Epson Stylus 860, Stylus1160 Service Manual

®
SERVICE MANUAL
SERVICE MANUAL
SERVICE MANUALSERVICE MANUAL
Color ink jet printer
Stylus COLOR 860/1160
SEIJ99003
EPSON Stylus COLOR 860/1160 Revision C
Notice:
n All rights reserved. No part of this manual may be reproduced, stored in a retrieval system, or tran smi tted in any form or by any means,
electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of SEIKO EPSON CORPORATION.
n The contents of this manual are subject to change witho ut notice. n All effort have been made to ensure the accuracy of the contents of this manual. However, should any errors be detected, SEIKO EPSON
would greatly appreciate being informed of them.
n The above not withstanding SEIKO EPSON CORPORATION can assume no responsibility for any errors in this manual or the conse quences
thereof.
EPSON is a registered trademark of SEIKO EPSON CORPORATION.
General Notice: Other product names used herein are for identification purpose only and may be trademarks or registered trademarks of their
respective owners. EPSON disclaims any and all rights in those marks.
Copyright © 1999 SEIKO EPSON CORPORATION. Printed in Japan.
EPSON Stylus COLOR 860/1160 Revision C
PRECAUTIONS
Precautionary notations through out the text are categorized relative to 1)Personal injury and 2) damage to equipment.
DANGER Signals a precaution which, if ignored, could result in serious or fatal personal injury. Great caution should be exercised in
performing procedures preceded by DANGER Headings. WARNING Signals a precaution which, if ignored, could result in damage to equipment. The precautionary measures itemized below should always be observed when performing repair/maintenance procedures .
DANGER
1. ALWAYS DISCONNECT THE PRODUCT FROM THE POWER SOURCE AND PERIPHERAL DEVICES PERFORMING ANY MAINTENANCE
OR REPAIR PROCEDURES.
2. NOWORK SHOULD BE PERFORMED ON THE UNIT BY PERSONS UNFAMILIAR WITH BASIC SAFETY MEASURES AS DICTATED FOR
ALL ELECTRONICS TECHNICIANS IN THEIR LINE OF WORK.
3. WHEN PERFORMING TESTING AS DICTATED WITHIN THIS MANUAL, DO NOT CONNECT THE UNIT TO A POWER SOURCE UNTIL
INSTRUCTED TO DO SO. WHEN THE POWER SUPPLY CABLE MUST BE CONNECTED, USE EXTREME CAUTION IN WORKING ON POWER SUPPLY AND OTHER ELECTRONIC COMPONENTS.
WARNING
1. REPAIRS ON EPSON PRODUCT SHOULD BE PERFORMED ONLY BY AN EPSON CERTIFIED REPAIR TECHNICIAN.
2. MAKE CERTAIN THAT THE SOURCE VOLTAGES IS THE SAME AS THE RATED VOLTAGE, LISTED ON THE SERIAL NUMBER/RATING
PLATE. IF THE EPSON PRODUCT HAS A PRIMARY AC RATING DIFFERENT FROM AVAILABLE POWER SOURCE, DO NOT CONNECT IT TO THE POWER SOURCE.
3. ALWAYS VERIFY THAT THE EPSON PRODUCT HAS BEEN DISCONNECTED FROM THE POWER SOURCE BEFORE REMOVING OR
REPLACING PRINTED CIRCUIT BOARDS AND/OR INDIVIDUAL CHIPS.
4. IN ORDER TO PROTECT SENSITIVE MICROPROCESSORS AND CIRCUITRY, USE STATIC DISCHARGE EQUIPMENT, SUCH AS ANTI-
STATIC WRIST STRAPS, WHEN ACCESSING INTERNAL COMPONENTS.
5. REPLACE MALFUNCTIONING COMPONENTS ONLY WITH THOSE COMPONENTS BY THE MANUFACTURE; INTRODUCTION OF
SECOND-SOURCE ICs OR OTHER NONAPPROVED COMPONENTS MAY DAMAGE THE PRODUCT AND VOID ANY APPLICABLE EPSON WARRANTY.
EPSON Stylus COLOR 860/1160 Revision C
PREFACE
This manual describes basic functions, theory of electrical and mechanical operations, maintenance and repair procedures of Stylus COLOR 860/
1160. The instructions and procedures included herein are intended for the experienced repair technicians, and attention should be given to the precautions on the preceding page. The chapters are organi zed as fol lows:
CHAPTER 1. PRODUCT DESCRIPTIONS
Provides a general overview and specifications of the product.
CHAPTER 2. OPERATING PRINCIPLES
Describes the theory of electrical and mechanical operations of the product.
CHAPTER 3. TROUBLESHOOTING
Provides the step-by-step procedures for troubleshooting.
CHAPTER 4. DISASSEMBLY AND ASSEMBLY
Describes the step-by-step procedures for disassembling and assembling the product.
CHAPTER 5. ADJUSTMENTS
Provides Epson-approved methods for adjustment.
CHAPTER 6. MAINTENANCE
Provides preventive maintenance procedures and the lists of Epson-approved lubricants and adhesives required for servicing the product.
APPENDIX
Provides the following additional information for reference:
• EEPROM Address Map
• Connector Pin Assignments
• Component Layout
• Parts List and Exploded Diagrams
• C298MAIN Board Circuit Diagram
EPSON Stylus COLOR 860/1160 Revision C
Revision Status
Revision Issued Date Description
A August 19, 1999 First Release
Second release
B October 5, 1999
C November 25,1999
• Correction has been made due to overall review of the manual.
• Appendix has additional information. Third release
• Correction has been made due to overall review of the manual.
• Some T.B.D have been made clear.
• Appendix has additional information.
- Fig7-3, 7-4 has been mounted.
EPSON Stylus COLOR 860/1160 Revision C
PRODUCT DESCRIPTION
FEATURES .................................... ...... ....... ...... ....... ...... ....... ...... ....... ........... 9
SPECIFICATIONS ...................................................................................... 10
Physical Specification ......................................................................................... 10
Printing Specification ......................................................................................... 10
Paper Feeding ..................................................................................................... 11
Input Data Buffer ................................................ ..... ........................................ ... 11
Electric Specification .......................................................................................... 11
Environmental Condition .................................................................................... 12
Reliability ........................................................................................................... 12
Safety Approvals .................................................................................. ..... ......... 12
Acoustic Noise .................................................................................................... 12
CE Marking ........................................................................................................ 12
INTERFACE ............................................................................................... 13
Parallel Interface (Forward Channel) ................................................................. 13
Parallel Interface (Reserve Channel) .................................................................. 16
USB Interface ..................................................................................................... 17
Prevention of Data Transfer Time-out ................................................................ 18
Interface Selection .............................................................................................. 18
IEEE1284.4 Protocol .......................................................................................... 18
OPERATOR CONTROLS ........................................................................... 19
Operating Switch ................................................................................................ 19
Control Panel ...................................................................................................... 19
Switches .......................................................................................................... 19
Indicators ........................................................................................................ 19
Panel Functions ................................................................................................... 20
Printer Condition and Panel Status ................................ ...... ............................... 21
Printer Initialization ............................................................................................ 21
Errors .................................................................................................................. 22
PAPER ......................................................................................................... 23
Paper Handling ................................................................................................... 23
Paper Specification ............................................................................................. 23
Cut Sheet ........................................................................................................ 23
Transparency, Glossy Paper ........................................................................... 23
Envelope ......................................................................................................... 23
Index Card ...................................................................................................... 24
Printing Area ....................................................................................................... 25
Cut Sheet ........................................................................................................ 25
Envelopes ....................................................................................................... 26
INK CARTRIDGE ....................................................................................... 27
Black Ink Cartridge ............................................................................................ 27
Color Ink Cartridge ............................................................................................. 27
Operating Principles
Overview ...................................................................................................... 29
Printer Mechanism ......................................................................................... ..... 29
Printing Mechanism ....................................................................................... 30
Printing Process .............................................................................................. 31
Carriage Mechanism .............................. ..... ...... ........................................ ..... 32
Platen Gap (PG) Adjust Mechanism .............................................................. 33
Paper Feeding Mechanism ............................................................................. 33
CR Lock Mechanism ...................................................................................... 35
Paper Loading Mechanism ............................................................................. 36
Pump Mechanism ........................................................................................... 38
Capping Mechanism ....................................................................................... 39
Electrical Circuit Operating Principles ......................................................... 40
C298PSB/PSE Board .......................................................................................... 41
C298MAIN Board .............................................................................................. 43
Printhead Driver Circuit ................................................................................. 45
Reset Circuit ................................................................................................... 46
CR Motor Driver Circuit ................................................................................ 47
PF Motor Driver Circuit ............................................... .................................. 49
ASF/Pump Motor Driver Circuit .................................................................... 50
EEPROM Control Circuit .............................................................................. 50
Sensor Circuit ........................................................................... ..... ................. 51
Troubleshooting
Overview ...................................................................................................... 54
Troubleshooting with LED Error Indications ..................................................... 55
Remedies for Paper Out Error ........................................................................ 57
Remedies for the Paper Jam Error .................................................................. 59
Remedies for No I/C and Ink Out Errors ....................................................... 60
Remedies for the Maintenance Error ............................................................. 62
Remedies for Fatal Error ................................................................................ 63
Isolating the Faulty Part on the Power Supply Board ........................................ 66
EPSON Stylus COLOR 860/1160 Revision C
Isolating the Faulty Part according to the Phenomenon ..................................... 68
Disassembly and Assembly
Overview ...................................................................................................... 75
Precautions for Disassembling the Printer .......................................................... 75
Tools ................................................................................................................... 76
Specification for Screws ..................................................................................... 77
Service Checks After Repair ......................................... ...... ..... .......................... 78
Disassembly Procedures ............................................................................... 79
Removing the Upper Housing ............................................................................ 80
Removing the Circuit Board Assembly .............................................................. 81
Removing the Operation Panel ........................................................................... 83
Disassembling the Printer Mechanism ............................................................... 84
Removing the Printhead Unit ......................................................................... 85
Removing the Waste Ink Absorber Tray Assembly ....................................... 87
Removing the Ink System Assembly ............................................................. 89
Removing the CR Motor Assembly ............................................................... 92
Removing the DE Assembly (include the ASF/Pump motor) ....................... 93
Removing the ASF Assembly ........................................................................ 97
Removing the Paper Feed Roller Assembly............................................................. 99
Removing the Right and Left LD Roller Assembly............................................... 104
Removing the CR Assembly ........................................................................ 105
Disassembling the CR Assembly............................................................................ 108
Removing the PF Roller Assembly and Paper Eject Roller Assembly ........ 110
Remove the PF Motor Assembly ................................................................. 114
Removing the PE Detector Assembly .......................................................... 115
Adjustment
Overview .................................................................................................... 117
Required Adjustments ...................................................................................... 117
Adjustment Tools Required .............................................................................. 118
Adjustment ................................................................................................ 119
Parallelism Adjustment ............................................................. ...... .................. 119
Backlash value Adjustment for PF motor ......................................................... 122
Adjustment by Adjustment Program ................................................................ 125
About Adjustment Program .......................................................................... 125
How to set up the program ........................................................................... 125
Choose the Model ......................................................................................... 126
Market Destination Check ............................................................................ 127
Head Voltage ID Input ................................................................................. 128
Head Angular Adjustment ............................................................................ 131
Bi-D Adjustment .......................................................................................... 134
USB ID input ................................................................................................ 137
Initial Ink Charge Operation ........................................................................ 141
Head Cleaning Operation ............................................................................. 142
Protection Counter Check/Reset .................................................................. 143
Recovery for the clogged nozzle .................................................................. 145
Print A4 pattern ............................................................................................ 146
PF Loop scale unit assembling procedure ................................................... 147
Assembling the PF Loop scale unit .................................................................. 147
Sticking the PF Loop scale unit to Gear 76 ...................................................... 149
Maintenance
Overview .................................................................................................... 151
Cleaning ............................................................................................................ 151
Service Maintenance ......................................................................................... 151
Lubrication ........................................................................................................ 152
Appendix
Connector Summary .................................................................................. 161
Connector Pin Assignment ............................................................................... 161
EEPROM ADDRESS MAP ............................................................................. 164
Circuit Board Component Layout .............................................................. 169
Exploded Diagrams and Parts List for Stylus COLOR 860 ......................... 172
Exploded Diagrams and Parts List for Stylus COLOR 1160 ....................... 180
Circuit Diagram ......................................................................................... 189

PRODUCT DESCRIPTION

CHAPTER
EPSON Stylus COLOR 860/1160 Revision C

1.1 FEATURES

The major features of EPSON color inkjet printers EPSON Stylus COLOR 860/ 1160 are:
o High Color Print Quality
n 1440 (H) X 720 (V) dpi printing n Four Color Printing (YMCK) n Traditional and New Microweave
o Built-in Auto Sheet Feeder
n Holds 100 cut-sheets (64g/m n Holds 10 envelopes n Holds 30 transparency films
o Two Built-in Interfaces
n Bi-directional parallel I/F (IEEE-1284 level 1 device) n USB
o Windows/Macintosh exclusive
2
)
PRODUCT DESCRIPTION FEATURES 9
EPSON Stylus COLOR 860/1160 Revision C

1.2 SPECIFICATIONS

This section covers specifications of the printers.

1.2.1 Physical Specification

o Weight: 6.0kg (without ink cartridges) for Stylus Color 860
8.0kg (without ink cartridges) for Stylus Color 1160
o Dimension:
[Stylus Color 860]
Storage: 450 mm (W) x 269 mm (D) x 175 mm (H) Printing: 450 mm (W) x 628 mm (D) x 303 mm (H)
[Stylus Color 1160]
Printing: 609 mm (W) x 766 mm (D) x 414 mm (H)

1.2.2 Printing Specification

o Print Method
n On demand ink jet
o Nozzle Configuration
n Monochrome 144 nozzles (48 x 3 staggered) n Color 48 nozzles x 3 (Cyan, Magenta, Yellow)
o Print Direction
n Bi-direction with logic seeking
Table 1-2. Raster Graphics Mode
Model
Stylus Color 860
Stylus Color 1160
Horizontal
Resolution
180 dpi 8.26 inches 1488 23.8/19 IPS 360 dpi 8.26 inches 2976 23.8/19 IPS 720 dpi 8.26 inches 5952 19 IPS 180 dpi 12.716 inches 2289 23.8/19 IPS 360 dpi 12.716 inches 4578 23.8/19 IPS 720 dpi 12.716 inches 9156 19 IPS
o Control Code
n ESC/P Raster command n EPSON Remote command
o Character Tables
n Two international character sets:
- PC 437 (US, Standard Europe)
- PC 850 (Multilingual)
o Typ eface
n Bit map LQ font:
EPSON Courier 10 CPI
Printable Area Available Dot CR Speed
o Print Speed & Printable Columns
Table 1-1. Character Mode
Model Character Pitch Printable Colum n LQ Speed
Stylus Color 860 10 CPI (Pica) 80 238 CPS*
Stylus Color 1160 10 CPI (Pica) 127 238 CPS*
*This value is the speed of normal-dot printing.
PRODUCT DESCRIPTION SPECIFICATIONS 10
EPSON Stylus COLOR 860/1160 Revision C

1.2.3 Paper Feeding

o Feed Method
n Friction feed with ASF
o Paper Path
n Cut-sheet ASF (Top entry, Front out)
o Feed Speed
n 2.36 inch/sec (Normal, Continuous feed) n 4.5 inch/sec (Fast, Continues feed)

1.2.4 Input Data Buffer

n 256KB

1.2.5 Electric Specification

[120V Version]
Rated Voltage: AC120V Input Voltage Range: AC99∼132V Rated Frequency Range: 50∼ 60Hz Input Frequency Range: 49.5∼ 60.5Hz Rated Current: 0.4A (for Stylus Color 860)
0.4A (for Stylus Color 1160)
Power Consumption: Approx. 18W (ISO10561 Letter Pattern)
Approx. 3.5W in standby mode (for Stylus Color 860) Approx. 18W (ISO10561 Letter Pattern) Approx. 3.5W in standby mode (for Stylus Color 1160) Energy Star compliant
Insulation Resistance: 10M ohms min.
(between AC line and chassis, DC 500V)
Dielectric Strength: AC 1000V rms. 1 minutes or
AC 1200V rms. 1 second (between AC line and chassis)
[220 240V Version]
Rated Voltage: AC220V∼240V Input Voltage Range: AC198∼264V Rated Frequency Range: 50∼60Hz Input Frequency Range: 49.560.5Hz Rated Current: 0.2 A (for Stylus Color 860)
0.2 A (for Stylus Color 1160)
Power Consumption: Approx. 18W (ISO10561 Letter Pattern)
Approx. 3.5W in standby mode (for Stylus Color 860) Approx. 18W(ISO10561 Letter Pattern) Approx. 3.5W in standby mode (for Stylus Color 1160) Energy Star compliant
Insulation Resistance: 10M ohms min.
(between AC line and chassis, DC 500V)
Dielectric Strength: AC 1500V rms. 1 minute
(between AC line and chassis)
PRODUCT DESCRIPTION SPECIFICATIONS 11
EPSON Stylus COLOR 860/1160 Revision C

1.2.6 Environmental Condition

o Temperature
n Operating: 10 to 35°C (see the figure below for condition) n Non-operating: -20 to 60°C (with shipment container)
1 month at 40°C and 120 hours at 60°C
o Humidity
n Operating: 20 to 80% RH
(without condensation / see the figure below for condition)
n Non-operating: 5 to 85% RH
(without condensation / with shipment container)
o Resistance to Shock
n Operating: 1G, within 1 ms n Non-operating: 2G, within 2 ms (with shipment container)
o Resistance to Vibration
n Operating: 0.15G n Non-operating: 0.50G (with shipment container)
90
80 70 60
Humidity (%)
50 40 30 20
27
10
20
Temperature (°C)
30
35
40

1.2.7 Reliability

Total Print Volume: 75,000 pages (A4, Letter) Print Head Life: 3 billion dots/nozzle

1.2.8 Safety Approvals

[120V Version]
Safety Standards: UL1950
CSA22.2 No.950
EMI: FCC part 15 subpart B Class B
CSA C108.8 Class B
[220240V Version]
Safety Standards: EN60950 (VDE) EMI: EN55022 (CISPR Pub.22) Class B
AS/NZS 3548 Class B

1.2.9 Acoustic Noise

Level: Approx. 42dB(A) (According to ISO 7779)
-Used media : Plain Paper
- Print Quality: Fine

1.2.10 CE Marking

[220240V Version]
Low Voltage Directive 73/23/EEC: EN60950 EMC Directive 89/336/EEC: EN55022 Class B
EN61000-3-2 EN61000-3-3 EN50082-1
IEC801-2 IEC801-3 IEC801-4
Figure 1-1. Temperature/Humidity Range
PRODUCT DESCRIPTION SPECIFICATIONS 12
EPSON Stylus COLOR 860/1160 Revision C

1.3 INTERFACE

The EPSON Stylus COLOR 860/1160 provide USB and parallel interface as standard.

1.3.1 Parallel Interface (Forward Channel)

Transmission Mode: 8 bit parallel, IEEE-1284 compatibility mode Synchronization: By STROBE pulse Handshaking: BY BUSY and ACKNLG signal Signal Level: TTL compatible level Adaptable Connector: 57-30360 (amphenol) or equivalent
BUSY signal is set high before setting either -ERROR low or PE high, and held high until all these signals return to their inactive state.
DATA
-STROBE
BUSY
-ACKNLG
data byte n
thold
tbusy
treply
tstb
tack
tnbusy
tsetup
tready
Figure 1-2. Data Transmission Timing
data byte n+1
tnext
BUSY signal is at high level in the following cases:
n During data entry (see data transmission timing). n When input data buffer is full. n During -INIT signal is at low level or during hardware initialization. n During printer error (see -ERROR signal). n When the parallel interface is not selected.
ERROR signal is at low level when the printer is in one of the following states:
n Printer hardware error (fatal error) n Paper-out error n Paper-jam error n Ink-out error
PE signal is at high level during paper-out error.
Table 1-3.
Parameter Minimum Maximum
tsetup 500ns -
thold 500ns -
tstb 500ns -
tready 0 -
tbusy - 500ns
tt-out* - 120ns
tt-in** - 200ns treply 0 -
tack 500ns 10us
tnbusy 0 -
tnext 0 -
* Rise and fall time of every output signal. ** Rise and fall time of every input signal. *** Typical timing for tack is shown on the following page.
PRODUCT DESCRIPTION INTERFACE 13
EPSON Stylus COLOR 860/1160 Revision C
Table 1-4. Typical Time of tack
Parallel I/F Mode Typical Time of tack
High Speed 1us
Normal Speed 3us
Table 1-5. Signal Level: TTL Compatibl e (IEEE-1284 level 1 device)
Parameter Minimum Maximum Condition
VOH* - 5.5V
VOL* -0.5V -
IOH* - 0.32mA VOH = 2.4V
IOL* - 12mA VOL = 0.4V
CO - 50pF
VIH - 2.0V
VIL 0.8V -
IIH - 0.32mA VIH = 2.0V
IIL - 12mA VIL = 0.8V CI - 50pF
* A low logic level on the Logic H signal is 2.0V or less when the printer
is powered off, and this signal is equal to or exceeding 3.0V when the printer is powered on. The receiver shall provide an impedance equivalent to 7.5K ohm to ground.
Table 1-6. Connector Pin Assignment and Signals
Pin No.
1 -STROBE 19 In
2 DATA0 20 In 3 DATA1 21 In 4 DATA2 22 In 5 DATA3 23 In 6 DATA4 24 In 7 DATA5 25 In 8 DATA6 26 In 9 DATA7 27 In
10 -ACKNLG 28 Out
11 BUSY 29 Out
12 PE 28 Out
13 SLCT 28 Out
Signal
Name
Return
GND Pin
In/Out Functional Descri ption
The strobe pulse. Read-in of data is performed at the falling edge of this pulse.
The DATA0 through DATA7 signals represent data bits 0 to 7, respectively.
Each signal is at high lev el when data is logical 1 and low le vel whe n data is logical 0.
This signal is a negative pulse indicating that the printer can accept data again.
A high signal indic ates that the printer cannot receive data.
A high signal indicates paper-out error.
Always at high level when the printer is powered on.
14 -AFXT 30 In Not used.
The falling edge of a negative pulse
31 -INIT 30 In
32 -ERROR 29 Out
36 -SLIN 30 In Not used.
or a low signa l on this l ine c auses the printer to initialize. Minimum 50us pulse is necessary.
A low signal indicates printer error condition.
PRODUCT DESCRIPTION INTERFACE 14
EPSON Stylus COLOR 860/1160 Revision C
Table 1-6. Connector Pin Assignment and Signals (continued)
Pin No.
18 Logic H - Out
35 +5V - Out
17
16,33,
19-30 15,34 NC - - Not connected
Signal
Name
Chassis
GND
GND - - Signal GND
Return
GND Pin
- - Chassis GND
In/Out Functional Description
Pulled up to +5V via 3.9 K ohm resistor.
Pulled up to +5V via 3.3K ohm resistor.
NOTE: In/Out refers to the direction of signal flow seen from the printer
side.
PRODUCT DESCRIPTION INTERFACE 15
EPSON Stylus COLOR 860/1160 Revision C

1.3.2 Parallel Interface (Reserve Channel)

Transmission Mode: IEEE-1284 nibble mode Adaptable Connector See forward channel. Synchronization: Refer to the IEEE-1284 specification Handshaking: Refer to the IEEE-1284 specification Data Trans. Timing: Refer to the IEEE-1284 specification Signal Level: IEEE-1284 level 1 device
See forward channel.
Table 1-7. Connector Pin Assignment and Signals
Pin No.
1 HostClk 19 In Host clock signal. 2 DATA0 20 In 3 DATA1 21 In 4 DATA2 22 In 5 DATA3 23 In 6 DATA4 24 In 7 DATA5 25 In 8 DATA6 26 In 9 DATA7 27 In
10 PtrClk 28 Out Printer clock signal.
11
Signal
Name
PtrBusy /
DataBit-3,7
Return
GND Pin
29 Out
In/Out Functional Description
The DATA0 through DATA7 signals represent data bits 0 to 7, respectively.
Each signal is at high level when data is logical 1 and low level when data is logical 0.
These signals are used to transfer the 1284 extensibility request values to the printer.
Printer busy signal and reverse channel transfer data bit 3 or 7.
Table 1-7. Connector Pin Assignment and Signals (continued)
Pin No.
32
36 1284-Active 30 In 1284 active signal.
18 Logic-H - Out
35 +5V - Out
17
16,33,
19-30 15,34 NC - - Not connected
Note) In/Out refers to the direction of signal flow from the printer’s point of view.
Signal
Name
-DataAvail / DataBit-0,4
Chassis
GND
GND - - Signal GND
Extensibility Request:
The printer responds affirmatively when the extensibility request values are 00H or 04H, which means,
00H: Request Nibble Mode Reverse Channel Transfer. 04H: Request Device ID;
Return Data Using Nibble Mode Rev Channel Transfer.
Return
GND Pin
29 Out
- - Chassis GND
In/Out Functional Description
Data available signal and reverse channel transfer data bit 0 or 4.
Pulled up to +5V via 3.9K ohm resistor.
Pulled up to +5V via 3.3K ohm resistor.
12
13
14 HostBusy 30 In Host busy signal. 31 -INIT 30 In Not used.
AckDataReq / DataBit-2,6
Xflag /
DataBit-1,5
28 Out
28 Out
Acknowledge data request signal and reverse channel tran sfer data bit 2 or 6.
X-flag signal and reverse channel transfer data bit 1 or 5.
PRODUCT DESCRIPTION INTERFACE 16
EPSON Stylus COLOR 860/1160 Revision C
Device ID:
The printer sends the following device ID string when requested.
When IEEE1284.4 is enabled,
[00H] [5AH] (for Stylus Color 860) [00H] [5CH] (for Stylus Color 1160) MFG: EPSON; CMD: ESCPL2, BDC, D4; MDL: Stylus[SP]COLOR[SP]860/1160; CLS: PRINTER; DES: EPSON[SP]Stylus[SP]COLOR[SP]860/1160;
When IEEE1284.4 is disabled,
[00H] [57H] (for Stylus Color 860) [00H] [59H] (for Stylus Color 1160) MFG: EPSON; CMD: ESCPL2, BDC; MDL: Stylus[SP]COLOR[SP]860/1160; CLS: PRINTER; DES: EPSON[SP]Stylus[SP]COLOR[SP]860/1160;
NOTE 1:[00H] denotes a hexadecimal value of zero. NOTE 2:MDL value depends on the EEPROM setting. NOTE 3:CMD value depends on the IEEE1284.4 setting.

1.3.3 USB Interface

Standard: Based on:
“Universal Serial Bus Specifications Rev. 1.0” “Universal Serial Bus Device Class Definition
for Printing Devices Version 1.0” Bit Rate: 12Mbps (Full Speed Device) Data Encoding: NRZI Adaptable Connector: USB Series B Recommended Cable Length: 2 meters
Table 1-8. Connector Pin Assignment and Signals
Pin No. Signal Name I/O Function Description
1VCC -
2 -Data Bi-D Data
3+DataBi-D
4 Ground - Cable ground
Pin #2
Cable power. Max. power consumption is 2mA.
Data, pull up to +3.3 V via 1.5K ohm resistor.
Pin #1
Pin #3
Pin #4
Figure 1-3. USB Pin Assignment
PRODUCT DESCRIPTION INTERFACE 17
EPSON Stylus COLOR 860/1160 Revision C

1.3.4 Prevention of Data Transfer Time-out

Generally, hosts abandon data transfer to peripherals when the peripheral is in the busy state for dozens of seconds continuously. To prevent this kind of time­out, the printer receives data very slowly, several bytes per minute, even if the printer is in the busy state. The slowdown starts when the remaining input buffer becomes several hundreds of bytes, and the printer finally gets into the busy state continuousl y when the input buffe r is full. USB and IEEE1284.4 on the parallel interface do not require such function.

1.3.5 Interface Selection

The printer has two built-in interfaces: the USB and parallel interface. These interfaces are selected automatically.
o Automatic Selection
In this automatic interface selection mode, the printer is initialized to the idle state while scanning which interface receives data when it is powered on. Then the interface which received data first is selected. When the host stops data transfer and the printer is in the stand-by state for seconds, the printer is returned to the idle state. As long as the host sends data or the printer interface is in the busy state, the selected interface is let as it is.
o Interface State and Interface Selection
When the parallel interface is not selected, the interface gets into the busy state. When the printer is initialized or returned to the idle state, the parallel interface gets into the ready state. Note that the interrupt signal such as the
-INIT signal on the parallel interface is not effective while that interface is not selected.
o Automatic Selection
An initial state is compatible interface and starts IEEE1284.4 communication when magic strings (1284.4 synchronous commands) are received.
o On
An initial state is IEEE1284.4 communication and data that received it by the time it is able to take synchronization by magic string (1284.4 synchronous commands) is discarded.
o Off
An initial state is compatible interface and never starts IEEE1284.4 communication even if magic strings (1284.4 synchronous commands) are received.

1.3.6 IEEE1284.4 Protocol

The packet protocol described by IEEE1284.4 standard allows a device to carry on multiple exchanges or conversations which contain data and/or control information with another device at the same time across a single point-to-point link. The protocol is not, however, a device control language. It does provide basic transport-level flow control and multiplexing services. The multiplexed logical channels are independent of each other and blocking of one has no effect on the others. The protocol operates over IEEE1284.
PRODUCT DESCRIPTION INTERFACE 18
EPSON Stylus COLOR 860/1160 Revision C

1.4 OPERATOR CONTROLS

1.4.1 Operating Switch

Operating switch is located on the control panel.

1.4.2 Control Panel

1.4.2.1 Switches
There are two non-lock type push switches, one lock-type push switch, and four LED lights.
Load/Eject
Cleaning
Power
1.4.2.2 Indicators
(1) Power
Lights when the operating switch is “ON” and AC power is supplied.
(2) Paper Out
Lights during the paper-out condition, and blinks during the paper-jam condition.
(3) Ink Out (Black)
Lights during no black ink condition, and blinks during the black ink low condition.
(4) Ink Out (Color)
Lights during no color ink condition, and blinks during the color ink low condition.
3
Figure 1-4. Control Panel
PRODUCT DESCRIPTION OPERATOR CONTROLS 19
4
2
1
EPSON Stylus COLOR 860/1160 Revision C

1.4.3 Panel Functions

Table 1-9. Panel Functions
Switch Function
Load / Eject
(Push for less than 2 sec.*)
Load / Eject
(Push for 2 sec.*)
Cleaning
(Push for 2 sec.*)
Cleaning
(Push for less than 2 sec.*)
* It is described in the user’s manual that three seconds are required. **This function is not available in printing status.
• Loads or ejects a paper.
• When the carriage is on the ink cartridge replacement position, return the carriage to the capping position.
• Starts the ink cartridge replacement sequence.**
• Moves the carriage to the cartridge replacement position.
• Starts cleaning of the printhead.
• In the condition of “In k Low”, “Ink Out” , or “No I nk Cartridge ”, starts the ink cartridge replacement sequence.**
• When the carriage is on the ink cartridge replacement position, return the carriage to the capping position.
Table 1-10. Panel Function with Power On
Switch Pressing with Power On Function
Load / Eject
Cleaning
Load/Eject
+
Cleaning
*1: One of the following actions is carried out according to the content of 1BH of EEPROM.
Content of 1BH of
EEPROM, [bit7] [bit6]
*2: Not described in the user’s manual. *3: See the table below.
• 1) Starts status printing. *1
• Changes code pages / Selec t IEEE1284.4 mode fo r parallel I/F. *2
• Enters the special settings mode. (Factory use only). *3
Action
00 11 01 Start hex-dump printing. 10 Start self test printing.
Print firmware version, ink counter, selected code page and nozzle check pattern.
Table 1-11. Special Setting Mode
Switch Function
Load / Eject
Cleaning
(Push for 10 seconds)
• Initialize EEPROM and reset timer IC.
• Reset the ink overflow counter in EEPROM.
PRODUCT DESCRIPTION OPERATOR CONTROLS 20
EPSON Stylus COLOR 860/1160 Revision C

1.4.4 Printer Condition and Panel Status 1.4.5 Printer Initialization

Table 1-12. Printer Condition and LED Status
Indicators
Printer Status
Power On Condition On - - - 9 Ink Sequence Blink - - - 6 Ink Cartridge
Replacement Mode Data Processing Blink - - - 8 Paper Out - - - On 4 Paper Jam Condition - Off Off Blink 3 No Ink Cartridge /
Ink End (Black) Ink Level Low (Black) - Blink - - 7 No Ink Cartridge or
Ink End (Color) Ink Level Low (Color) - - Blink - 7 Enter EEPROM and
Timer IC Reset Maintenance
Request Fatal Error Blin k On On Blink 1
Power
Blink - - - 5
-On- -7
--On-7
- ON (for 1 second only) -
Blink Blink Blink Blink 2
Ink Out (Black)
Ink Out
(Color)
Paper Out
Priority
There are three kinds of initialization methods, and the following explains each initialization.
1. Power-on Initialization This printer is initialized when turning the pri nte r power on, or prin ter recognized the cold-reset command (remote RS command).
When printer is initialized, the following actions are performed: (a) Initializes printer mechanism. (b) Clears input data buffer. (c) Clears print buffer. (d) Sets default values.
2. Operator Initialization This printer is initialized when turning the printer power on again within 10 seconds from last power off, or printer recognized the -INIT signal (negative pulse) of parallel interfac e.
When printer is initialized, the following actions are performed: (a) Cap the printer head. (b) Eject a paper. (c) Clears input data buffer. (d) Clears print buffer. (e) Sets default values.
3. Software Initialization The ESC@ command also initializ e the printer.
When printer is initialized, the following actions are performed: (a) Clears print buffer. (b) Sets default values.
PRODUCT DESCRIPTION OPERATOR CONTROLS 21
EPSON Stylus COLOR 860/1160 Revision C

1.4.6 Errors

o Ink Out
When the printer runs out most of the ink of any color, it indicates ink-low and keeps printing. When the printer runs out the whole ink of any color, it stops printing and indicates ink-out error. User is then requested to install a new ink-cartridge in this state. An ink-cartridge that has been taken out once should never be used again. Re-installation of the cartridge not filled fully upsets the ink level detection and may eventually cause a serious problem in the print head.
o Paper Out
When the printer fails to load a sheet, it goes into a paper out error.
o Paper Jam
When the printer fails to eject a sheet, it goes into a paper jam error.
o No Ink-Cartridge
When the printer detects that ink-cartridge comes off, it goes into this error mode.
o Maintenance Request
When the total amount of ink wasted through cleanings and flushing reaches to the limit, printer indicates this error and stops. In such a case, the absorber in the printer enclosure needs to be replaced with new one by service personnel.
o Fatal Errors
Carriage control error or CG access error.
PRODUCT DESCRIPTION OPERATOR CONTROLS 22
EPSON Stylus COLOR 860/1160 Revision C

1.5 PAPER

1.5.1 Paper Handling

Do not perform reverse feed more than 9.5mm (0.38”).

1.5.2 Paper Specification

1.5.2.1 Cut Sheet
[Size]
For Stylus Color 860/1160:
A4: Width 210mm (8.3”) x Length 297mm (11.7”) Letter: Width 216mm (8.5”) x Length 279mm (11.0”) B5: Width 182mm (7.2”) x Length 257mm (10.1”) Legal: Width 216mm (8.5”) x Length 356mm (14.0”) Statement: Width 139.7mm (5.5”) x Length 215.9mm (8.5”) Executive: Width 184.2mm (7.25”) x Length 266.7mm (10.5”) Photo Paper: Width 101.6mm (4”) x Length 152.4mm (6”)
For Stylus Color 1160 only:
A3: Width 297mm (11.7”) x Length 420mm (16.5”) A3+: Width 329mm (13.0”) x Length 483mm (19.0”)
1.5.2.2 Transparency, Glossy Paper
[Size]
For Stylus Color 860/1160:
A4: Width 210mm (8.3”) x Length 297mm (11.7”) Letter: Width 216mm (8.5”) x Length 279mm (11.0”)
For Stylus Color 1160 only:
A3+: Width 329mm x Length 483mm (Glossy Paper)
[Thickness]
0.075mm (0.003”) - 0.085mm (0.0033”)
*Transparency printing is available only at normal temperature.
1.5.2.3 Envelope
[Size]
No.10: Width 241mm (9 1/2”) x Length 104.8mm (4 1/8”) DL: Width 220mm (8.7”) x Length 110mm (4.3”) C6: Width 162mm (6.4”) x Length 114mm (4.5”)
[Thickness]
0.16mm (0.006”) - 0.52mm (0.02”)
[Thickness]
0.08mm (0.003”) - 0.11mm (0.004”)
[Weight]
2
64g/m
[Quality]
Exclusive paper, Bond paper, PPC
(17Ib.) - 90g/m2 (24Ib.)
[Weight]
45g/m2 (12Ib.) - 75g/m2 (20Ib.)
[Quality]
Bond paper, Plain paper, Air mail
Note1: Envelope printing is available only at normal temperature. Note 2: Keep the longer side of the envelope horizontally at setting.
PRODUCT DESCRIPTION PAPER 23
EPSON Stylus COLOR 860/1160 Revision C
1.5.2.4 In dex Card
[Size]
A6 Index Card: Width 105mm (4.1”) x Length 148mm (5.8”) A5 Index Card: Width 148mm (5.8”) x Length 210mm (8.3”) 5 x 8” Index Card: Width 127mm (5.0” x Length 203mm (8.0”) 10 x 8” Index Card: Width 127mm (5.0”) x Length 203mm (8.0”)
[Thickness]
Less than 0.23mm (0.0091”)
PRODUCT DESCRIPTION PAPER 24
EPSON Stylus COLOR 860/1160 Revision C

1.5.3 Printing Area

1.5.3.1 Cut Sheet
See the figure below and tables on the right for printable areas for Raster Graphics mode and Character mode.
PW
LM
Printable Area
RM
TM
PL
Table 1-13. Character Mode
Paper
Size
A3 (*1) 3mm (0.12”) 3mm (0.12”) 3mm (0.12”)
A4 3mm (0.12”) 3mm (0.12”) 3mm (0.12”)
Letter 3mm (0.12”) 9mm (0.35”) 3mm (0.12”)
B5 3mm (0.12”) 3 m (0.12”) 3mm (0.12”)
Legal 3mm (0.12”) 9mm (0.35”) 3mm (0.12”)
Statement 3mm (0.12”) 3mm (0.12”) 3mm (0.12”)
Executive 3mm (0.12”) 3mm (0.12”) 3mm (0.12”)
Left Margin
(min.)
Right Margin
(min.)
Top Margin
(min.)
Bottom Margin
(min.)
14mm (0.54”) /3mm (0.12”) (*2)
14mm (0.54”) /3mm (0.12”) (*2)
14 mm (0.54”) / 3mm (0.12”) (*2)
14 mm (0.54”) / 3mm (0.12”) (*2)
14 mm (0.54”) / 3mm (0.12”) (*2)
14 mm (0.54”) / 3mm (0.12”) (*2)
14 mm (0.54”) / 3mm (0.12”) (*2)
BM
Figure 1-5. Printable Area for Cut Sheet
PRODUCT DESCRIPTION PAPER 25
EPSON Stylus COLOR 860/1160 Revision C
Table 1-14. Raster Graphics Mode
Paper
Size
A3* 3 mm (0.12”) 3 mm (0.12”) 3 mm (0.12”)
A3+* 3 mm (0.12 ”) 3 mm (0.12”) 3 mm (0.12”)
A4 3 mm (0.12”) 3 mm (0.12”) 3 mm (0.12”)
Letter 3 mm (0.12”) 3 mm (0.12”) 3 mm (0.12”)
B5 3 mm (0.12”) 3 mm (0.12”) 3 mm (0.12”)
Legal 3 mm (0.12”) 3 mm (0.12”) 3 mm (0.12”)
Statement 3 mm (0.12”) 3 mm (0.12”) 3 mm (0.12”)
Exclusive 3 mm (0.12”) 3 mm (0.12”) 3 mm (0.12”)
* For Stylus Color 1160 only. ** Bottom margin can be reduced to 3mm when paper dimension is
*** Refer to 1.5.2 Paper Specification for PW (paper width) and PL
Left Margin
(min.)
Right Margin
(min.)
Top Margin
(min.)
Bottom Margin
(min.)
14 mm (0.54”) / 3mm (0.12”) **
14 mm (0.54”) / 3mm (0.12”) **
14 mm (0.54”) / 3mm (0.12”) **
14 mm (0.54”) / 3mm (0.12”) **
14 mm (0.54”) / 3mm (0.12”) **
14 mm (0.54”) / 3mm (0.12”) **
14 mm (0.54”) / 3mm (0.12”) **
14 mm (0.54”) / 3mm (0.12”) **
defined by using command, otherwise it is not reduced (14mm). As for an area between 3mm and 14mm margin, printing quality may decline.
(paper length).
1.5.3.2 Envelopes
LM
Printable Area
Figure 1-6. Printable Area for Envelopes
Table 1-15. Envelope Margin
Size
#10 3 mm (0.12”) 28 mm (1.10”) 3 mm (0.12”) 14 mm (0.55”)
DL 3 m m (0.12”) 7 mm (0.28”) 3 mm (0.12”) 14 mm (0.55”)
Left Margin
(min.)
Right Margin
(min.)
Top Margin
(min.)
Bottom Margin
RM
TM
BM
(min.)
C6 3 mm (0.12”) 3 mm (0.12”) 3 mm (0.12”) 14 mm (0.55”)
PRODUCT DESCRIPTION PAPER 26
EPSON Stylus COLOR 860/1160 Revision C

1.6 INK CARTRIDGE

1.6.1 Black Ink Cartridge

Type: Exclusive Cartridge Color: Black Print Capacity: 900 pages/A4
(ISO/IEC 10561 Letter Pattern at 360 dpi) Ink Life: 2 years from date of production Storage Temperature:
Storage: -20 Packing: -30 Transit: -30
Dimension: 27.8 mm (W) x 52.7 mm (D) x 38.5 mm (H)
27.8
o
C to 40 oC (within a month at 40 oC)
o
C to 40 oC (within a month at 40 oC)
o
C to 60 oC (within 120 hours at 60 oC
and within a month at 40
52.7
o
C)
51.2

1.6.2 Color Ink Cartridge

Type: Exclusive Cartridge Color: Magenta, Cyan, Yellow Print Capacity: 300 pages / A4 (360 dpi, 5% duty each color) Ink Life: 2 years from date of production Storage Temperature:
Storage: -20 Packing: -30 Transit: -30
Dimension: 42.9 mm (W) x 52.7 mm (D) x 38.5 mm (H)
o
C to 40 oC (within a month at 40 oC)
o
C to 40 oC (within a month at 40 oC)
o
C to 60 oC (within 120 hours at 60 oC
and within a month at 40
52.7
42.9
43.2
38.5
o
C)
51.2
38.5
41.4
Figure 1-8. Color Ink Cartridge
26.3
Figure 1-7. Black Ink Cartridge
Note 1: Ink cartridge can not be refilled. The ink cartridge is prepared only
for article of consumption. Note 2: Do not use the ink cartridge which contains life-expired ink. Note 3: Ink will be frozen under -4
o
C environment; however, it will be usable after being left at room temperature for more than three hours.
PRODUCT DESCRIPTION INK CARTRIDGE 27

OPERATING PRINCIPLES

CHAPTER
EPSON Stylus COLOR 860/1160 Revision C

2.1 Overview

This section describes the operating principles of the printer mechanism and electrical circuit boards. The EPSON Stylus COLOR 860/1160 has the following boards:
o
Main board: C298MAIN Board (Stylus COLOR 860/1160)
o
Power supply board: C298PSB/PSE Board (Stylus COLOR 860/1160)
o
Panel board: C298PNL Board (Stylus COLOR 860)
C304PNL Board (Stylus COLOR 1160)

2.1.1 Printer Mechanism

Unlike other EPSON ink jet printers, the motor for power source. Use of the DC motor enable the printer to lower noise during printing to a great extent. Table 2-1 shows the various motor types used in the printer and their applications.
Table 2-1. Motor Types and Corresponding Applications
Motor Name Type Application / Feature
CR Motor DC with brush
PF Motor DC with brush
Pump/ASF
4-Phase 48-pole stepping motor
Stylus COLOR 860/1160
Used to drive the carriag e maki ng littl e noise . A a linear scale is used to monitor the motor’s operating condition.
• Drives paper feeding rollers used to send paper at specified speeds and load/eject paper.
• CR lock lever operation
• To monitor paper feeding pitch, a loop scale is attached beside the high-precision gear.
Like the Stylus COLOR 800 and Stylus Pro 5000, this motor manages pump drive and paper loading from ASF.
Since this is a stepping motor, it has no scales or photo sensors that are used to monitor the motor’s operating condit ion .
uses DC
The basic structure of the printer mechanism is mostly common to the Stylus COLOR 400/600/440/640/740, except that the Stylus COLOR 860/1160 uses a Pump/ASF motor. With this motor equipped, the paper loading mechanism and the pumping mechanisms are independently driven, which allows the printer to offer higher throughput as a result.
Figure 2-1 shows the printer mechanism block diagram for the Stylus COLOR 860/1160.
Loop Scale
Plain Gear
PF Motor Pinion
PF Motor
Flashing Window (at 80th or 136th column)
Photo Interrupter (Encoder for CR)
Star Wheel Roller
Bk I/C Sensor
CMY I/C Sensor
Carriage Unit
Printhead (one unit)
Timing Belt Cap Unit
(without a valve)
Pump Unit
CR Guide Shaft
PF Roller
Liner Scale
PF Drive Gear
Encoder (PF)
ASF Sensor
Detector Wheel
Loading Shaft
Loading Rollers
PE Sensor
Pump/ASF Motor (stepping motor)
CR Motor (DC motor)
PG Lever
Figure 2-1. Printer Mechanism Block Diagram
Operating Principles Overview 29
EPSON Stylus COLOR 860/1160 Revision C
2.1.1.1 P rinting Mechanism
The basic operating principles of the printhead, which plays a major role in printing, are the same as previous models; ones that use a on-demand type U­CHIP head method. (Refer to Figure1-1.) Also, unlike the Stylus Color IIs, 820 and 200, the Stylus COLOR 860/1160 is not an automatic correction type. So, in order to correct dispersion of multi layer piezo electric element that drives each nozzle, you are required to input a VH value written on the top surface of the printhead by using an exclusive program when you replace the printhead, control board, or printer mechanism. (Note there are no resistor arrays to determine the VH voltage on the main control board.) Following explains printhead.
o PZT
PZT is an abbreviation of Piezo Electric Element. Print signals from the Main board are sent through the driver board on the printhead unit to the PZT. Then, the PZT pushes the top cavity whic h has ink sto red to discharge the ink from each nozzle on the nozzle plate.
o Cavity Set
The ink absorbed from the ink cartridge goes through the filter and then is stored temporarily in this tank called “cavity” until PZT is driven.
I/C Sensor Actuator
Nozzle Plate
PZT
Nozzle Selector Board
Ink Cartridge
Needle
Filter
Cavity
o Nozzle Plate
Figure 2-2. Printing Mechanism
The board with nozzle holes on the printhead surface is called Nozzle Plate.
o Filter
When the ink cartridge is installed, if any dirt or dust around the cartridge needle is absorbed into the head, there is a great possibility of causing nozzle clog and disturbance of ink flow, and finally causing alignment failure and dot missing. To prevent this problem, a filter is set below the cartridge needle, where ink is filtered.
Operating Principles Overview 30
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