Epson stylus 1160 rev c schematic

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SERVICE MANUAL

SERVICE MANUALSERVICE MANUAL

Color ink jet printer

Stylus COLOR 860/1160

SEIJ99003

EPSON Stylus COLOR 860/1160 Revision C

Notice:

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.

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

)

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: 49.5∼60.5Hz 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)

80 70 60

Humidity (%)

50 40 30 20

Temperature (°C)

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

[220∼240V 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

[220∼240V 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

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.

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.

36 1284-Active 30 In 1284 active signal.

18 Logic-H - Out

35 +5V - Out

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.

14 HostBusy 30 In Host busy signal. 31 -INIT 30 In Not used.

AckDataReq / DataBit-2,6

Xflag /

DataBit-1,5

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.

Figure 1-4. Control Panel

PRODUCT DESCRIPTION OPERATOR CONTROLS 19

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]

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.

Printable Area

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)

14 mm (0.54”) / 3mm (0.12”) (*2)

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”) **

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

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

(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

C to 40 oC (within a month at 40 oC)

C to 60 oC (within 120 hours at 60 oC

and within a month at 40

52.7

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)

C to 40 oC (within a month at 40 oC)

C to 60 oC (within 120 hours at 60 oC

and within a month at 40

52.7

42.9

43.2

38.5

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

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:

Main board: C298MAIN Board (Stylus COLOR 860/1160)

Power supply board: C298PSB/PSE Board (Stylus COLOR 860/1160)

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

EPSON Stylus COLOR 860/1160 Revision C

2.1.1.2 P rinting Pro cess

Figure 2-3 and Figure 2-4 show the normal state and ejecting state of the printhead, respectively.

1. Normal State: When the print signal is not output, PTZ also does not move from a waiting state (normal state). (Refer to Figure 2-3.)

2) Ejecting Stat e: When the print signal is output from the C298MAIN board, IC (IR4C463S: Nozzle Selector) located on the printhead unit latches data once by 1-byte unit. An appropriate PZT latched by the nozzle selector is pushed into the cavity by the common voltage applied from the main board. By this operation, ink stored in the cavity spurts out from nozzles. (Refer to Figure 2-4.)

Ink Course Cavity

Figure 2-3. Print Head Normal State

PZT

Nozzle

Nozzle Plate

Figure 2-4. Print Head Ejecting State

Operating Principles Overview 31

EPSON Stylus COLOR 860/1160 Revision C

2.1.1.3 Carria ge Mechanism

The carriage mechanism for the Stylus COLOR 860/1160 is mostly the same as for other ink jet printers except it is driven by a DC motor. See the table below for the carriage motor specifications.

Table 2-2. Carriage Motor Specification

Items Specifications

Type DC Motor with brush Drive Voltage +42 V +/- 5%(DRV IC voltage) Internal Resistance 29.2 ohms +/- 25% Inductance 30.8 mH +/- 25% Drive Method Constant Current Chopping Driver IC LB1947

Unlike a stepping motor, the DC motor that drives the carriage can not detect the current carriage position by referring to the pulses given. Therefore, a linear scale is attached along the carriage operation range to enable the printer to mechanically detect the carriage position. The linear scale is also used to produce the print timing signal (PTS signal), to which the printer refers to for a correct ink ejection timing. For detailed information on the CR motor control circuit, see Section 2.2.

Carriage Motor

PF Roller

Timing Belt

Carriage Unit

Front Side

Rear Side

Parallelism Adjust Lever

The printhead, a core of the printing mechanism, is stored in the carriage unit. When the adjustment lever is moved up and down, this printhead is maintained tilt in a flexible and adjustable structure by the tilt adjustment mechanism. Also, the parallelism adjustment levers, mounted on the left and right sides of the carriage guide shaft, are used to set the carriage guide shaft parallel to the platen when the shaft has been installed to the printer mechanism. After this adjustment is completed, moving the PG adjustment lever sets the distance between the platen surface and the printhead surface to one of two possibilities: 1.14 mm or 1.84 mm. Moving the PG lever, you can rotate the shafts of the carriage guide shaft which itself is decentralized to change the distance. This is the mechanism that the user can use to adjust the appropriate PG value according to the printing result or any other environmental conditions such as thick paper.

Fixing Bushing

Carriage Guide Shaft

Eject Roller

Paper Guide (Front)

PF Motor

CR Lock Lever

Figure 2-5. Carriage Mechanism (Top view)

Operating Principles Overview 32

EPSON Stylus COLOR 860/1160 Revision C

2.1.1.4 Platen Gap (PG) Adjust Mechanism

The PG adjustment, at the left of the printer mechanism, consists of the PG lever, PF support lever, right/left parallelism adjustment levers, and CR guide shaft. The PG adjustment mechanism is designed to keep the platen gap correct for the paper thickness to prevent ink from smearing. The PG lever joins the CR guide shaft, which has an eccentricity via PG sub lever. Switching the lever from “0” to “+” rotates the CR shaft and changes the platen gap from narrow to wide.

Table 2-3. Platen Gap Adjust Lever Setting

Paper Lever Position PG adjustment value

All Media Front

If you find any print problems or use thick paper.

Rear

0 mm (1.14 mm between head and platen)

0.7mm (1.84 mm between head and platen)

2.1.1.5 Paper Feeding Mechanism

The paper feeding mechanism transports paper loaded from ASF using the PF rollers and paper eject rollers. A new type of DC motor is used for the PF motor. See the table below for the DC motor specifications.

Table 2-4. PF Motor Specifications

Item Description

Motor type DC Motor with Brush Drive voltage +42V +/- 5% (DRV IC voltage) Coil Resistance 31.1 ohm +/- 25% Drive frequency [Hz] 26.6mH +/- 25% Control method A3958

Unlike a stepping motor, the DC motor that drives the paper feeding mechanism can not measure the paper feeding amount by referring to the pulses given. For this reason, the loop scale and encoder sensor are directly attached to the left end of the PF roller shaft to mechanically control paper feed amount. See Section 2.2 for detailed information on the PF motor control circuit.

Drive from the PF motor is sent to the PF rollers and paper eject rollers as described below.

o To the PF rollers:

PF motor pinion gear

→ Spur gear (76) → PF rollers

o To the eject rollers:

PF motor pinion gear Spur gear (28)

Figure 2-6 in the next page gives the paper feeding mechanism block diagram, showing the parts along the PF motor drive transmission paths.

→ Spur gear (76) → Combination gear (13.5, 308) →

→ Paper eject rollers

Operating Principles Overview 33

EPSON Stylus COLOR 860/1160 Revision C

Front Paper Guide

Eject Roller

PF Motor

Figure 2-6. Paper Feeding Mechanism

The printer loads paper at the ASF, which is detected by the PE sensor attached to the right side of the top frame, and advances it to send the paper’s leading edge to the halfway of the front paper guide. Then, to correct deflection, the printer feeds the paper back specified steps toward ASF, and advances the paper again toward the front paper guide and stops it at the specified TOF (Top Of Form) position. Once the printer starts printing, it transports paper using the PF rollers and sub rollers, and as the printer transports or printing on the tailing 14 mm, it uses a star wheel gear and paper eject rollers. Like the Stylus COLOR 440/640/740, this printer also provides this extra printable range of 14 mm from the bottom edge, excluding the bottom margin of 3mm, by changing the position of the star wheel gear; it has been shifted by 5 this change, the tailing edge of paper is suppressed, and the printer can advance paper steadily when printing around the bottom area. See Figure 2-7 next page that shows how paper is transported and parts involved.

° from the top of the eject roller toward the front paper guide. Due to

[Previous Models]

Star Wheel Assy.

Paper

Eject Roller

Printhead

Platen

[Stylus COLOR 860/1160]

Five Degrees

Figure 2-7. Paper Transportation

Support Roller

Bottom margin 3 mm touch es

the printhead surface.

Steady

PF Roller

Operating Principles Overview 34

EPSON Stylus COLOR 860/1160 Revision C

2.1.1.6 CR Lock Mechanism

The carriage lock mechanism prevents the carriage from being left at an uncapped position for a long time, which is usually caused by vibration during printer transportation, user’s mishandling of the printer, and so on. The CR Lock mechanism is driven with the DC PF motor. For the motor specifications, refer to the Table 2-4 . The PF motor drive is used for the Paper Feed Mechanism also and the CR lock mechanism is controled depends on the direction of the PF motor rotationa. The CR lock mechanism is assembed on the right tip of the Paper Eject Roller as shown in the folloiwng figure.

Top view

Bushing 6

Paper Eject Roller

Figure 2-8. CR Lock mechanism

CR Lock Lev e r

Middle Frame

Right side view

CR unit

The carriage lock mechanism prevents the carriage from being left at an uncapped position for a long time, that is usually caused by vibration during printer transportation, user’s mishandling of the printer, and so on. If the carriage is left uncapped for a long time, ink on its surface will become gradually thick and not spurt from the nozzles as a result. To make matters worse, the holes (crater) of the nozzles may be completely clogged by the thick ink, and they may not be able to return to a normal condition just by a cleaning operation. To prevent this, the printer enters a carriage lock condition in the foll owi ng condi tio ns .

o After Power-off operation:

If the printer power is turned off in the middle of printing or any other performances, carriage lock takes place in the end after an initialization operation.

o After Power-on operation:

After the printer power is turned on and an automatic power-on cleaning is completed, carriage lock is performed. The power-on cleaning is an automatic head cleaning that runs when the printer power is turned on. The timer IC always calculates printer’s power off time using power from a lithium battery mounted on the C298MAIN board. The power-on cleaning function automatically selects a correct cleaning level according to the length of time which the printer has been turned off.

o After ejecting paper:

After the Load/Eject button is pressed and the paper is ejected, if the printer does not receive any data, it performs carriage lock and goes to a standby state. However, if paper is loaded by pressing the Load/Eject button, the printer does not perform the ca rria ge loc k opera tio n.

While the PF motor drive is used for paper feeding (PF motor rotation: CCW), the CR Lock lever is set under the Paper Eject Frame, but the CR Lcok lever rises up with clockwise rotation of the PF motor and locks the CR unit. Drive from the PF motor is sent to the CR Lock lever via Papaer Eject Roller as described below.

To the CR lock lever PF motor pinion gear (CW rotation) (13.5, 30.8)

→ Spur gear (28) → Paper eject rollers→ CR lock lever

→ Spur gear (76) → Combination gear

PF motor torque is always transmitted to the CR lock lever side, but the operation of the CR lock mechanism varies depending on the rotational direction of the PF motor, as shown in the table below.

Table 2-5. CR lock mechanism & PF rotational direction

Directions Corresponding Functions

Counterclockwise ckwise

• Release the CR lock lever.

• Sets the CR lock lever.

Operating Principles Overview 35

EPSON Stylus COLOR 860/1160 Revision C

2.1.1.7 Paper Loading Mechanism

The paper loading mechanism loads paper at the ASF unit and feeds paper to the PF rollers. The ASF unit, the same as in the Stylus COLOR 440/640/740, uses a 4-phase 48-pole PM type stepping motor for the ASF/Pump motor. Drive sent from this motor is switched between the ASF unit side and pump unit by the disengage mechanism. See Figure 2-6 for the ASF/Pump motor specifications.

Table 2-6. ASF/Pump Motor Specifications

Items Description

Motor type 4 Phase/ 48-pole /PM type pulse motor Drive method Bipolar drive Drive voltage +42V +/- 5% (DRV IC voltage) Coil Resistance 10.4 ohm +/- 10% Drive frequency [Hz] 15mH Control method A3958

The rotational directions and their functions are shown in the table below:

Table 2-7. ASF/Pump Motor Rotation

Torque from the ASF/Pump motor is transmitted to the ASF as described below:

o Torque transmission to the ASF unit

1) When the CR unit moves to the right end of the CR shaft, the DE lock lever is pushed to the right end.

2) The ASF-Pump motor rotates clockwise specified steps (viewed from the motor pinion gear side).

3) With the rotation of step 2), the planetary gear set in the disengage unit shifts to the combination gear (12, 22.4) side.

4) The CR unit moves specified steps from the right end of the CR shaft to the left. With this movement, the DE lock leve r fixes the planetary gear unit.

5) Torque from the ASF/Pump motor is transmitted as described below.

Motor pinion gear → Planetary gear (15.2) → Combination gear (12,

22.4)

→ Combination gear (14, 28) → Spur gear (32) in ASF

Figure 2-9 shows the disengage mechanism and the parts involved.

C om bination G ear 14,28

C om bination G ear 12,22.4

Planetary gear 15.2 unit

D E Lock Lever

Directions Corresponding Functions

Clockwise

Counterclockwise

• Sets the paper return lever.

• Switches torque to the ASF side.

• Loads paper at ASF.

P in io n fo r AS F/Pum p M otor

: P aper loading rotation

C om bination G ear 17.19,25.6

: A S F s id e s w itc h ro ta tio n

Figure 2-9. Disengage Mechanism

Operating Principles Overview 36

EPSON Stylus COLOR 860/1160 Revision C

Torque sent from the ASF/Pump motor to the ASF unit via the disengage mechanism is used for the following operation.

o Paper loading operation

Like the Stylus COLOR 440/640/740, ASF of this printer has the multiple paper

loading prevention mechanism to provide steady paper loading. This mechanism prevents a sheet of paper from falling from the paper set position into the paper path. A paper return lever in the mechanism pushes paper that may have fallen off back onto the hopper. After this motion is completed, the LD roller starts loading paper. The paper loading mechanism, including the multiple paper loading prevention mechanism, is described in the following steps.

LD Roller

Hopper Hopper Spring

Cam

1. When the printer power is turned on, the ASF/Pump motor rotates counterclockwise to detect ASF home position. Then the motor rotates clockwise specified steps to set the LD roller and paper turn lever in place. (See “Standby State” in Figure 2-10.)

2. When the paper loading signal is sent from the PC and the Load/Eject button is pressed, ASF/Pump motor turns counterclockwise to let the LD roller load paper. (See “Paper Pick Up State” in Figure 2-10.)

3. When the paper is transported to the PF roller, the LD roller stops where it loses friction. (See “PF Roller Paper Feed State” in Figure 2-10.)

4. When the next print signal is sent and Load/Eject button is pressed, the ASF/Pump motor rotates clockwise specified steps to set the LD roller and the paper return lever in place. (See “Standby State” in Figure 2-10.)

NOTE: If no print signal is sent for several seconds in step 4, the LD roller and the

paper return lever automatically return to the standby state.

Pinch Roller

Paper Return

Lever

[Stand-by State]

Pad

Pad Spring

[Paper Pickup State]

[PF Roller Paper Load State]

Figure 2-10. Multiple Paper Loading Prevention Mechanism

Operating Principles Overview 37

EPSON Stylus COLOR 860/1160 Revision C

2.1.1.8 Pump Mechanism

The pump mechanism absorbs ink from the printhead or the cap assembly. The wiper for head cleaning is attached in the cap assembly. The pump mechanism is driven by the ASF/Pump motor, a 4phase 48-pole PM type stepping motor. See Table 2-6 for the ASF/Pump motor specifications. Torque from the ASF/Pump motor is sent to the pump unit by the switching operation of the planetary gear in the disengage mechanism. The ASF/Pump motor torque is transmitted to the pump mechanism as described below.

o Torque transmission to the pump unit

1) When the CR unit moves to the right end of the CR s haft, the D E lock lever) is pushed to the right end.

2) The ASF-Pump motor rotates specified steps counterclockwise (viewed

from the motor pinion gear side).

3) With the rotation of step 2), the planetary gear set in the disengage unit

moves to the combination gear (17.19, 25.6) side.

4) The CR unit moves specified steps from the right end of the CR shaft to the

left. With this motion, the DE lock lever fixes the planetary gear set.

5) Torque from the ASF/Pump motor is transmitted as described below.

Motor pinion gear

→

Tension belt → Spur gear → Pump unit

C om bination G ear 14,28

→

Planetary gear (15.2) → Combination gear (17.19, 25.6)

: P um p ink absorption rotation

: P u m p s id e s w itc h ro ta tio n

C om bination G ear 12,22.4

Planetary gear 15.2 unit

D E L o c k L e v e r

Tension Belt

When the ASF/Pump motor torque is switched to the pump unit side by the disengage mechanism, the function of the pump mechanism varies depending on the rotational direction of the motor, as shown in the table below.

Table 2-8. ASF/Pump Motor Functions

Directions Corresponding Functions

• Switches torque to the ASF side.

Counterclockwise

Clockwise

• Ink absorption by the pump

• Sets the wiper.

• Releases the pump.

• Resets the wiper.

Figure 2-12 shows the operating principles of the pump mechanism.

Counterclockwise

Tube pressured

Clockwis

Tube released

Figure 2-12. Pump Mechanism

P in io n fo r A S F /P u m p M o to r

C o m b in a tio n G e a r 1 7 .1 9 ,2 5 .6

P u m p U n it G e a r

Figure 2-11. Torque to the Pump Mechanism

Operating Principles Overview 38

EPSON Stylus COLOR 860/1160 Revision C

2.1.1.9 Capping Mechanism

The capping mechanism, which is driven by the pump unit, caps the printhead closely to maintain air tightness of the cap. This operation is required to vacuum ink from the ink cartridges, printhead, cavity, and cap. Also, to moisten the inside of the cap while the printer power is off, this mechanism works to keep the cap and the printhead surface in a tight contact. This function prevents ink from clogging while the printer is not in use.

SC440/640/740 models

Flag for Carriage

Negative pressure

Ink Eject Valv e

Valve

For a specific feature of the Stylus COLOR 860/1160, it has a newly designed valveless capping mechanism instead of other printers’ capping mechanism that integrates an air valve. An air valve is usually equipped to remove bubbles created inside the cap by releasing the negative pressure. However, due to change in the ink sequence, the new valveless capping mechanism enables this printer to maintain the initial ink charge and cleaning effects at the same level as before. Figure 2-13 outlines the valveless capping mechanism.

SC860/1160 models

Flag for Carriage

Ink Eject Valve Negative pressure

Closed state

Released state

Flags for Frame

Air valve is not assembled in this portion.

Figure 2-13. Valveless Capping Mechanism

Operating Principles Overview 39

EPSON Stylus COLOR 860/1160 Revision C

2.2 Electrical Circuit Operating Principles

The electric circuit of the Stylus COLOR 860/1160 is composed of the following boards.

Main board: C298MAIN (Stylus COLOR 860/1160)

Power supply board: C298PSB/PSE (Stylus COLOR 860/1160)

Panel board: C298PNL (Stylus COLOR 860)

C304PNL (Stylus COLOR 1160)

Refer to Figure 2-13 for the major connection of the three boards and their roles.

C 298 P N L B oard (S C 860) C 304 P N L B oard (S C 1160)

C 298 M A IN B oard

3.3V R egulator

Power off

+5VD C

C298 PSB/PSE Board

+42VD C

Printer M echanism

C R M otor

PF M otor

AS F/P um p M otor

H ead D river B oard

Several S ensors

Figure 2-14. Electric Circuit of Stylus COLOR 860/1100

Operating Principles Electrical Circuit Operating Principles 40

EPSON Stylus COLOR 860/1160 Revision C

2.2.1 C298PSB/PSE Board

The Stylus COLOR 860 and Stylus COLOR 1160 are equipped with the C298PSB/PSE, the common power supply board for the both products. The basic structure of the circuit is the same as for the C257PSB/PSE board used in the Stylus COLOR 740. The power supply boards of these printers use a RCC switching regulator, which generates +42VDC for drive line and +5VDC for logic line to drive the printer. For one of the major characteristics of the C298PSB/PSE, it uses the secondary switch that is also used in the Stylus Color series. Use of the secondary switch enable the circuit to keep supplying voltage to 5 V line and 24 V line for approximately 30 seconds if the printer power is turned off through the panel switch. This extra time allows the printer to perform the following operations when the printer is turned off through the panel switch while it is in operation.

o When the printer is in a printing state, if the CR unit is away from the home

position, the CR unit can return to the home position to be locked before the printer power shuts down.

o When the printer is not in a printing state, if paper fed from ASF remains in

the printer, the paper is ejected before the printer power shuts down.

Table 2-9 in the right column shows the application of each voltage generated by C298PSB/PSE board.

NOTE: The 5VDC is only applied to the parts and locations shown in the Table 2-9.

The C298MAIN, like the C267MAIN-B board*, uses the 3.3V drive chips for most of the logic line chips (CPU, ASIC, ROM, DRAM). For this reason, those chips are not driven by the +5VDC but 3.3VDC that is reduced by the IC9 (3.3VDC regulator) on the C298Main Board.

* Used in the minor changed models of the Stylus COLOR 740, Stylus Pro

750, and Stylus Pro 1200.

Figure 2-15 in the right column shows the block diagram for the C298PSB/PSE board. The process from the input of AC voltage to the output of 42 V DC and 5 V is explained in the following page.

Table 2-9. Application of the DC Voltages

Voltage Application

+42VDC

CR Motor, ASF/Pump Motor, PF Motor Head driving power supply

Sensor circuit power supply voltage LED panel drive power supply

+5VDC

Nozzle selector control signal voltage I/F Control Circuit Slave CPU for DC motor control

ZD90

+42VD C Lin D rop L im ita tio n C irc u it

C84,Q84

Power Drop Delay Circuit

PSC S ignal from M ain board

PC1

+42 V D C

D51

+5 VD C

IC 5 1

+5V R egulator

ZD 81-86,Z D 51

+42VD C Line C onstant C ontrol

C51

Sm oothing Circuit

ZD53

+5V D C Line O ver Voltage L im ita tio n

ZD 52,87

+42VD C Line O ver Voltage L im ita tio n

TRANS(T1)

AC Input

C11

Sm oothing Circuit

O ver C urrent Protection

F1, TH 1

M ain S w itching Circuit

F ilte r C irc iu t

L1, C 1,C 2

Q2,Q3,Q31

Full W ave R e c tifie r c ir c u it

DB1

Abnorm al Feed back circuit

Photo Coupler

Figure 2-15. C298PSB/PSE Board Block Diagram

Operating Principles Electrical Circuit Operating Principles 41

EPSON Stylus COLOR 860/1160 Revision C

1. Regardless of the state of the power switch (On or OFF), the voltage is always applied to the primary side of the power supply board from the moment or at the state that AC-plug is plugged in. At this time, F1 plays a role of preventing AC100V from coming into the F1. L1 also prevents high harmonic wave noise generated in the RC circuit filter which consists of C1,C2 from going out, and eliminates the noise from outside here.

2) The AC is full-wave rectified by the diode bridge DB1, and converted to

x AC in voltage by the smoothing electrolytic capacitor C11.

3) The pressured up direct current turns Q1 on through the starting resistor R31 and starts the primary side of the circuit.

4) When the primary side is On, the energy (current) led by the electromagnetic induction through the trans (T1) does not flow to the secondary side since the diode (D51) on the secondary side is installed in the opposite direction.

5) When the energy which is charged in the trans is reaching the saturated state, the voltage which makes Q1 on becomes weak gradually. At the point that this voltage drops at the certain voltage, C13 absorbs the current in the opposite direction and Q1 is quickly shut off by the resulting sharp drop.

6) When the primary side is turned off, the energy charged in the T1 is opened according to the diode(D51 ) dire ction whi ch is inst all ed on the secondary side. Basically, 42 V DC is output by these circuit operations and the number of T1 spiral coil.

7) +5VDC is generated by pressured down this +42VDC as power supply. IC51 pressures down the +42VDC and generates precise +5VDC by chopping off the output, forming the standard santooth wave form by the outer RC integration circuit.

The C298PSB/PSE board has the various control circuits to stop voltage output if a malfunction occurs on the power supply board or the main board or while the printer mechanism is on duty. Following explains each control and protection circuit.

o +5V line over voltage protection circuit:

This protection circuit is in the same line as the +42V over voltage protection circuit is located. The output voltage level of the +5V line is monitored by a Zener diode. This circuit shuts down the +5V line forcefully when the voltage level exceeds +9V.

o +42VDC line drop limitation circuit:

This protection circuit is in the same line as +42V over voltage protection circuit is located. The output voltage level of the +42V line is monitored by a Zener diode. This circuit shuts down the +42V line forcefully when the voltage level drops to +36V.

o +42VDC line over voltage circuit:

This circuit is in the same line as +5V line over voltage protection circuit is located. The output level is monitored by two Zener diodes. If the voltage level exceeds +48VDC, this circuit shuts down the +42V line forcefully.

o +5V line constant voltage/constant current control circuit:

The output current is monitored by the +5VDC generation switching control IC (IC51), which also monitors the output voltage. This information is input to the internal comparator and stabilizes +5V line. The operations of the secondary side switch are explained below.

n When the power is turned on, Q1 repeats on/off automatically along

with the increase and decrease of energy on the trans coil at the primary side. While the power is on, the PSC signal is input to the power supply board from the C298MAIN board.

n This signal turns Q84 on and it becomes possible to discharge energy

between the terminals 8 and 9 of T1. At this time, even if the power is turned off, the electrolytic capacitor keeps Q84 on for a while, and by this electrolytic capacitor, voltage output is held at least 30 seconds. This time helps the printer to complete a power-off operation.

o +42V Line Constant Voltage Control Circuit:

The output level of the +42V line is monitored by a detection circuit composed of the seven Zener diodes. This circuit prevents the voltage from dropping for a constant level of the output voltage .

Operating Principles Electrical Circuit Operating Principles 42

EPSON Stylus COLOR 860/1160 Revision C

2.2.2 C298MAIN Board

The logic circuit of the C298MAIN is composed of the following:

n Logic line (CPU, ASIC, DRAM, EEPROM, and so on) n Various motor control/driver circuits (CR motor, PF motor, and ASF/

Pump motor)

n Head control/driver circuits n Interface control (parallel I/F, USB I/F) n Sensor circuits n Timer circuits n Reset circuits

This main board is mainly different form other models in the following two points.

o Us e of the 3.3V chip s in the log ic circu it

The 3.3 V regulator (IC9) on the C298MAIN produces 3.3 V by pressuring down the 5.5 VDC, also generated on this board, to drive several chips. See the table below that separately shows the chips driven by the +5V and +3V.

Table 2-10. 3.3V Drive Chips & 5.5V Drive Chips

+5V 3.3V

P-ROM 16M (IC2)

C90A11CA CPU (IC20)

CN3 USB

IC7

IC21

Address

Data

Address

Data

E0BA13KA

PDIUSBF11A

CR Encoder senser

Head

D-RAM 16M (IC3)

E05B70OD ASIC (IC8)

CN8 HD FFC

Batt1

CN12

CN9 HD FFC

CR1

Timer & Reset IC (IC5)

EEPROM (IC6)

C90A120A Slave CPU (IC15)

CN11 CN 6

CN5

PE Sensor

PF Encoder Sensor

Q3&Q4

Common Driver (IC10 or IC11)

IC4 74VHC1612B4

CN14

Motor Driver (IC18)

C298 PNL (for SC860) C303 PNL (for SC1100)

ASF Sensor

CR Motor

PF Motor

CN13

Motor Driver (IC19)

CN1 Parallel

ASF/Pump Motor

CN7

Motor Driver (IC12)

Sensors I/F Circuit PNL Board Slave CPU

Use of the slave CPU

CPU ASIC P-ROM D-RAM

Figure 2-16. Block Diagram for the C298MAIN Board

Since the CR motor and PF motor of this printer are DC motors, the slave CPU is attached on the main board in addition to the CPU and ASIC. This slave CPU, serving to control the DC motors only, reduces duty of the CPU and ASIC for faster data processing.

See Figure 2-16 for the C298MAIN board block diagram.

Operating Principles Electrical Circuit Operating Principles 43

EPSON Stylus COLOR 860/1160 Revision C

Table 2-11 shows the functions of the CPU, ASIC, and slave CPU.

Table 2-11. Functions of the CPUs and ASIC

IC Location Function

• Sets the c urrent value for the ASF/Pump motor.

CPU IC20

ASIC IC8

Slave CPU for DC motors

IC15

• Measures the printhead tem per ature .

• Several interrupting functions

• Outputs the system clock sig nal.

• Controls interfaces.

• Controls the printhead drive waveform circ uit.

• Transfers serial data to the printhead.

• Controls the ASF/Pump motor

• Receives panel control signals and sensor signals

• EEPROM

• Controls detection of the signals output from the encoder.

• Sets the current value for the PF motor and CR motor.

• Controls the PF motor and CR motors.

Operating Principles Electrical Circuit Operating Principles 44

EPSON Stylus COLOR 860/1160 Revision C

2.2.2.1 Printhead Driver Circuit

The printhead driver circuit consists of the following two components:

n Common driver IC (IC10: E09A14RA) directly attached to the

C298MAIN board.

n Nozzle selector IC (Sharp IR2C95F or EPSON SED6125T0A) on the

head board.

The common driver (IC10: E09A14RA) generates a reference drive waveform according to the output signals from the C298MAIN board. The reference drive waveform is amplified by the transistors Q3 and Q4 and then transferred to the nozzle selector IC on the head board. Print data is converted to serial data by the ASIC (IC8 E05B70CD) and then sent to the nozzle selector IC on the head board. Based on the serial data, the nozzle selector IC determines the nozzles to be actuated. The selected nozzles are driven by the drive waveforms produced by the common driver. See Figure 2-17 for the printhead driver circuit block diagram.

o Head common driver circuit

The reference head drive waveform is produced in the common driver (IC10: E09A14RA) based on the following 12 signal lines output from the ASIC (IC8 E05B70CD); A0-A4, CLK1, CLK2, RST, FLOOR, DATA, DCLK, and E. By the DATA signal output from the ASIC (IC8 E05B70CD), the original data for the head drive waveform is written in the memory in the IC10. The addresses for the written data are determined by the A0 - A4 signals, and, of among, data used to determine the waveform angles is selected. Then, setting the selected data, producing trapezoid waveform value, and canceling the data are performed by the rising edges of the CLK1 and CLK2 signals.

o Head nozzle selector circuit

Printing data is converted into serial data by the ASIC (IC8 E05B70CD). Then the converted data is allocated to the six rows, the number of the head nozzle rows, to be transferred to the nozzle selector (Sharp IR2C95F) through the six signal lines (HS01 to HS06). Data transmission from the ASIC (IC8 E05B70CD) to the nozzle selector synchronizes with the LAT signal and SCK clock signal. Referring to the transferred data, nozzles to be activated are selected, and the PZTs of the selected nozzles are driven by the drive waveform output from the head common driver.

HW A0 HW A1 HW A2 HW A3 HW A4

HW CLK1 HW CLK2 HW FLR HW RST HW SDATA HW SCLK

HW SLAT

IC 8 A S IC E05B70C D

HCH

HLAT CRAI0 CRAI1

SW CO SW C1

HS01 HS02 HS03 HS04 HS05 HS06

HSOCMD

HSOCLK

to C P U A N 0 p o rt

AO A1 A2 A3 A4 CLK1 CLK2

FLOO R RST DATA DCLK E

IC 1 0 Commom D r iv e r IC

VCC

NPNB

PNPB

CN8

CN9

COM COM

VHV VHV

CH LAT ENA ENB

N o z z le S e le c o r IC IR 2C 95F

COB COA

SI1 SI2 SI3 SI4 SI5 SI6

SP NCHGHNCHG

SCK

THM

Figure 2-17. Printhead Driver Circuit

H ead D rive P u ls e

Operating Principles Electrical Circuit Operating Principles 45

EPSON Stylus COLOR 860/1160 Revision C

2.2.2.2 Reset Circuit

Reset circuits are attached on the C298MAIN board to monitor the two voltages: +5V for the logic line and +42V for the drive line. When each circuit detects abnormality on the corresponding line, it outputs a reset signal to reset CPU and ASIC. This function is necessary to prevent the printer from operating abnormally. IC5 RTC-9820SA, a reset circuit IC, is attached directly on the main board. This IC monitors both the +5V and +45 lines but can reset them independently. See Figure 2-18 for the block diagram for the reset circuits.

o +5V line reset circuit

The VDD port of the IC5 reset IC monitors the +5V line. When the IC detects an abnormal voltage level (4.3 V or lower), it outputs a reset signal from the RST port to CPU and ASIC.

o +42V line reset circuit

The VIN port of the IC5 reset IC monitors the +45V line. When the IC detects an abnormal voltage level (35.5V or lower), it outputs a reset signal from the VDT port to CPU and ASIC.

NOTE: IC5, also serving as RIC (Real Time Clock), manages timer control when the

printer power is turned off. Power for this operation is supplied from the BAT1.

+42V

+5V

VIN VDD

D2 SB007-03C PTB

BAT1 CR2032

C18

0.1U

C19

0.1U

C21

0.1U

VBK

GND

Figure 2-18. Reset Circuit Block Diagram

VDT

FRST

RST

C E SCLK DATA

+3.3V

R26

3.3K

R27

3.3K

IC 8 E05B 70C D

NMI

MRES

RESET

TCE TCLK TDATA

Operating Principles Electrical Circuit Operating Principles 46

EPSON Stylus COLOR 860/1160 Revision C

2.2.2.3 CR Motor Driver Circuit

The Stylus COLOR 860/1160 is equipped with a DC motor for the CR motor. In addition to the CPU and ASIC, a slave CPU is mounted on the C298MAIN board. Since the slave CPU is exclusively used to control DC motors, it reduces duty of CPU and ASIC to offer faster data processing.

o CR motor driver circ uit

The internal equivalent circuit of the CR motor driver IC (LB1947) is as shown below.

CN8 Head FFC

ENA

ENB

IC 8 E05B70C D

CRAI0

CRAI1

NMI

RXD1

TXD 1

CRBI3

CRPH AB

CREN BB

CRAI2

CRBI2

CRBI3

CPU

P25

IC 1 5 C 90A 13C A

NMI

P31

P33

P32

P30

P64

RES

MD2

P12

P11

P13

P27

P26

PE1

PE2

PE0

PE4

PA0

DA1

+42V

IC 1 8 LB1947

VBB

IN 1

IN 2

VREF

R138

4.4B K

R139

4.99B K

OUTA

OUTB

GND

IC 2 4 M 62552FP

+5V

R112

0.499

C 117 1500p

C115

0.1U

CR-A CR-B

R 115 68BK

R114

12.7K

Unlike a stepping motor, the DC motor that drives the carriage

can not detect the current carriage position by referring to the pulses given. For this reason, a linear scale is attached along the carriage operation range to detect the carriage position. The linear encoder sensor outputs two kinds of TTL level pulses Phase A and Phase B to IC8 ASIC.

1/180 inches

1/720 inches

Phase A

Phase B

Phase A

Phase B

LED

LEN S

Photo D iodes

1/360 inches

CR Motor CW rotation

CR motor CCW

C om parators

Phase A

Phase B

Figure 2-19. Internal Equivalent Circuit of the CR Motor Driver IC

The

IC15 slave C PU from the linear encoder via IC8 ASIC. The CPU also sets an appropriate drive current value for the CR position and the direction in which the CR moves based on the data transmitted from the ASIC. So the slave CPU outputs specified control signals to the motor driver. The motor driver IC18 then outputs the CR motor drive current to the CR motor based on the signals sent from the

controls the CR position by referring to the pulses sent

IC15 slave CPU

Direction for the current CR’s movement is detected based on the waveforms of the Phase A and Phase B that are out of phase, while carriage position is controlled by using the waveforms output from Phase A on a cycle basis (1 cycle: 1/180 inches). Phase between the output waveforms A and B is as shown in Figure 2-20. Note all edges in Phase A, Phase B output waveforms (1/720-inch cycle) are used to control the CR position while it is in the home position for ink system.

Figure 2-20. CR Linear Scale Encoder Pulse

Operating Principles Electrical Circuit Operating Principles 47

EPSON Stylus COLOR 860/1160 Revision C

Home position detection (capping position detection) Home position is detected based on the pulses output from the linear scale sensor and CD motor control current value. The basic home position detection sequence is as described below:

1/180 inches

1)The linear encoder pulse counter in the IC15 slave CPU is reset during a power-on sequence.

2)The CR motor moves clockwise and the CR moves from left to right. IC15 slave CPU once assumes that the CR comes in contact with the right frame when the following conditions are satisfied:

nThe slave CPU detects the motor control current value 720mA nP1 (= number of pulses output for the above CR movement) is 30* or

less.

* Specified value that indicates CR is movable in the home position.

(All edges in the waveform are used in this condition.)

3)The CR motor rotates counterclockwise and the CR moves from right to left, and the IC15 slave CPU assumes that it detects the CR lock lever position when the following conditions are satisfie d:

nIC15 slave CPU detects the motor control current value 500 mA. nDifference X between P1 and P2 (= number of pulses output while

the CR moves from the right frame) is 30 or less.

4)The CR motor rotates counterclockwise and the CR moves from left to right again, and if IC15 slave CPU detects the motor control current value 720 mA, it assumes that the CR comes in contact with the right frame again.

5)Difference between P1 and P3 (= number of pulses output for the CR’s movement from the CR lock lever to the right frame) is 4 or less.

Phase A

PTS

1/360 inches

Figure 2-21. Print Timing Signal and Linear Encoder Phase A

NOTE: If the drive voltage for the CR motor reaches 800mA, a fatal error occurs.

When all conditions in the sequence are satisfied, the printer detects the CR is

in the home position.

o PTS (Print Timing Signal) production

The circuit produces PTS signal (cycle: 1/360 inches) by dividing waveform cycles for Phase A (cycle: 1/180 inches). The print timing signal is used to eject ink at a correct timing.

Operating Principles Electrical Circuit Operating Principles 48

EPSON Stylus COLOR 860/1160 Revision C

2.2.2.4 PF Motor Driver Circuit

TheStylus COLOR 860/1160 is equipped with a DC motor for the PF motor. In addition to the CPU and ASIC, a slave CPU is mounted on the C298MAIN board. Since the slave CPU is exclusively used to control DC motors, it reduces duty of CPU and ASIC to offer faster data processing. The block diagram for the PF motor driver circuit is as shown below:

OUTA

OUTB

CP1

CP2

VREG

SENSE

GND GND GND

IC 2 4 M 62552FP

+42V

C119

0.22U

C120 022U

C 116

0.22U

R113

0.24

PF-A PF-B

C13

0.1U

CN12 PF Encorder

ENA

ENB

IC 8 E05B70CD

CRPHAA

CRENBA

NMI

RXD1

CRBI3

CRPHAB

CRAI2

CRBI0

CRAI3

CPU

P25

IC 1 5 C 90A 13C A

NMI

P31

P33TXD 1

P32

P30

P64CRENBB

RES

MD2

P17

P15

P20

P21

PD3

PD1

PD0

PD4

PD6

PD5

PD7

DA0

SCO N

IC 1 9 A3958S B

MODE

PHASE

ENABLE

RANGE

REF

OSC

CLO CK

DATA

STOROBE

R138

4.4B K

R139

4.99B K

Unlike a stepping motor, the DC motor that drives the PF motor can not detect a paper feeding amount by referring to the pulses given. For this reason, a loop scale is attached on the Gear 76 to mechanically detect a paper feeding amount. The loop scale encoder sensor outputs two kinds of TTL level pulses Phase A and Phase B to IC8 ASIC.

1/1440 inches

Phase A

Phase B

PF motor CW rotation

1/5760 inches

Phase A

PF motor CCW rotation

Phase B

LEN S

Photo D iodes

C om parators

LED

Phase A

Phase B

Figure 2-22. PF Motor Driver Circuit Block Diagram

IC15 slave CPU controls paper feeding amount by referring to the encoder pulses sent from IC8 ASIC. It also sets a proper drive current value according to the paper feeding amount and direction. So it outputs specified control signal to the motor driver. The motor driver IC19 outputs PF motor drive current to the PF motor according to the control signals from the IC15 slave CPU.

Rotational direction of the PF motor is determined by the phase between the output waveforms of Phase A and Phase B. Refer to Figure 2-23 for different phase for each direction.

NOTE: If the drive voltage for the PF motor reaches 1A, a fatal error occurs.

Figure 2-23. Loop Scale Encoder Pulse

Operating Principles Electrical Circuit Operating Principles 49

EPSON Stylus COLOR 860/1160 Revision C

2.2.2.5 ASF/Pump Motor Driver Circuit

The block diagram for the ASF/Pump motor is as shown below:

+42V

IC 8 E05B70CD

DATA Bus

PFPHAA

PFPHAB

PFENBA PFENBB

IC 1 5 C90A13CA

SW A2

Current control signals

PHASE1 PHASE2

ENABLE1 ENABLE2

VREF1

VREF2

DA0

IC 1 2 LB11847

OUTA

OUTB

VBB

VCC

GND

IC 2 2 SN 104B 00P S R

C69

0.1U

ASF-A

ASF-B

+42

C79

C75

100U

0.1U

CN6 ASF SEN SO R

2.2.2.6 EEPROM Control Circuit

Since EEPROM is nonvolatile memory, it keeps information written if the printer power is turned off. Information stored in EEPROM is various adjustment values, factory values, and printer status values. See Appendix for EEPROM Address Map that provides detailed information on the values stored in EEPROM. EEPROM is connected to ASIC with 4 lines and each line has the following function.

n CS: Chip selection signal n CK: Data synchronism clock pulse n DI: Data writing line (serial data) at power off. n DO: Data reading line (serial data) at power on.

The EEPROM control circuit is as shown below:

+5V

93C 56 (IC 7 )

Vcc

ORG

GND

206

205

204

203

E05B 70C D (IC 8 )

EECS

EECK

EECO

EECI

Figure 2-24. ASF/Pump Motor Circuit Block Diagram

Figure 2-25. EEPROM Circuit Block Diagram

Operating Principles Electrical Circuit Operating Principles 50

EPSON Stylus COLOR 860/1160 Revision C

2.2.2.7 Sensor Circuit

The Stylus COLOR 860/1160 is equipped with the following five sensors to detect the status of the printer.

n I/C detection sensor n Head Thermistor sensor n PE sensor n ASF home position sensor n PF motor encoder sensor n CR unit encoder sensor

The block diagram for the sensor circuit is as shown below:

CN4 PE Sensor

PRV

C89

GND

C90

CN6 ASF H P Sensor

ASFV

C93

GND

C94

ASF

CN12 PF M otor E ncoder S ensor

ENA

ENB

CN8 C R M otor E ncolder S ensor

ENA

ENB

CN9 I/C D e te c tio n S e n s o r & T h e r m is to

COB CCB THM

IC 2 0 C P U C90A11CA

+5v

R57 200

SW A1

AN0

DATA Bus

+5v

IC 8 A S IC E05B 70C D

SW A2

CRPHAA

CRENBA

CRAI0

CRAI1

SW C0 SW C1

R93 200

Figure 2-26. Sensor Circuit Block Diagram

Function and detection method of each sensor is as described below.

o I/C detection sensor (for black I/C and color I/C)

The I/C detection sensor included in the CR unit determines whether a black or color ink cartridge is installed. When an I/C is installed, this sensor detects a mechanical contact with the cartridge and outputs a LOW signal to the ASIC. If no cartridge is installed, it outputs a HIGH signal to the ASIC.

o Head thermistor

The head thermistor is attached directly on the head driver board. It monitors the temperature around the printhead and feeds back the temperature to the CPU analog port. The printer refers to this information to control head driver voltage based on the ink viscosity.

o PE sensor

The PE sensor is located at the bottom right edge of the top frame in the printer mechanism. This sensor detects paper on the rear paper guide, using a photo sensor and PE sensor lever that are included in the sensor. When paper passes, the PE sensor does not interrupt the photo sensor terminals. So a LOW signal is output to the ASIC. If there is no paper, on the other hand, the lever cuts in between the photo sensor terminals, which outputs a HIGH signal to the ASIC.

o ASF HP sensor

The ASF HP sensor, located at the left edge of the ASF, detects the ASF home position. This sensor consists of the ASF HP detector wheel and a photo sensor. A small portion of the ASF HP sensor has a cutout, and when the cutout comes into position between the photo diode terminals, ASF home position is detected. In this status, the photo diode terminals are not blocked, and a LOW signal is output to the ASIC. Referring to the ASF home position detected by this sensor, the printer drives the ASF/Pump motor to set the LD roller and paper return lever ready for paper loading.

o PF moto r enc ode r sens or

The PF motor encoder sensor includes the loop scale attached to the left end of the PF roller and the linear encoder. The minimum resolution of the sensor is 1/1440 inches (minimum 1/5760 inches with all edges of Phase A and Phase B), and the sensor outputs HIGH signals for the black lines and LOW signals for the transparent parts to the ASIC. The printer controls the PF motor based on the signals output from this sensor.

Operating Principles Electrical Circuit Operating Principles 51

EPSON Stylus COLOR 860/1160 Revision C

CR unit encoder sensor CR unit encoder sensor includes the linear encoder in the CR unit and the scale plate attached along the CR scanning direction. The minimum resolution of the sensor is 1/180 inch, (minimum 1/720 inches with all edges of Phase A and Phase B) and outputs HIGH signals for the black bands of the scale and LOW signals for the transparent parts to the ASIC. The printer controls the CR motor based on the signals output from this sensor. The sensor also detects the CR home position.

Operating Principles Electrical Circuit Operating Principles 52

TROUBLESHOOTING

CHAPTER

EPSON Stylus COLOR 860/1160 Revision C

3.1 Overview

This chapter describes how to troubleshoot problems. It consists of the sections shown in the flowchart below. When identifying and troubleshooting problems, be sure to proceed to the correct section specified in the flowchart.

Isolating the faulty part on the pow er supply board

(Section 3.1.2)

Is the printer pow er on?

Yes

Troubleshooting w ith LED error indications

(Section 3.1.1)

Isolating the faulty part according to the exhibited phenom enons

(Section 3.1.3)

Following sections show detailed informat ion on each step in the flowchart. Be sure to perform troubleshooting without neglecting the correct order specified in each section.

First of all, following tables show you the Motor Resistance and the sensor check informations.

Table 3-1. Motor Resistance and Measurement Procedure

Motor Name Location Check Point

CR Motor • CN14 (Main boa rd) Pin 1 & 2, 31.1 OHM +/- 25% PF Motor • CN13 (Main Board) Pin 1 & 2, 31.1 OHM +/- 25% ASF/Pump Motor • CN7 (Main Board) Pin 1& 3,

Pin 2 & 4,

10.4 OHM+/-10%

Table 3-2. Sensor Check an Measurement Procedure

Sensor Connector No.

PE Sensor CN4 Pin 1 & 2 •0V

ASF/HP Sensor CN6 Pin 1 & 2 • 0V

PF Motor Enscorder Sensor

CR Motor Encorder Sensor

Black I/C Detection Sensor

Color I/C Detection Sensor

CN12 •0V

CN8 • 0V

CN9 Pin 15 & Pin 18

CN9 Pin 15 & Pin 17

Measurement value

•5V

• 5V

•5v

•5V

•0V

•5V

•0V

Status

Detect the Paper No Paper

Detect the ASF HP Not detect ASF HP

Transparency slit Black Slit

I/C is not installed I/C is installed

Figure 3-1. Troubleshooting Flowchart

Troubleshooting Overview 54

EPSON Stylus COLOR 860/1160 Revision C

3.1.1 Troubleshooting with LED Error Indications

This section describes how to troubleshoot the problem when the printer indicates an error at power on and can not print . The Stylus COLOR 860/1160 can detect the following six errors and seven status, and indicates them with the LEDs, as shown below.

Table 3-3. Error Indication of Operation Panel

Printer Status

Power On Condition On - - - 9 Ink Sequence Blink - - - 6 Ink Cartridge Replacement

Mode Data Processing Blink - - - 8 Paper Out On Off Off On 4 Paper Jam Condition On 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 Blink Blink Blink Blink 2

Power Ink Out (Black) Ink Out (Color) Paper Out

Blink - - - 5

-On- -7

--On-7

- ON (for 1 second only) -

Indicators

Priority

Fatal Error Blink On On Blink

Troubleshooting Overview 55

EPSON Stylus COLOR 860/1160 Revision C

See the following tables which show the error conditions and corresponding possible causes:

Table 3-4. Error Condition and the Possible Causes

No. Error Condition Possible Causes

1 Paper Out Error

(Refer to Section

3.1.1.1.)

2 Paper Jam Error

(Refer to Section

3.1.1.2.)

3 NO I/C or Ink Out

Error (Refer to Section3.1.1.3)

4 Maintenance

Error (Refer to Section 3.1.1.4))

1. Failure in paper feeding

2. Connector for the PE sensor is disconnected.

3. The PE sensor actuator is acting improperly. The sensor base is not fixed properly.

4. The PE sensor is defective.

5. ASF dose not move co rrectly

1. The paper in use is longer than specified.

2. The PE sensor remains on because it is covered with paper debris or dust.

3. The PE sensor actuator is not acting properly. The sensor base is not fixed properly.

4. The PE sensor is defective

5. The Hopper Release Lever is not assembled correctly.

1. The counter is not showing the actual remaining ink

level.

2. Ink cartridge sensor actuator is not acting properly.

3. The micro switch is not mounted correctl y.

The connector (green) is disconnected.

4. The connector (green, 3-pin) on the small board

directly attached to the printhead surface side is disconnected. Note the connector (green, 4-pin) is irrelevant as it is for the encoder.

5. The micro swi tch is defecti ve.

6. The value for the ink consumption counter in the

EEPROM is destroyed.

Usual waste ink over-flow is requested. Note this error can be cleared by the special function

through the control panel operation and the Adjustment program.

Table 3-4. Error Condition and the Possible Causes (continued)

No. Error Condition Possible Causes

5 Fatal Error

(Refer to Section

3.1.1.5)

1. The CR Encorder FFC has come off from the CR Encorder Sensor board. The CR Encorder sensor is not mounted in the CR Assy.

2. The CR liner scale has come off. The CR liner scale is not placed through the encoder located at the back of the carriage.

3. The ASF sensor has come off. The connector for the ASF sensor is not disconnected.

4. The ASF sensor is defective or dose not detect the ASF HP position caused by any factor.

5. The PF or CR Encorder Sensor is defective or dose not detect the slite pattern on the each scale.

6. The coil for the CR motor has burnt.

7. The coil for the PF motor has burnt.

8. Coil for the ASF/Pump motor has burnt

9. ASF Gear 32 is disengaged to the Combination Gear 14,28 which is assembled in the DE unit.

10. Torsion Spring 0.618 comes off from the DE Lock Lever and the hook of DE unit.

Troubleshooting Overview 56

EPSON Stylus COLOR 860/1160 Revision C

3.1.1.1 Remedies for Paper Out Error

This section provides check points and corres ponding actions which are necessary when the Paper Out Error problem has occurred because of either of the following reasons:

n Paper is set in the ASF hopper but not fed. n Paper is fed but not detected by the PE sensor actuator.

Be sure to follow the steps in the order described in the tables.

NOTE:If the finding the detail phenomenon which fits the defective

printer, take the Check & Action described in the right col umn. If “No”, proceed to the next step.Remedies for Paper Error.

Table 3-5. Remedies for Paper Out Error

Step Detail Phenomenon Check & Actions

1 When the Paper

Feed SW is pressed, the ASF LD roller attempts to feed the paper. But the paper is not loaded. After that, the Panel LED indicates the Paper Out Error.

2 When the Paper

Feed SW is pressed, the ASF LD roller feeds the paper to the PF roller. But, ASF LD roller rotates again an d the PF roller advances the paper over the TOF position.

After that, the Panel LED indicates the Paper Out Error.

3 Ditto

Set a cleaning sheet in the ASF up side down. Then holding the top edge, press the Load/Eject button, and the micro pearl on the paper load roller (a semicircular roller) surface is removed. To remove severe smear, staple a cloth moistened with alcohol to a post card and clean the roller in the same manner.

N on-adhesive A rea

C L S heet

Adhesive A rea

This side dow n

Check if the connector (yellow, 3-pin) fo r the PE sensor is connected to PE sensor or CN5 on the Main Board.

Bottom view of the printer m echanism

C onnector for the PE sensor

• Using your hand, try activating the actuator in the same condition as it is det ecting incom ing pa per. Then release the actuator and check if the actuator automatically returns to its original position with the tension of the spring.

• Referring to the illustration above , chec k that the sensor base is securely installed to the frame. If the sensor base is floating or installed insecurely, instal it securely.

(U s e a p o s t c a r d for the base sheet.)

Staplers

C loth m oistened w ith alcohol

Tension spring

Troubleshooting Overview 57

EPSON Stylus COLOR 860/1160 Revision C

Table 3-5. Remedies for Paper Out Error (continued)

Step Detail Phenomenon Check & Actions

4 When the Paper

Feed SW is pressed, the Paper is ASF LD roller feed the paper to the PF roller. But, ASF LD roller rotate again and the PF roller advances the paper over the TOF position.

After that, the Panel LED indicates the Paper Out Error.

5 When the Paper is

feed with the Load/ Eject SW, it seems that the Hopper is moving correctly. But, the paper is not loaded and the Paper Out Error is indicated on the Operation Panel.

Check if the PE sensor is defective. Measure the voltage at the yellow 3-pin connector CN5 on the Main Board by activating the actuator manually to check that the voltage is correct as follows.

The actuator is in ter m inals: 5V The actuator is out of terminals: 0V

Main Board CN5

Pin 3 (PE)

Pin 2 (G N D)

M/C

RED

WHT

M/C

CRH PE ASF

BLK

M/C

Hand-rotate the shaft in the ASF in the paper feed direction and check if the hopper hops out every time you rotate the shaft.

NOTE: Even though the ASF HP sensor is in the prop er

condition for detecting th e ASF h ome posit ion, If the hopper is not operating at the correct timing for paper feeding, paper is not loaded. Therefore, if the ASF sensor is working without this correct combination, reassembly or replace the ASF. In case the ASF HP sensor detect the ASF HP in the paper feed sequence, the Panel LED indicates the Fatal Error.

Troubleshooting Overview 58

EPSON Stylus COLOR 860/1160 Revision C

3.1.1.2 Remedies for the Paper Jam Error

This section includes the check points a nd correspondi ng actions whi ch are necessary when the Paper Jam Error constantly occurs when the printer is turned on or feeding paper. The printer detects the Paper Jam Error in the following Condi tions.

n When the printer is turned on, the PE sensor detects the paper

and attempt to eject it by rotating the PF roller. But, the Low signal (paper detect status) is not removed.

Be sure to follow the steps in the order described in the tables.

NOTE:If the finding for the question is Yes, take the action described in

the right column. If “No”, proceed to the next step.

Table 3-6. Remedies for Paper Jam Error

Step Detail Phenomenon Check & Actions

1 When the Paper is

ejected, the PF roller advance the paper. But, the Paper is not ejected completely. And, Paper Jam is indicated.

2 When the printer is

turned on, the PF roller rotates continuously about 10 sec. After that, Panel LED indicate s the Paper Jam.

•Ditto

• When the Paper is

loaded from the ASF, the Top of the Paper is loaded to the PF roller. But it dose not reach to the Paper Guide Front. And Panel LED indicates

the Paper Jam. If Paper Feed Operation is repeated, Fatal Error

is indicate.

Make sure if the paper length is beyond the specifications is used.

Make sure that any paper dust or material push up the tip of the PE sensor Actuator. Viewing the PE sensor from the front, check that the actuator is the correct position: the actuator falls in the cutout without any paper.

PE Senso Actuator

PE P aper G uide

ssem bly (R ig ht)

PF R oller

Referring to Step 3 in Section 3.1.1.1 “Remedies for Paper Out Error”, check the sensor condition.

Referring to Step 4 in Section 3.1.1.1 “Remedies for Paper Out Error”, Check the sensor function.

Make sure if the ASF Hopper Release Lever is assembled properly to the LD roller shaft in the ASF.unit. Refer the following figure.

Left ASF Hopper

Right ASF Hopper

Troubleshooting Overview 59

EPSON Stylus COLOR 860/1160 Revision C

3.1.1.3 Remedies for No I/C and Ink Out Errors

This section includes the check points a nd correspondi ng actions whi ch are necessary when the black i nk (or color ink) LED comes on or blinks at power on despite the ink cart ridge has been r eplaced wi th a new one . Be sure to follow the steps in the order described in the tables.

NOTE:If the finding for the question is Yes, take the action described in

the right column. If “No”, proceed to the next step.

Table 3-7. Remedies for No I/C and Ink Out Errors

Step Detail Phenomenon Check & Actions

1 Dot missing occurs

despite the Ink end condition is not indicated. And the dot missing number is increased every printing.

or Enough ink is

remaining in the cartridge, but the printer shows the Ink low or Ink end condition and can not continue to print.

2 If the I/C is removed

and reset into the CR unit, the Ink Out LED is not turn on and off.

Make sure the I/C was replaced with the new one in the I/C replacement sequence. If not, explain the situation to the user well and replaced the I/C with new one in the I/C replacement sequence. The ink consumption counter, sepa rately set for black and color ink, adds up points according to ink weight used to form one dot. This counter is reset (the value returns to zero) when t he I/C replacemen t sequence is performed and I/C is replaced. If the I/C is replaced with the used I/C in the I/C replacement sequence , the foll owin g adversit ies wi ll occur.

• Ink has run out but the printer continues to print and starts false firing, which damages the print head.

If the new I/C is installed without entering the I/C replacement sequence , the ink consumptio n counter is not reset and the following adversities will occur.

• Enough ink is remaining in the cartridge, but the printer shows the Ink low or Ink end condi tion and can not continue to pri nt.

Turn the both actuators (rig ht and lef t) manua lly and check that they properly push the micro switches. Then, also check that the actuators return to their normal conditions shown in the figure below automatically.

M icro S w itches

Actuator 1

Actuator 2

Troubleshooting Overview 60

EPSON Stylus COLOR 860/1160 Revision C

Table 3-7. Remedies for No I/C and Ink Out Errors (continued)

Step Detail Phenomenon Check & Actions

3 If the I/C is removed

and reset into the CR unit, the Ink Out LED is not turn on and off.

4 Ditto Remove the I/C Detector holder from the CR unit

5 Ditto

If the micro switch is not properly attached, the actuators possibly fail to touch the micro switch. Therefore, check that the micro switch is securely attached to the carriage by the hooks.

onnector

M icro S w itches

H ooks

and check if the connector (green, 3-pin) is disconnected from the head circuit board.

1. Keeping the left micro switch pressed down, place the probes of the tes te r to the middle and left p ins to check for electrical continuity.

2. Keeping the right micro switch pressed down,

place the probes of the tester to the middle and right pins to check for electrical continuity.

Step1

Step2

Table 3-7. Remedies for No I/C and Ink Out Errors (continued)

Step Detail Phenomenon Check & Actions

6 Ditto If the address for the ink cons um pti on information in

the EEPROM is garbled and the printer shows the Ink Out (Ink End) error constantly, the printer sets the interface signal “BUSY” to High and stops communication with any other peripheral devices.

Therefore, it is effective to replace the I/C with a new one to forcibly overwrite the address with 00H.

Push 1

Push 2

See table 3.2 about the measuremen t valu e.

Troubleshooting Overview 61

EPSON Stylus COLOR 860/1160 Revision C

3.1.1.4 Remedies for the Maintenance Error

While the printer is in this error condition, it disables all operations including data communication except for the panel operat ion specified to clear the error. Therefore, follow the steps described in Table 3-8 to solve the problem.

Table 3-8. Remedies for the Maintenance Error

Step Actions Correct LED condition

1 Turn the printer on while pressing the

Load/Eject and the Cleaning buttons, and the Paper Out LED starts blinking. (Blinks for three seconds.)

2 While the Paper Out LED is blinking (for

three seconds), press the Cleaning button for ten seconds.

The Paper Out LED is blinking.

The follo wing three red LEDs blink and turn off. Ink Out LED (Black), Ink Out LED (Color), and Paper Out LED.

NOTE:During the Step 2, if the Load/Eject button is pressed, the

Maintenance Error is not cleared but the EEPROM initialization mode is activated instead. The EEPROM initialization can be used to recover from conditions such as the print e r does not accept any data from the PC. The EEPROM initialization mode initializes the fo llo w i n g it e ms :

o Accumulated power-off time:The value for the Timer IC is reset. o CL Timer: The CL timer, which is also called fire-

waiting timer, secures the printer specific period of time so bubbles formed around the printhead during a cleaning vanish.

o I/F selection: Selects “Auto”, the factory default,

from 3 I/F selection items: Auto, Parallel, USB.

Troubleshooting Overview 62

EPSON Stylus COLOR 860/1160 Revision C

3.1.1.5 Remedi es for Fatal Error

A fatal error is basically caused by any of the following conditions:

-The printer does not detect the carriage in the home position.

-The printer does not detect signals from the linear scale.

-The ASF sensor does not detect the ASF home position. The following tables show various causes of the error and

corresponding solutions. Be sure to fol low the steps correctly to solve

Step Detail Phenomenon Check & Actions

3 When the Printer is

Table 3-9. Remedies for Fatal Error (continued)

Referring to the figure below, check that the ASF turned on, the CR moves a little and it sounds the ASF Hopper moving. After that, the Panel LED indicates the Fatal Error.

sensor is attached to the correct position.

Check that both connectors 1 and 2 are securely

connected.

AS F S ensor

SF Frame

(Left)

the problems.

NOTE:If the finding the detail phenomenon which fit the defective

printer, take the Check & Action desc ribed in the righ t column. I f “No”, proceed to the next step.Remedies for Fatal Error

Table 3-9. Remedies for Fatal Error

Step Detail Phenomenon Check & Actions

1 When the Printer is

powered on:

• The CR unit moves in the capping area.(CR unit is fixed with CR lock lever.)

• The CR unit moves and strikes the left frame because it is not fixed with the CR lock.

After that, the Panel LED indicates the Fatal Error.

Check the CR Encorder sensor board visually.

• In case the CR Encorder sensor board is not mounted in the sensor mo unt ing pos ition, mount it in the CR mounted position securely.

• In case the CR Encorder FFC is disconnected from the connector on the CR Encorder sensor board, connect it securely.

CR Encorder Sensor

4 Ditto Check for the correct voltages at 3-pin connector

C onnector 1

Main Board CN 6

M/C

shown in the figure below. Turn the printer on and check the voltage is correct as follows:

• When the ASF HP Wheel is i n the HP, the voltage is 0 VDC.

• When the ASF HP Wheel is out of the HP, the voltage raises to 5 VDC.

To Pin 1

To Pin 3

(ASF)

(CRHP)

C onnector 2

CRH PE ASF

WHT

M/C

BLK

Main Board CN6

M/C

RED

CRH PE ASF

M/C

RED

WHT

M/C

BLK

2 Ditto Referring to step 2 in Section 4.2.4.7 and Figure 4-

49, check that the CR liner scale is set between the sensor parts. Also check that the sensor is free from dust and paper debris.

To Pin 2 (GND)

T o P in 2 (G N D )

M/C

Troubleshooting Overview 63

EPSON Stylus COLOR 860/1160 Revision C

Table 3-9. Remedies for Fatal Error (continued)

Step Detail Phenomenon Check & Actions

5 When the Printer is

turned on, the CR move a little and the PF motor also moves little. After that, the Panel LED indicates the Fatal Error.

6 When the Printer is

turned on, the CR motor dose not move at all. (PF motor moves.)

After that, the Panel LED indicates the Fatal Error

• Check for the correct waveform at 5 pins of FFC. The PF Motor Encorder Sensor FFC is c onn ec ted to CN12 on the C298 Main Board . Check tha t both connectors Pin 1 & 4 or Pin 1& 2.

• Check for the correct w avehorm at 21pins of H ead FFC. The Head FFC is connected to CN8 on the C298 Main Board. Check th at both conn ectors Pin 2 & GND or Pin 4& GND.

Since the CR motor is DC motor, measure the coil resistance using the tester as following figure

<Resistance: 31.1

Ω ± 25%>

Table 3-9. Remedies for Fatal Error (continued)

Step Detail Phenomenon Check & Actions

7 When the Printer is

turned on, the PF motor dose not move. After that, the Panel LED indicates the Fatal Error.

8 When the Printer is

turned on, it dose no t sound the ASF Hopper moving. After that, the Panel LED indicates the Fatal Error

Since the PF motor is DC motor, measure the coil resistance using the tester as following figure

<Resistance: 31.1

Ω ± 25%>

PF Motor

Since the Pump/ASF motor is controlled by the Bipolar system, measure the coil resistance using the tester as shown below.

<Resistance: 10.4

Note: Be

Ω ± 10%>

Step 1

sure to measure the resistance at two points

To P in 3

shown in the figure below.

ASF/Pump

CR Motor

Motor

To P in 4

To P in 1

To P in 2

Step 2

CR Motor

Troubleshooting Overview 64

EPSON Stylus COLOR 860/1160 Revision C

Table 3-9. Remedies for Fatal Error (continued)

Step Detail Phenomenon Check & Actions

9 When the Printer is

turned on,

• it dose not sound the hopper moving.

• it sounds as if the gear tooth strike noisy and the AS F Hopper dose not move.

After that, the Fatal Error is indicated on the Panel LED.

• Make sure if the ASF unit is not assembled to the suitable position as following figures

SC 860 ASF

Gear 32

Combination Gear 14,28

SC 1160 ASF

Gear 32

10 When the Printer is

turned on, the ASF dose not move at all.

Make sure that the Torsion Spring 0.618 is hung to between the DE lock lever and the hook on the DE

unit as following figure. After that, the Panel LED indicates the Fatal Error

Torsion Spring 0.618

DE Lock Lever

Troubleshooting Overview 65

EPSON Stylus COLOR 860/1160 Revision C

3.1.2 Isolating the Faulty Part on the Power Supply Board

This section explains how to troubleshoot the following problems: o The printer is turned on, but the initialization is not performed and

LED on the control panel do not come on.

o Problems after power on Be sure to perform troubleshooting in the order specified, because the

parts involved are mentioned in the disassembly procedure to facilitate servicing.

Table 3-10. Isolating the Faulty Part on the Power Supply Board

Step Check Point Action

1 Is the Panel FFC

disconnected from the connector on the panel board?

2 Is the Panel FFC

disconnected from the CN11 (black, 12-pin) on the Main Board.

3 Is the 3pin of the Panel

FFC breaking wire condition?

The power switch fo r this prin ter is in the seco ndary side. Ther efore, if the FFC does not transfer signals, the printer does not operate despite the power supply board and the main board are properly connected.

This printer uses the power switch on the secondary side. Therefore, if the FFC does not transfer signals, the printer does not operate despite the power suppl y board and the main boa rd are properly connected.

Check the 3pin’s line on the Panel FFC with the circuit tester.

Table 3-10. Isolating the Faulty Part on the Power Supply Board

Step Check Point Action

7 Is the choke coil L1

broken?

8 Is the transformer (T1)

broken?

Viewing the reverse side of the power supply board, check for the proper continuity at the two points indicated in the figure below.

Referring to the figure below, check if the transformer is disconnec ted between the po les. Try every combination in each group marked with a blue box.

4 Has the fuse (F1) on

the power supply board blown?

5 Is CN1 on the power

supply board disconnected?

6 Is CN10 on the Main

Board disconnected?

Check if the line in the F1 located beside the CN1 on the powe r supply board has blown.

Check that the connec tors CN1, which are used to apply AC power to the primary side on the PS board, are properly c o nnected.

Check that the connector CN10, which are used to apply the DC voltage to the Main board, are properly connected.

Troubleshooting Overview 66

EPSON Stylus COLOR 860/1160 Revision C

Table 3-10. Isolating the Faulty Part on the Power Supply Board

Step Check Point Action

9 Is the main switching

FET (Q1) defective?

10 Is the NPN connection

transistor defective?

Check the electric al con tinuit y of the s witchi ng FE T by trying four patterns below. Be sure to pay attention to the po larity. If the mai n switching FET is good, the findings should be as shown under the figure.

Step.1

Step.3

Step.2

Step.4

Step 1: Off, Step 2: On, Step 3: Off, Step 4: Off Check the electrical continuity of the NPN

connection transistor on the C298 PSB/SE board by trying four patterns below. Be sure to pay attention to the polarity. If the NPN contact transistor is good, the findings should be as shown under the figure. Note the NPN connection transistor is shown in the circuit diagram as described below.

Step.1

Step.3

NPN Tr

Step.2

Step.4

Step 1: On, Step 2: Off, Step 3: Off, Step 4: On

Table 3-10. Isolating the Faulty Part on the Power Supply Board

Step Check Point Action

11 Is the PNP connection

transistor defective?

Check the PNP connection transistor on the C298 PSB/SE board in the same manner described in the previous step.

Step.2

Step.4

Step.1

Step.3

PNP Tr

Step 1: Off, Step 2: On, Step 3: Off, Step 4: On

12 Is the +5 V regulator

(IC51) defective?

Check the IC51 for the oscillation waveform (measured by using a oscillo scope) output from the Pin 2. If the output waveform is as shown below, it means the IC51 is working properly.

GND

IC 5 1

O scillation w aveform

5-pin(O S C )

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EPSON Stylus COLOR 860/1160 Revision C

3.1.3 Isolating the Faulty Part according to the Phenomenon

Refer to this section if you could not solve the problem in Section 3.1.1 or Section 3.1.2 or need more information to isolate the cause according to the exhibited phenomenon. The contents mostly cover the problems relating to the C298 and their remedies.

Table 3-11. Phenomenons Exhibited

No. Phenomenon Exhibited Table to refer to

1 CR motor does not rotate. Table 3-12 2 PF motor does not rotate. Table 3-13 3 pump/ASF motor does not rotate. Table 3-14 4 Cleaning does not solve the print problem. Table 3-15

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EPSON Stylus COLOR 860/1160 Revision C

Table 3-12. CR Motor does not Operate

Step Check Point Action

1 Getting ready

for inspecting waveforms.

2 Check of the

waveform and remedies

The connector CN14 used to control the CR motor is indicated in the figure below. Using the oscillo scope, check for the waveform for each phase at the indicated connector. To check the waveform, press the Load/Eject button to attempt to move the carriage. Be sure to leave the cable for the CR motor connected.

NOTE: The GND can be output by placing the p robe of

the oscillo scope to the tapped hole in the bottom plate on the board with a screw. Note the connector has no ground line since this printer drives the motor with the bipolar system.

While trying to drive the CR motor, the waveform output from each phase should be as shown in the figure. If the waveform output from each phase is as shown below, replace the CR moto r. I f n ot, rep lac e the IC1 8 ( CR mo tor driver IC) or C298 Main Board.

V1=0.1V

C298Main Board

Table 3-13. PF Motor does not Operate

Step Check Point Action

1 Getting ready

for inspecting waveforms.

2 Check of the

waveform and remedies.

The CN13 connector used to control the PF motor is indicated in the figure below. Using the oscillo scope, check for the waveform for each phase output from the indicated connector. To check the waveform, press the Load/Eject button to attempt the ASF paper feeding. Be sure to leave the cable for the PF motor connected.

NOTE: The GND can be output by placing the pro be of

the oscillo scope to the tapped hole in the bottom plate on the boa rd with a screw. Note the connector has no ground line since this printer drives the motor with the bipolar system.

While trying to drive the PF motor, the waveform output from each phase should be as shown in the figure. If the waveform output from each phase is as shown in the figure, replace the PF motor. If not, re pla ce the IC1 9 (PF motor driver IC) or C298 Main Board.

V1=0.1V

C298Main Board

Black Line :C R -A

R ed Line: C R -B

50V 50V

S A M P L E C 2 0 u S

NOTE: The GND can be output by placing the p robe of

the oscillo scope to the tapped hole in the bottom plate on the board with a screw.

50V 50V

NOTE: The GND can be output by placing the pro be of

the oscillo scope to the tapped hole in the bottom plat e on the board with a screw.

B la ck L in e :P F -A

R ed Line: P F-B

S A M P L E C 2 0 u S

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EPSON Stylus COLOR 860/1160 Revision C

Table 3-14. Pump/ASF Motor does not Operate

Step Check Point Action

1 Getting ready for

inspecting waveforms.

The CN7 for the Pump/ASF motor is located on the Main Board. Using the oscillo scope, check the waveform for each phase output from the indicated connector. To check the waveform, press the Load/ Eject button to attempt the ASF paper feeding. Be sure to leave the cable for the Pump/ASF motor connected.

NOTE: The GND can be output by placing the probe

of the oscillo scope to the tapped hole in the bottom plate on the board with a screw. Note the connector has no ground line since this printer drives the motor with the bipolar system.

C298Main Board

Table 3-14. Pump/ASF Motor does not Operate (continued)

Step Check Point Action

2 Check of the

waveform and remedies.

While trying to drive the Pump/ASF motor, the waveform output from each phase should be as shown below. If the waveform s ou tpu t from ea ch p has e are as shown below, replace the Pump/ASF motor. If not, replace the IC12 (Pump/ASF motor driver IC) or C298 Main Board.

The GND can be output by placing the probe of the oscillo scope to the tapped hole in the bottom plate on the board with a screw.

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EPSON Stylus COLOR 860/1160 Revision C

Table 3-15. Cleaning does not Solve the Print Problem

Step Check Point Action

1 Repeat the cleaning

7 or 8 times.

2 Trying the initial ink

charge operation.

3 Reinstalling the

printhead FFC.

Unlike the previous products, the Stylus Color 860/ 1160 is not equipped with the CL3 (dummy cleaning). Therefore, you can repeat the cleaning every time you press th e Cleaning button with out running a self-test nor any printing.

You can repeat the initial ink charge operation in the way described below:

1. Using the exclusive program, reset the initial ink charge flag in the EEPROM.

2. Turn the pr inter back on. (Refer to Chapter 5 for details.)

Remove the u pper case and check if the FFCs are properly connected to the CN8 and CN9 on the C298 Main Board. Even though they are not installed aslant as shown below, disconnect the FFC once and con nect t hem a gain, t hen run a pri nt check.

C298 Main Board

Table 3-15. Cleaning does not Solve the Print Problem (continued)

Step Check Point Action

4 Check the cap for

any foreign matter, dirt, or damage.

5 Has the Tension

Spring assembled in the Cap Unit come off?

Release the carriag e lock to move t he carri age un it away from the home position. Then, have a close look at the cap rubber and check for any problem below.

Foreign m atter

Dust

D am aged area on the rubber

R ubber

a rt o f th e c a

If the Tension Spring assembled in the Cap Unit, comes off, the sealing ability lowers and the cap rubber portion dose not fit to the surface of the printhead. And the ink is not absorbed from the head. Therefore, check that the Compression Spring is securely assembled in the following figured portion.

Compression Spring

Cap Assembly

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EPSON Stylus COLOR 860/1160 Revision C

Table 3-15. Cleaning does not Solve the Pr int Problem (continued)

Step Check Point Action

6 Is any ink tube

disconnected from the cap unit?

7 Is the FFC

disconnected from the printhead board?

Referring to the figure below, check the following points:

• The ink tube is inserted to the Cap assembly

securely as following figure.

• There is no damage on the ink tube.

Remove the Head FFC holder from the CR unit, and check that two FFC are properly connected. Even though no slant connection or disconnection is found, disconnect the FFC once an d in st all them again.

Table 3-15. Cleaning does not Solve the Print Problem (continued)

Step Check Point Action

8 Is the head driver

transistor defective?

If you see the C298 Main from the heat sink side, the following two power transistors can be found:

• Q3 and Q4: Outputs the common voltage To check if eac h pai r t rans is tor is wo rki ng properly,

check the trapezoid waveform at the emittor terminal of the charging side. Check the waveform while running a print.

Head FFC

• Check the continuity of each transistor by referring the Step 11 for the “Isolating the Faulty Part on the Power Supply Board”

Head Board

NOTE: Frequency of waveform and voltage level

(p-p) varies if printing is performed through the driver. Therefore, as long as the trapezoid waveform is output, the head driver IC is considered good, and the printhead must be replaced in that case.

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EPSON Stylus COLOR 860/1160 Revision C

Table 3-15. Cleaning does not Solve the Pr int Problem (continued)

Step Check Point Action

9 Is the head driving

pre-driver defective?

If a trapezoid waveform is not output in the previous step, check al l the power transi stors (Q 3 Q4) for base waveform s. Like t he head tran sistor in Step 8, the base terminal input the simi lar trapezoid waveforms from the pre driver IC, but any wave form is not input at Emita terminal. Replace the Power Transisto r.

If the waveforms are not output correctly on Base terminal of each Power Transistor, replace the IC10 or 11 on C298 Main Board. Otherwise, replace the C298 Main Board.

Troubleshooting Overview 73

DISASSEMBLY AND ASSEMBLY

CHAPTER

EPSON Stylus COLOR 860/1160 Revision C

4.1 Overview

This chapter describes procedures for disassembling the main components of EPSON Stylus COLOR 860/1160. Unless otherwise specified, disassembly units or components can be reassembled by reversing the disassembly procedure. Therefore, no assembly procedures are included in this chapter. Precautions for any disassembly or assembly procedure are described under the heading “CHECK POINT”. Any adjustments required after disassembling the units are described under the heading “REQUIRED ADJUSTMENT”.

4.1.1 Precautions for Disassembling the Printer

See the precautions given under the heading “WARNING” and “CAUTION” in the right column and the following page, respectively, when disassembling or assembling EPSON Stylus Color 440/640/740.

W ARNING

n Disconnect the power cable before disassembling or

assembling the printer.

n Wear protective goggles to protect your eyes from ink. If ink

gets in your eye, flush the eye with fresh water and see a doctor immediately.

n If ink comes into contact with your skin, wash it off with

soap and water. If irritation occurs, contact a physician.

n A lithium battery is installed on the main board of this

printer. Be sure to observe the following instructions when serving the battery:

n Keep the battery away from any metal or other batteries so

that electrodes of the opposite polarity do not come in contact with each other.

n Do not heat the battery or put it near fire. n Do not solder on any part of the battery. (Doing so may

result in leakage of electrolyte from the battery, burning or explosion. The leakage may affect other devices close to the battery.)

n Do not charge the battery. (An explosion may be generated

inside the battery, and cause burning or explosion.)

n Do not dismantle the battery. (The gas inside the battery

may hurt your throat. Leakage, burning or explosion may also be resulted.)

n Do not install the battery in the wrong direction. (This may

cause burning or explosion.)

n Danger of explosion if the battery is incorrectly replaced.

Replace only with the same or equivalent type recommended by the manufacture. Dispose the used batteries according to government’s law and regulations.

CAUTION

Risque d’explosion si la pile est remplacée incorrectment. Ne remplacer que par une pile du même type ou d’un type équivalent recommandé par le fabricant. Eliminer les piles déchargées selon les lois et les règles de sécurité en vigueur.

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EPSON Stylus COLOR 860/1160 Revision C

CAUTION

n Never remove the ink cartridge from the carriage unless

this manual specifies to do so.

n When transporting the printer after installing the ink

cartridge, be sure to pack the printer for transportation without removing the ink cartridge.

n Use only recommended tools for disassembling,

assembling or adjusting the printer.

n Apply lubricants and adhesives as specified. (See Chapter

6 for details.)

n Make the specified adjustments when you disassemble the

printer. (See Chapter 4 for details.)

n When assembling, if an ink cartridge is removed and needs

to be installed again, be sure to install a new ink cartridge because of the following reasons;

n Once the ink cartridge mounted on the printer is removed,

air comes into and creates bubbles in the cartridge. These bubbles clog ink path and cause printing malfunction.

n If an ink cartridge in use is removed and is reinstalled, ink

quantity will not be detected correctly since the counter to check ink consumption is cleared.

n Because of the reasons above, make sure to return the

printer to the user with a new ink cartridge installed.

4.1.2 Tools

Table 4-1 lists the tools recommended for disassembling, assembling, or adjusting the printer. Use only tools that meet these specifications.

Table 4-1. Tool List

Tools

(+) Driver No.2 O.K. B743800200 (+) Driver No.1 O.K. B743800100 Tweezers O.K. B741000100 Hexagon Box Driver

(Opposite side:5.5mm)

Commercially

Available

O.K. B741700100

Code

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EPSON Stylus COLOR 860/1160 Revision C

4.1.3 Specification for Screws

Table 4-2 shows screw specifications. During assembly and disassembly, make sure that the specified types of screws are used at proper locations, referring to the table below. Note that the screw numbers described in the manual correspond to the numbers in the table.

Table 4-2. Screw Characteristic

No. Body Name Size

1 +Bind, S-tite M3X6

5 +Pan head (C.P.) M3X6

8 +Bind, S-tight, M3X10

+Bind, P-tite (CBP tight)

+Pan head, B-tite Sems W1

+Bind, S-tight, Sems R2(CBS Sems)

+Pan head, B-tite Sems W1

M3X6

M3X8

M2.5X5

M3X8

M3X6

1.7 X 5

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EPSON Stylus COLOR 860/1160 Revision C

4.1.4 Service Checks After Repair

Before returning the printer after servicing, use the check list below, which enables you to keep record of servicing and shipping more efficiently.

Table 4-3. Inspection Checklist for the Repaired Printer

Category Component It em to check Is Check Required?

Self-test Is the operation normal? oChecked / oNot necessary On-line test Was the on-line test successful? oChecked / oNot necessary Printhead Is ink ejected normally from all nozzles? oChecked / oNot necessary

Does the carriage move smoothly? oChecked / oNot necessary Any abnormal noise during movement? oChecked / oNot necessary

Carriage mechanism

Printer units

Paper feeding mechanism

Adjustment Specified adjustment items Are adjusted conditions all right? oChecked / oNot necessary

Lubricant Specified lubricated item

Function ROM version Newest version: oChecked / oNot necessary

Shipment package

Others Attached items Are all attached items from users included? oChecked / oNot necessary

Ink cartridges are the ink cartridges installed correctly? oChecked / oNot necessary Protection conditions during

transport

Any dirt or obstacles around the shaft of carriage guide?

Is the CR motor at the correct temperature (not over heating)?

Is paper fed smoothly? oChecked / oNot necessary Does paper get jammed? oChecked / oNot necessary Does paper get skew during paper feeding? oChecked / oNot necessary Are papers multi fed? oChecked / oNot necessary Does the PF motor get overheated? oChecked / oNot necessary Abnormal noise during paper feeding? oChecked / oNot necessary Is the paper path clear of all obstructions? oChecked / oNot necessary

Is lubrication applied to the specified locations? oChecked / oNot necessary Is the quantity of lubrication adequate? oChecked / oNot necessary

Is all the pointed parts firmly fixed? oChecked / oNot necessary

oChecked / oNot necessary

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EPSON Stylus COLOR 860/1160 Revision C

4.2 Disassembly Procedures

The flowchart below shows procedures for disassembly.

Figure 4-1. Flowchart of Disassembly

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EPSON Stylus COLOR 860/1160 Revision C

4.2.1 Removing the Upper Housing

Since the printer mechanism itself structures the bottom part, the printer mechanism appears just by removing the Upper Housing.

1. Open the printer cover and turn the PG adjustment lever towards (+) side.

2) Remove 4 screws (No.8) securing the Upper Housing, and remove it upward. Refer to Figure 4-2. The left column’s photos show you the Stylus Color 860 and right column’s photos show you the Stylus Color 1160.

Stylus COLOR 860

Stylus COLOR 1160

CAUTION

CHECK

POIN T

Lift up and remove the Upper Housing, pulling it forward. (Since it collides with the carriage)

After assembling the Upper Housing, confirm the Head FFC is placed in the gutter which is located at the back side of the of the Upper Housing. In case the Head FFC is not placed in the gutter, it may damage the head FFC.

No.8 Screws

Upper Housing

No.8 Screws

Figure 4-2. Removing the Upper Housing

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EPSON Stylus COLOR 860/1160 Revision C

4.2.2 Removing the Circuit Board Assembly

Since the Main Board and Power Supply Circuit Board are built in a separate bracket from the Printer Mechanism, remove the whole bracket from the printer mechanism.

NOTE: The Main board and the Power Supply Board equipped with the Stylus

COLOR 860/1160 are the same, as listed below:

nStylus COLOR 860:C298MAIN, C298PSB/PSE nStylus COLOR 1160:C298MAIN, C298PSB/PSE

1. Remove the Upper Housing. (Refer to Section 4.2.1.)

2) Remove the 7 screws (No.1) securing the M/B Shield Plate on the printer mechanism. Refer to Figure 4-3.

No.1 Screws

3) Pull out the “M/B Shield Plate Assembly” a little bit and remove cables which are hung on the holders A and B as you can see in Figure 4-3. Then take all cables below out of the connectors on the main board.

nCN1(AC Source on PS board) nCN5 (PE sensor) nCN6 (ASF HP sensor) nCN7 (ASF/Pump motor nCN8 (Head FFC1) nCN9 (Head FFC2) nCN10 (PS Cable) nCN11 (Control Panel) nCN12 (PF Encoder Sensor)

After removing all the cables from the Main Board, detach the Shield Plate M/B Assembly completely from the printer mechanism.

4) When removing each Circuit Board unit from the “M/B Shield plate”, remove the screws securing each unit and shield plate.

n C298MAIN: Total 12 screws

(No.1 screw: 9 screws) (No.5 screw: 3 screws)

n C298PSB/PSE: Total 4 screws (No.1 screw: 4 screws)

Refer to the next page for Figure 4-4. Also, when removing the Power Supply Board, remove the cable connecting to the CN10 (locking type) on the Main Board.

Holder A

No.1 Screws

Holder B

No.1 Screws

Figure 4-3. Removing the M/B Shield Plate

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EPSON Stylus COLOR 860/1160 Revision C

C298PSB/PSE

Board

Shield Plate M/B

Assembly

No1. Screws

No5. Screws

Earth Plate

No1. Screws

C298MAIN Board

ADJUSTMENT

REQUIRED

CHECK

POIN T

Be sure to perform the following adjustments after replacing the Main Board;

1. Head voltage ID Input (Refer to Chapter 5.)

2. Bi-D adjustment, including Head Gap Adjustment (Refer to Chapter 5.)

3. USB ID data input (Refer to Chapter 5.)

Be sure to exchange the following parts also when replacing the Main Board;

1. Waste Ink Absorption Pad

2. Ink Cartridge (BK & Color)

This parts exchange is required since the several ink counters stored in the EEPROM are lost whe n the Main Board is replaced.

Make sure each cable is set in the correct cable holder (A or B) on the M/B Shield Plate. Refer to Figure 4-5.

Cable Holder A

Cable Holder B

Figure 4-4. Removing Each Circuit Board

PE Detector

CAUTION

n Since the CN10 is a locking connector, be sure to release

the locks before removing the cables. Also, make sure to lock them when connecting the cable.

Cable

ASF HP Sensor Cable

Panel FFC

Head FFC

CR Encoder Sensor FFC

CR, PF Motors

Figure 4-5. Setting the Cables to Holders A and B

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EPSON Stylus COLOR 860/1160 Revision C

4.2.3 Removing the Operation Panel

The panel board equipped with each printer is as follows:

- Stylus COLOR 860: C298PNL

- Stylus COLOR 1160: C304PNL

1. Remove the Upper Housing. (Refer to Section 4.2.1.)

2) Remove two screws (No.1) securing the Operation Panel Assembly. Then:

Stylus COLOR 860: Disconnect the Operation Panel Assembly from the

Printer Mechanism.

Stylus COLOR 1160: Release the joint for the protrusion on the Operation

Panel and the gutter of the Right Sub Frame, and remove the Operation Panel Assembly from the Printer Mechanism Refer to Figure 4-6. The left column’s figures show the Stylus COLOR 1160 and the ones in the right column show the Stylus COLOR 860.

3) Stylus COLOR 860: Remove two screws (No.3) and detach the Sub Right Panel Housing from the Operation Panel Assembly.

Stylus COLOR 1160: Remove four screws (No.3) securing th e C304PNL

board. Note the Stylus COLOR 1160 does not have a Sub Right Panel Housing.

4) Remove the Panel Shield Plate and the C298PNL/C304PNL board from the Operation Panel Assembly.

5) Disconnect the Panel FFC from the connector on the C298PNL/C304PNL board.

Stylus COLOR 1160

SC1160 Operation Panel

Jointing position

SC1160 Sub Right Frame

No.1 Screws

Operation Panel

SC1160

Stylus COLOR 860

No.1 Screws

SC860

Operation Panel

Assembly

Sub Right

Panel Housing

CAUTION

No.3 Screws

Removing the Operation Panel Assembly also separates the

No.3 Screws

stacker assembly from the Printer Mechanism, since the Stacker Assembly is held with Operation Panel.

Figure 4-6. Removing the Operation Panel

Disassembly and Assembly Disassembly Procedures 83

EPSON Stylus COLOR 860/1160 Revision C

4.2.4 Disassembling the Printer Mechanism

Since Stylus Color 860/1160 do not have the Lower Housing, the printer mechanism part should already appear by now. Therefore, this section explains procedures for disassembling the major parts or units of the printer mechanism.

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EPSON Stylus COLOR 860/1160 Revision C

4.2.4.1 Removing the Printhead Unit

1. Remove the Upper Housing. (Refer to Section 4.2.1.)

2) Slide the CR Lock Lever to the front side with tweezers or small driver and release the CR Lock Lever from the CR unit. Then move the CR Assembly to the left.

3) Take both black and color ink cartridges out of the CR Assembly.

4) Remove the blue covers for black and color ink cartridges from the CR Assembly.

5) Remove the Torsion Spring 49 from the left side of the CR Assembly and one screw (No.2) securing the Fastener Head Plate. Then take out the Fastener Head Plate. Refer to Figure 4-7.

6) Remove the Head FFC Holder from the CR Assembly by releasing four hooks. (Two hooks; Left/Right sides of CR unit, Two hooks; Back side of the CR unit) Refer to Figure 4-7.

One hook for Head FFC Holder

Torsion Spring 49

No.2 Screw

One hook for Head FFC Holder

Head FFC Holder

Fastener Head

Two hooks for Head FFC Holder

Plate

Figure 4-7. Removing the Printhead

7) Remove the two Head FFCs that connect to the Printhead Drive Circuit Board built in the CR Assembly and remove the narrow FFC from the CR Encoder Sensor Board on the CR Assembly.

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EPSON Stylus COLOR 860/1160 Revision C

CHECK

POIN T

CAUTION

ADJUSTMENT

REQUIRED

n Make sure that the earth board is installed at the right corner

of the CR unit correctly. There are 2 pins used to determine the location. Refer to Figure 4-8.

n When you install the printhead to the carriage, make sure

that the protrusion on the carriage side is placed in the Uditch of the printhead. Refer to Figure 4-8.

n Since the ink cartridge once taken out can not be used

again, be sure to install a new ink cartridge when you return the printer to the user.

n Before packing the printer for transportation, make sure

new ink cartridges are installed and the carriage is locked with the CR lock lever securely.

When you replace the printhead unit, perform the following adjustments. (Refer to Chapter 5 for more details.):

1. Initial ink charge (Refer to Chapter 5/Section 5.2.3.9.)

2. Head Voltage ID Input (Refer to Chapter 5/Section 5.2.3.5.)

3. Head Angular Adjustment (Refer to Chapter 5/Section

5.2.3.6.)

4. Bi-D Adjustment (Chapter 5 /Section 5.2.3.7.)

Carriage Assembly

Printhead Surface

Printhead Circuit Board

Printhead

Nozzle Selector is included in the printhead.

Figure 4-8. Installing the Printhead

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EPSON Stylus COLOR 860/1160 Revision C

4.2.4.2 Removing the Waste Ink Abso rber Tray Assembly

1. Remove the Upper Housing. (Refer to Section 4.2.1.)

2) Remove one screw (No.1) securing the Left Housing Panel to the Printer Mechanism. Refer to Figure 4-9.

3) Remove two screws (No.1) securing Left Sub Frame and remove Left Sub Frame. Refer to Figure 4-9.

Paper Eject Assy

No3. Screws

No. 1 Screw

No. 1 Screws

Left Sub Frame

Left Housing Panel

Figure 4-9. Removing the Left Housing Panel &Left Sub Frame

4) Insert a screw driver through the center hole in the Paper Eject Assembly and remove one screw (No.3) securing the Lower Paper Support Front to the Waste Ink Absorber Tray Assembly. Refer to Figure 4-10.

5) Inserting a screw driver through the cutout, remove No. 3 screw* securing Waste Ink Absorber Tray Assembly to the right bottom part of the mechanism. Refer to Figure 4-10. * One screw for SC860 and two screws for SC1160

6) On the Left side of the printer mechanism, using tweezers or a small screw driver, carefully shift the Tray Spacer securing the Waste Ink Absorber Tray Assembly to left horizontally. Refer to Figure 4-10.

7) Remove the Waste Ink Absorber Tray Assembly pulling it downward.

Lower Paper Support Front

Tray Spacer

Waste Ink Absorber Tray Assy

Figure 4-10. Removing two No.3 screws and Tray Spacer

Disassembly and Assembly Disassembly Procedures 87

EPSON Stylus COLOR 860/1160 Revision C

CAUTION

ADJUSTMENT

REQUIRED

1. When installing the Waste Ink Absorber Tray Assembly, make sure to fix it with the Spacer Tray in the left side of the printer mechanism. Refer to Figure 4-11.

2. Be careful not to damage Loop Scale when removing the Tray Spacer.

1. After the replacing the Waste Ink Absorber, perform the following Panel Reset Function for ink overflow counter. Turn on the Printer while holding the “Load/Eject SW”+”Cleaning SW”, then hold “Cleaning SW” for 10 seconds. Otherwise, perform the counter reset operation by using the adjustment program. For details, Refer to Chapter 5 Section 5.2.3.11.

Spacer Tray

Figure 4-11. Installing the Spacer Tray

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EPSON Stylus COLOR 860/1160 Revision C

4.2.4.3 Removing the Ink System Assembly

NOTE: The Pump Assembly and Cap Assembly are included in the Ink System

Assembly

1. Remove the Upper Housing. (Refer to Section 4.2.1.)

2) Remove the Operation Panel. (Refer to Section 4.2.3.)

3) Remove two screws (No.1) securing the Right Sub Frame. Refer to Figure 4-12.

Raise the printer mechanism in the direction indicated with the arrow.

Figure 4-13. Raising the Printer Mechanism

NO.1 Screws

Right Sub Frame

Figure 4-12. Removing the Right Sub Frame

4) Remove the Waste Ink Absorber Tray Assembly (Refer to Section 4.2.4.2.)

5) Raise the Printer Mechanism toward ASF side so that you can see the bottom of the Printer Mechanism. Refer to Figure 4-13.

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EPSON Stylus COLOR 860/1160 Revision C

6) From the Middle Frame, remove three screws (No.1) securing the Pump Assembly in the Ink System Assembly. Then, from the Right Frame, remove one screw (No.1) securing the Cap Assembly in the Ink System Assembly. Refer to Figure 4-14.

7) Release three hooks fixing the Cap Assembly to the Metal plate for Ink System Assembly and remove the Cap Assembly. Refer to Figure 4-14.

8) Remove the ink tube carefully from the Cap Assembly.

Middle Frame

CAUTION

1. When replacing the cleaner head built in the Pump assembly, be careful of the following points.

n Do not touch the cleaner head with your bare hands.

Use gloves or tweezers.

n Do not smear the head cleaner with oil or grease. n When installing the cleaner head, set the rubber side

(black side) toward the right side of the frame.

2. When replacing the Cap Assembly, do not touch the sealing rubber portion of the Cap Assembly.

3. The components parts of the Pump Assembly are no individually supplied as ASP. So please replace the whole Pump Assembly when the Pump Assembly needs replacing.

No.1 Screws securing the Pump Assembly

No.1 Screw securing the Cap Assy.

Cap Assembly

Three hooks fixing the Cap Assy.

Figure 4-14. Removing the Pump Assembly & Cap Assembly

Disassembly and Assembly Disassembly Procedures 90

EPSON Stylus COLOR 860/1160 Revision C

CHECK

POIN T

n Since the spring is included among the gears in the pump

assembly, make sure that the parts do not pop out during disassembly and assembly.

n When assembling the Cap Assembly to the Ink System

Assembly, make sure that the Ink absorption Pad has been set in the Cap Assembly. Refer to Figure 4-15.

n When assembling the printer, be careful not to crush or leave

any stress on the ink tube connecting the pump assembly and the cap assembly.

n Check that the ink tube is connected securely to the connect

portion of the Cap Assembly. Refer to the Figure 4-16.

n Check that the ink tube is placed correctly in the Ink System

Assembly. Refer to Figure 4-16.

n After installing the Pump Assembly, ensure that the cleaner

parts move back and forth by rotating the Gear.

n After setting the three protrusions of Cap Assembly to the

suitable fixing holes of the metal plate, secure the Ink System Assembly to the Middle Frame with the screws. See Figure 4-14.

Ink Absorption Pad

About 45

About 60-90°

Figure 4-15. Setting the Ink Absorption Pad

Cap Assembly

Pump Assembly

Ink Tube

Figure 4-16. Placing the Ink Tube in the Ink System

Disassembly and Assembly Disassembly Procedures 91

EPSON Stylus COLOR 860/1160 Revision C

4.2.4.4 Removing th e CR Motor Assembly

1. Remove the Upper Housing. (Refer to Section 4.2.1)

2) Using tweezers or a small screw driver, slide the CR Lock Lever to front and release the CR Lock Lever from the CR unit. Then move the CR unit to the center area of the CR shaft.

3) Loosen the CR Timing Belt by pushing the Driven Pulley Holder to right using a screw driver, and remove the Timing Belt carefully from the pinion gear on the CR motor. Refer to Figure 4-17.

Top Frame

CR Motor

Driven Pulley Holder

CR Timing Belt

Figure 4-17. Removing the Timing Belt

4) Remove two screws (No.1) while holding the CR motor and remove the CR motor assembly. Refer to Figure 4-18.

CAUTION

No.1 Screws

Figure 4-18. Removing the CR Motor Assembly

n When you remove the Timing Belt from the pinion gear on

CR motor, be careful not to damage the CR Encoder Slit Plate.

n When you remove the CR motor through the hole in the Top

Frame, make sure the pinion gear does not hit the edge of the hole.

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EPSON Stylus COLOR 860/1160 Revision C

4.2.4.5 Removing the DE Assembly (include the ASF/Pump motor)

1. Remove the Upper Housing (Refer to Section 4.2.1)

2) Remove the Ink System Assembly (Pump Assembly & Cap Assembly) (Refer to Section 4.2.4.3)

3) Remove the CR Motor Assembly. (Refer to Section 4.2.4.4.)

4) Raise the Printer mechanism toward ASF side so that you can see the bottom of the Printer Mechanism. Refer to Figure 4-19.

Tension Spring 7.3

Raise the Printer Mechanism in the direction shown with the arrow.

Figure 4-19. Raising the Printer Mechanism

5) Using tweezers, remove the Tension Spring 7.37 on the Middle Frame and loosen the No. 1 screw securing the Metal Plate for Combination gear 12,22.92. Refer to Figure 4-20.

No. 1 Screw

Combination Gear 12, 22.92

Figure 4-20. Removing the Tension Spring

6) Loosen the Tension Belt by pushing down the Metal Plate for Combination Gear 12,22.92 and remove the Tension Belt from the Combination gear 12,

22.92. Refer to Figure 4-21.

Tension Belt

Combination Gear 12, 22.92

Metal Plate for Combination Gear 12, 22.92

Figure 4-21. Removing the Tension Belt

Disassembly and Assembly Disassembly Procedures 93

EPSON Stylus COLOR 860/1160 Revision C

7) Remove the Torsion Spring 0.618 between DE Lock Lever and the hook on the DE unit. Refer to Figure 4-22.

Torsion Spring 0.618

DE Lock Lever

Figure 4-22. Removing the Tension Spring 0.618

8) Push down the hook on the DE unit carefully and slide the DE Lock Lever until it touches the right frame. The left end of the DE Lock lever comes off the hole (for DE Lock Lever) in the DE unit. Refer to Figure 4-23.

9) Pull the left edge of the DE Lock Lever to your side slightly and slide it to the left carefully to remove the DE Lock Lever from the hole in the Top Frame. Refer to Figure 4-23.

10) Remove two screws (No.1 & No. 3) securing the DE unit. Refer to Figure 4-24.

n No.1 Screw: Securing the DE Unit to the Middle Frame. n No. 2 Screw: Securing the DE unit to the Top Frame.

DE Lock Lever

Hook on the DE Unit

Fixing the h ol e in the Top Frame

Figure 4-23. Removing the DE Lock Lever

No. 2 Screw on the Top Frame

Screw driver

No. 1 Screws on the Middle Frame

Figure 4-24. Removing the DE Assembly

Disassembly and Assembly Disassembly Procedures 94

EPSON Stylus COLOR 860/1160 Revision C

11) Remove the several cables from the hook on the DE Assembly and disconnect the connector from the PE sensor.

12) Slide the DE Assembly to the right.

13) Remove two screws (No.3) securing the ASF/Pump Motor to the DE unit. Refer to Figure 4-25.

CAUTION

n When you push down the hook in Step 8 to remove the DE

Lock Lever, be careful not to break the hook.

n Do not damage the CR Encoder Slit plate when removing the

No.2 screw from the Top Frame in Step10.

14) Push down Planetary Gear 15.2 unit to the Pump drive engagement side to release the pinion gear of ASF/Pump motor in the DE Assembly. (See Figure 4-26.)

No. 3 Screws

CHECK

POIN T

n Check that all gears are assembled in the DE unit.

Refer to Figure 4-26.

n Before you assemble the ASF/Pump motor to the DE unit, set

the Planetary gear 15.2 unit to the Pump drive side.

n Make sure that the Panel FFC is placed on the bottom frame

before you assemble the DE uni to the Middle Frame.

n Set the Tension Belt to the 17.19 gear of the Combination

Gear 17.19, 25.6 before securing the DE unit to the Middle Frame. Refer to Figure 4-27.

n Make sure that the three protrusions on the DE unit fit in the

ASF/Pump Motor

DE Assembly

Figure 4-25. Removing the ASF/Pump Motor from DE Unit

15) Remove the ASF/Pump Motor from the DE Assembly.

corresponding holes in the Middle Frame.

n After setting the Tension Belt to the Gear 22.92 of the

Combination Gear 12, 22.92, hang the Tension Spring 7.3 in the following order. Refer to Figure 4-28.

1. To the hook on the Middle Frame.

2. To the hook on the Metal plate for the Combination Gear 12,22.92

n Make sure that the following cables ar e set in the hook on the

DE unit when assembling the unit.

- PE Sensor cable

- ASF/Pump motor cable

- CR motor cable.

Disassembly and Assembly Disassembly Procedures 95

EPSON Stylus COLOR 860/1160 Revision C

Combination Gear 12, 22.4

Combination Gear 17.19, 25.6

Planetary Gear 15.2

Figure 4-26. Gear Engagement in DE Assembly

Combination Gear 14, 28

Combination Gear

17.19, 25.6

DE Assembly

Tension Belt

Figure 4-27. Setting the Tension Belt to 17.19 Gear

Tension Spring 7.3

Hook on the Middle Frame

Hook on the Metal Plate for Combination Gear 12, 22.9

Figure 4-28. Setting the Tension Spring 7.37

Disassembly and Assembly Disassembly Procedures 96

EPSON Stylus COLOR 860/1160 Revision C

4.2.4.6 Removing the ASF Assembly

1. Remove the Upper H ousing. (Refer to Section 4.2.1.)

2) Remove the following Cables from the cable hook in right side (viewed from back) of the ASF Assembly.

- ASF HP Sensor Cable

- PF Motor Cable

3) Remove two screws (No.7 and ASF fixing screw) securing the ASF unit to the Bottom Frame. Refer to Figure 4-29.

ASF Assembly (Right Side)

ASF Fixing Screw

ASF Assembly (Left Side)

No. 7 Screw

Figure 4-29. Removing the ASF Assembly (1)

4) Slide the ASF unit to the right (viewed from back) and pull it backward carefully while holding up the Sub Paper Support Upper. Refer to Figure 4-30.

Sub Paper Support Upper

Figure 4-30. Removing the ASF Assembly (2)

Disassembly and Assembly Disassembly Procedures 97

EPSON Stylus COLOR 860/1160 Revision C

CHECK

POIN T

n When installing the ASF assembly, make sure that the

protrusion on the ASF is assembled into the fixing hole in the Middle Frame.

n Engage the Gear 32 (ASF Unit) and Combination Gear 14,28

(DE unit) carefully when installing the ASF unit is to the Bottom Frame. Otherwise, gears may be damaged. Refer to Figure 4-31.

Stylus COLOR 860

Combination Gear 14, 28

Stylus COLOR 1160

Middle Frame

Fixing Hole

Gear 32

Protrusion on the ASF

CHECK

POIN T

n Screws for ASF Assembly should be used a t the follo wing

positions. (Looking from the back of printer). Refer to Figure 4-29.

- Right Side (viewed from the back): ASF Fixing Screw

- Left side (viewed from the back): Screw No.7

n Make sure the ASF HP sensor cable and the PF Motor

Cable are set in the hook on the right side (viewed from the back) of ASF unit. Refer to Figure 4-32.

Setting the ASF HP Sensor and PF Motor Cable to the hook.

Fixing Hole

Gear 32

Figure 4-32. Setting the ASF HP Sensor & PF Motor cable

Combination Gear 14, 28

Middle Frame

Protrusion on the ASF

Figure 4-31. Assembling notice for ASF Assembly.

Disassembly and Assembly Disassembly Procedures 98

EPSON Stylus COLOR 860/1160 Revision C

4.2.4.6.1 Removing the Paper Feed Roller Assembly

1. Remove the ASF assembly. (Refer to Section 4.2.4.6.)

2) Remove the Gear 32 from the right edge of the LD Shaft by releasing the hook in the Gear 32. Refer to Figure 4-33.

3) Remove the Right Hopper Release Lever from the right edge of the LD Roller Shaft. Refer to Figure 4-33.

Right Hopper Release Lever

Gear 32

Hook portion

Figure 4-33. Removing the Gear 32 & LD Roller

4) Move the left Paper Feed Roller Assembly to the center. Then:

Stylus COLOR 860: Remove the Left LD Roller Fixing Bushing (white

plastic) attached to the left end of the LD Roller Shaft. Refer to Figure 4-34.

Stylus COLOR 1160: Remove the E-Ring attached to the left end of the

LD Roller Shaft. Refer to Figure 4-34.

5) Slide the LD roller shaft to the left side and remove the ASF HP Detection Wheel after releasing its hook. Refer to Figure 4-34.

SC860

Left LD Roller Fixing Bushing

ASF HP Detector Wheel

SC1160

E-Ring

LD Roller Shaft

Hook on the ASF HP Detector Wheel

Figure 4-34.

Removing the LD Roller Fixing Bushing & ASF HP Detector Wheel

Disassembly and Assembly Disassembly Procedures 99

EPSON Stylus COLOR 860/1160 Revision C

6) Release the Hopper Assembly fixing hooks from the protrusion at the top left corner of the ASF Frame by following the step in Figure 4-35.

Fixing Protrusion in the ASF Frame

ASF Hopper Assembly

Step 2

Step 1

Figure 4-35. Releasing the Hopper Assembly

7) Set the right arm portion of the Hopper Assembly to the square hole in the right side of the ASF Frame and remove the Hopper Assembly carefully. Refer to Figure 4-36.

Right arm portion of the Hooper Assembly

Square hole in the right side of the ASF Assembly

Figure 4-36. Setting the Right Arm of Hopper Assembly

Disassembly and Assembly Disassembly Procedures 100

Epson stylus 1160 rev c schematic

Specifications and Main Features

Frequently Asked Questions

User Manual

PRODUCT DESCRIPTION

1.1 FEATURES

1.2 SPECIFICATIONS

1.2.1 Physical Specification

1.2.2 Printing Specification

1.2.3 Paper Feeding

1.2.4 Input Data Buffer

1.2.5 Electric Specification

1.2.6 Environmental Condition

1.2.7 Reliability

1.2.8 Safety Approvals

1.2.9 Acoustic Noise

1.2.10 CE Marking

1.3 INTERFACE

1.3.1 Parallel Interface (Forward Channel)

1.3.2 Parallel Interface (Reserve Channel)

1.3.3 USB Interface

1.3.4 Prevention of Data Transfer Time-out

1.3.5 Interface Selection

1.3.6 IEEE1284.4 Protocol

1.4 OPERATOR CONTROLS

1.4.1 Operating Switch

1.4.2 Control Panel

1.4.2.1 Switches

1.4.2.2 Indicators

1.4.3 Panel Functions

1.4.4 Printer Condition and Panel Status 1.4.5 Printer Initialization

1.4.6 Errors

1.5 PAPER

1.5.1 Paper Handling

1.5.2 Paper Specification

1.5.2.1 Cut Sheet

1.5.2.2 Transparency, Glossy Paper

1.5.2.3 Envelope

1.5.2.4 In dex Card

1.5.3 Printing Area

1.5.3.1 Cut Sheet

1.5.3.2 Envelopes

1.6 INK CARTRIDGE

1.6.1 Black Ink Cartridge

1.6.2 Color Ink Cartridge

OPERATING PRINCIPLES

2.1 Overview

2.1.1 Printer Mechanism

2.1.1.1 P rinting Mechanism

2.1.1.2 P rinting Pro cess

2.1.1.3 Carria ge Mechanism

2.1.1.4 Platen Gap (PG) Adjust Mechanism

2.1.1.5 Paper Feeding Mechanism

2.1.1.6 CR Lock Mechanism

2.1.1.7 Paper Loading Mechanism

2.1.1.8 Pump Mechanism

2.1.1.9 Capping Mechanism

2.2 Electrical Circuit Operating Principles

2.2.1 C298PSB/PSE Board

2.2.2 C298MAIN Board

2.2.2.1 Printhead Driver Circuit

2.2.2.2 Reset Circuit

2.2.2.3 CR Motor Driver Circuit

2.2.2.4 PF Motor Driver Circuit

2.2.2.5 ASF/Pump Motor Driver Circuit

2.2.2.6 EEPROM Control Circuit

2.2.2.7 Sensor Circuit

TROUBLESHOOTING

3.1 Overview

3.1.1 Troubleshooting with LED Error Indications

3.1.1.1 Remedies for Paper Out Error

3.1.1.2 Remedies for the Paper Jam Error

3.1.1.3 Remedies for No I/C and Ink Out Errors

3.1.1.4 Remedies for the Maintenance Error

3.1.1.5 Remedi es for Fatal Error

3.1.2 Isolating the Faulty Part on the Power Supply Board

3.1.3 Isolating the Faulty Part according to the Phenomenon

DISASSEMBLY AND ASSEMBLY

4.1 Overview

4.1.1 Precautions for Disassembling the Printer