 % of total ink amount) and requires approximately seven minutes to execute. The CL timers for each color, accumulated printing timer, initial ink charge flag, and one-time flag are reset at the completion of this sequence.
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Chapter 2 Operating Principles

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2.2 Printer Mechanism Operating Principles

ASF Mechanism Pump Motor Disengage Mechanism Paper Feed Mechanism

CR Lock Mechanism PF Motor

Figure 2-1. Printer Mechanism Block Diagram

EPSON Stylus COLOR 800 Service Manual

2.2.1 Printing Mechanism

Printhead Driver Board

Ink Cartridge Sensor Lever Cartridge Needle

PZT Cavity Nozzle Plate

Filter Ink Tube

Figure 2-2. Printhead Structure

EPSON Stylus COLOR 800 Service Manual

2.2.1.1 Printing Process

2.2.1.2 Printing Methods

EPSON Stylus COLOR 800 Service Manual

2.2.2 Carriage (CR) Mechanism

Driven Pulley CR Guide Shaft

CR Motor Pinion Gear

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EPSON Stylus COLOR 800 Service Manual

2.2.3 Paper Feed Mechanism

YPaper feed part

YPaper eject part

Gear (70 mm)

Gear (19 mm)

Gear (17 mm)

Paper Eject Roller

Front Paper Guide Assembly

Figure 2-5. Paper Feed Mechanism

EPSON Stylus COLOR 800 Service Manual

2.2.4 Platen Gap (PG) Adjust Mechanism

Figure 2-6. PG Adjust Mechanism

EPSON Stylus COLOR 800 Service Manual

2.2.5 CR Lock Mechanism

Gear (70 mm)

Gear (19 mm)

Paper Eject Roller Gear (17 mm)

Front Paper Guide

Compression Spring (5.85 g)

Figure 2-7. CR Lock Mechanism

2.2.6 ASF Mechanism

YDisengage Mechanism Switch Process

EPSON Stylus COLOR 800 Service Manual

The figure below shows movements in steps 3 to 5.

Gear (11.5 mm) Slider Shaft

Gear (16 mm) (Slider Mechanism)

Combination Gear (12 mm, 15 mm)

Figure 2-8. ASF Mechanism

YTransmission Process for Pump Motor Torque

EPSON Stylus COLOR 800 Service Manual

YASF Multi Feed Prevention Mechanism

Pad Spring Paper Feedback Lever

Figure 2-9. ASF Multi Feed Prevention Mechanism

YASF Multi Feed Prevention Mechanism Operating Principles

EPSON Stylus COLOR 800 Service Manual

2.2.7 Ink System

Capping Mechanism Black Ink Cartridge Color Ink Cartridge

Pump Drive Shaft Gear (21.6 mm)

Pump 2 Pump Reduction Shaft

Pump Mechanism Waste Ink Drain Pads