Epson 1160 CFS Installation Instructions Manual

Installation Instructions: Filled Epson 1160 CFS

Procedure:

1. Fill Cartridges with Ink
Get a place to work where you can spill a little ink and not ruin anything. Spread
some newspapers down and have plenty of paper towels handy. Make sure you have
good lighting.

Materials:

• Continuous Flow Cartridges, color and black with tubes attached

• 4 MIS-Syringe (10 cc)

• 4 Bottom Fill Adapters (MIS-BADPT)

• 4 Bottles of ink, one of each color (CMYK)

• 4 Rivets (MIS-Rivet)

Follow the table below for determining how much ink to inject into each chamber.
The instructions for each color are identical, just the volume of ink injected is
different.

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Color Volume (cc)
Black 22

Cyan 10

Magenta 10

Yellow 10

See the photo below to determine which color goes into which chamber. You must
not make a mistake on this, it is vital to be correct. Use a felt tip pen and label

each chamber with the correct letters.... K, C, M, Y.

Do not remove foil pull tabs from top of cartridges. This is important.

ARC-SO20089-E = ARC-SO20191-E ARC-SO20108-E = ARC-SO20189-E

Follow these steps for each chamber, starting with Black.......

A) Use the Bottom Fill Adapter and puncture the clear seal over the exit port for the

color you are about to inject. Only puncture the one you are going to put ink into.

B) Unwrap the syringe, remove the protective cap, and attach a green needle to the end

of the syringe. Twist it on with your fingers, so it is tight.

C) Make sure the syringe plunger is down all the way, then insert the tip of the needle

into the ink and pull ink into the syringe. Pull in a 1/2 to 1 cc more than is shown in
the table above. (For the black you will have to do this in two steps, 11 cc , and 11 cc
more).

D) Hold the syringe, needle pointed up, and remove the needle and attach the Bottom

Fill Adapter.

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E) While holding the syringe vertical, pointed up, wrap some paper towel around the tip

of the Bottom Fill Adapter, and carefully push on the syringe to remove any air
trapped in the top of the syringe. If you push too hard, ink will shoot up to the
ceiling, be very gentle.

F) Now that the air is gone, adjust the volume of ink in the syringe so that you have the

amount shown in the above table. Hold the syringe tip over the open ink bottle and
push the syringe plunger until you have the bottom of the rubber plunger at the right
mark.

G) Hold the cartridge being filled at eye level, keeping the cartridge orientated in its

normal position. Insert the tip of the Bottom Fill Adapter into the exit port on the
bottom of the cartridge. Don't turn the cartridge upside down. Push the tip firmly
into the exit port and slowly inject the ink into the cartridge.

Keep the cartridge at a 45 degree angle, front down, for the first half of the ink
injection. Then, for the second half, keep the cartridge level. Never turn cartridge
upside down.

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H) Put the cartridge down on your work surface or bench, and insert a Rivet into the

exit port you just filled. Don't turn the cartridge upside down. Make sure the Rivet
is all the way in, so the head is touching the cartridge. Use a paper towel and wipe
any excess ink off the bottom of the cartridge. The Rivet will prevent leakage and
cross contamination from other inks.

I) Now go to the next color and repeat this process until all 4 of the chambers are full.

Take the filled cartridges and tubing to a place near your printer and set them on a
flat surface. Put a pencil or some sheets of paper under the end of the cartridge so
that it is perfectly level. Make sure the end of the tubes are open and not kinked or
twisted.

You are done for today. Let the freshly filled cartridges age overnight. You can
continue in the morning or later in the day with the next step in the process. This is
important, don't try to rush it. The ink needs about 8 hours to get fully absorbed by
the sponge. Any bubbles or gases will come to the surface and disappear.

2. Establish Working Condition of Printer- Make sure nozzle check is perfect
With an image on your screen and paper in the printer, click on file | print, then on
printer properties. When you see the Utility tab on the printer properties dialog
box, click on it, then on Nozzle check. This can also be done from the Control Panel
| Printers section by right clicking on the correct printer and then clicking on
properties.

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The nozzle check is very important. If your printer can not produce a PERFECT
nozzle check, then there is something wrong with it and you should not proceed
with the installation of the CFS.
Here is what a perfect nozzle check should look like….

There are 48 segments in each section. Each one of these represents an inkjet
nozzle on the print head. They must all be working properly before you proceed.

3. Remove the printer cover –

Figure 1

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The printer cover un-snaps from the printer housing. There are no screws holding
it. Just a little bit of force in the right direction and it pops off. Keep it near by to
use to cover the printer if you plan on leaving it unattended for a long period of
time, like a vacation break. You do not have to remove the printer cover, but it has
to be up when the printer is running.

4. Remove Cartridge Clamps – See photo

Push the paper feed button and hold it down until the cartridge holder moves to
the left. Pull the power plug out when the cartridge holder is in its left position.
This will keep it from returning to the right unexpectedly. Don't plug the power in
until later.

Use a thin flat screw driver blade to remove the clamps. Be sure not to break them.
You may need them some day. Remove the black clamp first. This will give you more
room to remove the larger color clamp. Follow the instructions on the above photo.
You may need a small flash light to help you see what is happening where the clamps
attach. They will both come out clean with no damage to either the clamp or the
printer, so don’t be over aggressive. It is a bit of a puzzle but it can be done easily.
Both the blue piece and the black piece have to be removed.

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5. Install Tubing Bracket - 6 1/2" from right end of printer opening – See photo

The 6 1/2” is not from the outside of the printer, but from the inside opening of
the housing to the center of the bracket. Use an alcohol swab to clean the plastic
before attaching the bracket. Once it goes down, it is there to stay, so don’t put it
in the wrong spot. This is important. If you have to remove it, use a wide blade
screwdriver and twist it under the bracket.

Note: If you have a refurbished 1160 with a housing that does not look like the one
above, use the bracket with the 45 degree bend instead of the long flat bracket.

6. Prepare Cartridges for Installation
Put some newspaper or paper towels in front of your printer.

Do not remove foil pull tabs from top of cartridges. This is important.

Insert the cartridges into the cartridge holder. Make sure the black felt pads are
on the cartridges. There should be 2 on the black cartridge and 2 on the color
cartridge. When you insert the cartridges be careful that the felt pads do not
come off or change position. You will have to insert the cartridge slowly to get a
nice tight fit. Make sure the cartridges are down all the way and seated firmly on
the bottom of the cartridge holder. These felt pads will prevent the cartridge
from coming loose or from being pulled out by the tension on the tubes.

Do not lift the cartridges off the posts or out of the cartridge holder once
they are down. This will introduce a large air pocket into the print heads and
may prevent the printer from working properly. This is very important.

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7. Attach Ribbon Tube to Bracket

Move the cartridges to the left position, manually. Power is still off.
Insert tubing into the bracket so that the tube closest to you is in the front. This is
the yellow tube. Make sure the tubing is secure and all the way into the bracket. Use
some alcohol to lubricate the tubing and the bracket. Pull the tubing through the
bracket to take up the slack. You will have to make some adjustments so that the
tube is not to tight when the carts are in the left most position. As the cartridges
traverse from left to right, the tubing should not touch the bottom of the carriage.

8. Install the Switch Activator
These two pieces of rigid foam are the Switch Activators (see photo). Push them
down gently into the front of the cartridge holder, where the end of the clamp
previously went. They must be inserted deep to activate the switch. They are tight
enough to stay in place by themselves, no tape is necessary. If you push too hard, it
will make the lights will come back on again when the power is on. Just push hard
enough to activate the switch.
When you are done with the cartridges push them all the way to the right until
they stop. This is important so that the belt does not jump when you turn the
power back on.

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9. Set up the ink bottles
Put the tops that have the holes in them, on the 4 oz bottles of ink. Put the ink
bottles in the acrylic tray as shown in the above photo. Check to verify that there
is a vent hole in each of the tops to let air into the bottles. If any of the vent holes
are missing, you will have to make one using a 1/16 diameter drill.

10. Insert the tubes into the bottles
Set up the bottle tray next to the right hand side of the printer. Trim the tubing
length so that the tubes will make a turn into the bottle with out rising up. There
must be 3 ¾ inch of tubing inside the bottle. The bottles are arranged in order K-C,
M-Y from front to back. You just want to have a neat orderly tube arrangement.
After you cut the tubes to length, use a black marker and make a mark on each
tube 3 ¾ inch from the end of the tube. Insert the tubes through the larger hole in
the center of the cap until the black mark is just inside the cap. Don’t cut the
tubes too short.

It is very important to get the right tube into the right color bottle or the
cartridges will be ruined. Check the label on the CFS cartridge and trace down the

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yellow tube from the cartridge to the end of the tube. The yellow tube is the one
closest to you as you look at the cartridges in the printer.

If you are installing MIS Original Quadtone inks……..
100% = Black 25% = Cyan 75% = Magenta 50% = Yellow
For Full Spectrum Quadtone, VM Quadtone and color inks follow the bottle labels.

You can rearrange the bottles if you find a neater sequence to keep the tubes from
tangling. You can also separate the tubing from the ribbon by pulling them apart. Do
what ever you have to do to get a neat arrangement.

The ink bottle tray must be on the same surface as the printer. Do not elevate the
tray or set it below the printer surface. Put the tray in a position so that the
ribbon tubing is not touching the paper in the feed tray.

If the bottles are too high, the ink will flood the print head and it will not work. If
the bottles are too low, the print head will not have enough power to pull up the ink
and it will not work. The best level for the bottles is the same level that the
printer is sitting on.

11. Establish Working Condition of the Cartridges
At this point, the tubing has some ink in it and the ends have been installed in the
ink bottles, the switch activators are installed and the tubing bracket is installed.
Now make sure the carriage is all the way to the right most position and plug the
printer into the power outlet and turn on the power.

Load the MIS purging image (purge4.tif on diskette) using Photoshop, Paintshop
Pro, Corel or any graphics program. This image and some others, are on the diskette
that came with the CFS. If you don’t have this image or you have a Mac computer,
you can download it from the MIS website (www.inksupply.com), it is on the bottom
CFS page.

Assuming you have the file loaded, go to file and click on print, when the printer
dialog box comes up, click on properties, then click on the utilities tab. See Figure 1
on the first page.

Run a nozzle check. It most likely will not be acceptable.

Run the first cleaning cycle, then another nozzle check. You should see the ink
begin to fill up the tubes.

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Run second cleaning cycle, then another nozzle check. On the second cleaning cycle
there is about 7 seconds worth of pumping and the ink should travel several inches
up the tubes.

If the nozzle check is good, skip the third cleaning cycle. If necessary, run a third
cleaning cycle, then another Nozzle check.

Print 10 pages of the purging image (purge4.tif) then run 3 more cleaning cycles,
then 10 more copies of purge4. Repeat the cleaning cycles and printing of purge4
until the inks reach the cartridges. Check the nozzles. If they are perfect, you are
ready to start printing. If not, run a cleaning cycle and check them again.

If all went well, you are almost finished. You can print some images and use the
printer like you normally would use it. If you see any banding, run a couple of nozzle
check – cleaning cycles. It will clear up.

When the day is done, check your tubes. The ink should be right up to the
cartridges. The next morning, the ink will have retracted a little bit, as much as 4
inches back from the cartridges. This is normal. When you start to print again the
ink will be drawn into the cartridges and it will function normally.

In the morning, if you see the ink has retracted more than half way back to the
bottles, on any of the tubes, this is a problem. It means there is an air leak. There
is no fix for this, other than a new continuous flow cartridge. We will replace it at
no cost if this occurs.

You should enjoy printing with a minimum of problems. Occasionally you will have to
run a couple of cleaning cycles, just like you would have to without the CFS. The
bottles hold approximately 12 cartridges full of ink, when they get to 1/4 full,
remove the top and add more ink. There is no vacuum in the bottles, they are
vented to atmosphere. The tops can be removed at any time.

12. Resetting the Out of Ink Switches –
On the 1160 printer there are two switches in the front of the cartridge holder.
These switches get released and then pushed in each time you remove the Switch
Activators (previously done by the cartridge clamps). These switches control the
lights on the front panel of the printer. When an out of ink condition occurs, the
lights come on and the printer will not print again until the switches are reset.

Removing the cartridges is not desirable. When the cartridges are lifted off of
the printer posts, inside the cartridge holder, an air pocket forms in the

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prechamber of the cartridge. This air pocket then gets sucked in by the print head
and requires a couple of cleaning cycles to clear it out. It is a pain.

Hold the paper feed button on the printer for 3 seconds. The cartridges will move
to the left position. Remove the Switch Activators (not the cartridges) and put
them right back in position, this reset the switches. The light or lights will not go
off. Push the paper feed button again and the cartridges will return to the right,
the printer will run one cleaning cycle and the lights will go off.

Let it finish the cleaning cycle, then run a nozzle check. If the nozzle check is
good, you are all set to continue printing. If the nozzle check is not good, then you
will have to run additional “nozzle check – cleaning cycles”. Remember only do 3,
then print some purge4 pages and do 3 more if you have to. Always stop when you
get a good nozzle check.

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