Epson EPL-5500 User Manual

EPSON TERMINAL PRINTEREPL-5500SERVICE MANUALEPSON4005431

Chapter 1 General DescriptionTable of Contents1.1 FEATURES 1-11.2 SPECIFICATIONS 1-31.2.1 Basic Specification . . . . . . . . . . . . . . . . . . .

4.1 ADJUSTMENTSThis section describes the adjustment procedures for the EPL-5500. You must perform theseadjustments after servicing the printer, esp

Chapter 5 TroubleshootingTable of Contents5.1 OVERVIEW 5-15.2 SELF-DIAGNOSTIC FUNCTION 5-15.2.1 SOFT ERROR . . . . . . . . . . . . . . . . . . . .

5.1 OVERVIEWThe EPL-5500 has a sophisticated, built-in, self-diagnostic function that reduces the troubleshootingtime by identifying failed parts or

5.2.2 Service Call ErrorIf the printer detects a fatal error that unrecoverable by the user, the printer indicates it with the LEDlights as "Serv

Note that if any digit of corresponding error number is "0", both yellow andred LED lights go on and off once at the same time.EPL-5500 Serv

Example: "Standard ROM error" (error number = 1130)OrderLED(Yellow)LED(Red)Interval State1 ON OFF Short Service Call Error B indication2 OFF

Error No.Error Code Error Condition43211000 C1000 RAM Validation error1001 C1001 System RAM check error1002 C1002 Standard RAM error1003 C1003 Optiona

5.3 TROUBLESHOOTINGThis section describes troubleshooting abnormal operations and print quality problems.5.3.1 Troubleshooting of Abnormal Operation

Table 5-5. The Printer Does Not Operate at AllCause Step Checkpoint Finding SolutionConnector CN207 on theC169 MAIN-B Board may bedisconnected.1Is co

Cause Step Checkpoint Finding SolutionThe interlock switch lever isbad.1Does the switch turn on whenthe case is closed?NoReplace the interlocklever.Th

1.5.7 Developing Cartridge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-361.5.8 Lower Paper Cassette Unit . . .

Table 5-8. The LED Does Not Come On (2)Cause Step Checkpoint Finding SolutionThe paper take-up solenoidcoil may be open or shorted.1Disconnect connec

Table 5-8. The LED Does Not Come On (2) (Continued)Cause Step Checkpoint Finding SolutionThe main motor coil may beopen or shorted.2Disconnect connec

Table 5-9. The LED Does Not Come On (3)Cause Step Checkpoint Finding SolutionThe standard tray hasproblems.1Is the standard tray OK?NoRefer to Table

Table 5-10. The LED Does Not Come On (4)Cause Step Checkpoint Finding SolutionThe consumables may not beinstalled.1Are the consumables installed?NoIn

Cause Step Checkpoint Finding SolutionThe optical unit may be bad.1——Replace the opticalunit.The C169 MAIN-B Board maybe bad.2——Replace the C169MAIN-

Table 5-15. Laser Light ErrorCause Step Checkpoint Finding SolutionThe optical unit may bedead.1——Replace the opticalunit.The C169 MAIN-B Boardmay be

Table 5-21. C1003 ErrorCause Step Checkpoint Finding SolutionThe optional SIMM may bebad. 1Is the operation OK afteryou remove the optionalSIMM?YesRe

Table 5-26. C1320 ErrorCause Step Checkpoint Finding SolutionThe optional interface cardmay be bad.1——Replace the optionalinterface card.The C169 MAI

5.4.2 Print Quality AnomaliesThis section describes how to isolate possible causes of a print quality problem .Table 5-28. Print Quality AnomaliesSy

Table 5-28. Print Quality Anomalies (Continued)Symptom Possible Cause Part Name Check Item RemedyBlank print Poor development ImagingcartridgeCheck wh

Rev. A 1-iii

Table 5-28. Print Quality Anomalies (Continued)Symptom Possible Cause Part Name Check Item RemedyToner smudges onthe back side of thesheet.Improper ch

Chapter 6 MaintenanceTable of Contents6.1 MAINTENANCE 6-16.1.1 User Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-ii Rev. A

6.1 MAINTENANCEThe EPL-5500 is a page printer that uses an electrophotographic printing method. Unlike mostimpact or ink-jet printers, the key compo

6.1.1.2 Replacement of ConsumablesThis printer uses a consumable photoconductor unit and toner cartridge. The life of photoconductorunit is 20,000 pa

EPL-5500 Service Manual MaintenanceRev. B 6-3

Appendix A Reference MaterialsTable of ContentsA.1 CONNECTOR PIN ASSIGNMENTS A-1A.1.1 Main Board (C169 MAIN-B Board) . . . . . . . . . . . . . . . .

A.1 CONNECTOR PIN ASSIGNMENTSFigures A-1 and A-2 illustrate the interconnection of the primary components. Table A-1 gives thesize and a description

1234M1Main motor5432M2Polygon motor12341CN1MCN206ϕAϕAϕBϕBPOLYGON CTLDC5VGNDDC24VN.C.12M3Fan motorCN211FANDC24VCN210123123CN3SANODE(PC1)GNDPC3PC3CN208P

Table A-1. Board Connector SummaryConnector Description Pins ReferenceMain Board (C169 MAIN-B Board)CN1 Centronics parallel interface 36 pins Table 1-

1.1 FEATURESThe EPSON EPL-5500 is non-impact page printer that combines a semi-conductor laser withelectrophotographic technology. This printer is sm

A.1.1 Main Board (C169 MAIN-B Board)Table A-2. CN2 Pin AssignmentsPin No. Signal Name I/O Description1Vss—Ground2DQ0I/OData bus bit 03DQ16I/OData bu

Table A-2. CN2 Pin Assignments (Continued)Pin No. Signal Name I/O Description50DQ24I/OData bus bit 2451DQ9I/OData bus bit 952DQ25I/OData bus bit 2553

Table A-3. CN4 Pin Assignments (Continued)Pin No. Signal Name I/O Description21RDORead strobe signal22WROWrite strobe signal23IREQOInterrupt to option

Table A-4. CN5 Pin AssignmentsPin No. Signal Name I/O Description1Vss—Ground2D0I/OData bus bit 03D16I/OData bus bit 164D1I/OData bus bit 15D17I/OData

Table A-4. CN5 Pin Assignments (Continued)Pin No. Signal Name I/O Description50D24I/OData bus bit 2451D9I/OData bus bit 952D25I/OData bus bit 2553D10I

Table A-7. CN204 Pin AssignmentsPin No. Signal Name I/O Description1HV-C—2HV-TI3HV-S—4HV-S2—5HV-B6BIAS-MO7GND2—Ground8+24—+24 VDCTable A-8. CN205 Pin

Table A-12. CN209 Pin AssignmentsPin No. Signal Name I/O Description1+24 V—+24 VDC2FEED2OLower cassette solenoid on3NC—No connected4+5V—+5 VDC5GND1—Gr

A.2 CIRCUIT DIAGRAMS 16 19 20 21 22 23 24 25 26 27 28 29 30 33 2 3 4 5 6 7 8 9 1 36 14 31 10 11 12 13 32 35 17 15 18 34CN1PIFR8 1KR29 1K 1

TOD XVIDEOXHSYNCXR2122.2KR2082.2K 1 2 3 4 8 7 6 5RM2013.3KR21110KP54/CNTR0 15P72/SCLK2 9P53/INT4 16P71/SOUT2 10P70/SIN2 11P00 56P86/RTP4 66P56/DA

LNF16.3A, 125VR1470KC10.22uF125VNR1ENC271D-10Z7D271L1Z0408, Z0462C3C4C3, C42200pF125VC20.1uF125VBD1D258A 50D2S860Th1100-g,M100 10C,M10007CNTH9D100LAC1

Table 1-1 lists the optional units available for the EPL-5500.Table 1-1. Options for the EPL-5500Cat. No. Description NoteC83218✽Windows Printing Syst

+5123N.HEATER360WL.123N.HEATER360WL.CN2INL1SW1 WH1WH2F1250V5AC1250V0.33uFVS1470VL1CM102L2CM102R11/4W470KR21/4W470KC2250V2200pFC3250V2200pFC4250V0.1uFR

A.3 CIRCUIT BOARD COMPONENT LAYOUTFigure A-7. C169 MAIN-B Component Layout (Front)Appendix EPL-5500 Service ManualA-16 Rev. A

Figure A-8. C169 MAIN-B Component Layout (Rear)EPL-5500 Service Manual AppendixRev. A A-17

EPSON OVERSEAS MARKETING LOCATIONSEPSON AMERICA, INC EPSON DEUTCHLAND GmBH20770 Madrona Avenue, Zülipicher Straße 6, 40549 DüsseldorfP.O. Box 2842 Ger

EPSON

1.2 SPECIFICATIONSThis section provides statistical data for the EPL-5500.1.2.1 Basic SpecificationsPrinting method: Laser beam scanning and dry ele

Standard paper Xerox 4024 DP paper20 lb (75 g/m2)Normal paper Regular photocopier paperBond paperRecycled paper16 to 24 lb (60 to 90 g/m2)Special pap

Usability of special papers: See Table 1-4.Table 1-4. Usability of Special PapersInput OHP Envelopes Labels Card Stock LetterheadStandard built-in pap

1.2.2 Electrical SpecificationsTable 1-5. Electrical Requirements and RangesDescription 100 V Version 200 V VersionRated voltage 100 ∼ 120 VAC 220 ∼

1.2.6 Applicable StandardsSafety Standards120 VAC model: UL 1950, CSA 22.2 No. 950 Deviation 3220/240 VAC model: EN 60950 (IEC950), NEMKO (IEC950), SE

- ii -

1.2.9 Software SpecificationsBuilt-in modes: HP LaserJet 4 emulation (PCL 5e)EPSON GL/2 mode (GL-like mode)Note:EPSON GL/2 mode is similar to the GL

Table 1-7. Built-in Fonts (Continued)Resident FontsApplicable ModeHP LJ4GL/2Scalable fontsSwiss 742Bold Italic SWCSSwiss 721Roman SWMSSwiss 721Bold SW

1.3 INTERFACE SPECIFICATIONSThe EPL-5500 is equipped with the following external interfaces:❏ Parallel interface❏ Optional LocalTalk/serial interface

Table 1-8. Parallel Interface Pin AssignmentsPin No. Signal Name I/O Description1STROBEINSTROBE is a strobe pulse used to read data from the hostcompu

1.3.1.2 Reverse ModeReverse mode for the EPL-5500 supports the IEEE-P1284 nibble mode. This printer can run inreverse mode, in which the printer can

Figure 1-4 shows the switch diagram for the parallel interface state.ForwardDataTransferForwardIdleSTROBEACK and BUSYCompatibility ModeTerminateNegoti

Figure 1-5 shows the negotiation timing chart.Notes:1. This signal is set to HIGH when no data is being sent.This signal is set to LOW during sending

Figure 1-7 shows the timing chart for termination.Notes:1. The signal is HIGH when HB DNA.The signal is LOW when HB DA.2. The signal is set to HIGH, i

1.3.2 Serial InterfaceThis printer can use the optional LocalTalk/serial interface module.Type: RS-232C/current loopTransfer system: Full duplexSynch

HandshakingWhen the vacant area for data in the input buffer drops to 256 bytes, the printer outputs an X-OFFcode or sets the DTR signal level to LOW,

NOTICEAll rights reserved. Reproduction of any part of this manual in any form whatsoever without SEIKOEPSON’s express written permission is forbidde

1.3.3 Optional LocalTalk InterfaceThis printer can use the optional LocalTalk/ serial interface module.Type: LocalTalkSignal level: Same as RS-422 si

1.4 OPERATING INSTRUCTIONSThis section describes functions performed through the control panel, such as printing a statussheet, hexadecimal dump, and

Functions of Pressing the Button❏ While the Red light flashes slowly:Function of button Clears an error.Operation Hold down the button until the yello

1.4.2 Printer Settings FunctionsThe printer settings function from the Remote Control Panel (software) lets the user control most ofthe printer’s fun

ESCP2 * (Continued) Auto CR ON, OFFAuto LF OFF, ONBit Image Dark, Light, BarCodeZero Char0, φFX* Font Courier, Prestige, Roman, Sans serif, ScriptPitc

Table 1-12. Printer Settings (Continued)Menu Item Available OptionsJOB PAGE PROTECT AUTO, ONRESOLUTION 600, 300IMAGE OPTIMUM AUTO, OFF, ONTIMEOUT 5 t

1.4.3 Service ModeThis printer has the following four service modes:❏ Hexadecimal dump mode❏ EEPROM format mode❏ Factory reset mode❏ Default setti

1.4.3.4 Default SettingsThe default settings function is used to enter printer settings. The procedure for entering defaultsettings is:1. To enter th

EMULATION PARALLEL LJ4211ESCP2*212FX*213I239X*214PS*215GL2221AUTO*222SERIAL* LJ4232LT*AUX*SERIAL* ESC/P2*233LT*AUX*SERIAL* FX*234LT*AUX*SERIAL* I239X*

Table 1-14. Default Settings Code (Continued)Menu Item Available OptionsDeafult SettingsCodes1stCode2ndCode3rdCodeESC/P2* / FX* CG Table PcUSA253Ital

PRECAUTIONS Precautionary notations throughout the text are categorized relative to 1) personal injury and 2)damage to equipment. DANGERSignals a prec

1.4.4 Display of MessagesThis printer indicates three types of messages with the LED lights or status sheet: status messages,error messages, and the

1.4.5 Printer SharingThis section describes printer sharing. This printer has two methods of printer sharing, port fixedmode and auto sense mode. The

1.4.6 Emulation Mode Switch FunctionThis section describes the emulation mode switch function.1.4.6.1 Emulation Switch by SPLThe two types of emulat

The main improvement of this technique is in eliminating “jaggies” in diagonal lines. It is mosteffective when the dot map data fits the development c

1.4.8 Toner Save ModeThe Toner Save Mode uses about 50% less toner than normal. The printer saves toner by substiutinga gray shade for the black insi

1.5 MAIN COMPONENTSTo simplify maintenance and repair, the main components of the EPL-5500 have been designed foreasy removal and replacement. The ma

1.5.1 C169 MAIN-B BoardThe C169 MAIN-B board is a video controller and engine controller board. The primary functions ofthis board are receiving prin

1.5.2 PWB-E BoardThe PWB-E is the power supply board, which consists of a switching regulator circuit. It convertsthe AC line voltage into +24 V and

1.5.4 Optical UnitThe optical unit consists of the laser diode (semi-conductor laser), the mirror motor (scanner motor)which drives the polygon mirro

1.5.6 Photoconductor UnitCore mechanisms of the printing process, such as charging and imaging, are integrated into thisunit.1.5.7 Developing Cartri

SAFETY INFORMATIONThis printer is a page printer which operates by means of a laser. There is no possibility of danger fromthe laser, provided the pri

Chapter 2 Operating PrinciplesTable of Contents2.1 ENGINE OPERATION 2-12.1.1 Print Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 2-20. High-Voltage Supply Block Diagram . . . . . . . . . . . . . . . . . . . . . . 2-13Figure 2-21. Print Process . . . . . . . . . . . . .

2.1 ENGINE OPERATIONThis section describes the functions and operating principles of the EPL-5500 engine. Figure 2-1shows the locations and names of

2.1.1 Print ProcessThis section describes the print process from paper feeding to paper exit. Figure 2-2 shows adiagram of the print process.Optical

2.1.1.1 Paper FeedingPaper can be fed into the printer from the paper feed tray (150 sheets) or from the manual feed slot(1 sheet at a time). Install

Second Paper Feed Unit (Optional Lower Cassette)This unit contains no drive motor, so the main motor (M1) drive is transmitted to the paper take-upand

2.1.1.3 Laser ExposureThe laser beam, emitted from the optical unit, makes an invisible static image. The SOS (start ofscan) sensor, installed on th

2.1.1.5 Image TransferThe electrode comb is an image transfer system that transfers the toner image on the PC drum ontothe paper.2.1.1.6 FusingThe t

2.1.2 Engine ControlThis section describes engine control, the power supply board, and the high-voltage supply board.The engine is controlled by the

2.1.2.1 Main Motor Functions and ControlThe M1 main motor transmits the drive to the printer rollers and the optional second paper feed unit(lower ca

For Finland, Sweden Users;VAROITUSLaitteen käyttäminen muulla kuin tässä käyttöohjeessa mainitulla tavalla saat-taa altistaa käyttäjän turvallisuusluo

Figure 2-12 shows the main motor drive circuit. The M1 main motor is a four-phase stepping motorcontrolled by the CPU (IC201) on the main board (C169

2.1.2.3 Fuser ControlThe heater lamp, powered by AC voltage, heats the fuser. When the power supply board receivesa FUSER signal from the main board

EPL-5500 Service Manual Operating PrinciplesRev. B 2-11

If any of the following conditions are detected, the printer indicates a fuser error:1. If the thermistor detects the temperature has not risen by 20º

2.1.2.5 Laser Diode DriveFigure 2-17 shows the laser diode drive circuit. Laser diode emission is controlled by three signals(LDATA, LDAPC1, and LDA

2.1.2.6 Bias Voltages and Laser Drive TimingFigure 2-20 is a diagram of the drum charge bias voltage, image transfer bias voltage, and thedeveloping

Figure 2-21 shows the print process.Figure 2-22 shows the start print sequence. The printer’s engine starts printing when it receives thePRINT signal

2.1.2.7 Fan Motor ControlThe fan motor (M3) rotates at engine initialization, and stops after 2 sec. The fan motor also rotatesduring printing. When

2.2 VIDEO CONTROLLER OPERATIONThe video controller section generates the video signals for received data. The video controllersection is the C169 MA

Table 2-1 lists the functions of the main elements of the video controller section in C169 MAIN-BBoard.Table 2-1. Functions of C169 MAIN-B Board Main

For Europe[Label inside printer]The following laser safety label will be attached inside the printer as shown below.For Denmark, Finland, Sweden, and

Print data and commands transmitted from the host computer via the parallel or optional interfacesare read using the CPU interrupt process and stored

2.2.1.1 Reset CircuitThe entire system (CPU and external devices) can be initialized if the RESET signal (CPU pin 113)are active simultaneously. This

2.2.1.3 Interrupt ControlThe ASIC E05A93 determines the priority level of the interrupt and outputs it to terminals IRL0 -IRL3. Then an interrupt is

2.2.1.5 Parallel Interface CircuitFigure 2-31 shows a circuit block diagram of the parallel interface. Data sent from the hostcomputer is latched wi

2.2.1.6 Video InterfaceThe ASIC E05A92 maps the SRAM into a memory space different from the system memory. TheCPU transmits data from the V-RAM (in

Chapter 3 Disassembly and AssemblyTable of Contents3.1 GENERAL INFORMATION 3-13.1.1 Precautions for Disassembly/Assembly. . . . . . . . . . . . . .

Figure 3-24. Removing the Paper Separator. . . . . . . . . . . . . . . . . . . . . . . . . . 3-17Figure 3-25. Paper Exit Sensor . . . . . . . . . .

3.1 GENERAL INFORMATIONThis chapter describes disassembly/assembly procedures to be used for replacing the mainassemblies of the EPL-5500.3.1.1 Prec

3.1.3 Small PartsIn the following sections, abbreviations are used for small parts, such as screws and washers.Tables 3-2 and 3-3 list these abbrevia

3.1.4 Service Checks after RepairCheck the repaired unit using the following list on completion of servicing.Table 3-3. Checks after RepairItem Loca

PREFACEThis manual describes functions, theory of electrical and mechanical operations, maintenance, and repairof EPL-5500.The instructions and proced

3.2 DISASSEMBLY AND ASSEMBLYThis section describes and illustrates the procedures for removing and disassembling thecomponents of the EPL-5500. Clea

3.2.2 Removal of the Controller SectionThe control section is comprised of the controller board (the C169 MAIN-B Board).3.2.1.1 Main Board (C169 MAI

3.2.3 Disassembling the EngineThis section describes disassembling the engine, including the high voltage unit (PWB-F) andpower supply board (PWB-E).

3.2.3.2 Image Transfer Unit Removal1. Open the top cover.2. Remove the harness cover A. (Refer to Section 3.2.3.3.)3. Remove the 2 screws (#5) and h

ASSEMBLY POINTSAfter reinstalling the image transfer unit, check that the unit smoothly moves up anddown.5. Remove the remove the electrode comb.ASSEM

3.2.3.3 Upper Unit Removal1. Open the upper unit.2. Remove the right cover and left cover. (Refer to Section 3.2.1.1.)3. Disconnect connectors CN202

3.2.3.4 High-Voltage Supply Board (PWB-F) Removal1. Open the top cover.2. Remove 1 screw (#5) from the PWB-F cover.3. Remove the PWB-F cover.4. Remov

3.2.3.5 Power Supply Unit (PWB-E) Removal1. Remove the upper unit. (Refer to Section 3.2.3.3.)2. Remove 6 screws (#4:2, #7:2), and remove the PWB-E c

3.2.3.6 Fusing Unit Removal1. Open the top cover. (Refer to Section 3.2.3.3.)2. Remove the image transfer unit. (Refer to Section 3.2.3.2.)3. Remove

7. Remove the harness cover.8. Remove the fusing entrance guide.Figure 3-17. Removing the Harness CoverFigure 3-18. Removing the Fusing Entrance Gui

REVISION SHEETRevision Issue Date Revision PageRev. A October 06, 1995 1st issueRev. B March 15, 1996Revise the whole pages of thefollowing chapte

10. Remove 4 screws (#5), and remove the fusing unit.ASSEMBLY POINTSAfter reinstalling the fusing unit, check the direction of the bushings on the pap

3.2.3.7 Fusing Unit DisassemblyThis section describes how to remove the paper exit sensor, heater lamp, lower fusing roller, andupper fusing roller.H

Thermistor1. Remove the fusing unit. (Refer to Section 3.2.3.6.)2. Remove the 1 screw (#4), and remove the thermistor.ASSEMBL POINTSWhen reinstalling

Paper Separator1. Remove the fusing unit. (Refer to Section 3.2.3.6.)2. Release the lock of the holder and remove the 3 paper separator.ASSEMBLY POINT

Fusing Roller1. Remove the fusing unit. (Refer to Section 3.2.3.6.)2. Remove the 2 G-rings from the fusing unit.CAUTIONWhen reinstalling the G-rings:❒

5. Take out the lower fusing roller.Thermal Fuse1. Remove the fusing unit. (Refer to Section 3.2.3.6.)2. Remove 2 screws (#5), and remove the thermal

3.2.3.8 Main Motor Removal1. Remove the housing components. (Refer to Section 3.2.1.1.)2. Remove 1 screw (#4) which fixing the motor bracket and the

3.2.3.9 Paper Take-Up Sensor and Paper Take-Up Solenoid Removal1. Remove the housing components. (Refer to Section 3.2.1.1.)2. Turn over the printer

3.2.3.10 Paper Take-Up Roller Removal1. Remove the main motor. (Refer to Section 3.2.3.8.)2. Remove the paper guide assembly. (Refer to Section 3.2.3

Chapter 4 AdjustmentTable of Contents4.1 ADJUSTMENT 4-14.1.1 Print Position Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .