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EPSON TERMINAL PRINT ER EPSON/Stylus Color 200 EPSON/Stylus 200 SERVICE MANUAL EPSON Rev.A 4006645.
NOTICE All rights reserved. Reproduction of any part of this manual in any form whatsoever without SEIKO EPSON’s express written permission is forbidden. The contents of this manual are subjects to change without notice. All efforts have bee n made to ensure the accuracy of the contents of this manual.
PRECAUTIONS Precautionary notations throughout the tex t are categorized relative to 1) personal jnjuury and 2) damag e to equipment. DANGER Signals a precaution which, if ignored, could result in serious or fatal personal injury. Great caution should be exercised in performing procedure s preceded by DANGER Headings.
PREFACE This manual describes functions, theory of electrical and mechanical operations, maintenance, and repair of Epson Stylus Color 200 /Epson Stylus 200. The instructions and procedures included herein are inte nded for the experience repai r technician, and attention should be given to the precautions on the preceding page.
REVISION SHEET Revision Issue Date Contents Rev.-A July 15,1996 1st issue -v-.
TABLE OF CONTENTS CHAPTER 1. PRODUCT DESCRIPTION CHAPTER 2. OPERATION PRINCIPLES CHAPTER 3 DISASSEMBLY AND ASSEMBLY CHAPTER 4. ADJUSTMENT CHAPTER 5. TROUBLESHOOT ING CHAPTER 6.
Chapter 1 Product Description Table of Contents 1.1 OVERVIEW 1-1 1.2 SPECIFICATIONS 1-2 1.2.1 Printing Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 1.2.2 Paper Handling Specifications . . . . . . . . .
List of Figures Figure 1-1. Exterior View of EPSON Stylus Color 200 . . . . . . . . . . . . . . . . . . 1-1 Figure 1-2. Nozzle Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Figure 1-3. Printable Area . . . . .
1.1 FEATURES The Epson Stylus Color 200/Epson Stylus 200 printer are color ink jet dot matrix printers that come with a 64-nozzle black printhead and a 60-noz zle CMY color printhead, either of which can be installed in the printer.
1.2 SPECIFICATIONS This section provides statistics and other detailed information for the printer. 1.2.1 Printing Specifications Print system: On-demand ink jet system Nozzle configuration: 64 nozzles (10 × 2 + 11 × 4 standard ): monochrome 60 nozzles (20 × 3 standard): color Printing direction: Bidirectional with logic-seeking Table 1-1.
Character tables: Legal and 14 international sets Table 1-2. Character Tables Character Tables Bitmap Fonts Scalable Fonts EPSON Roman EPSON Sans Serif EPSON Courier EPSON Roman EPSON Sans Serif EPSON Roman T EPSON Sans Serif H Standard Italic Supported Supported Supported PC437 (U.
1.2.2 Paper Handling Specifications Feeding method: Friction feed paper is fed from the built-in auto sheet feeder (ASF). Line spacing: 1/6 inch feed or programmable in 1/360 inch minimum inc rements. Paper path: Cut sheets are fed from the built-in auto sheet feeder (ASF).
The adjust lever on the uppe r case must be set to the proper position for the paper thickness, as shown in Table 1-4. Table 1-4. Adjust Lever Settings Paper Lever Position Paper Thickness Cut Sheets Front (0 position) 0 mm Envelops Rear (+position) 0.
1.2.4 Ink Cartridge Specifications Table 1-6. Black I/C Specifications Item Specifications Type Exclusive cartridge Color and Weight Approximately 54 g (internal ink weight is 36 g ± 0.
1.2.5 Electrical Specifications Table 1-8. Rated Electrical Ranges Specification 120 V Version 220 - 240 V Version Rated voltage 120 VAC 220 - 240 VAC Input voltage range 103.5 ∼ 132 V 198 ∼ 264 V Rated frequency range 50 ∼ 60 Hz 50 ∼ 60 Hz Input frequency range 49.
1.2.7 Reliability Total print volume: 25,000 pages (A4, letter) MTBF: 4000 POH (Duty 7%) MCBF: 1 million pass ( except print head) Printhead life: 1000 million dots/nozzle (color and monochrome) 1.2.8 Safety Approvals Safety standards: 120 V version: UL1950 with D3, CSA C22.
1.3 INTERFACE SPECIFICATIONS The EPSON Stylus Color 200/EPSON Stylus 200 is standa rd-equipped with an 8-bit paral lel and serial interface. 1.3.1 Parallel Interface Specifications (Forward Channel) D.
Table 1-10 and 1-11 shows the connector pin assignments and signal functions of the 8-bit parallel interface. Table 1-10. Signal and Connector Pin Assignments for Parallel Interface Pin No. Signal Name I/O* Description 1 -STROBE I Strobe pulse. Input data is latched at falling edge of the signal.
1.3.2 Parallel Interface (Reverse channel) Transmission mode IEEE-1284 nibbl e mode Adapatable connector 57-30360 (Amphenol) or equivalent Snynchronization Refer to the IEEE-1284 specification Handsha.
1.4 OPERATIONS This section describes the basic operations of the printer. 1.4.1 Control Panel The control panel for this printer has 2 non-lock-type push buttons, and 3 LED indicators for easy opera tion of the various printer functions.
Table 1-13. Built-in Functions on the Panel Button Function 1’st switch Switch pushed with power on and release 2’nd switch Switch pushed within 3 seconds after power on ^ Cleaning ——— Self .
1.4.3 Default Settings The printer can save some printer setting parameters that define its functions at initialization. You can change these parameters using the printer’s default setting mode. 1.4.3.1 Default Setting Items You can use default setting mode to change settings listed in the table below.
Table 1-17. Default Setting Items (Continued) Item Contents Auto line feed Off On Loading position 8.5 mm 3 mm Thick paper Envelopes Index card (portrait) Note: The underlined value is the factory setting. 1.4.3.2 Changing the Default Settings User is requested to operate 2 buttons watching 3 lights on the control panel.
1.4.4 Error Conditions The printer can detect various errors and indicate them with LEDs. Refer to Table 1-14. 1.4.5 Printer Initialization There are three initialization methods: power-on initialization, software initialization and operator initialization.
1.5 MAIN COMPONENTS The main components of the Stylus Color IIs are : ❏ Printer mechanism (M-4C11) ❏ Main control board (C199 MAIN Board) ❏ Power supply unit (C160 PSB/PSE Board) ❏ Control panel board (C160 I/F Board) ❏ Housing 1.
1.5..2 Power Supply Board (C160 PSB/PSE Board) The power supply board (C160 PSB/PSE Boar d) consists of an RCC switching regulator circuit. This board does not have a power switch connec ted to the secondary circuit like the Stylus Color series.
1.5.4 Printer Mechanism (M-4C11) The M-4C10 printer mechanism is equipped with a repla ceable 64-nozzle black printhead and 60-nozzle color (CMY) printhead, and it can print at a high resolution (720 dpi) using the special coated paper.
Chapter 2 Operating Principles Table of Contents 2.1 OVERVIEW 2-1 2.1.1 C199 Main Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 2.1.1.1 Carriage Motor Driver Circuit . . . . . . . . . . . . . . . . . .
2.1 OVERVIEW Since the printer mechanism of the EPSON Stylus COLOR 200 is the same as for the EPSON Stylus COLOR IIs, this section only describe s the differences in electrical circuitry. 2.1.1 C199 MAIN BOARD The main control board for the EPSON Stylus COLOR 200 is the C199 MAIN board.
2.1.1.1 Carriage Motor Driver Circuit Carriage motor drive r IC UDN2917EB (IC8) outputs a constant current to drive the carriage motor. CPU M3772152BFP (IC2) determines the motor phase and speed, and then sends a signal to the UDN2917EB car riage motor driver IC (IC8) via a 4-bit signal transmission line.
In the Table 2-1, if the control sequence is executed in incremental order , the carriage motor rotates clockwise (CW). (The CR moves from 1st column to 80th column.) Signals output from ports P105, P106, and P107 of the CPU deter mine the reference trip curr ent level used by the motor driver IC for drive curr ent control.
Chapter 3 Disassembly and Assembly Table of Contents 3.1 OVERVIEW 3-1 3.1.1 Precau tions for Disassembling the Printer . . . . . . . . . . . . . . . . . . . . . . 3-1 3.2 DISASSEMBLY AND ASSEMBLY 3-1 3.2.1 Upp er Case Removal . . . . . . . . . . . . .
LIST OF FIGURES Figure 3-1. Upper Case Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Figure 3-2. C199 Main Board Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Figure 3-3. ASF Sensor Removal .
3.1 OVERVIEW This section describes procedure s for disassembling the main components of the printer. Unless otherwise specified, disassembled units or components can be reassembled by reversing the disassembly procedure. Therefore, no assembly proced ures are included.
3.2.1 Upper Case Removal 1. 1. Remove the sheet guide from main unit. Then remove 2 CBB (M4 × 11) screws securing the upper case to the bottom case. 2. Open the front cover; then remove 2 CBB (M4 × 11) screws securing the upper case to the bottom case.
3.2.2 C199 MAIN Control Board and ASF Sensor Removal 1. Remove the upper case (see Section 3.2.1). 2. Remove 4CBB (M3 × 6) screws attaching the shield frame to the C160 MAIN Board. 3. Remove 7 connectors (CN1, CN8, CN7, CN4, CN3, CN5, CN6) on the main board.
5. Remove 3 CPS (M3 × 6) screws fixing the board frame to the mechani sm and 1 CPS (M3x6) screw fixing the metal stay between the board frame and the right side frame. Then remove the met al stay. 6. Remove 2 CPS (M3 × 6) screws fixing the transpearency plat e, then remove it.
3.2.4 C160 PSB/PSE Board Removal 1. Remove the upper case (see Section 3.2.1). 2. Remove 1 CBB (M3 × 10) screw securing the power supply board to the lower case, 1 CPS (M3 × 6) screw securing the bo.
3.2.5 M-4C11 Printer Mechanism Removal 1. Remove the upper case (see Section 3.2.1). 2. Remove the C199 MAIN Boa rd (see Section 3.2.2). 3. Remove the C160 I/F Board (see Section 3.2.3). 4. Remove the C160 power supply board (see Section 3.2.4). 5. Remove 4 CBB (M4 x 11) screws securing the printe r mechanism to the lower case.
3.2.6 Printer Mechanism Disassembly The procedures described in this section explain how to remove compon ents within the printer mechanism. 3.2.6.1 Carriage Unit Removal 1. Remove the printer mechanism (see Section 3.2.6). 2. Remove the blue PG lever.
4. Remove the parallelism adjust lever by rotating it toward front while pulling the lever knob. 5. Remove the timing belt while pressing the pulley holder, then remove the ca rriage unit along with the carriage guide shaft. Parallelism Adjust Lever Lever Knob 1 2 Figure 3-9.
3.2.6.2 ASF Unit Removal 1. Remove the printer mechanism (see Section 3.2.5). 2. Press down the tab on the left side; then pull the ASF unit toward you. 3. Press the tab on the right side; then remove the ASF unit. When you remove the ASF, be extrem ely careful of the PE sensor.
3.2.6.4 Pickup Roller Unit Removal 1. Remove the printer mechanism (see Section 3.2.5). 2. Remove the ASF unit (see Section 3.2.6.2). 3. Remove the PE sensor (see Section 3.2.6.3). 4. By rotating it, remove 1 shaft holder securing the roller shaft to the frame.
3.2.6.6 Paper Feed Roller Unit Removal 1. Remove the printer mechanism (see Section 3.2.5). 2. Remove the carriage unit (see Section 3.2.6.1). 3. Remove the carriage home position sensor (see Section 3.2.6.5). 4. Remove the tension spring holding the tension roller assembly to the sub frame.
3.2.6.8 Head Cleaner Replacement 1. Remove the printer mechanism (see Section 3.2.5). 2. Remove the front frame (see Section 3.2.6.6). 3. Use tweezers to unhook the head cleaner. ❏ Never touch the head cle aner with your bare hands. ❏ When attaching the head cle aner, wear gloves and use clean tweezers to handle it.
3.2.6.9 Cap Unit Removal 1. Remove the printer mechanism (see Section 3.2.5). 2. Remove the front frame (see Section 3.2.6.6). 3. Remove 1 CPS (M3x6) screw securing the cap unit to the lower frame. 4. Remove 1 CPS (M3x6) screw securing the black holde r to the frame 5.
3.2.6.10 Paper Feed Motor Removal 1. Remove the printer mechanism (see Section 3.2.5). 2. Remove the pump unit. (see Section 3.2.6.9). 3. Remove the 2 CBB (M3 x 10) screws securing the pape r feed motor to the motor frame. Pin HOLE Pin Holder Pump Unit Pin Figure 3-20.
Chapter 4 Adjustment Table of Contents 4.1 OVERVIEW 4-1 4.1.1 Bi-D (Bidirectional Printing) Alignment Adjustment . . . . . . . . . . . . . . . 4-2 4.1.2 Head Angle Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 4.
4.1 OVERVIEW This section describes adjustments required when the printer is disassembled and assembled for repair. ❒ After removing an ink cartridge, always install a new cartridge immediate ly. During adjustments and testing, use cartridges designed exclusively for service : Monochrome:1023206 CMY (Color):1029341 Table 4-1.
4.1.1 Bi-D (Bidirectional Printing) Alignment Adjustment The bidirectional alignment adjustment is required when the printer me chanism, main board, or printhead (or printhead board) is repla ced. Performing this adjustment determines the compensation value needed to rectify any deviation in the print position.
4.1.2 Head Angle Adjustment The adjust lever on the ca rriage unit calibrates the printhead mounting position on the carriage unit. You must adjust the position of this lever properly to compensate for deviations in the carriage unit and the printhead.
4.1.4 Platen Gap Adjustment This adjustment is required after you have removed the carriage unit from the main unit or replaced the carriage unit. Adjust the distance between the printhead nose and the pape r surface to 1.
4.1.5 EEPROM Rese t Procedure Like other EPSON ink jet printe rs, this printer is equipped with an EEPROM on the main board. This EEPROM stores status information and ink system manageme nt parameters.
4.1.5.2 EEPROM Initialization for Main Board Replac ement If the main board malfunctions and is unable to read out the contents of the EEPROM, replac e the main board with a new one, and follow the steps below. 1. Replace the ink cartridge currenly installed on the printhead with a new one.
Chapter 5 Troubleshooting Table of Contents 5.1 OVERVIEW 5-1 5.2 Repair the C160 Power Supply Board 5-3 5.3 Repair the C199 Main Control Board 5-4 5.4 Repair of PRINTER MECHANISM 5-6 5.5 Dot missing Troubleshooting Guide 5-7 LIST OF FIGURES Figure 5-1.
5.1 OVERVIEW This section describes troubleshoot ing at the unit level and for abnorma l printing(missing-aligned dots). The EPSON Stylus Color 200/Epson Stylus 200 uses a new print head tha t is different from the previous Stylus Color print head. Be cause of its designs, the status monitor indic ates when the cartridge is low or out of ink.
Table 5-2. Sensor Status Sensor Point Signal Level Status PE Sensor CN7 Pin 1 (PE) to Pin 2 (GND) H (5 V) Paper exists L (GND) No paper (paper end) CO Sensor CN4 Pin 3 (CO) to Pin 8 (GND) L (GND) Cart.
5.2 Unit-Repair - C160 Power Supply Board This section describes how to repair the C160 power supply board and main board. The table below provides various symptoms, likely causes, and check points. The checkpoints refer to waveforms, resistances, and other values to check to evaluate the operation of each compon ent.
5.3 Unit Repair - C199 Main Control Board This section describes the problems related to the main controller board (C199 Main). The table below provides various symptoms, likely causes, and checkpoints. The checkpoints refer to wave forms, resistance, and other values to be checked to evaluate the operation of each component.
So lution Phen omen on Condi ti on C au se Checkpoint s Carriage does not operat e normal ly . Driv e pulse does not outp ut . CPU is defe ctive. IC12 i s defe ctive. Do es the wa ve -fo rm cor re ct ? (Che ck pi n ei t her a t 9 and 10. ) Replace C PU .
5.4 Repair of PRINTER MECHANISM Any problems related to the printer mechani sm should be repaired according to the troubleshooting procedures in Table 5-5. Table 5-5. Repair of the Printer Mechanism Symptom Condition Cause Checkpoint Solution The pump mechanism does not operate.
5.5 Dot missing Trouble shooting Guide This section describes how to recover the clogged nozzle when you rece ive the dot-missing printer. Since the print head of this printer is the new system, it is.
5.5.1 How to recover the dot-missing with the brand-new ink cartridge The following flow-chart shows the way of recovering a clogged nozzle with the ink ca rtridge. The section that is indicated out of each items shows the additional explanation when you need more information.
5.5.1.1 How to Perform the 360-DPI Printing It is possible to confirm the any problems with the 360-DPI check pattern printing. Also, if you receive the white banding problem, you can confirm the wrong condition quickly. Please perform the proper repair referring under explanations.
5.5.1.3 Performing the CL operation for 2 ~ 3 times This section describes the cleaning operation if you find a print missing on the 360-DPI check pattern. You need a confirmation either the CL opeartion is correctly performed or not in this function.
5.5.1.4 Is the Head angle correct? This section describes either the head angle cond ition is correct or not. Refer to Section 4.1.3 for the ac rual adjustment. [Step 1] Perform the head angle adjustment. (Refer to Section 4.1.3.) Note: If the head angle condition is wrong, white or color banding problem will be appe ared on the graphic pattern.
Chapter 6 Maintenance Table of Contents 6.1 PREVENTIVE MAINTENANCE 6-1 6.1.1 Printhead Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 6.1.2 Waste Ink Drain Tank Replacement . . . . . . . . . . . . . . .
6.1 PREVENTIVE MAINTENANCE This printer must be lubricated only O-11 when you need a lubrication for carriage guide shaft. If you lubricate with another oil, it could permanently damage the print head unit.
3. Hold down the Load/Eject button as the printer is turned back on. This prints a demonstration page in order to check the result. 4. Turn off the printer to exit demonstration mode. If the cleaning operation is performed more than 4 times continuously, ink is not absorbed because of dummy CL sequence function.
6.1.3 Lubrication and Adhesives The printer must be lubricated properly when it is disassembled for com ponent replacement, or if mechanic al noise exceeds a ce rtain level.
Figure 6-1. Lubrication and Adhesive Point Maintenance Epson Stylus Color 200 / Epson Stylus 200 6-4 Rev. A.
Appendix Table of Contents A.1 CONNECTOR SUMMARY A-1 A.1.1 Detail of Connector Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2 A.2 CIRCUIT DIAGRAMS A-5 A.3 CIRCUIT BOARD COMPONENTS Layout A-10 A.4 EXPLODED DIAGRAMS A-11 LIST OF FIGURES Figure A-1.
A.1 CONNECTOR SUMMARY The figure below shows the interconnection betwe en the major components of the Epson Stylus Color 200/Epson Stylus 200. AC IN LET C160PSB CN1 CN2 CN 6 CN1 CN7 PE CN9 ASF CN8 HP C199MAIN CN4 CN5 CN3 Ce ntr onics PF MO TOR CR MOT OR CN2 SERIAL Head Figure A-1.
A.1.1 Connector Summary This section describes the connector summary. The table A-1 lists the connoctor summary for every connectors on the C199 main and the C160 power supply board. Also, the table A-2 to table A-10 lists the detail signals for every connectors.
Table A-3. Connector Pin Assignments — CN2 Pin I/O Name Description 1 I DTR Data terminal ready signal 2 O TXD- Transmit data signal 3 — GND Signal Ground 4 I RXD- Receive data signal 5 O TXD+ Transmit data signal 6 I RXD+ Receive data signal Table A-4.
Table A-6. Connector Pin Assignments — CN5 Pin I/O Name Description 1 O PFA PF motor drive phase A 2 O PF-/A PF motor drive phase /A 3 O PF-B PF motor drive phase B 4 O PF-/B PF motor drive phase /B Table A-7. Connector Pin Assignments — CN6 Pin I/O Name Description 1.
A.2 CIRCUIT DIAGRAM Figure A-2. C160 PSB Board Circuit Diagram Epson Stylus Color 200/Epson Stylus 200 Appendix Rev. A A-5.
Figure A-3. C160 PSE Board Circuit Diagram Appendix Epson Stylus Color 200/ Epson Stylus 200 A-6 Rev. A.
Figure A-5. C160 PSB Board Component Layout Figure A-6. C160 PSE Board Component Layout Epson Stylus Color 200/Epson Stylus 200 Appendix Rev. A A-9.
A.3 Circuit Board Component Layout Figure A-7. C199 Main Control Board Component Layout Appendix Epson Stylus Color 200/ Epson Stylus 200 A-10 Rev. A.
A.4 Exploded Diagram Figure A-8. EPSON Stylus Color 200 Exploded Diagram (1) Epson Stylus Color 200/Epson Stylus 200 Appendix Rev. A A-11.
Figure A-9. EPSON Stylus Color 200 Exploded Diagram (2) Appendix Epson Stylus Color 200/ Epson Stylus 200 A-12 Rev. A.
Figure A-10. EPSON Stylus Color 200 Exploded Diagram (3) Epson Stylus Color 200/Epson Stylus 200 Appendix Rev. A A-13.
EPSON.
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