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

o All rights reserved. No part of this manual may be reproduced, stored in a retrieval system, or transmitted in any form or by any means electronic,

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.

Copyright © 2000 SEIKO EPSON CORPORATION.
Imaging & Information Product Division
TPCS Quality Assurance Center
TPCS Department

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

n

Added disassembly and reassembly cautions to 4.2.1 Housing Removal

n

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

Revision:

Corrections of Chapter 5 Adjustment.

n

Revision:

n

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

n

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

n

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

2

)

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)

90

80

70

60

Humidity (%)

50

40

30

20

27

10

20

Temperature (°C)

35

30

40

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

32

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.

11

12

13

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

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

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

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.

21

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

PRODUCT DESCRIPTION OPERATOR CONTROLS 14

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

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

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

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]

2

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.

PW

LM

Printable Area

RM

TM

PL

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”) *

14 mm (0.54”) / 3mm
(0.12”) *

14 mm (0.54”) / 3mm
(0.12”) *

14 mm (0.54”) / 3mm
(0.12”) *

14 mm (0.54”) / 3mm
(0.12”) *

14 mm (0.54”) / 3mm
(0.12”) *

Bottom Margin

(min.)

BM

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

LM

RM

TM

Printable Area

BM

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)

o

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

o

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

o

C to 60 oC (within 120 hours at 60 oC

and within a month at 40

o

C)

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)

o

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

o

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

o

C to 60 oC (within 120 hours at 60 oC

and within a month at 40

o

C)

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

o

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

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

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 2.1.2.2.)

Ink Path

Nozzle

PZT drive voltage

PZT

Ink Cavity

Nozzle plate

o Multiple shot printing

This printing mode is developed to improve the print quality on plain paper or
transparencies in low resolution. The multiple shot printing mode uses normal dot
and the number of dot shots varies from 1 shot to maximum 4 shots depending on
the print data to enable sharp image output even in a low resolution.

o Variable dot printing

This printing mode is developed to improve the print quality on exclusive paper.
This mode is basically the same as variable dot printing mode used on other
products /; micro dot, middle dot, and large dot compose this mode. Print dot size
varies according to print data and this mode enables even sharper image output on
exclusive paper.

Figure 2-3. Printhead printing process

2.1.2.2 Printing Method

For print dot system, Stylus COLOR 680/777/777i has the following two kinds of
printing modes.

n Multiple shot printing

n Variable dot printing

The above two printing modes are automatically selected depending on the media and
the resolution setting of the printer driver. The following explains each printing mode.

Operating Principles Overview 26

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

2.1.3 Carriage Mechanism

The carriage mechanism consists of Carriage motor (CR motor), Carriage unit
(including printhead), CR timing belt, CR guide shaft, CR guide frame, CR home
detector (HP/PE sensor) etc. The carriage mechanism moves the carriage back and
forth according to the drive from the carriage motor. The following stepping motor is
mounted to drive CR mechanism. (See the table below.)

Table 2-1. Carriage Motor Specification

Items Specifications

Type 4-Phase/ 200-Pole HB Stepping motor

Drive Voltage +42 V +/ - 5% (DRV IC voltage)

Coil Resistance 7.8 Ω +/ - 10% (per phase at 25 degree)

Inductance 14 mH +/ - 20%(1KH 1VmA)

Drive Method Bi-Polar drive

Driver IC LB11847

The drive from CR motor is transferred to the CR unit via CR timing belt. And the CR
home position is detected with the HP/PE sensor. This sensor is available as CR HP
detector only in the HP (home position) detection sequence & pump operation
sequence. (not available in the paper feeding sequence for the CR HP detector because
it is used for only PE sensor during the paper feeding sequence.) Moreover, unlike the
previous products, this printer dose not have the PG adjustment mechanism (1.7mm).

CR home position is detected with the HP/PE/IC sensor and the detection plate molded
in the CR unit as following figure. When the CR home position is detected with this
sensor, HIGH signal is output to the CPU.

HP detection Lever

CR HP detection plate

Low signal

Right side view

CR HP detection plate

HP/IC detection Lever

High signal

Figure 2-5. CR home position

CR unit

HP/PE Sensor

CR Guide shaft

CR Motor

CR Timing belt

Figure 2-4. Carriage Mechanism (Top view)

Operating Principles Overview 27

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

2.1.4 Paper Feeding Mechanism

The paper feeding mechanism consists of Paper feed motor (PF motor), PF roller,
Paper eject roller, Star wheel roller, and so on. The paper feeding mechanism feeds
paper loaded from ASF using the PF roller and Paper Eject Roller & Star wheel roller.
For this mechanism, the PF motor mentioned in the right Table 2-2 is used on this
product.

The drive of the PF motor is transfer to the PF roller and the Paper Eject Roller as
following Figure 2-6. Following shows you how to transfer the PF motor drive to the
PF roller and the Paper Eject Roller.

o PF motor drive transmission path

PF Motor Pinion Gear (CW)

(CW) → Spur Gear 15 (CCW) →
(CCW) →

Spur gear 35.2(CW)

→ Combination Gear 16, 21.6 (CCW) → Spur Gear 73.6

Combination Gear 37.6, 44.4 (W) → Spur Gear 23.2

Table 2-2. PF Motor Specifications

Item Description

Motor type 4-Phase/ 200-Pole HB Stepping motor

Drive voltage +42 V +/ - 5% (DRV IC voltage)

Coil Resistance 7.8 Ω +/ - 10% (per phase)

Inductance 13.5 mH +/ - 20%(1kH 1Vrms)

Driving method Bi-Polar drive

Driver IC LB11847

Spur Gear 35.2

PF roller

Spur Gear 23.2

Spur Gear 15

Combination gear

37.6, 44.4

Figure 2-6. Paper Feeding Mechanism

Paper loaded from ASF is advanced by the following roller.

o Paper feed roller & Paper guide roller (assembled on the Top Frame) → Paper

eject roller & Star wheel roller (assembled on the Paper eject frame).

Additionally, the top & end of the paper is detected with the HP/PE sensor.
In case the PE sensor dose not detect the paper in the paper loading sequence, the
printer detects the “Paper out error”. If the paper is detected after complete the paper
eject sequence, the printer detects the “Paper jam error”.

Operating Principles Overview 28

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

o

2.1.5 Paper Loading Mechanism (ASF Unit)

The Paper loading mechanism is positioned at the printer rear. The Paper loading
mechanism loads paper at the ASF unit and feeds paper to the PF roller.

This ASF unit was designed newly for this product and consists of LD roller, Pad
holder (Paper return plate), ASF Frame, Hopper, and so on.
For the major feature of this ASF unit, ASF HP sensor is not used and the single LD
roller is built in the ASF unit.
Drive sent from the PF motor is always transmitted to the ASF unit side. But, the
Change lever and the Clutch mechanism switch ON/OFF the PF motor drive to the LD
roller with the motor rotational direction.

Drive from the PF motor is transmitted to the ASF unit as described below:

o Switch the PF motor drive to ASF unit side

PF Motor pinion gear rotates CCW direction with a specific steps
Gear 16, 21.6 (CW)
Combination Gear 37.6, 44.4 (CCW)

the Clutch mechanism lock position

→ Spur Gear 73.6(CCW) → Spur Gear 15(CW) →

→ Change Lever rotates (CCW) → Release

Following Figure 2-7 shows you the switching path for PF motor drive to ASF unit
side.

→ Combination

Transfer the PF motor drive to LD roller

PF Motor pinion gear rotates CW direction

→ Spur Gear 73.6 (CW) → Spur Gear 15 (CCW) → Combination Gear 37.6, 44.4

(CW)

→ Change Lever rotates (CW) → Spur Gear 23.2 (CCW) → Spur Gear 35.2

→ Combination Gear 16, 21.6 (CCW)

(CW) (include the clutch mechanism) → LD roller (CW).

Following Figure 2-9 shows the PF motor drive transmission path to the LD roller unit
built in the ASF unit. The LD roller is assembled on the same shaft that the Spur gear

35.2 is assembled.

Spur Gear 35.2

Change Lever

Spur Gear 15

Spur Gear 23.2

Combination Gea r

37.6, 44.4

Figure 2-8. PF motor drive transmission path

Spur Gear 35.2

Change Lever

Spur Gear 23.2

Spur Gear 15

Combination Gear

37.6, 44.4

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

Table 2-3. ASF unit function & PF Motor rotational direction

Directions Corresponding Functions

Clockwise (*1)

Counterclockwise (*1)

• Picks up and loads paper

• Release the DE lever & Clutch mechanism

Figure 2-7. Switch the PF motor drive to ASF unit side

(*1): The PF Motor rotational direction = seen from the right side of the printer.

o Clutch Mechanism

Unlike the previous products, this product dose not have a ASF HP sensor.
Instead of the ASF HP sensor, Change lever and the Clutch mechanism are used to
detect the ASF home position. Following figures describe the mechanism.

Operating Principles Overview 29

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

NOTE:

The Clutch gear is molded on
the back side of the Spur gear

35.2 such as Combination gear.

Spur gear 35.2

Clutch lever

Step1

Change Lever

Clutch gear

Clutch

Figure 2-9. Disengage & Clutch mechanism

The Clutch mechanism transmits the PF motor drive to the LD roller shaft only when
the Clutch gear rotates CW direction after the Change lever releases the Clutch lever. If
the Clutch gear rotates CCW direction, the PF motor drive is not transmitted to the LD
roller. This is due to the combination of the shape of the Clutch gear and the Clutch
lock tooth such as described on the figure.

1. When the paper is advanced with the PF roller, the Change lever is set on the
Clutch lever and the Clutch is pushed down as above Step1’s figure. As the
result, the Clutch gear (*1) is released from the Cluck lock tooth and the drive
from the PF motor is not transmitted to the LD roller shaft.

2. When the PF pinion gear rotates CCW direction in the above Step2’s figure, the
Change lever moves to the left direction with the CCW rotation of Combination
gear 37.6, 44.4. The Clutch turns back to the engagement position by the tension
force of the Tension spring 0.143 and the Clutch gear is engaged with the Clutch
lock tooth as above Step2’s center figure.

3. When the PF pinion gear rotates CW direction in the above Step3’s figure, the
Change lever moves to the right direction with the CW rotation of the
Combination gear 37.6, 44.4. And the drive from the PF motor is transmitted to the
LD roller shaft via Clutch gear and Clutch lock tooth.

4. The LD roller shaft rotates about 360 degree and the Change lever push the Clutch
lever and the PF motor drive is interrupted. This position is the ASF home
position.

Step2

Tension spring 0.143

Clutch lock tooth

Step3

LD roller shaft

Unlike the previous products, The Paper return plate is built in the ASF frame instead
of the Paper return lever. The Paper separation pad is also stacked on the plate.
It works with the spring force of the Torsion spring 25.7 (mounted in the ASF frame)
as following figure.

Hopper

Compression spring 4.80

ASF frame

LD roller

Paper Return

Plate

Torsion spring 25.7

Figure 2-10. Paper Return Plate

The Paper return plate is set to return the paper to the paper stand-by position in the
ASF unit when the ASF unit is in the standby mode. When the paper is fed with the
LD roller, the Paper return plate is stored in the ASF frame by the LD roller.

Following figures show you the ASF paper loading sequence and the operation of the
each mechanism.

o Paper Return Plate (Pad holder)

Operating Principles Overview 30

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

.

When the paper is advanced with
the PF roller, Change lever push
down the Clutch lever as right
figure and the Clutch lock tooth is
disengaged from the Clutch gear.
As the result, the drive from the PF
motor is interrupted and the LD
roller dose not rotate.
This position is the ASF home
position.
The Paper return plate is set to
avoid that the paper is slipped
down from the paper set position.

The PF motor pinion gear rotates
CW direction and the drive from the
PF motor is transmitted to the ASF
LD roller shaft through the Clutch
lock tooth and the Clutch gear.
The ASF hopper release lever rotates
with the ASF LD roller and release
the ASF Hopper. The ASF hopper is
pushed with the Compression spring

4.80 and the paper is picked up with
the ASF LD roller.

LD roller

LD roller shaft

Paper return plate

PF motor pinion

gear CW rotation

ASF Hopper
release lever

Clutch lever

Step 1

Change lever

Step 3

Clutch gear

Clutch lock tooth

Clutch

LD roller shaft

Hopper

gear CCW rotation

Compression

spring 4.80

Printer front side

PF motor pinion

ASF Frame

Step 2

Tension spring 0.143

Step 4

Paper return plate

When the paper is loaded (pick up) from
the ASF uni t, the Change lever m oves to
the printer front side with the CCW
rotation of the PF motor pinion gear and
releases the Clutch lever. As the result,
the Clutch turns back to the engagement
position by the tension force of the
Tension spring 0.143.
And the Clu tch lock tooth i s engaged
with the Clutch gear as right figure.

The ASF L D roller rotates CW direction
moreover and the Paper return plate is
stored under the ASF frame.
The paper is advanced up to the PF roller
and the ASF LD roller & the clutch rotate
to the “Step1” position. The Clutch lever
is locked with the Change lever.
The drive from the PF motor is
interrupted and the drive is transmitted to
the PF roller side.

PF motor pinion

gear CW rotation

ASF hopper

release lever

PF motor pinion

gear CW rotation

Figure 2-11. ASF Paper Loading Sequence

Operating Principles Overview 31

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

2.1.6 Ink System Mechanism

Ink system mechanism consists of pump unit (include the CR lock lever) and capping
mechanism. Ink system mechanism drives the pump unit that presses cap to the
printhead and ejects ink from ink cartridge, head cavity and cap to the waste ink pad.

2.1.6.1 Pump Unit & Wiper mechanism

The pump unit is driven by PF motor. PF motor drive is always transmitted to the paper
feeding mechanism and pump unit through the following gears. Refer to the Figure
2-13.

PF Motor Pinion Gear (CW)

→ Spur Gear 15 (CCW) → Combination Gear 37.6, 44.4 (CW) → Spur Gear 36.8 (CCW) →
Combination Gear 9.6, 24 (CW)→ Pump Unit Gear (CCW)

The Pump unit and Wiper mechanism drives according to the PF motor rotational
direction, as shown in the right table.

→ Combination Gear 16, 21.6 (CCW) → Spur Gear 73.6 (CW)

Table 2-4. PF motor rotational direction & Ink System Mechanism

Directions Functions

•Sets the wiper.

Counterclockwise (*1)

Clockwise (*1)

• Absorbs ink by the pump unit

• Set the CR lock lever

• Resets the wiper.

(*1): The PF Motor rotational direction = seen from the right side of the printer.

Following figure shows the overview of the pump mechanism operation.

Figure 2-12. Pump mechanism

Capunit

Wiper

Pumpunit

CR lock lever

Spur Gear 15

Combination Gear 9.6, 24

Pump Unit Gear

Spur Gear 36.8

Combination Gear

37.6, 44.4

Figure 2-13. PF motor drive transmission path to the Pump unit

Operating Principles Overview 32

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

2.1.6.2 Capping Mechanism

The capping mechanism covers the printheads with the cap holder to prevent the nozzle
from increasing viscosity when the printer is in stand-by mode or when the printer is
off. This product has valveless cap system. Air valve function used for the previous
models pumps and ejects ink only inside the cap by absorbing ink with the valve open.
By opening the Air valve, the negative pressure is decreased and only the ink inside the
cap is ejected. (the ink is not absorbed from Ink cartridge or head cavity.)
But, valveless cap system, this operation is done out side of the capping area.
The CR moves to left side of the Cap assembly and the pump absorbs the ink inside the
cap.

Viewed from front side

CR unit

Slider cap

Printhead

Cap

Waste Ink tube

Slide up

Figure 2-14. Cap Mechanism

Operating Principles Overview 33

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

2.2 Electrical Circuit Operating Principles

The electric circuit of the Stylus COLOR 680/777/777i consists of the following
boards.

o Main board: C383 MAIN Board

o Power supply board: C383 PSB/PSE Board

o Panel board: C383 PNL Board

This section provides operating principles of C383 Board and C383 PSB/PSE Board.
Refer to Figure 2-15 for the major connection of the each boards and their roles.

C383 PNL Board

Printer Mechanism

C383 MAIN Board

CR Motor

PF Motor

Head Driver Board

2.2.1 C383 PSB/PSE board

The power supply boards of Stylus COLOR 680/777/777i use a RCC (Ringing Chalk
Converter) circuit, which generates +42VDC for drive line and +5VDC for logic line to
drive the printer. The application of the output voltage is described below.

Table 2-5. Application of the DC Voltages

Voltage Application

• Motors (CR Motor, PF Motor)

+42VDC

+5VDC

AC voltage input from AC inlet first goes through filter circuit that removes high
frequency components and is then converted to DC voltage via the rectifier circuit and
the smoothing circuit. DC voltage is then lead to the switching circuit and FET Q1
preforms the switching operation. By the switching operation of the primary circuit,
+42VDC is generated and stabilized at the secondary circuit. This +42VDC generated
by the secondary circuit is converted to +5VDC by the chopping regulator IC of the
secondary circuit.

• Printhead common voltage

• Printhead nozzle selector 42V drive voltage

• C383MAIN control circuit logic

•Sensor

HP/PE/IC Sensor

+5VDC

C383 PSB/PSE Board

+42VDC

Figure 2-15. Electric Circuit

Operating Principles Electrical Circuit Operating Principles 34

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

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

D51

+5VDC+42VDC

IC51

+5V Regulator

R92,R93,Q91,ZD51

+42VDC Line

Constant

Control

C51

Smoothing

Circuit

ZD53

+5VDC Line

Over Voltage

Limitation

ZD52,87

+42VDC Line

Over Voltage

Limitation

ZD91

C84,Q84

Power Drop

Delay Circuit

PSC Sigual from

Main board

+42VDC Line

Drop Limitation

PC1

Photo Coupler

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 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

2

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

TRANS(T1)

according to the diode(D51) direction which is installed 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 C383PSB/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.

AC Input

Smoothing

Circuit

Over Current

Protection

F1,TH1

Q1C11

Switching

Filter Circuit

L1,C1

Main

Circuit

Q2,Q31,Q32,Q33

Full Wave

Rectifier circuit

DB1

Abnomal Feed

back circuit

o +42V Line Constant Voltage Control Circuit:

Figure 2-16. C383PSB/PSE Board Block Diagram

The C383 PSB/PSE board has the various control circuits to stop voltage output if a
malfunction occurs on the power supply board or the main board while the printer
mechanism is on duty. Following explains each control and protection 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 35

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

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
C383MAIN 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.

Operating Principles Electrical Circuit Operating Principles 36

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

2.2.2 C383 MAIN Board

The printer mechanism is controlled by C383 MAIN.
See Figure for the C383 MAIN board block diagram.

D-RAM 4M

(IC5)

D-RAM 16M

(IC8)

Reset IC
(IC16)

EEPROM
(IC15)

Motor Driver

(IC12)

Motor Driver

(IC13)

Common

Driver (IC10)

Parallel I/F IC

(IC6)

CN3
USB

P-ROM

USB IC
(IC3,IC2)

(IC1)

Address

Data

E01A15CA
CPU (IC9)

Q2&Q3

CN4

CN12

CN7

CN9

CN8

CN1 Parailel I /F

CN11

CR Motor

PF Motor

C383PNL

HP/PE Senser

Head

o Use of the 3.3V chips in the logic circuit

The 3.3 V regulator (IC11) on the C383MAIN 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 2-6. 3.3V Drive Chips & 5.5V Drive Chips

+5V 3.3V

Sensors

I/F Circuit

PNL Board

o

Timer IC & Lithium battery are not mounted

CPU

P-ROM

D-RAM

Unlike the previous products, the Timer IC and the Lithium battery are not
mounted on the Main board. So, this product perform the Power-on cleaning or
Timer cleaning based on the time command which is sent from the printer driver.

o D-RAM

4Mbit and 16Mbit D-RAMS are mounted on the Main board.

o One CPU controls the all function on the main board.

Figure 2-17. Block Diagram for the C383 MAIN Board

Following shows you the major characteristic of this main board.

Operating Principles Electrical Circuit Operating Principles 37

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

2.2.2.1 Main elements

Table 2-7 shows the function of the each main elements on C383 MAIN.

Table 2-7. Main Elements of the C383MAIN

IC Location Function

CPU
E01A15CA

PROM IC1

RAM IC5, IC8 Bus= 16 bit, 4Mbit DRAM and 16Mbit DRAM

EEPROM IC15

Reset IC IC16

Common Driver IC10

Motor Driver IC12 CR motor drive IC

Motor Driver IC13 PF motor drive IC

IC9

16bit CPU mounted on the MAIN board is driven by
clock frequency 24MHz and controls the printer.

• Capacity 8/16/32/64MB, Bus= 16 bit

• Program for CPU

1kbit EEPROM

• Default value setting

• Parameter backup

Reset IC

• For +5V; reset when +4.2V is detected

• For +42V, reset when +33.2 is detected

Head drive control HIC

• Generates head common voltage.

selector IC on the head board. Print data is converted to serial data by the CPU (IC9)
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 2-18 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 CPU (IC9), 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 CPU (IC9). Then the converted
data is allocated to the six rows, the number of the head nozzle rows, to be
transferred to the nozzle selector through the six signal lines (HS01 to HS06). Data
transmission from the CPU (IC9) 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.

Parallel I/F IC IC6 IEEE1284 parallel I/F transceiver IC.

USB IC IC2, IC3 USB transceiver IC

2.2.2.2 Printhead Driver Circuit

The printhead driver circuit consists of the following two components:

n Common driver IC (IC10:E09A14RA) directly attached to the C383MAIN

board.

n Nozzle selector IC on the head board.

The common driver (IC10:E09A14RA) generates a reference drive waveform
according to the output signals from the C383MAIN board. The reference drive
waveform is amplified by the transistors Q2 and Q3and then transferred to the nozzle

Operating Principles Electrical Circuit Operating Principles 38

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

CPU (IC9) converts PF motor phase control signal to LB11847 micro step drive form
and outputs to motor driver IC (IC13) LB11847 from port 101, 112. Based on this
signal, IC13 determines the phase mode.

The current value on each phase is determined by CPU (IC9) and outputs from port
104, 105, 107, 108, 109, 110 to driver IC (IC13). Motor driver IC generates motor
driver waveform based on these input signals and controls the motor. If the printer dose
not receive any data from PC for 5 minutes, CPU set the motor drive current to 0 via
port 104, 105, 107, 108, 109, 110 and the motor drive is turned off to save the power
consumption.

E01A15CA

(IC9)

DA1

PFAI 1
PFAI 2
PFAI 3

PFBI 1
PFBI 2
PFBI 3

PFPHAA
PFPHAB

PFENBA
PFENBB

123

104
105
107

108
109
110

101
112

102
111

+5V

+5V

25
24
23
22
18
19
20
21

27
16

26
17

2
13

3

12

1
5

10

4

11

LB11847-K

(IC13)

IA1
IA2
IA3
IA4
IB1
IB2
IB3
IB4

PHASE1

PHASE2

ENABLE1
ENABLE2

VHEF1
VHEF2

CR1F
CR2
MD
DECAY1

DECAY2
E1

E2

OUTA

OUTA-

OUTB

OUTB-

VBB

VCC

GND

7

6

9

8

14

+5V

28

15

CN7

1

3

Rotor

2

4

+42V

HWCLK1
HWCLK2

HWFLR
HWRST
HWSDATA
HWSCLK
HWSLAT

IC9 CPU
E01A15CA

HSOCMD
HNCHG
HSOCLK

HWA0

HWA1
HWA2
HWA3
HWA4

HCH
HLAT
CRAI0

CRAI1

SWCO

SWC1
HS01

HS02
HS03

HS04
HS05
HS06

AN0

A0

A1
A2
A3

A4
CLK1
CLK2

FLOOR

RST

DATA

DCLK
E

F1

IC10
Commom
Driver IC

VCC

NPNB

PNPB

COM
COM

CN8

CN9

COM
COM

VHV

VHV

CH
LAT

ENA

ENB

Nozzle Sel ecor IC Head Drive

COB
COA
SI1

SI2
SI3
SI4
SI5
SI6

SP
NCHG

SCK

THM

Pulse

FB

Figure 2-18. Printhead Driver Circuit

Figure 2-19. PF Motor Driver Circuit Block Diagram

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

The motor driver IC (IC13) on the MAIN board drives PF motor. This product uses 4­phase 200-pole hybrid type stepping motor and performs constant current bi-polar
drive.

Operating Principles Electrical Circuit Operating Principles 39

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

2.2.2.4 CR Motor Driver Circuit

The motor driver IC (IC12) on the MAIN board drives PF motor. This product uses 4­phase 200-pole hybrid type stepping motor and performs constant current bi-polar
drive.

CPU (IC9) converts PF motor phase control signal to LB11847 micro step drive form
and outputs to motor driver IC (IC12) LB11847 from port 81, 94. Based on this signal,
IC12 determines the phase mode.

The current value on each phase is determined by CPU (IC9) and outputs from port 83,
84, 85, 86, 87, 88, 90, 91 to driver IC (IC12). Motor driver IC generates motor driver
waveform based on these input signals and controls the motor. If the printer dose not
receive any data from PC for 5 minutes, CPU set the motor drive current to 0 via port
83, 84, 85, 86, 87, 88, 90, 91 and the motor drive is turned off to save the power
consumption.

E01A15CA

(IC9)

83

CRAI 0

84

CRAI 1

85

CRAI 2

86

CRAI 3

87

CRBI 0

88

CRBI 1

90

CRBI 2

91

CRBI 3

81

CRPHAA

94

CRPHAB

82

CRENBA

93

CRENBB

122

DA0

+5V

Figure 2-20. CR Motor Driver Circuit Block Diagram

25
24
23
22
18
19
20
21

27
16

26
17

2

13

3

12

1
5

10

4

11

LB11847-K

(IC12)

IA1
IA2
IA3
IA4
IB1
IB2
IB3
IB4

PHASE1

PHASE2

ENABLE1
ENABLE2

VHEF1
VHEF2

CR1F
CR2
MD
DECAY1

DECAY2
E1

E2

OUTA

OUTA-

OUTB

OUTB-

VBB

VCC

GND

7

6

9

8

14

+5V

28

15

1

3

2

4

+42V

CN12

Rotor

2.2.2.5 Reset Circuit

Reset circuits consist of the rest IC (IC16). Reset circuits are mounted on the MAIN
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 (IC9). This function is necessary to prevent the printer from
operating abnormally. This IC monitors both +5V and +45 lines but can reset them
independently. The reset circuits outputs reset signal when +5V line becomes 4.2V or
lower or +42V line becomes 33.2V or lower.

Unlike the previous products, the timer IC is not built in the reset IC and the Lithium
battery also is not equipped on the main board.

.

+42V

IC16

BH6150F-E2

1

NC1

2

IN

3

NC2

GND

4

Figure 2-21. Reset Circuit Block Diagram

Main signal lines are explained below;

n OUT1: Interrupt signal

n OUT2: Reset line

n IN: +42V line monitoring line

n VCC: +5V line monitoring line

MRES

VCC

OUT1

OUT2

+5V

IC9

E01A15CA

119

8

7

6

5

128

127

MRES

NMI

RESET

Operating Principles Electrical Circuit Operating Principles 40

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

2.2.2.6 EEPROM Control Circuit

Since EEPROM is nonvolatile memory, it keeps written information if the printer
power is turned off. When the printer is turned ON, CPU (IC9) reads data from
EEPROM (IC15) and when the power is turned OFF it stores data to EEPROM.

Information stored in EEPROM is listed below.

n Various ink counter (I/C consumption counter, waste pad counter, etc.)

n Mechanical setting value (Head ID, Bi-D adjustment, USB ID, etc.)

See Table 7-9, “EEPROM Address Map,” on page 124 that provides detailed
information on the values stored in EEPROM.

98

97

96

95

E01A15CA
(IC9)

ECS

ECK

EDI

EDO

+5V

EEPROM­93C (IC15)

8

VCC

7

NC

6

ORG

5

GND DO

1

CS

2

SK

3

DI

4

o HP/PE Sensor

This sensor uses photo interrupter method and detects the following three status.
The photo interrupt component and two detection levers consists of this sensor.

n CR home position

The CR home position is detected on the right edge of the CR shaft with the
HP/PE sensor during the power on sequence. In case the CR home position is
detected in the power on sequence, this sensor outputs HIGH signal to the
CPU.
When the LOW signal is output to the CPU in the detection position, the CR
unit is out of home position.

n Paper Top & End position

When the Paper is in the paper path, this sensor outputs the HIGH signal.
When the Paper is not in the paper path, this sensor outputs the LOW signal.
This status is always monitored during the printer is in the power on status
with this sensor.

o Thermistor (THM)

The thermistor is attached directly on the printhead driver board. It monitors the
temperature around the printhead and determines the proper head drive voltage
according to the ink viscosity that varies by the temperature. This information is
fed back to the CPU analog port. When the temperature rises, the head drive
circuit lowers the drive voltage: When the temperature lowers, the head drive
circuit rises the drive voltage.

Figure 2-22. EEPROM Circuit Diagram

The block diagram for the sensor circuit is shown below

EEPROM is connected to CPU 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.

2.2.2.7 Sensor Circuit

C383 MAIN is equipped with the following two sensors to detect the status of the
printer. Unlike the previous product, ASF HP sensor is not equipped on the ASF and
the ASF HP is determined with the clutch mechanism (“Paper Feeding Mechanism”).

Operating Principles Electrical Circuit Operating Principles 41

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

:

IC 9

E01A15CA

SWA0

+5V

+5V

232

HPPV

3

GND

2

HPPE

1

CA4

HP/PE Sensor

125

AN0

Figure 2-23. Sensor Circuit Diagram

GND

13

THM

CN9

Head FFC

Operating Principles Electrical Circuit Operating Principles 42

TROUBLESHOOTING

CHAPTER

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

3.1 Overview

This chapter describes how to identify troubles in two levels: unit level repair and
component level repair. Refer to the flowchart in this chapter to identify the defective
unit and perform component level repair if necessary. This chapter also explains motor
coil resistance, sensor specification and error indication.

START

Unit level Troubleshooting

Unit repair

Assemble & Adjustment

Table 3-2. Sensor Check Point

Sensor Name Check Point Signal Level Switch Mode

Off

• Out of HP range

• No paper

• Detect the I/C

On

• Within HP range

• Detect the paper

• Not detects the I/C

HP/PE Sensor CN4/Pin 1 and 2

Thermistor

(THM)

TH1 (on the Head
driver board)

Less than 0.7V

More than 2.4V

Analog signal 10 K (at 24

°C)

END

Figure 3-1. Troubleshooting Flowchart

Table 3-1. Motor, Coil Resistance

Motor Location Check Point Resistance

CR Motor CN12

PF Motor CN7

Pin 1 and 3

Pin 2 and 4

Pin 1 and 3

Pin 2 and 4

7.8 Ohms
(at 25

7.8 Ohms ±10%

(at 25

± 10%

°C/ phase)

°C/ phase)

Troubleshooting Overview 44

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

3.2 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 EPSON Stylus COLOR 680/685/777/777i can
detect the following six errors and seven status, and indicates them with the LEDs, as
shows below.

Table 3-3. Error Indicator of the Operation Panel

Printer Status

Power Error

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

Indicators

Priority

Printer Status

Maintenance request
(Ink Overflow Counter error)

Fatal error *1 Off On 1

Special setting Blink2 Blink2 -

Power Error

Alt Blink Alt Blink 2

Indicators

Priority

" - " : 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.

*1: Refer to 1.4.6“Errors” on page 17.

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

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

Ink level low (Color) - Blink 8

Ink end
(Black and Color)

No Ink Cartridge
(Black and Color) *1

Reset, Timer IC reset,
EEPROM clear

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

- On -> On 8

- On 7

On (1s) On (1s) -

Troubleshooting Troubleshooting with LED Error Indications 45

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

Table 3-4. Error Condition and possible cause

Symptom Possible Cause Check table

Paper out error indication
(Paper is not loaded
correctly)

Paper jam error indication

Multiple papers are always
loaded

Paper is always loaded
without any print job

Fatal error indication

Any error indication is not
displayed. But, the paper is
not ejected completely.
Paper jam dose not occur.

• The friction of the LD roller is lowered due
to the paper dust.

• The clutch mechanism is broken.

• Tension spring 0.143 come off in the clutch
mechanism.

• Compression spring 0.98 comes off.

• Tip of Change lever has any damage.

• PF motor is broken.

• Star wheel assembly is not assembled on
the Paper eject frame.

• The Spur gear 15 is not assembled
correctly.

• The paper guide front is not assembled
correctly or has any damage.

• The PE detection lever dose not move
smoothly.

• The paper return plate dose not work
correctly.

• The Change lever is broken in the Clutch
mechanism.

• HP sensor lever or PE sensor lever dose not
move smoothly.

• HP/PE sensor is defective.

• CR motor is defective.

• PF motor is defective.

• Main board is defective.

• Printer Housing dose not secured with
screw on -the printer mechanism.

• Paper eject roller gear is disengaged from
the pump’s gears.

• The Paper eject frame is not assembled in
the Paper eject frame.

Table 3-5

Table 3-6

Table 3-7

Table 3-8

Table 3-9

Table 3-11

Table 3-12

Table 3-13

Table 3-14

Table 3-15

Symptom Possible Cause Check table

Dot missing occur and it is
not recovered with CL

Print quality is not good

• Vertical banding

• Horizontal banding

• Printing is blurred

• Ink stains the paper

Indecators of Power and
Error blink at the same time

(not Blink2 mode)

• Pump unit dose not absorb the ink from the
printhead.

• Cap unit dose not stick on the surface of the
printhead completely.

• The printhead is broken.

• The head FFC has any damage.

• The main board is defective.

• The accuracy of the CR motor is lowered.

• The lack of the lubricant around the CR
unit.

• The both I/C is not held in the CR unit
securely.

• The Paper eject frame is deformed.

• Any foreign material is sticking around the
printhead.

• Paper feed accuracy is lowered.

• Printer driver setting is not suitable.

• Paper path has ink stain somewhere.

• Thermistor of the Head is damaged

• FFC of the Head does not work (break or
disconnected)

Table 3-16

Table 3-17

Table 3-18

Table 3-19

•Exhnange
the
thermistor

• Connect or
exchange
the FFC.

Troubleshooting Troubleshooting with LED Error Indications 46

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

If the problem fits to the detail phenomenon in the table, make sure the check point and
repair the product following the corresponding remedy mentioned in the table when
you find the defective parts in the check point.

Table 3-5. Paper out error indication

Step

No.

Detail phenomenon Check point Remedy

• Check the surface of

• Set a cleaning sheet in
the LD roller if the
micro pearl or severe
smear is adhered.

ASF LD roller attempt
to load the paper.

1

But, paper is not
loaded at all. The LD
roller seems slipping.

If it is no problem,
proceed the next step.

LD roller

Non-adhesive A rea

the ASF up side down.
Then holding the top
edge, try to load the
paper from the Printer
driver. The micro pearl
on the LD 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.

(Use a post card
for the base sheet)

CL Sheet

Adhesive Area

This side down

Staplers

Cloth moistened
with alcohol

Step

No.

Detail phenomenon Check point Remedy

ASF LD roller dose not
attempt to load the
paper. But, the PF
motor and the Spur gear

35.2 is rotating.

2

Spur gear 35.2

ASF LD roller dose not
attempt to load the
paper. But, the PF

3

motor and the Spur gear

35.2 is rotating.

• Check if the clutch
tooth is broken.

Clutch tooth

If it is no problem,
proceed the next step.

1. Check if the tension
spring 0.143 comes
off in the Clutch
mechanism.

Tension spring

0.143

• Replace the clutch
mechanism with new
one.

1. Se the tension spring

0.143 in the clutch
mechanism.

• If the problem is not
solved, replace the LD
roller with new one.

2. Set the Compression
spring 1.47 in the
Change lever.

Troubleshooting Troubleshooting with LED Error Indications 47

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

Table 3-6. Paper out error indication (continued) Table 3-7. Paper jam error indication

Step

No.

Detail phenomenon Check point Remedy

When the print data is
sent to the printer, ASF
LD roller continue to
load the paper even if
the first paper is loaded

4

to the PF roller and the
paper is ejected while
the ASF hopper is
flapping.

When the printer is
turned on, ASF hopper

5

dose not operate at all
in the power on
sequence.

1. Check if the tip of the
Change lever has any
damage.

Change lever

comp. spring 1.47

2. Check if the
Compression spring

1.47 comes off from
the Change lever.

If it is no problem,
proceed the next step.

1. Check if the PF motor
connector is connected
to the CN7.

2. Check if the PF motor
coil resistance is about

7.8 ohm by using
tester
Refer to Table 3-1.

1. Replace the Change
lever with new one.

2. Set the Compression
spring 1.47 in the
Change lever.

1. Connect the PF motor
connector to the CN7 on
the Main board.

2. Replace the PF motor
with new one.

3. If the problem is not
solved, replace the Main
board with new one.

Step

No.

Detail phenomenon Check point Remedy

Paper is not ejected
completely and

1

jammed around the
Paper eject frame.

2 Ditto

• Check if the star wheel
assembly is assembled
in the Paper eject
frame.

Star wheel assy

If it is no problem,
proceed the next step.

• Check if the Paper
eject roller is rotating
correctly.

Paper eject roller

Spur gear 25.6

If it is no problem,
proceed the next step.

• Remove the jammed
paper and assemble the
Star wheel assembly in
the Paper eject frame
completely.
If the hook portion of the
Star wheel assembly is
broken, replace the Star
wheel assembly with
new one.

• Set the tip of the Spur
gear 25.6 to the
Combination gear 11.6,

36.8 and assemble it
correctly.

Troubleshooting Troubleshooting with LED Error Indications 48

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

Table 3-8. Paper jam error indication (continued) Table 3-9. Paper jam error indication (continued)

Step

No.

Detail phenomenon Check point Remedy

The paper is jammed

3

around the Front paper
guide.

Paper is loaded
correctly from ASF.

But, after complete the
print job, paper jam
indicated on the screen

4

without any paper jam.

If you send the new
print job in this
condition, the General
error is indicated on
the screen.

1. Check if the Front
paper guide is floating
from the assemble
position.

2. Check if there is any
damage around the
rear edge of the each
rib on the Front paper
guide.

Front paper guide

If it is no problem,
proceed the next step.

• Check if the Torsion
spring 0.22 comes off
on the both PE sensor
lever.

Tension spring

0.22

PE sensor lever

1. Assemble the Front
paper guide front to the
suitable portion and
confirm the PF
grounding spring is
securing the Front paper
guide.

PF grounding spring

Front Paper guide

2. Replace the Front paper
guide with new one.

• If the Torsion spring

0.22 is not set on the
correct position, set it
correctly. If any paper
dust is placed around the
PE sensor lever, remove
it.

• If it is no problem,
proceed the next step.

Step

No.

Detail phenomenon Check point Remedy

When the paper is
loaded from the ASF
and ejected without
any printing. After
eject the paper,
paper eject sequence

5

is continued.

If any print job is
sent to the printer,
General error is
displayed.

1. Check if the CN4
connector cable for
HP/PE sensor cable is
disconnected on the
Main board or sensor.

2. Check if the HP/PE
sensor operates
correctly by using the
tester. Refer to Table
Table 3-2..

1. Connect the CN4
connector cable to the
CN4 on the Main board.

2. Replace the HP/PE
sensor with new one.

3. If the problem is not
solved, replace the Main
board with new one.

Troubleshooting Troubleshooting with LED Error Indications 49

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

Table 3-10. No Ink Cartridge or Ink Out error indication

Step

Step

Detail phenomenon Check point Remedy

No.

A [No Ink Cartridge]
or [Ink Out Error]
message is displayed
when the power to
the printer is
switched on.

1

No.

Detail phenomenon Check point Remedy

Any error indication is
not displayed on the

1

monitor. But, multiple
papers are always
loaded from ASF.

1. Check to ascertain that
an ink cartridge has
been set in place.

2. Check the remaining

ink with the printer
driver or STM3.

3. Check to ascertain that

the head FFC is been
attached correctly to
the head.

4. Check to ascertain that

the head FFC has been
attached correctly to
the main board.

1. Set the ink cartridge in
place.

2. Remove and then reset

the ink cartridge in place.

3. Replace the ink cartridge

(faulty CSIC.)

4. Replace the ink cartridge

(faulty CSIC.)

Table 3-11. Multiple papers are always loaded

Check if the Paper return
plate is operating
correctly in the ASF
when the paper is loaded.

• Assemble the torsion

spring 25.7 in the ASF
frame.

Table 3-12. Paper is always loaded without any print job

Step

No.

Detail phenomenon Check point Remedy

Paper is always loaded
from ASF without any
print job.

ASF hopper
continue to flapping
when the printer is
turned on.

1

1. Check if the tip of the
Change lever has any
damage.

Change lever

comp. spring 1.47

2. Check if the
Compression spring

1.47 comes off from
the Change lever.

1. Replace the Change
lever with new one.

2. Set the Compression
spring 1.47 in the
Change lever.

Torsion spring 25.7

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

Step

No.

Detail phenomenon Check point Remedy

When the printer is
turned on, the printer

1

continue the paper
eject sequence even if
the paper is not in the
paper path.

Table 3-13. Fatal Error indication

1. Check if the Torsion
spring 0.22 comes off
on the both HP sensor
lever.

HP sensor lever

Torsion spring

0.22

2. Check if the Torsion
spring 0.22 comes off
on the both PE sensor
lever.

Tension spring

0.22

1. Set the Torsion spring

0.22 on the HP sensor
lever.

2. Set the Torsion spring

0.22 on the PE sensor
lever.

Step

No.

Detail phenomenon Check point Remedy

When the printer is
turned on, the CR unit

2

dose not move at all in
the power on sequence.

When the printer is
turned on, PF roller

3

dose not rotate at all in
the power on sequence.

1. Check if the CR
motor connector is
connected CN12 on
the Main board.

2. Check if the coil
resistance of the CR
motor is about 7.8ohm
by using the tester.
Refer to Table3-1.

1. Check if the PF motor
connector is connected
to the CN7.

2. Check if the PF motor
coil resistance is about

7.8 ohm by using
tester.

1. Connect the CR motor
connector to the CN12
on the Main board.

2. Replace the CR motor
with new one.

3. If the problem is not
solved, replace the Main
board with new one.

1. Connect the PF motor
connector to the CN7 on
the Main board.

2. Replace the PF motor
with new one.

3. If the problem is not
solved, replace the Main
board with new one.

PE sensor lever

3. Check if the CN4
connector cable is
connected on the CN4

3. Connect the CN4
connector cable to the
CN4 on the Main board.

on the Main board or
sensor.

4. Check if the HP/PE
sensor work correctly

4. Replace the HP/PE
sensor with new one.

by using the tester.
Refer to Table 3-2.

5. If the problem is not
solved, replace the Main
board with new one.

Troubleshooting Troubleshooting with LED Error Indications 51

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

Table 3-14. Fatal Error indication (continued) Table 3-15. Paper is not ejected completely without any error indication

Step

No.

Detail phenomenon Check point Remedy

When the printer is
turned on, it sounds
strange noise and the

4

CR unit is stopped
around the CR lock
lever.

1. Check if the Top
housing is secured
with the fixing screw
at the front side.

Top housing

2. Check if the Change
lever is placed to the
printer front side.

Change lever

1. Secure the Housing
fixing screw at the
printer front side.

2. Turn back the Change
lever to the printer back
side with the tweezer or
small screw driver.

Step

No.

Detail phenomenon Check point Remedy

Printing is normal. But,
the paper is not ejected
completely and the

1

bottom area stay
around the Paper eject
frame.

1. Check if the Paper
eject roller rotate when
the paper is ejected.

2. Check if the Paper
eject frame is secured
with the three fixing
screws to the Main
frame.

Paper eject frame

1. Assemble the Spur gear

25.6 to the Combination
gear 11.6, 36.8.

Spur gear 25.6

2. Secure the Paper eject
frame witt the two fixing
screws to the Main
frame.

3. Check if the PF motor
is operated. Check the
CN7 connector and the
coil resistance for PF
motor.

4. If the CR lock lever is
not released even if the
PF motor rotate in the
power on sequence,
check if one of the
gears has any damage
in the PF motor torque
transportation path.
Refer to Figure 2-13.

3. Connect the PF motor
cable to CN7 on the
Main board.
Replace the PF motor
with new one.

4. Change the damaged
gear with new one.

5. If the problem is not
solved, replace the Main
board with new one.

Troubleshooting Troubleshooting with LED Error Indications 52

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

Table 3-16. Dot missing occur and it is not recovered with CL Table 3-17. Dot missing occur and it is not recovered with CL

Step

No.

Detail phenomenon Check point Remedy

In the CL sequence,
the pump unit seems
work correctly. But,
ink is not ejected to the
waste ink pad at all.

1

Moreover, any ink is
not absorbed from the
head to the cap.

1. Check if ink is ejected
to the waste ink pad
via pump unit in the
CL sequence.

2. Check if there is any
foreign material
around the seal rubber
parts on the cap
assembly.

Cap seal rubber

parts

3. Check if any damage
is observed around the
seal rubber parts on
the cap assembly.

1. If ink is not ejected at all
to the waste ink pad in
the CL sequence,
proceed the following
check point 2).

2. Remove the foreign
material around the seal
rubber parts.

3. Replace the Cap
assembly with new one.

Step

No.

Detail phenomenon Check point Remedy

In the CL sequence,
the pump unit seems
work correctly. But,
any ink is not ejected
to waste ink pad.

1

Moreover, any ink is
not absorbed from the
head to the cap.

5. Check if the Pump
tube is connected to
the bottom of the Cap
assembly correctly

Pump tube

connection point

6. Check if the pump
tube has a little slack
between the Cap
assembly and the
pump unit when the
Cap assembly is slide
up completely.

Tube

Cap assy.

5. Connect the Pump tube
to the bottom of the Cap
assembly deeply.

6. Pump unit may coil the
pump tube inside the
unit.
In this case, pull out the
coiled tube from the
pump unit carefully.
After that, connect the
pump tube to the Cap
assembly after placing
the tube correctly.

4. Check if the two
compression spring
are assembled in the

4. Set the Compression
spring into the Cap
assembly.

Pump unit

Cap assembly
correctly.

7. If the problem is not
solved, replace the Pump
unit with new one.

Compression

spring

Troubleshooting Troubleshooting with LED Error Indications 53

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

Table 3-18. Dot missing occur and it is not recovered with CL (continued) Table 3-19. Print quality is not good

Step

No.

2

3

Detail phenomenon Check point Remedy

In the CL sequence,
ink is ejected to the
Waste ink pad (this
means pump unit & cap
unit are working
correctly). But, the dot
missing is not solved at
the specific nozzles
even if the several CLs
are performed.

In the CL sequence, ink
is ejected to the Waste
ink pad. But, dot
missing is occurred on
all nozzle in the printing
and is not solved in the
several CLs.

1. Check if the segment in
the nozzle check patter
is reduced every CL &
Nozzle check pattern
printing.

2. Check if any damage is
observed on the Head
FFC.

1. Check if the Head FFC
is connected to the CN8
and CN9 on the Main
board or Head FFC.

1. Replace the I/C with new
one in the I/C replacement
sequence.

2. Replace the Head FFC
with the new one.

3. Replace the printhead
with new one.

1. Connect the Head FFC
securely to the CN8 and
CN9 on the Main board or
Printhead.

2. Replace the Printhead
with new one.

3. Replace the Main board
with new one.

Step

No.

Detail phenomenon Check point Remedy

Vertical banding is
appeared against the CR
movement direction.
And it looks like uneven
printing.

1

CR movement

direction

1. Check if each segment
is printed correctly in
the nozzle check
pattern.

2. Check if the surface of
the CR guide shaft dose
not have any sever
stain.

3. Check if the surface of
the CR sliding portion
on the Paper eject frame
has enough oil.

G26 lubrication

4. Check if the CR guide
shaft is assembled in the
correct portion
securely.

1. Perform the CL and check
the nozzle check pattern.

2. Clean the surface of the
CR guide shaft with the
dry soft cloth and
lubricate G-55 inside the
CR guide shaft.

3. Clean the surface of the
CR sliding portion on the
Paper eject frame and
lubricate specific amount
of the G-26.

4. Reassemble the CR guide
shaft into the mounting
slat on the both side frame
and secure it with Rod
spring.

5. Replace the CR guide
shaft with new one.

5. Check if the surface of
the CR guide shaft is
flat.

6. Check if the surface of
the Paper eject frame is
flat.

6. Replace the Paper eject
frame with new one.

Troubleshooting Troubleshooting with LED Error Indications 54

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

Step

No.

Detail phenomenon Check point Remedy

1 Ditto

Micro banding appears
horizontally against the
paper feeding direction
and it appears with the
same width.

2

Table 3-20. Print quality is not good

CR movement

direction

1. Check if each segment
is printed correctly in
the nozzle check
pattern.

2. Check if the suitable

paper is used
according to the
printer driver setting.

3. Check if the Paper

feed roller is dirty.

4. Check if the following

parts do not have any
damage.

• Combination gear 16,

21.6

• Combination gear

11.6, 36.8

• Spur gear 73.6

• Spur gear 25.6

7. Replace the following
parts.

• CR motor

• CR timing belt

• Compression spring 19.6

1. Perform the CL and

check the nozzle check
pattern. by using the
Adjustment program.

2. Use the suitable paper
according to the printer
driver setting.

3. Clean the surface of the
PF roller carefully with
the soft brush

4. Replace the damaged
parts with new one.

5. Replace the Printhead
with new one.

Step

No.

Detail phenomenon Check point Remedy

3 Printing is blurred

4 Ink stains the paper

1. Check if the suitable
paper is used
according to the
printer driver setting.

2. Check if the correct
head ID is stored in the
EEPROM by using the
Adjustment program.

1. Check if the following
parts are stained with
ink.

• Upper paper driven
roller

• PF roller

• Paper guide front

• Paper eject roller.

2. Check if there is some
ink drops around the
backside of the
printhead.

3. If the bottom area of
the printed paper has
ink stain, check if the
Paper eject frame is
secured with three
screws.

4. If the bottom area of
the printed paper has
ink stain, check if the
Paper eject frame is
bent upward.

1. Use the suitable paper
according to the driver
setting.

2. Input 6 digits code of
the head ID into the
EEPROM by using the
Adjustment program.

1. Clean the ink stained
parts with soft cloth.

2. Wipe off the ink drop
with the soft cloth
carefully.

3. Secure the screws fixing
the Paper eject frame.

4. Replace the Paper eject
frame with new one.

Troubleshooting Troubleshooting with LED Error Indications 55

DISASSEMBLY AND ASSEMBLY

CHAPTER

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

4.1 Overview

This section describes procedures for disassembling the main components of the Stylus
Color 480. Unless otherwise specified, disassembly units or components can be
reassembled by reversing the disassembly procedure. Things, if not strictly observed,
that could result in injury or loss of life are described under the heading “Warning”.
Precautions for any disassembly or assembly procedures are described under the
heading “CAUTION”. Chips for disassembling procedures are described under the
heading “CHECK POINT”.
If the assembling procedure is different from the reversed procedure of the
disassembling, the procedure is described under the heading “REASSEMBLY”.
Any adjustments required after disassembling the units are described under the heading
“ADJUSTMENT REQUIRED”. When you have to remove any units or parts that are
not described in this chapter, refer to the exploded diagrams in the appendix.

Read precautions described in the next section before starting.

Disassembly and Assembly Overview 57

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

4.1.1 Precautions

See the precautions given under the handling “WARNING” and “CAUTION” in the

following column when disassembling or assembling this printer.

W A R N I N G

n Disconnect the power cable before disassembling or assembling

the printer.

n If you need to work on the printer with power applied,

strictly follow the instructions in this manual.

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

n

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

n Always wear gloves for disassembly and reassembly to avoid

iujury from sharp metal edges.

n To protect sensitive microprocessors and circuitry, use static

discharge equipment, such as anti-static wrist straps, when
accessing internal components.

n Never touch the ink or wasted ink with bare hands. If ink comes

into contact with your skin, wash it off with soap and water
immediately. If irritation occurs, contact a physician.

n When a lithium battery is installed on the main board of this

printer, make sure to observe the following instructions when
serving the battery:

1.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.

2.Do not heat the battery or put it near fire.

3.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.)

4.Do not charge the battery. (An explosion may be generated inside
the battery, and cause burning or explosion.)

5.Do not dismantle the battery. (The gas inside the battery may hurt
your throat. Leakage, burning or explosion may also be resulted.)

6.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.

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

W A R N I N G

C A U T I O N

n Avant de commencer, assurez vous que l’imprimante soit eteinte

et que le cordon d’alimentation soit debranche.

n Lorsque vous changez la pile au lithium, assurez vous que la

nouvelle respecte bien les caracteristiques requises.

n Lorque que vous installez la pile au lithium, faites attention a

l’inserer dans le bon sens en respectant la polarite.

n Veillez a jeter les piles usagees selon le reglement local.
n Ne rechargez pas les piles au lithium.

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.

C A U T I O N

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 Observe the specified torque when tightening screws.
n Apply lubricants and adhesives as specified. (See Chapter 6 for

details.)

n Make the specified adjustments when you disassemble the

printer.
(See Chapter 5 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;

1. Once the ink cartridge mounted on the printer is removed, air

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

2. 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.

n Make sure the tip of waste ink tube is located at correct position

when reassembling the waste ink tube. Otherwise it will cause
ink leakage.

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

4.1.2 Tools

Use only specified tools to avoid damaging the printer.

Name Supplier Parts No.

Phillips Screw Driver (No.1) EPSON B743800100

Phillips Screw Driver (No.2) EPSON B743800200

Nipper EPSON B740500100

Tweezers EPSON B741000100

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4.1.3 Work Completion Check

If any service is made to the printer, use the checklist shown below to confirm all
works are completed properly and the printer is ready to be returned to the user.

Table 4-1. Work Completion Check

Classifi-

cation

Main Unit

Adjustment

Item Check Point Status

Self-test Is the operation normal?

On-line Test Is the printing successful?

Printhead

Carriage
Mechanism

Paper Feeding
Mechanism

Specified
Adjustment

Is ink discharged normally from
all the nozzles?

Does it move smoothly?

Is there any abnormal noise
during its operation?

Is there any dirt or foreign
objects on the CR Guide Shaft?

Is the CR Motor at the correct
temperature?
(Not too heated?)

Is paper advanced smoothly?

• No paper jamming?

• No paper skew?

• No multiple feeding?

• No abnormal noise?

Is the PF Motor at correct
temperature?

Is the paper path free of any
obstructions?

Are all the adjustment done
correctly?

o Checked

o Not necessary
o Checked

o Not necessary
o Checked

o Not necessary
o Checked

o Not necessary
o Checked

o Not necessary
o Checked

o Not necessary
o Checked

o Not necessary

o Checked

o Not necessary

o Checked

o Not necessary
o Checked

o Not necessary
o Checked

o Not necessary

Table 4-1. Work Completion Check (continued)

Classifi-

cation

Lubrication

Function ROM Version Version:

Packing

Others

Item Check Point Status

Are all the lubrication made at

Specified
Lubrication

Ink Cartridge

Protective
Materials

Attachments,
Accessories

the specified points?

Is the amount of lubrication
correct?

Are the ink cartridges installed
correctly?

Have all relevant protective
materials been attached to the
printer?

Have all the relevant items been
included in the package?

o Checked

o Not necessary
o Checked

o Not necessary
o Checked

o Not necessary
o Checked

o Not necessary
o Checked

o Not necessary

o Checked

o Not necessary

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4.2 Disassembly

The flowchart below shows step-by-step disassembly procedures. When disassembling
each unit, refer to the page number shown in the figure.

Upper Housing

removal

Page 72

Operation Panel

removal

Printhead removal

Page 73

Ink System unit

removal

Page 86

removal

Page 86

CR Motor removal

Page 75

Pump unit removalCap unit removal

Page 86

Main Board unit

removal

Page 76

Circuit board

removal

Page 76

Waste Drain Ink Pad

PS Board unit

removal

Page 76

unit removal

Page 79

Removing the LD

Roller unit

Page 81

LD Roller removal

HP/PE Sensor

removal

Page 84

Figure 4-1. Disassembling Flowchart

Page 81

Removing the Paper

Eject Roller

Page 88 Page 92 Page 95

PF Motor removal

Page 90

CR unit removal

Removing the PF

Roller unit

Page xx

ASF frame unit

disassembling

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4.2.1 Housing removal

1. Remove 2 screws from the bottom holes of the left and right panels of the printer.

Figure 4-2. Removing 2 screws from the bottom direction

C H E C K

P O I N T

Some products have no these kind of fasten construction. Refer to
Step 4).

2. Open the printer cover and remove 2 screws (C.B.S-TITE R 3x6 F/Uc) at the
printer front side.

C.B.S-TITE R 3x6 F/Uc

Figure 4-3. Removing 2screws for Housing

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3. Remove 2 screws (C.B.S. 3x6 F/Zn) at the back of the printer and remove the
Housing.

C A U T I O N

When removing the Upper Housing from the left and right Panel,
don’t broke these parts since they were fastened slightly with glue.
(Refer to following pictures.)

Fasten Portion

Note: Some products are different from above fasten method. See
Step 1) of 4.2.1.

C.B.S 3x6 F/Zn screws

n Tightening Torque for screw

Figure 4-4. Removing 2scews for Housing

• C.B.S-TITE R3x6 F/Uc screw for housing front side: 6 +/- 1kgf.cm

• C.B.S 3x6 F/Zn screw for housing back side : 6+/- 1kgf.cm

n It is not necessary to glue the Upper Housing to the Left and

4. Remove the Upper Housing from the Left and Right Panel as well as the
Mechanism.

C A U T I O N

Right Panel.

n Ensure that C.B.S-TITE 3 x 6 F/Uc screws are used for the two

screws on the front side of the printer. The tips of these screws
are rounded for user’s safty.

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4.2.2 Operation Panel removal

The panel board equipped with printer is as follows:

- Stylus COLOR 680: C383PNL

1. Remove the Housing from the printer. (Refer to Section 4.2.1.)

2. Remove 2 screws (C.B.S 3x6 F/Zn) securing the Operation Panel Assembly. Then,
disconnect the Operation Panel Assembly from the Printer Mechanism.

3. Remove 2 screws (C.B.P-TITE 3x8 F/Zn) and detach the Sub Right Panel Housing
from the Operation Panel Assembly.

C.B.P-TITE 3x8 F/Zn

Figure 4-6. Removing 2 screws for C383PNL board

4. Remove the Panel Shield Plate and the C383PNL board from the Operation Panel

C.B.S 3x6 F/Zn

Figure 4-5. Removing 2 screws for Operation Panel

Assembly.

5. Disconnect the Panel FFC from the connector on the C383PNL board.

C H E C K

P O I N T

n Removing the Operation Panel Assembly also separates the

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

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4.2.3 Printhead removal

1. Remove the Housing from the printer. (Refer to Section 4.2.1.)

2. Open the Cover Cartridge and remove the both black and color ink cartridge.

3. Remove the Cover Cartridges for black and color ink cartridges from the CR
Assembly.

4. Remove the Head FFC Holder from the CR Assembly by releasing two hooks.
Refer to Figure 4-x.

Hooks

6. Remove two screws (C.B.P-TITE 3x6 F/Zn and +Bind B-TITE SEMS W2 2.5x5
F/Zn) tighiening the Printhead.

C.B.P-TITE 3x6 F/Zn

+Bind B-TITE SEMS W2 2.5x5 F/Zn

Figure 4-8. Removing the two screws tightening the Printhead

7. Remove the Printhead from the CR unit.

C H E C K

P O I N T

Figure 4-7. Removing the Head FFC Holder

5. Disconnect the Printhead's FFC from the connector on the Printhead.

n Place the Printhead’s FFC in the cable holder by the four

portions indicated in the following Figure4-9.

n Make sure that the Head Grounding Plate is installed to the

carriage correctly. Refer to Figure 4-10.

n Make sure that two holes of the Printhead correctly fit in the

installing position pins. Figure 4-10.

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Head installing position pins

Head grounding plate

Figure 4-10.

Printhead installing the position pin & the grounding plate.

n Tightening Torque for screw

• C.B.P-TITE 3x6 screw for printhead: 6+/1kgf.cm

A D J U S T M E N T

R E Q U I R E D

When the Printhead is replaced with a new one, following
adjustments must be performed in the order below:

1. Initial ink charge

2. Printhead ID input

3. Bi-d adjustment
When the Printhead is removed and reinstalled, only the following
adjustment is required.

1. Head cleaning

2. Bi-d adjustment

Figure 4-9. Placing the Printhead’s FFC

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4.2.4 CR motor removal

1. Remove the Housing from the printer. (Refer to Section 4.2.1.)

2. Using tweezers or a small screwdriver, 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
screwdriver, and remove the Timing Belt carefully from the pinion gear on the CR
motor. Refer to Figure 4-xx.

CR Timing belt

Step 2

Figure 4-11. Removing the Timing Belt

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4. Remove four Hexagon Nuts while holding the CR motor and remove the CR
motor assembly. Refer to Figure 4-11.

Hexagon nuts

Figure 4-12. Removing the CR motor

5. Take the CR motor's cable out from the cable hook in the Waste drain inkpad unit.

6. Disconnect the CR motor connector cable from the CN12 on the Main board with
tweezers.

A D J U S T M E N T

R E Q U I R E D

n The Gap adjustment (Bi-d adjustment) is required when the CR

motor is removed or replaced.

n Connect the CR motor connector cable to the CN12 on the Main

board. Use of tweezers or pincers is recommended to facilitate
the job, since the CN12 is not located near the rear edge of the
Main board.

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4.2.5 Waste drain ink pad unit removal

1. Remove the Housing from the printer. (Refer to Section 4.2.1.)

2. Remove one screw (C.B.P-TITE 3x8 F/Zn) on the front right side of the printer.
(viewed from front side)

C.B.P-TITE 3x8 F/Zn screw

3. Remove two screws (C.B.P- TITE 3x8 F/Zn) and take some cables off from the
cable hook in the Waste drain ink pad unit as shown in the following figure.

C.B.P-TITE 3x8 F/Zn

Figure 4-13. Removing one screw securing the Waste ink pad unit

C.B.P-TITE 3x8 F/Zn

Figure 4-14. Removing one screws & cables at the back side of the printer

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4. Remove the Waste drain ink pad unit from the printer

.

C H E C K

P O I N T

n When reassembling the Waste drain ink pad unit, be sure to set

the tip of the waste ink tube in the correct position of the Waste
drain ink pad. Otherwise it will cause ink leakage. Refer to
Figure4-15.

Tip of the Waste Ink Tube

n Tightening torque for screw

• C.B.P-TITE 3x8 screw for Waste drain ink pad unit : 9+/1 kgf.cm

Figure 4-15. Waste Ink Tube setting position

A D J U S T M E N T

R E Q U I R E D

When the Waste drain ink pad is replaced with a new one,
following service item is required.

n Waste drain ink counter reset operation.

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4.2.6 Circuit board removal

1. Remove the Housing from the printer. (Refer to Section 4.2.1.)

2. Remove three screws (C.B.S 3x6 F/Zn) securing the Circuit board unit at the front
side of the Printer mechanism.

C.B.S 3x6 F/Zn

3. Remove four screws (C.B.S 3x6 F/Zn) securing the Circuit board unit at the back
side of the Printer mechanism and remove two screws (C.B.S 3x6 F/Zn) securing
the Circuit board unit at the right side (viewed from back side).

C.B.S 3x6 F/Zn

Figure 4-17. Removing six screws at the printer back side & right side

Figure 4-16. Removing four screws at the printer front side

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4. Holding the Left housing lightly, pull down the Circuit board unit. Then
disconnect the following four cables from the corresponding connectors on the
Main board.

n CR motor connector cable : CN12

n PF motor connector cable : CN7

n Printhead FFC : CN8, CN9

n HP/PE sensor cable : CN4

5. Remove the following screws securing each circuit board to the Shield plate.
Figure Figure 4-18.

n C383 MAIN : Remove five screws.

C.B.S 3x6 F/Zn (Red circled screws) : 3pcs (for Main board)
C.P. 3x6 F/Zn (Yellow circled screws) : 2pcs (for Parallel I/F)

connector)

n C383PSB/E : Remove five screws.

C.B.S 3x6 F/Zn (Yellow circled screws) : 3pcs (for PS board)
C.B.S-TITE R 3x6 F/UC (Red circled screw) : 1pcs (for PS board)
C.B.(O) 4x5 F/ZG for 120V (Green circled screw) :1pcs (for Earth terminal)
Hexagon nut, Normal M4(Green circled) : 1pcs (for Earth terminal)
(C.B.S 3x6 F/Zn for 220V (Green circled screw) : 1pcs (for Earth terminal))

NOTE: 110V type of the PS board dose not have earth wire.

C383 MAIN Board

C383 PSE/PSE board

Figure 4-18. Remove the screw securing each circuit board

A D J U S T M E N T

R E Q U I R E D

When replacing the Main board with a new one, perform the
following service items.

n Before removing the Main board, connect the parallel I/F or

USB Cable and try to read out the following data by using the
Adjustment program. If this operation succeeds, replace the
Main board and write the read out data to the new Main board
through the Adjustment program.

1) I/C Ink consumption counter.

2) Waste ink drain pad counter.

3) Printhead ID input.

4) Gap adjustment (Bi-d adjustment)
In case the above mentioned data are not able to be read out from

the defective Main board, perform the following service items.

n Replace the both ink cartridges with a brand new one.
n Replace the Waste ink drain pad with a new one.
n Input the Printhead ID.
n Adjust the Bi-d alignment.

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

n Since the cable between C383 MAIN board and C383 PSB/E

board are directly soldered, take the following steps when
replacing only one circuit board in the service activity.

1. Take off the cable on the Main board by removing the solder by
heating it with the soldering iron.

2. Replace the defective circuit board with new one.

3. Insert the tip of the cable into the soldering hole of the ASP Main
board and solder it securely.

n Tightening Torque for screw

• C.B.S 3x6 F/Zn screw for PS board : 6+/- 1kgf.cm

• C.B.S-TITE R 3x6 F/Uc screw for PS board : 6+/- 1kgf.cm

• C.B.S 3x6 F/Zn screw for Main board : 6+/- 1kgf.cm

• C.P. 3x6 F/Zn screw for Parallel I/F connector : 6+/- 1kgf.cm

• C.B.S 3x6 F/Zn screw for Circuit unit : 6+/- 1kgf.cm

• C.B.(O) 4x5 F/ZG screw for Earth cable : 11+/-1kgf.cm

C H E C K

P O I N T

When replacing or removing the PS board, be sure to use the
following suitable screw to secure the PS board.

C.B.S-TITE R 3x6, F/UC

Figure 4-19. PS board fixing screws

Install a new cartridge before sending back the printer to the

n

user, since the ink cartridge once taken out can not be used
again.

n Installation of I/C must be carried out by I/C replacement

sequence. Otherwise, ink may not eject properly.

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

C H E C K

P O I N T

Check the Earth terminal and wire position. Refer to the following
figure. The earth wire for 120V must be placed back side of the
Heat sinker HT1. Be sure to leave at least 2.5 mm of space between
heat sink HT1 and thewire. If this is not possible, secure the wire
with tape or other methodto be sure that a minimum of 2.5 mm
spacing is preserved.And the earth wire for 220V must be placed
in front of the Heat sinker HT1 as following figure.

Earth terminal

120V Type

2.5mm

Heat sinker

Earth terminal

220V Type

Heat sinker

Figure 4-20. Earth terminal and wire position

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4.2.7 LD Roller removal

1. Remove the Housing from the printer. (Refer to Section 4.2.1.)

2. Take the Head FFC off from the Head FFC holder located along the LD roller
shaft holder.

Head FFC holder

LD roller shaft holder

3. Remove two screws (C.B.S 3x6 F/Zn) securing the LD roller holder to the Main
frame.

C.B.S 3x6 F/Zn screws

Figure 4-22. Removing two screws securing the LD roller holder

Figure 4-21. Taking Head FFC out from the FFC holder

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

4. Push the two hooks of the LD roller shaft holder as shown in the following figure.

5. Pull the LD roller shaft holder unit upward from the Main frame.

Two hooks for LD roller holder

Figure 4-23. Pushing two hooks of the LD roller shaft holder

6. Remove the LD roller along with the Clutch mechanism from the LD roller shaft
holder unit.

LD Roller shaft holder unit

Clutch mechanism

LD Roller

Washer

Figure 4-24. Removing the LD roller with Clutch mechanism

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

n Before assembling the LD roller shaft, make sure that the round

C A U T I O N

n Do not damage the tooth of the Spur gear 35.2 and the Spur gear

23.2 when assembling the LD roller shaft holder unit.

hole of the Clutch is set on the protrusion on the LD roller shaft
as shown in the following figure.

Spur gear 35.2

Spur gear 23.2

Spur gear 23.2

Figure 4-25.

Spur Gear 23.2 and Spur Gear 35.2

round hole on the Clutch

Protrusion on the LD roller shaft

Figure 4-26. Assembling the Clutch

n

Assemble the LD roller shaft holder unit to the printer
mechanism in the following procedure.

1) Set the tip of the Change lever to the printer front side.

Change lever

Figure 4-27. LD Roller shaft holder assembling

procedure (1)

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

2) Assemble the LD roller shaft holder unit while storing the
Paper return plate into the ASF frame.

Paper return plate

Figure 4-28. LD Roller shaft holder assembling

procedure (2)

n

Fasten the LD roller shaft holder with two C.B.S 3x6 F/Zn
screws in the order indicated in the following figure.

1

2

Figure 4-29. Fastening the LD roller shaft holder

Tightening torque for screw

n

C.B.S 3x6 F/Zn screw for LD roller shaft holder unit : 9+/1 kgf.cm

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4.2.8 HP/PE Sensor removal

1. Remove the Housing from the printer. (Refer to Section 4.2.1.)

2. Remove the LD roller from the LD roller shaft holder. (Refer to Section 4.2.7.)

3. Remove HP detection lever from the LD roller shaft holder and disconnect the
cable from the sensor connector.

HP/IC detection lever

HP/PE sensor

4. Release the two fixing hooks for the sensor from the LD roller shaft holder and
remove the sensor.

Two fixing hooks

Figure 4-31. Releasing two fixing hooks for the sensor

Figure 4-30. Removing the HP detection lever

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

Tor

C H E C K

P O I N T

n Make sure that the Torsion spring 0.22 is hung to the following

suitable position.

Torsion spring 0.22

PE sensor lever

Figure 4-32. Torsion spring 0.22 for PE detection lever

HP/IC sensor lever

C H E C K

P O I N T

n Make sure that the HP/PE sensor cable is placed to the suitable

groove on the LD roller shaft holder.

HP/PE sensor cable

HP/PE sensor

Figure 4-34. Sensor cable placing position (1)

HP/PE sensor cable

Torsion spring 0.22

Figure 4-35. Sensor cable placing position (2)

Make sure that the each sensor lever turn back smoothly by

n

Figure 4-33. Torsion spring 0.22 for HP detection lever

moving it after the sensor was assembled to the LD roller shaft
holder.

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4.2.9 Ink system unit removal (Cap & Pump unit )

1. Remove the Housing from the printer. (Refer to Section 4.2.1.)

2. Remove the Waste drain ink pad from the printer. (Refer to Section 4.2.6.)

3. Remove the LD roller holder from the Printer. (Refer to Section 4.2.8.)

4. Remove three screws (C.B.S 3x6 F/Zn) securing the Ink system frame and the Cap
assembly to the frame.

C.B.S 3x6 F/Zn screws

6. Release one hook for Cap assembly on the Ink system frame and take the Cap
assembly out from the Ink system frame.

7. Disconnect the waste drain ink tube carefully from the bottom of the Cap
assembly.

C A U T I O N

n Since the compression spring is included in the Pump assembly,

watch out for the spring and the gear that pop out from the unit
when the Pump assembly is removed from the Ink system unit.

n When replacing the cleaner head built in the Pump assembly, be

careful of the following points.

1) Do not touch the cleaner head with your bare hands. Ware
gloves or use tweezers.

2) Do not smear the head cleaner with oil or grease.

n When installing the Cleaner head, set the rubber side (black side)

facing toward the right side of the frame.

n When installing the Cleaner head, set the two square cut offs on

the Cleaner head into the two hooks on the Ink system.

Cleaner head

Figure 4-36. Removing three screws securing the Ink system

5. Remove the Ink system unit (Cap and Pump unit) carefully along with the Ink
system frame.

C A U T I O N

When the Ink system unit is removed, be careful that the gears do
not come off from each shaft on the Ink system frame.

n When replacing the Cap Assembly, do not touch the sealing

rubber portion of the Cap Assembly.

n The component parts in the Pump Assembly are not individually

supplied as ASP. So please replace the whole Pump Assembly
when replacing the Pump Assembly.

hook & cut off

n Be careful not to crush or leave any stress on the ink tube

connecting the pump assembly and the cap assembly.

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

C H E C K

P O I N T

n Make sure that all gears are set in each gear shaft on the Ink

system frame.

Combination gear

9.6, 24

Combination gear

37.6, 44.4

Figure 4-37. Gear engagement on the Ink system frame

n

Make sure that the ink tube is placed along the following
position.

Pump unit

n Tightening torque for screw

• C.B.S 3x6 F/Zn screw for Ink system frame & Cap assy.: 9+/1 kgf.cm

Cap assembly

Ink tube

Figure 4-38. Ink tube placing position

n

After installing the Pump Assembly, ensure that the cleaner
parts move back and forth by rotating the Gear.

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4.2.10 Paper Eject Roller removal

1. Remove the Housing from the printer. (Section 4.2.1 Housing removal)

2. Remove three screws (C.B.S 3x6 F/Zn) securing the Front frame to the Main
frame.

C.B.S 3x6 F/Zn screw

4. .Remove the Plain washer and then remove the Combination gear 11.6, 36.8
carefully. Refer to Figure 4-xx.

Combination gear 11.6, 36.8

Plain washer

Figure 4-40.

Figure 4-39. Removing the Front frame

3. Lift up the right side of the Front frame and slide it to the left side a little bit and
then remove it.

C A U T I O N

When removing the Front frame, if the CR unit is out of the CR
home position, the nozzle surface of the Printhead may come in
contact with Paper guide front as soon as the Front frame is
removed. This is because the CR unit is held with this frame.
Therefore, be sure to set the CR unit in the CR home position
before removing the Front frame. Otherwise, the dot missing
problem may occur.

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5. Open the spur gear 25.6 hook with a pair of tweezers and then slide the paper eject
roller to the right while pulling it toward to remove it.

A D J U S T M E N T

R E Q U I R E D

n When you replace the Frame front, make sure to lubricate the

specific amount of G26 to the Frame front. Refer to the Chapter
6 Figure6-5.

n When you replace the Paper eject roller with new one, make sure

to lubricate the specific amount of G26 to the Spur gear 25.6.
Refer to the Chapter 6 Figure.

n Assemble the Paper eject roller in the following procedure.

1. Set the Spur Gear 25.6 to the cut out hole in the Main frame.

2. Align the shape with the spur gear 25.6 hole, insert the paper
eject roller shaft, and then press the spur gear 25.6 hook until it
is closed.

3. Slide the paper eject roller and then insert it in the shaft guide

Spur gear 25.6

holder.

n When you assemble the Front frame to the Printer mechanism,

set the CR unit to the left side and assemble the Front frame
from the right side. Be careful not damage the CR lock lever.

n Fasten the Front frame with C.B.S Screw 3x6 F/Zn in the order

of 1,2.

2

1

Paper eject roller

n Tightening torque for screw

• C.B.S 3x6 F/Zn screw for Front frame : 9+/-1 kgf.cm

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4.2.11 PF motor removal

1. Remove the Housing from the printer. (Refer to Section 4.2.1.)

2. Remove the Waste drain ink pad unit from the printer. (Refer to Section 4.2.6.)

3. Remove the Front frame and Paper eject roller. (Refer to Section 4.2.10.)

4. Remove the Plain washer and then remove the Combination gear 11.6, 36.8
carefully. Refer to Figure 4-38.

Combination gear 11.6, 36.8

Plain washer

5. Remove three nuts (Hexagon Nut M3) securing the PF motor to the left frame.

Hexagon Nut M3

PF motor

Figure 4-42. Removing two screws securing the PF motor

6. Disconnect the connector cable for PF motor from CN7 on the Main board.

7. Remove the PF motor from the left frame.

Figure 4-41. Removing the Plain washer and Combination gear 11.6, 36.8

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C H E C K

P O I N T

Be sure that the PF motor cable is placed to the backward. Refer to
the Figure 4-43.

PF motor cable

Figure 4-43. PF motor cable

n Since the CN 7 is not located near the rear edge of the Main

board, it is easier to use the tweezers or pincers to connect the
cable to the CN7.

n Tightening torque for screw

• Hexagon Nut M3 for PF motor : 9+/1 kgf.cm

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4.2.12 CR unit removal

1. Remove the Housing from the printer. (Refer to Section 4.2.1.)

2. Remove the CR timing belt from the CR pinion gear. (Refer to Section 4.2.4.)

3. Release the Printhead FFC from the cable holders on the LD roller shaft holder.
And disconnect the Printhead FFC from the connectors CN8 and CN9 on the Main
board.

Figure 4-44. Taking Printhead FFC off

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4. Release two CR guide shaft rod springs from the both hooks on the left and right
sides of the Main frame.

Left CR guide shaft rod spring

Figure 4-45. Release Left Rod spring for CR shaft

Right CR guide shaft rod spring

Figure 4-46. Release Right Rod spring for CR shaft

5. Pull the left edge of the CR guide shaft upward to align it with the round cutout
portion. Then, holding the CR unit by hand, remove the CR guide shaft by sliding
it to left or right.

CR guide shaft

Figure 4-47. Removing the CR guide shaft

C A U T I O N

Remove the CR guide shaft while holding the CR unit by hand. If
you remove the CR guide shaft without holding the CR unit, the
nozzle surface of the Printhead may come in contact with the
Paper guide front, which causes the dot missing problem.

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C H E C K

P O I N T

n Unlike the previous products, the oil pad is not built in the CR

unit.

n Make sure that the tips of the CR guide shaft rod springs are set

in the holes in the Main frame.

n Make sure that the CR guide shaft rod springs are correctly set

in the suitable position. Refer to Figure 4-45,Figure 4-46.

n If you disassemble the CR unit after removing the CR unit from

the printer, make sure that the CR Grounding plate is assembled
in the suitable position in the CR unit. Refer to Figure 4-48.

n .Make sure that the CR slider is assembled on the CR unit.

CR Grounding plate

CR slider

Figure 4-48. Grounding plate assembling position

If you remove the Printhead from the CR unit, make sure that

n

the Head grounding plate is set in the CR unit. Refer to
Figure4-10.

n Make sure that the groove on the CR guide shaft must be set to

the left side.

C H E C K

P O I N T

A D J U S T M E N T

R E Q U I R E D

n If the CR unit is disassembled or replaced with a new one, make

sure that the CR timing belt is set in the assembling groove
correctly as following figure.

Assembling groove

CR timing belt

Figure 4-49. CR timing belt setting position

n When you replace the CR unit with a new one, lubricate it with

the suitable amount of the G-55 grease by the specified position.
Refer to Chapter 6 Figure 6-4.

n When you replace the CR Pulley shaft with new one, lubricate it

with the suitable amount of G-26 grease by the specific position.
Refer to Chapter 6 Figure6-3.

n When removing or replacing the CR unit with a new one, adjust

the Gap (Bi-d).

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4.2.13 Paper feed roller removal

1. Remove the Housing from the printer. (Refer to Section 4.2.1.)

2. Remove the Paper Eject roller. (Refer to Section 4.2.10.)

3. Remove the CR unit. (Refer to Section 4.2.12.)

4. Release the PF grounding spring from the Main frame.

PF grounding spring

5. Release one hook located on the right edge of the Front paper guide.

hook

Front paper guide

Figure 4-51. Release one hook of the Front paper guide

Figure 4-50. Releasing the PF grounding spring

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6. Lift up the left edge of the Front paper guide while slanting the Front paper guide
by pulling up its front edge, and then slide the Front paper guide to the left side
after releasing the right hook on the Front paper guide.

Step1

Paper guide front

Step1

Step2

Figure 4-52. Remove the Front paper guide

7. Fit the protrusions of the Left PF roller bushing to the notches in the frames as
shown in the following figure and remove the PF roller fasten spacer with tweezer.

Left PF roller bushing

1

2

PF roller fasten spacer

Figure 4-53.

Fit the protrusions of the Left PF roller bushing to each notches

8. Slide the Left PF roller bushing to right side as above figure Step 2.

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9. Fit the protrusions of the Right PF roller bushing to the notches in the frames as
shown in the following figure.

C H E C K

P O I N T

Right PF roller bushing

n After assemble the PF roller, make sure that the dowel of the

both left and right PF roller bushing holder fit in the cut hole of
both frames.

n After assemble the Front paper guide to the printer mechanism,

make sure that the hooks and the dowel pins on the Front paper
guide is set to the fitting positions secure. Slide the Front paper
guide to the right side by pushing it and make sure that the right
hook on the Front paper guide is locked to the frame securely.
If the Front paper guide is not fixed securely to the suitable
position, it may cause the paper jam problem.

Right hook

Two dowel pins

Figure 4-54. Fit the protrusions of the Left PF roller bushing to each

notches

10. Slide the PF roller to the left side along with the both PF roller bushings and
remove the PF roller from the printer mechanism.

A D J U S T M E N T

R E Q U I R E D

n When you replace the PF roller with new one, be sure to

Figure 4-55. Front paper guide assembling notice

lubricate a specific amount of G-26 between the Left PF roller
bushing holder and the left edge of the PF roller. Refer to
Chapter 6 Figure.

n When you assemble the Front frame to the Printer mechanism,

set the CR unit to the left side and assemble the Front frame
from the right side. Be careful not damage the CR lock lever.

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4.2.14 Disassembling ASF frame unit

1. Remove the Housing from the printer. (Refer to Section 4.2.1.)

2. Remove the LD roller shaft holder unit (Refer to Section 4.2.7.)

3. Remove two screws (C.B.S.-TITE (P4) 3x8, F/Zn screw, C.B.S-TITE (P4) 3x6 F/
Zn) securing the ASF frame unit and remove the ASF frame unit from the printer
mechanism.

Spur gear 23.2

C.B.S-TITE(P4) 3x8 F/Zn screw

ASF Frame unit

Figure 4-56. Removing the screws securing the ASF frame

4. Remove the Spur gear 23.2 from the ASF frame.

C.B.S-TITE 3x6 F/Zn

Figure 4-57. Removing the Gears from ASF frame unit

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5. Remove the Compression Spring 2.67 located between the ASF Frame and the
Hopper, and remove the Hopper from the ASF frame.

ASF Hopper

Compression spring 2.67

ASF Frame

Figure 4-58. Removing the Compression spring 2.67

6. Remove the Torsion spring 25.7 from the bottom of the ASF frame and the Pad
holder (Paper return plate).

Torsion spring 25.7

ASF Frame

Figure 4-59. Removing the Torsion spring 25.7

Disassembly and Assembly Disassembly 95