Epson Stylus Color 685, STYLUS COLOR 777, STYLUS COLOR 777i, STYLUS COLOR 680 Service Manual

Color Inkjet Printer

EPSON Stylus Color 680/685/777/777i

SEIJ00010

Notice

mechanical, photocopying, or otherwise, without the prior written permission of SEIKO EPSON CORPORATION.

o 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.

o The contents of this manual are subject to change without notice.

o 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.

o The above not withstanding SEIKO EPSON CORPORATION can assume no responsibility for any errors in this manual or the consequences

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.

PRECAUTIONS

Precautionary notations throughout 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. NO WORK 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.

4. WHEN DISASSEMBLING OR ASSEMBLING A PRODUCT, MAKE SURE TO WEAR GLOVES TO AVOID INJURIER FROM METAL PARTS WITH SHARP EDGES.

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.

About This Manual

This manual describes basic functions, theory of electrical and mechanical operations, maintenance and repair procedures of the printer. 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.

Manual Configuration

This manual consists of six chapters and Appendix.

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

Describes the step-by-step procedures for the troubleshooting.

CHAPTER 4. DISASSEMBLY / ASSEMBLY

Describes the step-by-step procedures for disassembling and assembling the product.

CHAPTER 5. ADJUSTMENT

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:

• Connector pin assignments

• Electric circuit boards components layout

• Electrical circuit boards schematics

• Exploded diagram & Parts List

Symbols Used in this Manual

Various symbols are used throughout this manual either to provide additional information on a specific topic or to warn of possible danger present during a procedure or an action. Be aware of all symbols when they are used, and always read NOTE, CAUTION, or WARNING messages.

A D J U S T M E N T

R E Q U I R E D

C A U T I O N

C H E C K

P O I N T

W A R N I N G

Indicates an operating or maintenance procedure, practice or condition that is necessary to keep the product’s quality.

Indicates an operating or maintenance procedure, practice, or condition that, if not strictly observed, could result in damage to, or destruction of, equipment.

May indicate an operating or maintenance procedure,

practice or condition that is necessary to accomplish a task efficiently. It may also provide additional information that is related to a specific subject, or comment on the results achieved through a previous action.

I.ndicates an operating or maintenance procedure, practice or condition that, if not strictly observed, could result in injury or loss of life.

Revision Status

Revision Issued Date Description

A August 10, 2000 First Release

Revision:

B August 31, 2000

C September 28, 2000

D November 22, 2000

E February 1, 20001

Added disassembly and reassembly cautions to 4.2.1 Housing Removal

Changed the resolution of bit map images when producing PDF files for clearer reading.

Revision:

Corrections of Chapter 5 Adjustment.

Revision:

Chapter 4, Page 62: Added the contents of “Warning”

Chapter 4, Page 63: Added the contents of “Caution”

Chapter 4, Page 75: Changed the picture of Figure 4-15 for easier viewing

Revision:

n Added Stylus Color 685 to the manual.

n Page 10: Corrected the contents of theTable 1-1.

n Page 11: Corrected the miss description of “1.2.3 Paper Feeding“.

n Page 21: Corrected the contents of the Table 1-12 and added notes to the table.

n Chaper 3: Added all the table titles

n Page 45: Corrected the contents of the Table 3-3 and added notes below the table.

n Page 46: Corrected “Check Table’s table no.“ of Table 3-4 and added new

symptom, possible causes.

CONTENTS

Chapter 1 PRODUCT DESCRIPTION

1.1 FEATURES ......................................................................................................... 4

1.2 SPECIFICATIONS ............................................................................................ 5

1.2.1 Physical Specification .................................................................................. 5

1.2.2 Printing Specification .................................................................................. 5

1.2.3 Paper Feeding .............................................................................................. 6

1.2.4 Input Data Buffer ......................................................................................... 6

1.2.5 Electric Specification ................................................................................... 6

1.2.6 Environmental Condition ............................................................................. 7

1.2.7 Reliability .................................................................................................... 7

1.2.8 Safety Approvals ......................................................................................... 7

1.2.9 Acoustic Noise ............................................................................................. 7

1.2.10 CE Marking ............................................................................................... 7

1.3 INTERFACE ....................................................................................................... 8

1.3.1 Parallel Interface (Forward Channel) .......................................................... 8

1.3.2 Parallel Interface (Reserve Channel) ......................................................... 11

1.3.3 USB Interface ............................................................................................ 12

1.3.4 Prevention of Data Transfer Time-out ....................................................... 13

1.3.5 Interface Selection ..................................................................................... 13

1.3.6 IEEE1284.4 Protocol ................................................................................. 13

1.4 OPERATOR CONTROLS .............................................................................. 14

1.4.1 Operating Switch ....................................................................................... 14

1.4.2 Control Panel ............................................................................................. 14

1.4.2.1 Switches ............................................................................................. 14

1.4.2.2 Indicators ........................................................................................... 14

1.4.3 Panel Functions .......................................................................................... 15

1.4.4 Printer Condition and Panel Status ............................................................ 16

1.4.5 Printer Initialization ................................................................................... 17

1.4.6 Errors ......................................................................................................... 17

1.5 PAPER ............................................................................................................... 18

1.5.1 Paper Handling .......................................................................................... 18

1.5.2 Paper Specification .................................................................................... 18

1.5.2.1 Cut Sheet ........................................................................................... 18

1.5.2.2 Transparency, Glossy Paper .............................................................. 18

1.5.2.3 Envelope ............................................................................................ 18

1.5.2.4 Index Card ......................................................................................... 19

1.5.3 Printing Area .............................................................................................. 20

1.5.3.1 Cut Sheet ........................................................................................... 20

1.5.3.2 Envelopes .......................................................................................... 21

1.6 INK CARTRIDGE ........................................................................................... 22

1.6.1 Black Ink Cartridge ................................................................................... 22

1.6.2 Color Ink Cartridge .................................................................................... 22

Chapter 2 Operating Principles

2.1 Overview ............................................................................................................ 24

2.1.1 Printer Mechanism ..................................................................................... 24

2.1.2 Printhead .................................................................................................... 25

2.1.2.1 Printing Process ................................................................................. 25

2.1.2.2 Printing Method ................................................................................. 26

2.1.3 Carriage Mechanism .................................................................................. 27

2.1.4 Paper Feeding Mechanism ......................................................................... 28

2.1.5 Paper Loading Mechanism (ASF Unit) ..................................................... 29

2.1.6 Ink System Mechanism ............................................................................. 32

2.1.6.1 Pump Unit & Wiper mechanism ....................................................... 32

2.1.6.2 Capping Mechanism .......................................................................... 33

2.2 Electrical Circuit Operating Principles .......................................................... 34

2.2.1 C383 PSB/PSE board ................................................................................ 34

2.2.2 C383 MAIN Board .................................................................................... 37

2.2.2.1 Main elements ................................................................................... 38

2.2.2.2 Printhead Driver Circuit .................................................................... 38

2.2.2.3 PF Motor (PF/ PUMP/ ASF Motor) Driver Circuit .......................... 39

2.2.2.4 CR Motor Driver Circuit ................................................................... 40

2.2.2.5 Reset Circuit ...................................................................................... 40

2.2.2.6 EEPROM Control Circuit ................................................................. 41

2.2.2.7 Sensor Circuit .................................................................................... 41

Chapter 3 Troubleshooting

3.1 Overview ............................................................................................................ 44

3.2 Troubleshooting with LED Error Indications ............................................... 45

5.2.4 USB ID input ........................................................................................... 104

5.2.5 Head Cleaning Operation ........................................................................ 106

5.2.6 Initial Ink Charge Operation .................................................................... 107

5.2.7 Refurbishment for DOA .......................................................................... 108

5.2.8 Protection Counter Check/Reset .............................................................. 109

5.2.9 Check pattern printing ............................................................................. 111

5.2.10 EEPROM check function ...................................................................... 112

5.2.11 CSIC Information .................................................................................. 113

Chapter 4 Disassembly and Assembly

4.1 Overview ............................................................................................................ 57

4.1.1 Precautions ................................................................................................. 58

4.1.2 Tools .......................................................................................................... 60

4.1.3 Work Completion Check ........................................................................... 61

4.2 Disassembly ....................................................................................................... 62

4.2.1 Housing removal ........................................................................................ 63

4.2.2 Operation Panel removal ........................................................................... 65

4.2.3 Printhead removal ...................................................................................... 66

4.2.4 CR motor removal ..................................................................................... 68

4.2.5 Waste drain ink pad unit removal .............................................................. 70

4.2.6 Circuit board removal ................................................................................ 72

4.2.7 LD Roller removal ..................................................................................... 76

4.2.8 HP/PE Sensor removal .............................................................................. 80

4.2.9 Ink system unit removal (Cap & Pump unit ) ............................................ 82

4.2.10 Paper Eject Roller removal ...................................................................... 84

4.2.11 PF motor removal .................................................................................... 86

4.2.12 CR unit removal ....................................................................................... 88

4.2.13 Paper feed roller removal ......................................................................... 91

4.2.14 Disassembling ASF frame unit ................................................................ 94

Chapter 5 Adjustment

5.1 Overview ............................................................................................................ 98

5.1.1 Required Adjustment ................................................................................. 98

5.1.2 Adjustment Program feature ...................................................................... 99

5.1.3 Adjustment Program Installation Procedure .............................................. 99

5.2 Adjustment Program Execution ................................................................... 100

5.2.1 Adjustment Program Initial Setting menu ............................................... 100

5.2.2 Head ID Input .......................................................................................... 100

5.2.3 Bi-D Adjustment ...................................................................................... 102

Chapter 6 Maintenance

6.1 Overview .......................................................................................................... 115

6.1.1 Cleaning ................................................................................................... 115

6.1.2 Service Maintenance ................................................................................ 116

6.1.3 Lubrication ............................................................................................... 116

Chapter 7 Appendix

7.1 Connector Summary ...................................................................................... 121

7.1.1 Major Component Unit ............................................................................ 121

7.1.2 EEPROM Address Map ........................................................................... 124

7.2 Component Layout ......................................................................................... 128

7.3 Exploded Diagram .......................................................................................... 130

7.4 Parts List ......................................................................................................... 135

7.5 Electrical Circuits ........................................................................................... 138

PRODUCT DESCRIPTION

CHAPTER

EPSON Stylus COLOR 680/685/777/777i Revision E

1.1 FEATURES

The major features of EPSON color inkjet printers EPSON Stylus COLOR 680/685/ 777/777i are:

o High Color Print Quality

n 2880 (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 1 transparency films

o Two Built-in Interfaces

n Bi-directional parallel I/F (IEEE-1284 level 1 device) n USB

o Windows/Macintosh exclusive

)

Figure 1-1. Product’s external view

PRODUCT DESCRIPTION FEATURES 4

EPSON Stylus COLOR 680/685/777/777i Revision E

1.2 SPECIFICATIONS

This section covers specifications of the printers.

1.2.1 Physical Specification

o Weight: 4.1kg (without ink cartridges)

o Dimension:

Storage: 450 mm (W) x 246 mm (D) x 182 mm (H) Printing: 450 mm (W) x 547 mm (D) x 279 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

Horizontal Resolution

360 dpi 209.8mm(8.26 inch) 2976 60.452cm/s(23.8 IPS)

720 dpi 209.8mm(8.26 inch) 5952 50.80cm/s(20 IPS)

1440 dpi 209.8mm(8.26 inch) 11904 50.80cm/s(20 IPS)

Printable Area Available Dot CR Speed

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)

o Typeface

n Bit map LQ font:

EPSON Courier 10 CPI

o Print Speed & Printable Columns

Table 1-1. Character Mode

Character Pitch Printable Column LQ Speed

10 CPI (Pica) 82 238 CPS*

*This value is the speed of normal-dot printing.

PRODUCT DESCRIPTION SPECIFICATIONS 5

EPSON Stylus COLOR 680/685/777/777i Revision E

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 126ms (4.96 inch) (10.16mm (0.4inch) feed)

n 114.3mm/sec(4.5 inch/sec) (Fast, Continues feed)

1.2.4 Input Data Buffer

n 32KB

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 Power Consumption: Approx. 17W (ISO10561 Letter Pattern)

Approx. 2.5W in standby mode Energy Star compliant

Insulation Resistance: 100M 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. 17W (ISO10561 Letter Pattern)

Approx. 2.5W in standby mode Energy Star compliant

Insulation Resistance: 100M ohms min.

(between AC line and chassis, DC 500V)

Dielectric Strength: AC 1500V rms. 1 minute

(between AC line and chassis)

PRODUCT DESCRIPTION SPECIFICATIONS 6

EPSON Stylus COLOR 680/685/777/777i Revision E

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)

Humidity (%)

Temperature (°C)

1.2.7 Reliability

Total Print Volume: 50,000 pages (A4, Letter)

or 5 years although less than 50.000 pages printing

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. 47dB(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 1-2. Temperature/Humidity Range

PRODUCT DESCRIPTION SPECIFICATIONS 7

EPSON Stylus COLOR 680/685/777/777i Revision E

1.3 INTERFACE

The EPSON Stylus COLOR 680/685/777/777i 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 1-3. 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 8

EPSON Stylus COLOR 680/685/777/777i Revision E

Table 1-4. Typical Time of tack

Parallel I/F Mode Typical Time of tack

High Speed 0.5us

Normal Speed 2us

Table 1-5. Signal Level: TTL Compatible (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. Signal Name

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 A high signal indicates paper-out error.

13 SLCT 28 Out

14 -AFXT 30 In Not used.

Return

GND Pin

In/Out Functional Description

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 level when data is logical 1 and low level when data is logical 0.

This signal is a negative pulse indicating that the printer can accept data again.

A high signal indicates that the printer cannot receive data.

Always at high level when the printer is powered on.

The falling edge of a negative pulse or a

31 -INIT 30 In

32 -ERROR 29 Out

36 -SLIN 30 In Not used.

18 Logic H - Out Pulled up to +5V via 3.9 K ohm resistor.

low signal on this line causes the printer to initialize. Minimum 50us pulse is necessary.

A low signal indicates printer error condition.

PRODUCT DESCRIPTION INTERFACE 9

EPSON Stylus COLOR 680/685/777/777i Revision E

Table 1-6. Connector Pin Assignment and Signals (continued)

Pin No. Signal Name

35 +5V - Out Pulled up to +5V via 3.3K ohm resistor.

17 Chassis GND - - Chassis GND

16,33,

19-30

15,34 NC - - Not connected

GND - - Signal GND

Return

GND Pin

In/Out Functional Description

NOTE: In/Out refers to the direction of signal flow seen from the printer side.

PRODUCT DESCRIPTION INTERFACE 10

EPSON Stylus COLOR 680/685/777/777i Revision E

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. Signal Name

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.

Return

GND Pin

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.

Table 1-7. Connector Pin Assignment and Signals (continued)

Pin No. Signal Name

36 1284-Active 30 In 1284 active signal.

18 Logic-H - Out Pulled up to +5V via 3.9K ohm resistor.

35 +5V - Out Pulled up to +5V via 3.3K ohm resistor.

17 Chassis GND - - Chassis GND

16,33,

19-30

15,34 NC - - Not connected

-DataAvail / DataBit-0,4

GND - - Signal GND

NOTE: In/Out refers to the direction of signal flow from the printer’s point of

view.

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

In/Out Functional Description

Data available signal and reverse channel transfer data bit 0 or 4.

14 HostBusy 30 In Host busy signal.

31 -INIT 30 In Not used.

PtrBusy /

DataBit-3,7

AckDataReq / DataBit-2,6

Xflag /

DataBit-1,5

29 Out

28 Out

Printer busy signal and reverse channel transfer data bit 3 or 7.

Acknowledge data request signal and reverse channel transfer data bit 2 or 6.

X-flag signal and reverse channel transfer data bit 1 or 5.

PRODUCT DESCRIPTION INTERFACE 11

EPSON Stylus COLOR 680/685/777/777i Revision E

Device ID:

The printer sends the following device ID string when requested.

When IEEE1284.4 is enabled,

[00H] [5AH] MFG: EPSON; CMD: ESCPL2, BDC, D4; MDL: Stylus[SP]COLOR[SP]XXX*; CLS: PRINTER; DES: EPSON[SP]Stylus[SP]COLOR[SP]XXX*;

When IEEE1284.4 is disabled,

[00H] [57H] MFG: EPSON; CMD: ESCPL2, BDC; MDL: Stylus[SP]COLOR[SP]XXX*; CLS: PRINTER; DES: EPSON[SP]Stylus[SP]COLOR[SP]860/1160; *XXX is 777 (for EAI spec) or 680 (for EURO/ASIA spec)

Note 1: [00H] denotes a hexadecimal value of zero.

Note2: MDL value depends on the EEPROM setting.

Note3: 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

1 VCC - Cable power. Max. power consumption is 2mA.

2 -Data Bi-D Data

3 +Data Bi-D Data, pull up to +3.3 V via 1.5K ohm resistor.

4 Ground - Cable ground

Pin #2

Pin #1

Pin #3

Pin #4

Figure 1-4. USB Pin Assignment

PRODUCT DESCRIPTION INTERFACE 12

EPSON Stylus COLOR 680/685/777/777i Revision E

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 time-out, 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 continuously when the input buffer 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 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.

o Automatic Selection

An initial state is compatible interface and starts IEEE1284.4 communication when magic strings (1284.4 synchronous commands) are received.

PRODUCT DESCRIPTION INTERFACE 13

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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 two LED lights.

Power

Maintenance

1.4.2.2 Indicators

(1) Power

Lights when the operating switch is “ON” and AC power is supplied.

(2) Error

Lights or blinks when some error has occur to the printer.

Ink Cartridge replacement

Figure 1-5. Control Panel

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1.4.3 Panel Functions

Table 1-9. Panel Functions

Switch Function

Maintenance

Ink Cartridge replacement

* This function is not available in printing status.

Switch Function

Maintenance

Ink Cartridge

replacement

Maintenance

Ink Cartridge

replacement

• Loads or Ejects the Paper (Pushing within 3seconds).

• Starts the Cleaning of head (Pushing for 3seconds).

• When carriage is on the Ink Cartridge change position, return carriage from Ink Cartridge change position.

• Starts the Ink Cartridge change sequence. *

Table 1-10. Panel Functions with Power On

• Start status printings.

• Select IEEE 1284.4 mode for parallel I/F. *1

• Enters the special setting mode (Factory use only). *3

Table 1-11. Special Setting Mode

Switch Function

Maintenance

Ink Cartridge replacement

(10 seconds)

• Initialize EEPROM.

• Reset the ink overflow counter in the EEPROM.

*1 Not described in the user's manual.

*2 See Table 1-11 for detailed information.

PRODUCT DESCRIPTION OPERATOR CONTROLS 15

EPSON Stylus COLOR 680/685/777/777i Revision E

1.4.4 Printer Condition and Panel Status

Table 1-12. Printer Condition and LED Status

Printer Status

Power ON condition On - 10

Ink sequence Blink - 6

Ink Cartridge change mode Blink - 5

Data processing Blink - 9

Paper Out *1 - On 4

Paper jam condition *1 - On 3

Ink end (Black) *1 - On -> Blink 8

Ink level low (Black) - Blink 8

Ink end (Color) *1 - On -> Blink2 8

Ink level low (Color) - Blink 8

Ink end (Black and Color)

No Ink Cartridge (Black and Color) *1

Power Error

- On -> On 8

- On 7

Indicators

Priority

*1: See 1.4.6 Errors for detailed information.

Blink2: On 0.2 sec + Off 0.2 sec + On 0.2sec + Off 0.4 sec.

Reset, Timer IC reset, EEPROM clear

Ink Overflow Counter reset On (2s) On (2s) -

Maintenance request (Ink Overflow Counter error)

Fatal error *1 Off On 1

Special setting Blink2 Blink2 -

On (1s) On (1s) -

Alt Blink Alt Blink 2

" - " : Indicator status don't change.

" A -> B " :A is a indicator condition when carriage is on Home Position.

B is a indicator condition in Ink exchange sequence.

PRODUCT DESCRIPTION OPERATOR CONTROLS 16

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1.4.5 Printer Initialization

There are three kinds of initialization methods, and the following explains each initialization.

1. Power-on Initialization This printer is initialized when turning the printer power on, or printer 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 interface.

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.

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 inkcartridge 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, or failed to read or write CSIC data, 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.

3. Software Initialization The ESC@ command also initialize the printer.

When printer is initialized, the following actions are performed: (a) Clears print buffer. (b) Sets default values.

PRODUCT DESCRIPTION OPERATOR CONTROLS 17

EPSON Stylus COLOR 680/685/777/777i Revision E

1.5 PAPER

1.5.1 Paper Handling

Do not perform reverse feed more than 1.8mm (0.07”).

1.5.2 Paper Specification

1.5.2.1 Cut Sheet

[Size]

A4: Width 210mm (8.3”) x Length 297mm (11.7”) A5: Width 148mm (5.8”) x Length 210mm (8.3”) A6: Width 105mm (4.1”) x Length 148mm (5.8”) Letter: Width 216mm (8.5”) x Length 279mm (11.0”) Half Letter: Width 139.7mm (5.5”) x Length 216mm (8.5”) B5: Width 182mm (7.2”) x Length 257mm (10.1”) Legal: Width 216mm (8.5”) x Length 356mm (14.0”) Executive: Width 184.2mm (7.25”) x Length 266.7mm (10.5”)

[Thickness]

0.08mm (0.003”) - 0.11mm (0.004”)

[Weight]

64g/m

(17Ib.) - 90g/m2 (24Ib.)

[Quality]

1.5.2.2 Transparency, Glossy Paper

[Size]

A4: Width 210mm (8.3”) x Length 297mm (11.7”) Letter: Width 216mm (8.5”) x Length 279mm (11.0”)

[Thickness]

0.075mm (0.003”) - 0.085mm (0.0033”)

[ASF hopper available capacity]

1 sheets

Note: 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”)

[Weight]

45g/m2 (12Ib.) - 75g/m2 (20Ib.)

Exclusive paper, Bond paper, PPC

[ASF hopper available capacity]

100 sheets

Note1: No wrinkled, scuffing, torn or folded paper be used.

Note2: No curled paper more than 5 mm be used.

PRODUCT DESCRIPTION PAPER 18

EPSON Stylus COLOR 680/685/777/777i Revision E

[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.

Note 3: Envelope printing is available only in the normal temperature.

Note 4: No wrinkled, scuffing, torn or folded paper be used.

Note 5: No curled paper more than 5mm be used.

Note 6: No paper with glue on flap be used.

Note 7: No double envelops nor with window envelops be used.

Note 8: Do not print on the back.

1.5.2.4 Index 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”)

[ASF hopper available capacity]

30 sheets

PRODUCT DESCRIPTION PAPER 19

EPSON Stylus COLOR 680/685/777/777i Revision E

1.5.3 Printing Area

1.5.3.1 Cut Sheet

See the figure below and tables on the right for printable areas.

Printable Area

Table 1-13. Printing Area

Left Margin

Paper Size

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”)

(min.)

* Bottom margin can be reduced to 3mm when paper dimension is

defined by using command, otherwise it is not reduced (14mm). As for an area between 3mm and 14mm margin, printing quality may decline.

** Refer to 1.5.2 Paper Specification for PW (paper width) and PL

(paper length).

Right Margin

(min.)

Top Margin

(min.)

14 mm (0.54”) / 3mm (0.12”) *

Bottom Margin

(min.)

Figure 1-6. Printable Area for Cut Sheet

PRODUCT DESCRIPTION PAPER 20

EPSON Stylus COLOR 680/685/777/777i Revision E

1.5.3.2 Envelopes

Printable Area

Figure 1-7. Printable Area for Envelopes

Table 1-14. Envelope Margin

Size

#10 3 mm (0.12”) 28 mm (1.10”) 3 mm (0.12”) 14 mm (0.55”)

Left Margin

(min.)

Right Margin

(min.)

Top Margin

(min.)

Bottom Margin

(min.)

DL 3 mm (0.12”) 7 mm (0.28”) 3 mm (0.12”) 14 mm (0.55”)

C6 3 mm (0.12”) 3 mm (0.12”) 3 mm (0.12”) 14 mm (0.55”)

PRODUCT DESCRIPTION PAPER 21

EPSON Stylus COLOR 680/685/777/777i Revision E

1.6 INK CARTRIDGE

1.6.1 Black Ink Cartridge

Type: Exclusive Cartridge Color: Black Print Capacity: 600 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: 28.1 mm (W) x 66.85 mm (D) x 43.3 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

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: 43.2 mm (W) x 66.85 mm (D) x 43.3 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

Figure 1-9. Color 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

Figure 1-8. Black Ink Cartridge

hours.

PRODUCT DESCRIPTION INK CARTRIDGE 22

OPERATING PRINCIPLES

CHAPTER

EPSON Stylus COLOR 680/685/777/777i Revision E

2.1 Overview

This section describes the operating principles of the printer mechanism and electrical circuit boards. The Stylus COLOR 680/777/777i has the following boards:

o Main board: C383 MAIN (C383 MAIN-B)

NOTE: C383 MAIN-B is compatible with C383 MAIN. Only some chips or parts

are different from each other due to different producers.

o Power supply board: C383 PSB/PSE

o Panel board: C383 PNL

2.1.1 Printer Mechanism

The printer mechanism for Stylus COLOR 680/777/777i is designed newly. But, the basic component of the printer mechanism is same as previous product. This printer consists of Print Head, Carriage Mechanism, Paper Feeding Mechanism, Paper Loading Mechanism, Ink System (Pump Mechanism, Cap Mechanism, and Carriage Lock Mechanism).

Like other EPSON ink jet printers, the Stylus COLOR 680/777/777i is equipped with two stepping motors; one for ASF, Paper feeding/ Pump mechanism, and one for CR mechanism. ASF unit uses rear entry front eject system. This ASF unit is also designed newly and single LD roller loads the paper to the printer mechanism.

PF Motor

Star Wheel Roller

CR unit

Paper Eject Roller

PF Roller

CR Timing belt

HP/PE/IC Sensor sensor

LD Roller

Paper feed back plate

Paper separation pad

ASF Hopper Spring

For cap assembly, Stylus COLOR 680/777/777i uses valveless mechanism; new design

CR lock lever

for this model.

Clutch mechanism

Pump Assembly

Cap Assembly

CR Motor

Figure 2-1. Printer Mechanism block diagram

Operating Principles Overview 24

EPSON Stylus COLOR 680/685/777/777i Revision E

2.1.2 Printhead

The printhead uses a new developed U-CHIPS head and Stylus COLOR 680/777/777i can perform multiple shot printing and variable printing.

The CSIC is mounted on the ink cartridge. By storing ink life data, this IC makes it possible to control the ink in ink cartridge unit.

The basic operating principles of the printhead, which plays a major role in printing, are the same as previous models; on-demand method which uses PZT (Piezo Electric Element). In order to uniform the amount of ejecting ink, the printhead has its own head ID (6 digits for this printhead) which adjust PZT voltage drive features. The printhead stores the head ID to EEPROM and generates appropriate PZT drive voltage to prevent amount of ink from varying by printheads.

Following explains printhead basic components.

o PZT

PZT is an abbreviation of Piezo Electric Element. Certain amount of voltage expands and contracts PTZ. The drive wave generated on MAIN board drives PZT and PZT pushes the top cavity which has ink stored to discharge the ink from each nozzle on the nozzle plate.

o Ink Cavity

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.

o Nozzle Plate

The board with nozzle holes on the printhead surface is called Nozzle Plate.

o CSIC Connection Circuit

This circuit connects the CSIC mounted on the ink cartridge and the main board. One end of the wire harness connects with the print head cable to the main board.

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.

Nozzle Plate

Ink Cartridge

PZT

CSIC

Needle

Cavity

Nozzle Selecto r Board

CSIC Connection Circuit

Filter

Figure 2-2. Printhead Sectional Drawing

2.1.2.1 Printing Process

This section explains the process in which the printheads of On-Demand inkjet printers eject ink from each nozzle.

1. Normal State: When no printing signal is sent from PC, or no PZT drive voltage is applied, PZT does not change shape, therefore PZT does not squeeze the cavity. Ink pressure inside the cavity is kept normal. (Refer to Figure 2-3.)

2) Ejecting State: When the print signal is output from the C383 MAIN board, IC (Nozzle Selector) located on the printhead unit latches data once by 1-byte unit. An appropriate PZT

Operating Principles Overview 25

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