Text preview for : Epson Stylus Color 860 Service Manual_Circuit Diagram.pdf part of Epson Stylus Color 860 Epson Stylus Color 860 Service Manual
Circuit Diagram (Schematics)
Back to : Epson Stylus Color 860 Se | Home
Color ink jet printer
Stylus COLOR 860/1160
®
SEIJ99003
Notice:
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, recording, or otherwise, without the prior written permission of SEIKO EPSON CORPORATION. The contents of this manual are subject to change without notice. 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. 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 © 1999 SEIKO EPSON CORPORATION. Printed in Japan.
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. Signals a precaution which, if ignored, could result in damage to equipment.
WARNING
The precautionary measures itemized below should always be observed when performing repair/maintenance procedures.
DANGER
1. ALWAYS DISCONNECT THE PRODUCT FROM THE POWER SOURCE AND PERIPHERAL DEVICES PERFORMING ANY MAINTENANCE OR REPAIR PROCEDURES. 2. NOWORK SHOULD BE PERFORMED ON THE UNIT BY PERSONS UNFAMILIAR WITH BASIC SAFETY MEASURES AS DICTATED FOR ALL ELECTRONICS TECHNICIANS IN THEIR LINE OF WORK. 3. WHEN PERFORMING TESTING AS DICTATED WITHIN THIS MANUAL, DO NOT CONNECT THE UNIT TO A POWER SOURCE UNTIL INSTRUCTED TO DO SO. WHEN THE POWER SUPPLY CABLE MUST BE CONNECTED, USE EXTREME CAUTION IN WORKING ON POWER SUPPLY AND OTHER ELECTRONIC COMPONENTS.
WARNING
1. REPAIRS ON EPSON PRODUCT SHOULD BE PERFORMED ONLY BY AN EPSON CERTIFIED REPAIR TECHNICIAN. 2. MAKE CERTAIN THAT THE SOURCE VOLTAGES IS THE SAME AS THE RATED VOLTAGE, LISTED ON THE SERIAL NUMBER/RATING PLATE. IF THE EPSON PRODUCT HAS A PRIMARY AC RATING DIFFERENT FROM AVAILABLE POWER SOURCE, DO NOT CONNECT IT TO THE POWER SOURCE. 3. ALWAYS VERIFY THAT THE EPSON PRODUCT HAS BEEN DISCONNECTED FROM THE POWER SOURCE BEFORE REMOVING OR REPLACING PRINTED CIRCUIT BOARDS AND/OR INDIVIDUAL CHIPS. 4. IN ORDER TO PROTECT SENSITIVE MICROPROCESSORS AND CIRCUITRY, USE STATIC DISCHARGE EQUIPMENT, SUCH AS ANTISTATIC 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.
PREFACE
This manual describes basic functions, theory of electrical and mechanical operations, maintenance and repair procedures of Stylus COLOR 860/ 1160. The instructions and procedures included herein are intended for the experienced repair technicians, and attention should be given to the precautions on the preceding page. The chapters are organized as follows:
CHAPTER 1. CHAPTER 2. CHAPTER 3.
PRODUCT DESCRIPTIONS OPERATING PRINCIPLES DISASSEMBLY AND ASSEMBLY
Provides a general overview and specifications of the product.
Describes the theory of electrical and mechanical operations of the product.
Describes the step-by-step procedures for disassembling and assembling the product.
CHAPTER 4. CHAPTER 5. CHAPTER 6.
ADJUSTMENTS TROUBLESHOOTING MAINTENANCE
Provides Epson-approved methods for adjustment.
Provides the step-by-step procedures for troubleshooting.
Provides preventive maintenance procedures and the lists of Epson-approved lubricants and adhesives required for servicing the product.
APPENDIX
Provides the following additional information for reference: · EEPROM Address Map · Connector Pin Assignments · C298MAIN Board Component Layout · C298MAIN Board Circuit Diagram
Revision Status
Revision A Issued Date August 19, 1999 Description First Release
Contents
PRODUCT DESCRIPTION
FEATURES ..................................................................................................10 SPECIFICATIONS ........................................................................................11 Physical Specification ..............................................................................11 Printing Specification ...............................................................................11 Paper Feeding .........................................................................................12 Input Data Buffer .....................................................................................12 Electric Specification ...............................................................................12 Environmental Condition .........................................................................13 Reliability .................................................................................................13 Safety Approvals .....................................................................................13 Acoustic Noise .........................................................................................13 CE Marking ..............................................................................................13 INTERFACE .................................................................................................14 Parallel Interface (Forward Channel) ......................................................14 Parallel Interface (Reserve Channel) ......................................................17 USB Interface ..........................................................................................18 Prevention of Data Transfer Time-out .....................................................19 Interface Selection ...................................................................................19 IEEE1284.4 Protocol ...............................................................................19 OPERATOR CONTROLS ............................................................................20 Operating Switch .....................................................................................20 Control Panel ...........................................................................................20 Switches ..............................................................................................20 Indicators .............................................................................................20 Panel Functions .......................................................................................21 Printer Condition and Panel Status .........................................................22 Printer Initialization ..................................................................................22 Errors .......................................................................................................23 PAPER .........................................................................................................24 Paper Handling ........................................................................................24 Paper Specification .................................................................................24 Cut Sheet ............................................................................................24 Transparency, Glossy Paper ...............................................................24 Envelope .............................................................................................24 Index Card ...........................................................................................25 Printing Area ...........................................................................................26 Cut Sheet ............................................................................................26 Envelopes ............................................................................................27 INK CARTRIDGE .........................................................................................28 Black Ink Cartridge ..................................................................................28 Color Ink Cartridge ..................................................................................28
OPERATING PRINCIPLES
OVERVIEW ..................................................................................................30 Printer Mechanism ..................................................................................30 Printing Mechanism .............................................................................31 Printing Process ..................................................................................32 Carriage Mechanism ...........................................................................33 Platen Gap (PG) Adjust Mechanism ...................................................34 Paper Feeding Mechanism .................................................................34 CR Lock Mechanism ...........................................................................36 Paper Loading Mechanism ..................................................................37 Pump Mechanism ................................................................................39 Capping Mechanism ............................................................................40 ELECTRICAL CIRCUIT OPERATING PRINCIPLES ...................................41 C298PSB/PSE Board ..............................................................................42 C298MAIN Board ....................................................................................44 Printhead Driver Circuit .......................................................................46 Reset Circuit ........................................................................................47 CR Motor Driver Circuit .......................................................................48 PF Motor Driver Circuit ........................................................................50 ASF/Pump Motor Driver Circuit ...........................................................51 EEPROM Control Circuit .....................................................................51 Sensor Circuit ......................................................................................52
TROUBLESHOOTING
OVERVIEW ..................................................................................................55 Troubleshooting with LED Error Indications ............................................ 56 Remedies for Paper Out Error .............................................................58 Remedies for the Paper Jam Error ......................................................60 Remedies for No I/C and Ink Out Errors ..............................................61 Remedies for the Maintenance Error ..................................................63 Remedies for Fatal Error .....................................................................64 Isolating the Faulty Part on the Power Supply Board ..............................67 Isolating the Faulty Part according to the Phenomenon ..........................69
ADJUSTMENT
OVERVIEW ................................................................................................117 Required Adjustments ...........................................................................117 Adjustment Tools Required ...................................................................118 ADJUSTMENT ...........................................................................................119 Parallelism Adjustment ..........................................................................119 Backlash value Adjustment for PF motor ..............................................122 Adjustment by Adjustment Program ......................................................125 About Adjustment Program ...............................................................125 How to set up the program ................................................................125 Choose the Model Name and Port name ..........................................126 Market Destination Check .................................................................127 Head Voltage ID Input .......................................................................128 Head Angular Adjustment .................................................................130 Bi-D Adjustment ................................................................................133 USB ID input ......................................................................................136 Initial Ink Charge Operation ...............................................................138 Head Cleaning Operation ..................................................................139 Protection Counter Check/Reset .......................................................140 Recovery for the clogged nozzle .......................................................142 Print A4 pattern .................................................................................143 PF LOOP SCALE UNIT ASSEMBLING PROCEDURE .............................144 Assembling the PF Loop scale unit .......................................................144 Sticking the PF Loop scale unit to Gear 76 ...........................................146
DISASSEMBLY AND ASSEMBLY
OVERVIEW ..................................................................................................76 Precautions for Disassembling the Printer ..............................................76 Tools ........................................................................................................77 Specification for Screws ..........................................................................78 Service Checks After Repair ...................................................................79 DISASSEMBLY PROCEDURES ..................................................................80 Removing the Upper Housing .................................................................81 Removing the Circuit Board Assembly ....................................................82 Removing the Operation Panel ...............................................................84 Disassembling the Printer Mechanism ....................................................85 Removing the Printhead Unit ..............................................................85 Removing the Waste Ink Absorber Tray Assembly .............................87 Removing the Ink System Assembly ...................................................89 Removing the CR Motor Assembly .....................................................92 Removing the DE Assembly (include the ASF/Pump motor) .......... 93 Removing the ASF Assembly ..............................................................97 Removing the Paper Feed Roller Assembly ....................................99 Removing the Right and Left LD Roller Assembly ........................104 Removing the CR Assembly .............................................................105 Disassembling the CR Assembly ..................................................108 Removing the PF Roller Assembly and Paper Eject Roller Assembly 110 Remove the PF Motor Assembly .......................................................114 Removing the PE Detector Assembly ...............................................115
MAINTENANCE
OVERVIEW ................................................................................................148 Cleaning ................................................................................................148 Service Maintenance .............................................................................148 Lubrication .............................................................................................149
APPENDIX
CONNECTOR SUMMARY .........................................................................158 Connector Pin Assignment ....................................................................158 EEPROM ADDRESS MAP ....................................................................161 CIRCUIT BOARD COMPONENT LAYOUT ...............................................166 EXPLODED DIAGRAM ..............................................................................167 PARTS LIST ...............................................................................................168 CIRCUIT DIAGRAM ...................................................................................169
PRODUCT DESCRIPTION
EPSON Stylus Color 860/1160
Revision A
1.1 FEATURES
The major features of EPSON color inkjet printers EPSON Stylus Color 860/ 1160 are:
High Color Print Quality
1440 (H) X 720 (V) dpi printing Four Color Printing (YMCK) Traditional and New Microweave Holds 100 cut-sheets (64g/m2) Holds 10 envelopes Holds 30 transparency films
Built-in Auto Sheet Feeder
Two Built-in Interfaces Bi-directional parallel I/F (IEEE-1284 level 1 device) USB
Windows/Macintosh exclusive
PRODUCT DESCRIPTION
FEATURES
9
EPSON Stylus Color 860/1160
Revision A
1.2 SPECIFICATIONS
This section covers specifications of the printers.
Model
Table 1-2. Raster Graphics Mode
Horizontal Resolution 180 dpi Stylus Color 860 360 dpi 720 dpi 180 dpi Stylus Color 1160 360 dpi 720 dpi Printable Area Available Dot 8.26 inches 8.26 inches 8.26 inches 12.716 inches 12.716 inches 12.716 inches 1488 2976 5952 2289 4578 9156 CR Speed 23.8/19 IPS 23.8/19 IPS 19 IPS 23.8/19 IPS 23.8/19 IPS 19 IPS
1.2.1 Physical Specification
Weight:
6.0kg (excluding ink cartridges)
Dimension: [Stylus Color 860] Storage: 450 mm (W) x 269 mm (D) x 175 mm (H) 450 mm (W) x 628 mm (D) x 303 mm (H) Printing:
[Stylus Color 1160] TBD
Control Code
1.2.2 Printing Specification
Print Method
ESC/P Raster command EPSON Remote command
Character Tables Two international character sets: - PC 437 (US, Standard Europe) - PC 850 (Multilingual)
On demand ink jet
Nozzle Configuration Monochrome 144 nozzles (48 x 3 staggered) Color 48 nozzles x 3 (Cyan, Magenta, Yellow)
Print Direction Bi-direction with logic seeking
Typeface
Bit map LQ font: EPSON Courier 10 CPI
Print Speed & Printable Columns
Table 1-1. Character Mode
Model Stylus Color 860 Stylus Color 1160 Character Pitch 10 CPI (Pica) 10 CPI (Pica) Printable Column 80 127 LQ Speed 238 CPS* 238 CPS*
*This value is the speed of normal-dot printing.
PRODUCT DESCRIPTION
SPECIFICATIONS
10
EPSON Stylus Color 860/1160
Revision A
[220 240V Version] Rated Voltage: Input Voltage Range: Rated Frequency Range: Input Frequency Range: Rated Current: Power Consumption:
1.2.3 Paper Feeding
Feed Method
Friction feed with ASF
Paper Path Cut-sheet ASF (Top entry, Front out)
Feed Speed 2.36 inch/sec (Normal, Continuous feed) 4.5 inch/sec (Fast, Continues feed)
Insulation Resistance:
1.2.4 Input Data Buffer
256KB Dielectric Strength:
AC220V240V AC198264V 5060Hz 49.560.5Hz 0.2 A (for Stylus Color 860) TBD (for Stylus Color 1160) Approx. 18W (ISO10561 Letter Pattern) Approx. 3.5W in standby mode (for Stylus Color 860) TBD (for Stylus Color 1160) Energy Star compliant 10M ohms min. (between AC line and chassis, DC 500V) AC 1500V rms. 1 minute (between AC line and chassis)
1.2.5 Electric Specification
[120V Version] Rated Voltage: Input Voltage Range: Rated Frequency Range: Input Frequency Range: Rated Current: Power Consumption: AC120V AC99132V 50 60Hz 49.5 60.5Hz 0.4A (for Stylus Color 860) TBD (for Stylus Color 1160) Approx. 18W (ISO10561 Letter Pattern) Approx. 3.5W in standby mode (for Stylus Color 860) TBD (for Stylus Color 1160) Energy Star compliant 10M ohms min. (between AC line and chassis, DC 500V) AC 1000V rms. 1 minutes or AC 1200V rms. 1 second (between AC line and chassis)
Insulation Resistance: Dielectric Strength:
PRODUCT DESCRIPTION
SPECIFICATIONS
11
EPSON Stylus Color 860/1160
Revision A
1.2.6 Environmental Condition
1.2.7 Reliability
Total Print Volume: 75,000 pages (A4, Letter) 3 billion dots/nozzle Print Head Life:
Temperature
Operating: Non-operating:
10 to 35°C (see the figure below for condition) -20 to 60°C (with shipment container) 1 month at 40°C and 120 hours at 60°C
1.2.8 Safety Approvals
[120V Version] Safety Standards: EMI: [220240V Version] Safety Standards: UL1950 CSA22.2 No.950 FCC part 15 subpart B Class B CSA C108.8 Class B EN60950 (VDE) EN55022 (CISPR Pub.22) Class B AS/NZS 3548 Class B
Humidity Operating: 20 to 80% RH (without condensation / see the figure below for condition) 5 to 85% RH (without condensation / with shipment container)
Non-operating:
Resistance to Shock
Operating: Non-operating:
1G, within 1 ms 2G, within 2 ms (with shipment container)
EMI:
Resistance to Vibration Operating: Non-operating: 0.15G 0.50G (with shipment container)
1.2.9 Acoustic Noise
Level: TBD (According to ISO 7779)
1.2.10 CE Marking
90 80 70 60
[220240V Version] Low Voltage Directive 73/23/EEC: EMC Directive 89/336/EEC:
Hum idity (% )
50 40 30 20
EN60950 EN55022 Class B EN61000-3-2 EN61000-3-3 EN50082-1 IEC801-2 IEC801-3 IEC801-4
10
20
27 30
35
40
Tem perature (°C)
Figure 1-1. Temperature/Humidity Range
PRODUCT DESCRIPTION
SPECIFICATIONS
12
EPSON Stylus Color 860/1160
Revision A
1.3 INTERFACE
The EPSON Stylus Color 860/1160 provide USB and parallel interface as standard. DATA -STROBE
data byte n data byte n+1
thold tsetup BUSY tready -ACKNLG treply tack tnbusy tbusy tstb tnext
1.3.1 Parallel Interface (Forward Channel)
Transmission Mode: Synchronization: Handshaking: Signal Level: Adaptable Connector: 8 bit parallel, IEEE-1284 compatibility mode By STROBE pulse BY BUSY and ACKNLG signal TTL compatible level 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. BUSY signal is at high level in the following cases:
Figure 1-2. Data Transmission Timing Table 1-3.
Parameter tsetup thold tstb tready tbusy tt-out* tt-in** treply tack tnbusy tnext Minimum 500ns 500ns 500ns 0 0 500ns 0 0 Maximum 500ns 120ns 200ns 10us -
During data entry (see data transmission timing). When input data buffer is full. During -INIT signal is at low level or during hardware initialization. During printer error (see -ERROR signal). When the parallel interface is not selected.
ERROR signal is at low level when the printer is in one of the following states: Printer hardware error (fatal error) Paper-out error Paper-jam error Ink-out error
PE signal is at high level during paper-out error.
* Rise and fall time of every output signal. ** Rise and fall time of every input signal. *** Typical timing for tack is shown on the following page.
PRODUCT DESCRIPTION
INTERFACE
13
EPSON Stylus Color 860/1160
Revision A
Table 1-4. Typical Time of tack
Parallel I/F Mode High Speed Normal Speed Typical Time of tack 1us 3us 1 2 3 4 5 VOH = 2.4V VOL = 0.4V 6 7 8 9 10 Pin No.
Table 1-6. Connector Pin Assignment and Signals
Signal Name -STROBE DATA0 DATA1 DATA2 DATA3 DATA4 DATA5 DATA6 DATA7 -ACKNLG Return GND Pin 19 20 21 22 23 24 25 26 27 28 In/Out Functional Description The strobe pulse. Read-in of data is performed at the falling edge of this pulse.
In In In In In In In In In Out
Table 1-5. Signal Level: TTL Compatible (IEEE-1284 level 1 device)
Parameter VOH* VOL* IOH* IOL* CO VIH VIL IIH IIL CI Minimum -0.5V 0.8V Maximum 5.5V 0.32mA 12mA 50pF 2.0V 0.32mA 12mA 50pF VIH = 2.0V VIL = 0.8V Condition
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. A high signal indicates paper-out error. Always at high level when the printer is powered on. Not used. The falling edge of a negative pulse or a low signal on this line causes the printer to initialize. Minimum 50us pulse is necessary. A low signal indicates printer error condition. Not used.
11 12 13 14
BUSY PE SLCT -AFXT
29 28 28 30
Out Out Out In
*
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.
31
-INIT
30
In
32 36
-ERROR -SLIN
29 30
Out In
PRODUCT DESCRIPTION
INTERFACE
14
EPSON Stylus Color 860/1160
Table 1-6. Connector Pin Assignment and Signals (continued)
Pin No. 18 35 17 16,33, 19-30 15,34 Signal Name Logic H +5V Chassis GND GND NC Return GND Pin In/Out Out Out Functional Description Pulled up to +5V via 3.9 K ohm resistor. Pulled up to +5V via 3.3K ohm resistor. Chassis GND Signal GND Not connected
Revision A
NOTE: In/Out refers to the direction of signal flow seen from the printer side.
PRODUCT DESCRIPTION
INTERFACE
15
EPSON Stylus Color 860/1160
Revision A
Table 1-7. Connector Pin Assignment and Signals (continued)
Pin No. 32 36 18 35 Signal Name -DataAvail / DataBit-0,4 1284-Active Logic-H +5V Chassis GND GND NC Return GND Pin 29 30 In/Out Out In Out Out Functional Description Data available signal and reverse channel transfer data bit 0 or 4. 1284 active signal. Pulled up to +5V via 3.9K ohm resistor. Pulled up to +5V via 3.3K ohm resistor. Chassis GND Signal GND Not connected
1.3.2 Parallel Interface (Reserve Channel)
Transmission Mode: Adaptable Connector Synchronization: Handshaking: Data Trans. Timing: Signal Level: IEEE-1284 nibble mode See forward channel. Refer to the IEEE-1284 specification Refer to the IEEE-1284 specification Refer to the IEEE-1284 specification IEEE-1284 level 1 device See forward channel.
Table 1-7. Connector Pin Assignment and Signals
Pin No. 1 2 3 4 5 6 7 8 9 10 11 Signal Name HostClk DATA0 DATA1 DATA2 DATA3 DATA4 DATA5 DATA6 DATA7 PtrClk PtrBusy / DataBit-3,7 AckDataReq / DataBit-2,6 Xflag / DataBit-1,5 HostBusy -INIT Return GND Pin 19 20 21 22 23 24 25 26 27 28 29 In/Out In In In In In In In In In Out Out Printer clock signal. 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. Host busy signal. Not used. 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. Functional Description Host clock signal. 17 16,33, 19-30 15,34
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: 04H: Request Nibble Mode Reverse Channel Transfer. Request Device ID; Return Data Using Nibble Mode Rev Channel Transfer.
12
28
Out
13 14 31
28 30 30
Out In In
PRODUCT DESCRIPTION
INTERFACE
16
EPSON Stylus Color 860/1160
Device ID: The printer sends the following device ID string when requested. When IEEE1284.4 is enabled, [00H] [5AH] (for Stylus Color 860) [00H] [5CH] (for Stylus Color 1160) MFG: EPSON; CMD: ESCPL2, BDC, D4; MDL: Stylus[SP]COLOR[SP]860/1160; CLS: PRINTER; DES: EPSON[SP]Stylus[SP]COLOR[SP]860/1160; When IEEE1284.4 is disabled, [00H] [57H] (for Stylus Color 860) [00H] [59H] (for Stylus Color 1160) MFG: EPSON; CMD: ESCPL2, BDC; MDL: Stylus[SP]COLOR[SP]860/1160; CLS: PRINTER; DES: EPSON[SP]Stylus[SP]COLOR[SP]860/1160;
Revision A
1.3.3 USB Interface
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) NRZI Data Encoding: Adaptable Connector: USB Series B Recommended Cable Length: 2 meters Standard:
Table 1-8. Connector Pin Assignment and Signals
Pin No. 1 2 3 4 Signal Name VCC -Data +Data Ground I/O Bi-D Bi-D Function Description Cable power. Max. power consumption is 2mA. Data Data, pull up to +3.3 V via 1.5K ohm resistor. Cable ground
NOTE 1:[00H] denotes a hexadecimal value of zero. NOTE 2:MDL value depends on the EEPROM setting. NOTE 3:CMD value depends on the IEEE1284.4 setting.
Pin #2
Pin #1
Pin #3
Pin #4
Figure 1-3. USB Pin Assignment
PRODUCT DESCRIPTION
INTERFACE
17
EPSON Stylus Color 860/1160
Revision A
1.3.4 Prevention of Data Transfer Time-out
Generally, hosts abandon data transfer to peripherals when the peripheral is in the busy state for dozens of seconds continuously. To prevent this kind of timeout, the printer receives data very slowly, several bytes per minute, even if the printer is in the busy state. The slowdown starts when the remaining input buffer becomes several hundreds of bytes, and the printer finally gets into the busy state continuously when the input buffer is full. USB and IEEE1284.4 on the parallel interface do not require such function.
Automatic Selection An initial state is compatible interface and starts IEEE1284.4 communication when magic strings (1284.4 synchronous commands) are received. 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. Off An initial state is compatible interface and never starts IEEE1284.4 communication even if magic strings (1284.4 synchronous commands) are received.
1.3.5 Interface Selection
The printer has two built-in interfaces: the USB and parallel interface. These interfaces are selected automatically.
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. 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.
1.3.6 IEEE1284.4 Protocol
The packet protocol described by IEEE1284.4 standard allows a device to carry on multiple exchanges or conversations which contain data and/or control information with another device at the same time across a single point-to-point link. The protocol is not, however, a device control language. It does provide basic transport-level flow control and multiplexing services. The multiplexed logical channels are independent of each other and blocking of one has no effect on the others. The protocol operates over IEEE1284.
PRODUCT DESCRIPTION
INTERFACE
18
EPSON Stylus Color 860/1160
Revision A
1.4 OPERATOR CONTROLS
1.4.1 Operating Switch
Operating switch is located on the control panel.
1.4.2.2 Indicators
(1) Power Lights when the operating switch is "ON" and AC power is supplied. (2) Paper Out Lights during the paper-out condition, and blinks during the paper-jam condition. (3) Ink Out (Black) Lights during no black ink condition, and blinks during the black ink low condition. (4) Ink Out (Color) Lights during no color ink condition, and blinks during the color ink low condition.
1.4.2 Control Panel
1.4.2.1 Switches
There are two non-lock type push switches, one lock-type push switch, and four LED lights.
Load/Eject Cleaning Power
3
4
2
1
Figure 1-4. Control Panel
PRODUCT DESCRIPTION
OPERATOR CONTROLS
19
EPSON Stylus Color 860/1160
Revision A
1.4.3 Panel Functions
Switch
Table 1-10. Panel Function with Power On
Pressing with Power On Function · 1) Starts status printing. *1 · Changes code pages / Select IEEE1284.4 mode for parallel I/F. *2 · Enters the special settings mode. (Factory use only). *3 Load / Eject Cleaning Load/Eject + Cleaning
Table 1-9. Panel Functions
Switch Load / Eject (Push for less than 2 sec.*) Load / Eject (Push for 2 sec.*) Cleaning (Push for 2 sec.*) Cleaning (Push for less than 2 sec.*) Function · Loads or ejects a paper. · When the carriage is on the ink cartridge replacement position, return the carriage to the capping position. · Starts the ink cartridge replacement sequence.** · Moves the carriage to the cartridge replacement position. · Starts cleaning of the printhead. · In the condition of "Ink Low", "Ink Out", or "No Ink Cartridge", starts the ink cartridge replacement sequence.** · When the carriage is on the ink cartridge replacement position, return the carriage to the capping position.
*1: One of the following actions is carried out according to the content of 1BH of EEPROM.
Content of 1BH of EEPROM, [bit7] [bit6] 00 11 01 10 Action Print firmware version, ink counter, selected code page and nozzle check pattern. Start hex-dump printing. Start self test printing.
* It is described in the user's manual that three seconds are required. **This function is not available in printing status.
*2: Not described in the user's manual. *3: See the table below.
Table 1-11. Special Setting Mode
Switch Load / Eject Function · Initialize EEPROM and reset timer IC.
· Reset the ink overflow counter in EEPROM. Cleaning (Push for 10 seconds)
PRODUCT DESCRIPTION
OPERATOR CONTROLS
20
EPSON Stylus Color 860/1160
Revision A
1.4.4 Printer Condition and Panel Status
Table 1-12. Printer Condition and LED Status
Indicators Printer Status Power Power On Condition Ink Sequence Ink Cartridge Replacement Mode Data Processing Paper Out Paper Jam Condition No Ink Cartridge / Ink End (Black) Ink Level Low (Black) No Ink Cartridge or Ink End (Color) Ink Level Low (Color) Enter EEPROM and Timer IC Reset Maintenance Request Fatal Error On Blink Blink Blink Blink Blink Ink Out (Black) Off On Blink Ink Out (Color) Off On Blink ON (for 1 second only) Blink On Blink On Blink Blink Priority Paper Out On Blink 9 6 5 8 4 3 7 7 7 7 2 1
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. 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
21
EPSON Stylus Color 860/1160
Revision A
1.4.6 Errors
Ink Out When the printer runs out most of the ink of any color, it indicates ink-low and keeps printing. When the printer runs out the whole ink of any color, it stops printing and indicates ink-out error. User is then requested to install a new ink-cartridge in this state. An ink-cartridge that has been taken out once should never be used again. Re-installation of the cartridge not filled fully upsets the ink level detection and may eventually cause a serious problem in the print head. Paper Out When the printer fails to load a sheet, it goes into a paper out error. Paper Jam When the printer fails to eject a sheet, it goes into a paper jam error. No Ink-Cartridge When the printer detects that ink-cartridge comes off, it goes into this error mode. 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. Fatal Errors Carriage control error or CG access error.
PRODUCT DESCRIPTION
OPERATOR CONTROLS
22
EPSON Stylus Color 860/1160
Revision A
1.5 PAPER
1.5.1 Paper Handling
Do not perform reverse feed more than 9.5mm (0.38").
1.5.2.2 Transparency, Glossy Paper
[Size] For Stylus Color 860/1160:
A4: Letter:
Width 210mm (8.3") x Length 297mm (11.7") Width 216mm (8.5") x Length 279mm (11.0")
1.5.2 Paper Specification
1.5.2.1 Cut Sheet
[Size] For Stylus Color 860/1160: A4: Width 210mm (8.3") x Length 297mm (11.7") Letter: Width 216mm (8.5") x Length 279mm (11.0") B5: Width 182mm (7.2") x Length 257mm (10.1") Width 216mm (8.5") x Length 356mm (14.0") Legal: Statement: Width 139.7mm (5.5") x Length 215.9mm (8.5") Executive: Width 184.2mm (7.25") x Length 266.7mm (10.5") Photo Paper: Width 101.6mm (4") x Length 152.4mm (6") For Stylus Color 1160 only: A3: Width 297mm (11.7") x Length 420mm (16.5") A3+: Width 329mm (13.0") x Length 483mm (19.0") [Thickness]
0.08mm (0.003") - 0.11mm (0.004")
For Stylus Color 1160 only:
A3+:
[Thickness]
Width 329mm x Length 483mm (Glossy Paper)
0.075mm (0.003") - 0.085mm (0.0033")
*Transparency printing is available only at normal temperature.
1.5.2.3 Envelope
[Size]
No.10: DL: C6:
[Thickness]
Width 241mm (9 1/2") x Length 104.8mm (4 1/8") Width 220mm (8.7") x Length 110mm (4.3") Width 162mm (6.4") x Length 114mm (4.5")
0.16mm (0.006") - 0.52mm (0.02")
[Weight]
[Weight]
64g/m2 (17Ib.) - 90g/m2 (24Ib.)
45g/m2 (12Ib.) - 75g/m2 (20Ib.)
[Quality]
[Quality]
Exclusive paper, Bond paper, PPC
Bond paper, Plain paper, Air mail
Note1: Note 2: Envelope printing is available only at normal temperature. Keep the longer side of the envelope horizontally at setting.
PRODUCT DESCRIPTION
PAPER
23
EPSON Stylus Color 860/1160
Revision A
1.5.2.4 Index Card
[Size]
A6 Index Card: A5 Index Card: 5 x 8" Index Card: 10 x 8" Index Card:
[Thickness]
Width 105mm (4.1") x Length 148mm (5.8") Width 148mm (5.8") x Length 210mm (8.3") Width 127mm (5.0" x Length 203mm (8.0") Width 127mm (5.0") x Length 203mm (8.0")
Less than 0.23mm (0.0091")
PRODUCT DESCRIPTION
PAPER
24
EPSON Stylus Color 860/1160
Revision A
1.5.3 Printing Area
1.5.3.1 Cut Sheet
See the figure below and tables on the right for printable areas for Raster Graphics mode and Character mode. PW LM RM
Paper Size A3 (*1) A4 Letter B5
Table 1-13. Character Mode
Left Margin (min.) 3mm (0.12") 3mm (0.12") 3mm (0.12") 3mm (0.12") 3mm (0.12") Right Margin (min.) 3mm (0.12") 3mm (0.12") 9mm (0.35") 3 m (0.12") 9mm (0.35") 3mm (0.12") 3mm (0.12") Top Margin (min.) 3mm (0.12") 3mm (0.12") 3mm (0.12") 3mm (0.12") 3mm (0.12") 3mm (0.12") 3mm (0.12") Bottom Margin (min.) 14mm (0.54") /3mm (0.12") (*2) 14mm (0.54") /3mm (0.12") (*2) 14 mm (0.54") / 3mm (0.12") (*2) 14 mm (0.54") / 3mm (0.12") (*2) 14 mm (0.54") / 3mm (0.12") (*2) 14 mm (0.54") / 3mm (0.12") (*2) 14 mm (0.54") / 3mm (0.12") (*2)
TM
Legal
Statement 3mm (0.12") Executive 3mm (0.12")
Printable Area
PL
BM
Figure 1-5. Printable Area for Cut Sheet
PRODUCT DESCRIPTION
PAPER
25
EPSON Stylus Color 860/1160
Revision A
Table 1-14. Raster Graphics Mode
Paper Size A3* A3+* A4 Letter B5 Legal Left Margin (min.) 3 mm (0.12") 3 mm (0.12") 3 mm (0.12") 3 mm (0.12") 3 mm (0.12") 3 mm (0.12") Right Margin (min.) 3 mm (0.12") 3 mm (0.12") 3 mm (0.12") 3 mm (0.12") 3 mm (0.12") 3 mm (0.12") 3 mm (0.12") 3 mm (0.12") Top Margin (min.) 3 mm (0.12") 3 mm (0.12") 3 mm (0.12") 3 mm (0.12") 3 mm (0.12") 3 mm (0.12") 3 mm (0.12") 3 mm (0.12") Bottom Margin (min.) 14 mm (0.54") / 3mm (0.12") ** 14 mm (0.54") / 3mm (0.12") ** 14 mm (0.54") / 3mm (0.12") ** 14 mm (0.54") / 3mm (0.12") ** 14 mm (0.54") / 3mm (0.12") ** 14 mm (0.54") / 3mm (0.12") ** 14 mm (0.54") / 3mm (0.12") ** 14 mm (0.54") / 3mm (0.12") **
1.5.3.2 Envelopes
LM RM
TM
Printable Area
BM
Statement 3 mm (0.12") Exclusive 3 mm (0.12")
Figure 1-6. Printable Area for Envelopes Table 1-15. Envelope Margin
Size #10 DL C6 Left Margin (min.) 3 mm (0.12") 3 mm (0.12") 3 mm (0.12") Right Margin (min.) 28 mm (1.10") 7 mm (0.28") 3 mm (0.12") Top Margin (min.) 3 mm (0.12") 3 mm (0.12") 3 mm (0.12") Bottom Margin (min.) 14 mm (0.55") 14 mm (0.55") 14 mm (0.55")
For Stylus Color 1160 only. 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).
* **
PRODUCT DESCRIPTION
PAPER
26
EPSON Stylus Color 860/1160
Revision A
1.6 INK CARTRIDGE
1.6.1 Black Ink Cartridge
Type: Color: Print Capacity: Ink Life: Storage Temperature: Storage: Packing: Transit: Dimension: Exclusive Cartridge Black 900 pages/A4 (ISO/IEC 10561 Letter Pattern at 360 dpi) 2 years from date of production -20 oC to 40 oC (within a month at 40 oC) -30 oC to 40 oC (within a month at 40 oC) -30 oC to 60 oC (within 120 hours at 60 oC and within a month at 40 oC) 27.8 mm (W) x 52.7 mm (D) x 38.5 mm (H)
27.8
1.6.2 Color Ink Cartridge
Type: Color: Print Capacity: Ink Life: Storage Temperature: Storage: Packing: Transit: Dimension: Exclusive Cartridge Magenta, Cyan, Yellow 300 pages / A4 (360 dpi, 5% duty each color) 2 years from date of production -20 oC to 40 oC (within a month at 40 oC) -30 oC to 40 oC (within a month at 40 oC) -30 oC to 60 oC (within 120 hours at 60 oC and within a month at 40 oC) 42.9 mm (W) x 52.7 mm (D) x 38.5 mm (H)
43.2
52.7
52.7
51.2
42.9
38.5
38.5
41.4
Figure 1-8. Color Ink Cartridge
26.3
Figure 1-7. Black Ink Cartridge
Note 1: Ink cartridge can not be refilled. The ink cartridge is prepared only for article of consumption. Note 2: Do not use the ink cartridge which contains life-expired ink. Note 3: Ink will be frozen under -4 oC environment; however, it will be usable after being left at room temperature for more than three hours.
PRODUCT DESCRIPTION
INK CARTRIDGE
51.2
27
OPERATING PRINCIPLES
EPSON Stylus COLOR 860/1160
Revision A
The basic structure of the printer mechanism is mostly common to the Stylus COLOR 400/600/440/640/740, except that the Stylus COLOR 860/ 1160 uses a Pump/ASF motor. With this motor equipped, the paper loading mechanism and the pumping mechanisms are independently driven, which allows the printer to offer higher throughput as a result. Figure 2-1 shows the printer mechanism block diagram for the Stylus COLOR 860/1160.
Loop Scale Intermittent Gear PF Drive Gear (high precision) Encoder (PF) ASF Sensor Detector Wheel
2.1 Overview
This section describes the operating principles of the printer mechanism and electrical circuit boards. The EPSON Stylus COLOR 860/1160 has the following boards:
Main board:
C298MAIN Board (Stylus COLOR 860/1160)
Power supply board: C298PSB/PSE Board (Stylus COLOR 860/1160) Panel board: C298PNL Board (Stylus COLOR 860) C304PNL Board (Stylus COLOR 1160)
2.1.1 Printer Mechanism
Unlike other EPSON ink jet printers, the Stylus COLOR 860/1160 uses DC motor for power source. Use of the DC motor enable the printer to lower noise during printing to a great extent. Table 2-1 shows the various motor types used in the printer and their applications.
PF Motor Pinion PF Motor Flashing Window (at 80th or 136th column) Photo Interrupter (Encoder for CR) Star Wheel Roller Bk I/C Sensor CMY I/C Sensor
Loading Shaft
Table 2-1. Motor Types and Corresponding Applications
Motor Name CR Motor Type DC with brush Application / Feature Used to drive the carriage making little noise. A a linear scale is used to monitor the motor's operating condition. · Drives paper feeding rollers used to send paper at specified speeds and load/eject paper. · CR lock lever operation · To monitor paper feeding pitch, a loop scale is attached beside the highprecision gear. Like the Stylus COLOR 800 and Stylus Pro 5000, this motor manages pump drive and paper loading from ASF. Since this is a stepping motor, it has no scales or photo sensors that are used to monitor the motor's operating condition.
Loading Rollers
Carriage Unit Printhead (one unit) Timing Belt Cap Unit (without a valve) PE Sensor Pump/ASF Motor (stepping motor)
PF Motor
DC with brush
Pump Unit CR Guide Shaft PF Roller Liner Scale CR Motor (DC motor) PG Lever
Pump/ASF
4-Phase 48-pole stepping motor
Figure 2-1. Printer Mechanism Block Diagram
Operating Principles
Overview
29
EPSON Stylus COLOR 860/1160
Revision A
2.1.1.1 Printing Mechanism
The basic operating principles of the printhead, which plays a major role in printing, are the same as previous models; ones that use a on-demand type U-CHIP head method. (Refer to Figure1-1.) Also, unlike the Stylus Color IIs, 820 and 200, the Stylus COLOR 860/1160 is not an automatic correction type. So, in order to correct dispersion of multi layer piezo electric element that drives each nozzle, you are required to input a VH value written on the top surface of the printhead by using an exclusive program when you replace the printhead, control board, or printer mechanism. (Note there are no resistor arrays to determine the VH voltage on the main control board.) Following explains printhead.
I/C Sensor Actuator
Nozzle Selector Board
Ink Cartridge Needle
PZT PZT is an abbreviation of Piezo Electric Element. Print signals from the PSB/PSE board are sent through the driver board on the printhead unit to the PZT. Then, the PZT pushes the top cavity which has ink stored to discharge the ink from each nozzle on the nozzle plate. Cavity Set The ink absorbed from the ink cartridge goes through the filter and then is stored temporarily in this tank called "cavity" until PZT is driven. Nozzle Plate The board with nozzle holes on the printhead surface is called Nozzle Plate. 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.
Filter
Nozzle Plate
PZT
Cavity
Figure 2-2. Printing Mechanism
Operating Principles
Overview
30
EPSON Stylus COLOR 860/1160
Revision A
2.1.1.2 Printing Process
Figure 2-3 and Figure 2-4 show the normal state and ejecting state of the printhead, respectively. 1. Normal State: When the print signal is not output, PTZ also does not move from a waiting state (normal state). (Refer to Figure 2-3.) 2) Ejecting State: When the print signal is output from the C298MAIN board, IC (IR4C463S: Nozzle Selector) located on the printhead unit latches data once by 1-byte unit. An appropriate PZT latched by the nozzle selector is pushed into the cavity by the common voltage applied from the main board. By this operation, ink stored in the cavity spurts out from nozzles. (Refer to Figure 2-4.) Ink Course PZT Cavity
Nozzle
Nozzle Plate
Figure 2-3. Print Head Normal State
Figure 2-4. Print Head Ejecting State
Operating Principles
Overview
31
EPSON Stylus COLOR 860/1160
Revision A
The printhead, a core of the printing mechanism, is stored in the carriage unit. When the adjustment lever is moved up and down, this printhead is maintained tilt in a flexible and adjustable structure by the tilt adjustment mechanism. Also, the parallelism adjustment levers, mounted on the left and right sides of the carriage guide shaft, are used to set the carriage guide shaft parallel to the platen when the shaft has been installed to the printer mechanism. After this adjustment is completed, moving the PG adjustment lever sets the distance between the platen surface and the printhead surface to one of two possibilities: 1.2 mm or 1.9 mm. Moving the PG lever, you can rotate the shafts of the carriage guide shaft which itself is decentralized to change the distance. This is the mechanism that the user can use to adjust the appropriate PG value according to the printing result or any other environmental conditions such as thick paper.
2.1.1.3 Carriage Mechanism
The carriage mechanism for the Stylus COLOR 860/1160 is mostly the same as for other ink jet printers except it is driven by a DC motor. See the table below for the carriage motor specifications.
Table 2-2. Carriage Motor Specification
Items Type Drive Voltage Internal Resistance Inductance Drive Method Driver IC Specifications DC Motor with brush +42 V +/- 5%(DRV IC voltage) 29.2 ohms +/- 25% 30.8 mH +/- 25% Constant Current Chopping LB1947
Unlike a stepping motor, the DC motor that drives the carriage can not detect the current carriage position by referring to the pulses given. Therefore, a linear scale is attached along the carriage operation range to enable the printer to mechanically detect the carriage position. (Same as the Stylus COLOR 900) The linear scale is also used to produce the print timing signal (PTS signal), to which the printer refers to for a correct ink ejection timing. For detailed information on the CR motor control circuit, see Section 2.2.
Carriage Motor PF Roller Timing Belt Carriage Unit
Front Side Rear Side Parallelism Adjust Lever Fixing Bushing Carriage Guide Shaft
Eject Roller Paper Guide (Front) PF Motor
CR Lock Lever
Figure 2-5. Carriage Mechanism (Top view)
Operating Principles
Overview
32
EPSON Stylus COLOR 860/1160
Revision A
2.1.1.4 Platen Gap (PG) Adjust Mechanism
The PG adjustment, at the left of the printer mechanism, consists of the PG lever, PF support lever, right/left parallelism adjustment levers, and CR guide shaft. The PG adjustment mechanism is designed to keep the platen gap correct for the paper thickness to prevent ink from smearing. The PG lever joins the CR guide shaft, which has an eccentricity via PG sub lever. Switching the lever from "0" to "+" rotates the CR shaft and changes the platen gap from narrow to wide.
2.1.1.5 Paper Feeding Mechanism
The paper feeding mechanism transports paper loaded from ASF using the PF rollers and paper eject rollers. A new type of DC motor is used for the PF motor. See the table below for the DC motor specifications.
Table 2-4. PF Motor Specifications
Item Motor type Description DC Motor with Brush +42V +/- 5% (DRV IC voltage) 31.1 ohm +/- 25% 26.6mH +/- 25% A3958
Table 2-3. Platen Gap Adjust Lever Setting
Paper All Media If you find any print problems or use thick paper. Lever Position Front PG adjustment value 0 mm (1.2 mm between head and platen) 0.7mm (1.9 mm between head and platen)
Drive voltage Coil Resistance Drive frequency [Hz] Control method
Rear
Unlike a stepping motor, the DC motor that drives the paper feeding mechanism can not measure the paper feeding amount by referring to the pulses given. For this reason, the loop scale and encoder sensor are directly attached to the left end of the PF roller shaft to mechanically control paper feed amount. See Section 2.2 for detailed information on the PF motor control circuit. Drive from the PF motor is sent to the PF rollers and paper eject rollers as described below.
To the PF rollers: PF motor pinion gear Spur gear (76) PF rollers To the eject rollers: PF motor pinion gear Spur gear (76) Combination gear (13.5, 308) Spur gear (28) Paper eject rollers
Figure 2-6 in the next page gives the paper feeding mechanism block diagram, showing the parts along the PF motor drive transmission paths.
Operating Principles
Overview
33
EPSON Stylus COLOR 860/1160
Revision A
[Previous Models]
Paper Front Paper Guide Eject Roller PF Motor
Printhead Star Wheel Assy.
Support Roller
Figure 2-6. Paper Feeding Mechanism
The printer loads paper at the ASF, which is detected by the PE sensor attached to the right side of the top frame, and advances it to send the paper's leading edge to the halfway of the front paper guide. Then, to correct deflection, the printer feeds the paper back specified steps toward ASF, and advances the paper again toward the front paper guide and stops it at the specified TOF (Top Of Form) position. Once the printer starts printing, it transports paper using the PF rollers and sub rollers, and as the printer transports or printing on the tailing 14 mm, it uses a star wheel gear and paper eject rollers. Like the Stylus COLOR 440/640/740, this printer also provides this extra printable range of 14 mm from the bottom edge, excluding the bottom margin of 3mm, by changing the position of the star wheel gear; it has been shifted by 5 ° from the top of the eject roller toward the front paper guide. Due to this change, the tailing edge of paper is suppressed, and the printer can advance paper steadily when printing around the bottom area. See Figure 2-7 next page that shows how paper is transported and parts involved.
Eject Roller Platen
PF Roller
Bottom margin 3 mm touches the printhead surface.
[Stylus COLOR 860/1160]
Five Degrees
Steady
Figure 2-7. Paper Transportation
Operating Principles
Overview
34
EPSON Stylus COLOR 860/1160
Revision A
The carriage lock mechanism prevents the carriage from being left at an uncapped position for a long time, that is usually caused by vibration during printer transportation, user's mishandling of the printer, and so on. If the carriage is left uncapped for a long time, ink on its surface will become gradually thick and not spurt from the nozzles as a result. To make matters worse, the holes (crater) of the nozzles may be completely clogged by the thick ink, and they may not be able to return to a normal condition just by a cleaning operation. To prevent this, the printer enters a carriage lock condition in the following conditions.
2.1.1.6 CR Lock Mechanism
The carriage lock mechanism prevents the carriage from being left at an uncapped position for a long time, which is usually caused by vibration during printer transportation, user's mishandling of the printer, and so on. The CR Lock mechanism is driven with the DC PF motor. For the motor specifications, refer to the Table 2-4 . The PF motor drive is used for the Paper Feed Mechanism also and the CR lock mechanism is controled depends on the direction of the PF motor rotationa. The CR lock mechanism is assembed on the right tip of the Paper Eject Roller as shown in the folloiwng figure.
After Power-off operation: If the printer power is turned off in the middle of printing or any other performances, carriage lock takes place in the end after an initialization operation. After Power-on operation: After the printer power is turned on and an automatic power-on cleaning is completed, carriage lock is performed. The power-on cleaning is an automatic head cleaning that runs when the printer power is turned on. The timer IC always calculates printer's power off time using power from a lithium battery mounted on the C298MAIN board. The power-on cleaning function automatically selects a correct cleaning level according to the length of time which the printer has been turned off. After ejecting paper: After the Load/Eject button is pressed and the paper is ejected, if the printer does not receive any data, it performs carriage lock and goes to a standby state. However, if paper is loaded by pressing the Load/ Eject button, the printer does not perform the carriage lock operation.
Top view CR Lock Lever Bushing 6
Right side view CR CR unit unit
Paper Eject Roller Middle Frame
Figure 2-8. CR Lock mechanism
While the PF motor drive is used for paper feeding (PF motor rotation: CCW), the CR Lock lever is set under the Paper Eject Frame, but the CR Lcok lever rises up with clockwise rotation of the PF motor and locks the CR unit. Drive from the PF motor is sent to the CR Lock lever via Papaer Eject Roller as described below. To the CR lock lever PF motor pinion gear (CW rotation) Spur gear (76) Combination gear (13.5, 30.8) Spur gear (28) Paper eject rollers CR lock lever
PF motor torque is always transmitted to the CR lock lever side, but the operation of the CR lock mechanism varies depending on the rotational direction of the PF motor, as shown in the table below.
Table 2-5. CR lock mechanism & PF rotational direction
Directions Counterclockwise ckwise Corresponding Functions · Release the CR lock lever. · ..Sets the CR lock lever.
Operating Principles
Overview
35
EPSON Stylus COLOR 860/1160
Revision A
Torque from the ASF/Pump motor is transmitted to the ASF as describe below:
2.1.1.7 Paper Loading Mechanism
The paper loading mechanism loads paper at the ASF unit and feeds paper to the PF rollers. The ASF unit, the same as in the Stylus COLOR 440/640/740, uses a 4-phase 48-pole PM type stepping motor for the ASF/ Pump motor. Drive sent from this motor is switched between the ASF unit side and pump unit by the disengage mechanism. See Figure 2-6 for the ASF/Pump motor specifications.
Torque transmission to the ASF unit 1) When the CR unit moves to the right end of the CR shaft, the DE lock lever is pushed to the right end. 2) The ASF-Pump motor rotates specified steps counterclockwise (viewed from the motor pinion gear side). 3) With the rotation of step 2), the planetary gear set in the disengage unit shifts to the combination gear (12, 22.4) side. 4) The CR unit moves specified steps from the right end of the CR shaft to the left. With this movement, the DE lock lever fixes the planetary gear unit. 5) Torque from the ASF/Pump motor is transmitted as described below. Motor pinion gear Planetary gear (15.2) Combination gear (12, 22.4) Combination gear (14, 28) Spur gear (32) in ASF
Table 2-6. ASF/Pump Motor Specifications
Items Motor type Drive method Drive voltage Coil Resistance Drive frequency [Hz] Control method Description 4 Phase/ 48-pole /PM type pulse motor Bipolar drive +42V +/- 5% (DRV IC voltage) 10.4 ohm +/- 10% 15mH A3958
Figure 2-9 shows the disengage mechanism and the parts involved.
Combination Gear (14, 28) Combination Gear (12, 22.4)
The rotational directions and their functions are shown in the table below:
Planetary Gear (15.2) Unit
Table 2-7. ASF/Pump Motor Rotation
Directions Clockwise Counterclockwise Corresponding Functions Sets the paper return lever. · Switches torque to the ASF side. · Loads paper at ASF.
ASF/Pump Motor Pinion
DE Lock Lever
Combination Gear (17.19, 25.6)
Figure 2-9. Disengage Mechanism
Operating Principles
Overview
36
EPSON Stylus COLOR 860/1160
Torque sent from the ASF/Pump motor to the ASF unit via the disengage mechanism is used for the following operation.
Revision A
Paper loading operation Like the Stylus COLOR 440/640/740, ASF of this printer has the multiple paper loading prevention mechanism to provide steady paper loading. This mechanism prevents a sheet of paper from falling from the paper set position into the paper path. A paper return lever in the mechanism pushes paper that may have fallen off back onto the hopper. After this motion is completed, the LD roller starts loading paper. The paper loading mechanism, including the multiple paper loading prevention mechanism, is described in the following steps.
1. When the printer power is turned on, the ASF/Pump motor rotates counterclockwise to detect ASF home position. Then the motor rotates clockwise specified steps to set the LD roller and paper turn lever in place. (See "Standby State" in Figure 2-10.) 2. When the paper loading signal is sent from the PC and the Load/Eject button is pressed, ASF/Pump motor turns counterclockwise to let the LD roller load paper. (See "Paper Pick Up State" in Figure 2-10.) 3. When the paper is transported to the PF roller, the LD roller stops where it loses friction. (See "PF Roller Paper Feed State" in Figure 2-10.) 4. When the next print signal is sent and Load/Eject button is pressed, the ASF/Pump motor rotates clockwise specified steps to set the LD roller and the paper return lever in place. (See "Standby State" in Figure 2-10.)
NOTE: If no print signal is sent for TBD seconds in step 4, the LD roller and the paper return lever automatically return to the standby state.
LD Roller
Hopper Cam
Hopper Spring
2 3
Pinch Roller
Paper Return Lever
Pad
Pad Spring
[Stand-by State]
[Paper Pickup State]
[PF Roller Paper Load State]
Figure 2-10. Multiple Paper Loading Prevention Mechanism
Operating Principles
Overview
37
EPSON Stylus COLOR 860/1160
Revision A
2.1.1.8 Pump Mechanism
The pump mechanism absorbs ink from the printhead or the cap assembly. The wiper for head cleaning is attached in the cap assembly. The pump mechanism is driven by the ASF/Pump motor, a 4phase 48pole PM type stepping motor. See Table 2-6 for the ASF/Pump motor specifications. Torque from the ASF/Pump motor is sent to the pump unit by the switching operation of the planetary gear in the disengage mechanism. The ASF/Pump motor torque is transmitted to the pump mechanism as described below.
When the ASF/Pump motor torque is switched to the pump unit side by the disengage mechanism, the function of the pump mechanism varies depending on the rotational direction of the motor, as shown in the table below.
Table 2-8. ASF/Pump Motor Functions
Directions Counterclockwise Clockwise Corresponding Functions · Ink absorption by the pump · Sets the wiper. · Releases the pump. · Resets the wiper.
Torque transmission to the pump unit 1) When the CR unit moves to the right end of the CR shaft, the DE lock lever) is pushed to the right end. 2) The ASF-Pump motor rotates specified steps counterclockwise (viewed from the motor pinion gear side). 3) With the rotation of step 2), the planetary gear set in the disengage unit moves to the combination gear (17.19, 25.6) side. 4) The CR unit moves specified steps from the right end of the CR shaft to the left. With this motion, the DE lock lever fixes the planetary gear set. 5) Torque from the ASF/Pump motor is transmitted as described below. Motor pinion gear Planetary gear (15.2) Combination gear (17.19, 25.6) Tension belt Spur gear (tbd) Pump unit
Combination Gear 14,28
Figure 2-12 shows the operating principles of the pump mechanism.
Counterclockwise
Clockwise
Figure 2-11 gives the pump mechanism block diagram, showing the parts involved.
Combination Gear 12,22.4 Planetary gear 15.2 unit DE Lock Lever Tension Belt Tube pressured Tube released
Figure 2-12. Pump Mechanism
ASF/Pump Motor Pinion
Combination Gear 17.19, 25.6
Pump Unit Gear
Figure 2-11. Torque to the Pump Mechanism
Operating Principles
Overview
38
EPSON Stylus COLOR 860/1160
Revision A
2.1.1.9 Capping Mechanism
The capping mechanism, which is driven by the pump unit, caps the printhead closely to maintain air tightness of the cap. This operation is required to vacuum ink from the ink cartridges, printhead, cavity, and cap. Also, to moisten the inside of the cap while the printer power is off, this mechanism works to keep the cap and the printhead surface in a tight contact. This function prevents ink from clogging while the printer is not in use. For a specific feature of the Stylus COLOR 860/1160, it has a newly designed valveless capping mechanism instead of other printers' capping mechanism that integrates an air valve. An air valve is usually equipped to remove bubbles created inside the cap by releasing the negative pressure. However, due to change in the ink sequence, the new valveless capping mechanism enables this printer to maintain the initial ink charge and cleaning effects at the same level as before. Figure 2-13 outlines the valveless capping mechanism.
SC440/640/740 models
Flag for Carriage
SC860/1160 models
Flag for Carriage
Negative pressure
Ink Eject Valve Ink Eject Valve Negative pressure Valve
Closed state
Released state
Flags for Frame Air valve is not assembled in this portion.
Figure 2-13. Valveless Capping Mechanism
Operating Principles
Overview
39
EPSON Stylus COLOR 860/1160
Revision A
2.2 Electrical Circuit Operating Principles
The electric circuit of the Stylus COLOR 860/1160 is composed of the following boards.
Main board:
C298MAIN (Stylus COLOR 860/1160)
Power supply board: C298PSB/PSE (Stylus COLOR 860/1160) Panel board: C298PNL (Stylus COLOR 860) C304PNL (Stylus COLOR 1160)
Refer to Figure 2-13 for the major connection of the three boards and their roles.
C 2 9 8 P N L B o a rd
P r in te r M e c h a n is m
C R
M o to r
P F M o to r