Epson Stylus 820 Service Manual
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Epson Stylus 820 Service Manual

Epson Stylus 820 Service Manual

Terminal printer
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EPSON TERMINAL PRINTER
Stylus
Stylus
COLOR IIs &
820
TM
TM

SERVICE MANUAL

EPSON
4005245

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Summary of Contents for Epson Stylus 820

  • Page 1: Service Manual

    EPSON TERMINAL PRINTER Stylus Stylus COLOR IIs & SERVICE MANUAL EPSON 4005245...
  • Page 2 All efforts 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 notwithstanding SEIKO EPSON can assume no resoinsibility for any errors in this manual or the consequence thereof.
  • Page 3 SUPPLY CABLE MUST BE CONNECTED, USE EXTREME CAUTION IN WORKING ON POWER SUPPLY AND OTHER ELECTRONIC COMPONENTS. WARNING REPAIRS ON EPSON PRODUCT SHOULD BE PERFORMED ONLY BY AN EPSON CERTIFIED REPAIR TECHNICIAN. MAKE CERTAIN THATTHE SOURCE VOLTAGES IS THE SAME AS THE RATED VOLTAGE, LISTED ON THE SERIAL NUMBER/RATING PLATE.
  • Page 4 Includes the step-by-step guide for product disassembly and assembly CHAPTER 4. ADJUSTMENTS Includes a step-by-step guide for adjustment. CHAPTER 5. TROUBLESHOOTING Provides Epson-approved techniques for adjustment. CHAPTER 6. MAINTENANCE Describes preventive maintenance techniques and lists lubricants and adhesives required to service the equipment.
  • Page 5 REVISION SHEET Revision Issue Date Contents Rev.-A August 25,1995 1st issue...
  • Page 6 TABLE OF CONTENTS CHAPTER 1. PRODUCT DESCRIPTION CHAPTER 2. OPERATION PRINCIPLES CHAPTER 3 DISASSEMBLY AND ASSEMBLY CHAPTER 4. ADJUSTMENT CHAPTER 5. TROUBLESHOOTING CHAPTER 6. MAINTENANCE APPENDIX -vi-...

  • Page 7: Table Of Contents

    Chapter 1 Operating Principles Table of Contents 1.1 OVERVIEW 1.2 SPECIFICATIONS 1.2.1 Printing Specifications ........1-2 1.2.2 Paper Handling Specifications .
  • Page 8 List of Figures Figure 1-1. Exterior View of the Stylus Color IIs(820) ....1-1 Figure 1-2. Nozzle Configuration ........1-2 Figure 1-3.
  • Page 9 Stylus Color IIs / Stylus 820 Product Description 1.1 FEATURES The Stylus Color IIs printer is a color ink jet dot matrix printer that comes with a 64-nozzle black printhead and a 60-nozzle CMY color printhead, either of which can be installed in the printer. The Stylus 820 version of the same printer comes standard with only the 64-nozzle black printhead;...

  • Page 10: Specifications

    Product Description Stylus Color IIs / Stylus 820 1.2 SPECIFICATIONS This section provides statistics and other detailed information for the printer. 1.2.1 Printing Specifications Print system: On-demand ink jet system Nozzle configuration: 64 nozzles (10 2 + 11 4 standard ): monochrome 60 nozzles (20 3 standard): color 120 dpi...

  • Page 11: Table 1-2. Character Tables

    10.5 points, 8 32 points (in units of 2 points) - EPSON Roman T 10.5 points, 8 32 points (in units of 2 points) - EPSON Sans Serif H 10.5 points, 8 32 points (in units of 2 points) Control codes:...

  • Page 12: Paper Handling Specifications

    Product Description Stylus Color IIs / Stylus 820 1.2.2 Paper Handling Specifications Feeding method: Friction feed paper is fed from the built-in auto sheet feeder (ASF). Line spacing: 1/6 inch feed or programmable in 1/360 inch minimum increments. Paper path: Cut sheets are fed from the built-in auto sheet feeder (ASF).

  • Page 13: Figure 1-4. Paper Select Lever

    Stylus Color IIs / Stylus 820 Product Description The adjust lever on the upper case must be set to the proper position for the paper thickness, as shown in Table 1-4. Table 1-4. Adjust Lever Settings Lever Position Paper Paper Thickness Front Normal position 0 mm...

  • Page 14: Ink Cartridge Specifications

    Product Description Stylus Color IIs / Stylus 820 1.2.4 Ink Cartridge Specifications Table 1-6. Black I/C Specifications Item Specifications Type Exclusive cartridge Color and Weight Approximately 54 g (internal ink weight is 36 g 0.5 g) Ink Life High-quality ink produces 800 thousand characters Validity 2 years (sealed in package) / 6 months (out of package) –30 to 40 C ( 22...

  • Page 15: Electrical Specifications

    Stylus Color IIs / Stylus 820 Product Description 1.2.5 Electrical Specifications Table 1-8. Rated Electrical Ranges Specification 120 V Version 220 - 240 V Version Rated voltage 120 VAC 220 - 240 VAC Input voltage range 103.5 132 V 264 V Rated frequency range 60 Hz 60 Hz...

  • Page 16: Reliability

    Product Description Stylus Color IIs / Stylus 820 1.2.7 Reliability Total print volume: 25,000 pages (A4, letter) Printhead life: 500 million dots/nozzle (color and monochrome) 1.2.8 Safety Approvals Safety standards: 120 V version: UL1950 with D3, CSA C22.2 # 950 with D3 220-240 V version: EN 60950 (TÜV, SEMKO, DEMKO, NEMKO, SETI)

  • Page 17: Interface Specifications

    Stylus Color IIs / Stylus 820 Product Description 1.3 INTERFACE SPECIFICATIONS The Stylus Color IIs is standard-equipped with an 8-bit parallel and serial interface. 1.3.1 Parallel Interface Specifications Data format: 8-bit parallel Synchronization: By STROBE pulse synchronization Handshaking: By BUSY and ACKNLG signals Signal level: TTL compatible level Adaptable connector:...
  • Page 18 Product Description Stylus Color IIs / Stylus 820 Table 1-10 shows the connector pin assignments and signal functions of the 8-bit parallel interface. Table 1-10. Signal and Connector Pin Assignments for Parallel Interface Pin No. Signal Name I/O* Description The STROBE pulse is used to read data from the host computer.

  • Page 19: Control Panel

    Stylus Color IIs / Stylus 820 Product Description 1.4 OPERATIONS This section describes the basic operations of the printer. 1.4.1 Control Panel The control panel for this printer has 3 non-lock-type push buttons, and 5 LED indicators for easy operation of the various printer functions.

  • Page 20: Table 1-12. Built-In Functions On The Panel

    Product Description Stylus Color IIs / Stylus 820 Table 1-12. Built-in Functions on the Panel Button Function Demonstration printing Load/Eject Self-test Pause Default setting mode (with printing) Alt + Load/Eject Non-smear printing Load/Eject + Pause Data dump mode (Hex mode) Pause + Alt Default setting mode (without printing) Pause + Load/Eject + Pause...
  • Page 21 Stylus Color IIs / Stylus 820 Product Description Indicators Power On when printer is on. Blinks during power on and off. Error On when printer encounters an error, such as ink end, paper out, paper jam, etc. Condensed On when printer is in the condensed mode (50% or 80%). Economy On when printer is in the economy mode.

  • Page 22: Default Settings

    Product Description Stylus Color IIs / Stylus 820 1.4.3 Default Settings The printer can save some printer setting parameters that define its functions at initialization. You can change these parameters using the printer’s default setting mode. 1.4.3.1 Default Setting Items You can use default setting mode to change settings listed in the table below.

  • Page 23: Table 1-16. Language Selections

    Stylus Color IIs / Stylus 820 Product Description Table 1-15. Default Setting Items (Continued) Item Contents Auto line feed 8.5 mm Loading position 3 mm Envelopes Thick paper Index card (portrait) Note: The underlined value is the factory setting. 1.4.3.2 Changing the Default Settings To change the printer’s default settings: Hold down the Pause button and turn on the printer.

  • Page 24: Table 1-17. Feature Selections

    Product Description Stylus Color IIs / Stylus 820 Table 1-17. Feature Selections Menu Setting Value Feature/ Error Condensed Economy Error Condensed Economy Setting Menu Character See Table 1-18. Table Print Auto Blinks Direction Bi-D Blinks Uni-D Blinks Network Blinks I/F Mode Blinks Auto Line Blinks...

  • Page 25: Table 1-18. Character Table Selection

    Stylus Color IIs / Stylus 820 Product Description Table 1-18. Character Table Selection Condensed Economy Version Settings Error LED Common Italic U.S.A. Blinks Italic France Blinks Italic Germany Blinks Italic U.K. Blinks Italic Denmark 1 Blinks Italic Sweden Blinks Italic Italy Blinks Italic Spain 1 Blinks...

  • Page 26: Error Conditions

    Product Description Stylus Color IIs / Stylus 820 1.4.4 Error Conditions The printer can detect various errors and indicate them with LEDs. Refer to Table 1-14. 1.4.5 Printer Initialization There are three initialization methods: hardware initialization, software initialization, and panel initialization.

  • Page 27: Main Conponents

    Stylus Color IIs / Stylus 820 Product Description 1.5 MAIN COMPONENTS The main components of the Stylus Color IIs are: Printer mechanism (M-4C10) Main control board (C160 MAIN Board) Power supply unit (C160 PSB/PSE Board) Control panel board (C160 I/F Board) Housing 1.5.1 Main Control Board (C160 MAIN Board) The main control board (C160 MAIN Board) consists of an M37720 16-bit CPU, E05B08 gate array, a...

  • Page 28: Power Supply Board(C160 Psb/Pse Board)

    Product Description Stylus Color IIs / Stylus 820 1.5.2 Power Supply Board (C160 PSB/PSE Board) The power supply board (C160 PSB/PSE Board) consists of an RCC switching regulator circuit. This board does not have a power switch connected to the secondary circuit like the Stylus Color series. Thus, if the printer is turned off, it cannot continue to operate in order to perform the head capping operation.

  • Page 29: Printer Mechanism((M-4C10)

    Stylus Color IIs / Stylus 820 Product Description 1.5.4 Printer Mechanism (M-4C10) The M-4C10 printer mechanism is equipped with a replaceable 64-nozzle black printhead and 60-nozzle color (CMY) printhead, and it can print at a high resolution (720 dpi) using the special coated paper. Figure 1-11.
  • Page 30 Chapter 2 Operating Principles Table of Contents 2.1 OVERVIEW 2.2 OPERATING PRINCIPLES OF THE PRINTER MECHANISM 2.2.1 Printer Mechanism ......... . 2-2 2.2.2 Printing Operations .
  • Page 31 List of Figures Figure 2-1. Printer Mechanism Block Diagram......2-1 Figure 2-2. Structure of Printhead ........2-2 Figure 2-3.
  • Page 32 Rev. A...

  • Page 33: Overview

    Stylus Color IIs / Stylus 820 Operating Principles 2.1 OVERVIEW This section describes the operating principles for the printer mechanism and the circuits of the Stylus Color IIs. 2.2 OPERATING PRINCIPLES OF THE PRINTER MECHANISM The Stylus Color IIs printer mechanism is composed of the printhead unit, paper feed mechanism, carriage drive mechanism, pump mechanism, and various sensors.

  • Page 34: Printer Mechanism

    The printer mechanism for this printer uses a drop-on-demand ink jet system similar to the system used on all other EPSON ink jet printers. However, the printhead in this system has been completely redesigned to make it more compact and ensure a high level of reliability. The figure below shows the structure of the printhead and ink supply system.

  • Page 35: Figure 2-3. Principles Of The Printing Operation

    Stylus Color IIs / Stylus 820 Operating Principles Principles of the Printing Operation The printhead operates in one of two modes to eject ink from each nozzle: Normal state No electrical charge is applied to the MLP (Multi-Layer Piezoelectric) element attached to the back of the cavity, and pressure inside the cavity is kept at a constant level.

  • Page 36: Printing Operations

    Operating Principles Stylus Color IIs / Stylus 820 2.2.2 Printing Operations Micro Weave Mode The Stylus Color IIs printer has a special printing mode, called “Micro Weave Printing Mode,” which can be selected from the custom printer driver. Using micro weave printing can improve the output quality, because it eliminates banding that can sometimes occur in normal mode.

  • Page 37: Figure 2-5. 720 Dpi Printing For Stylus Color Iis

    Stylus Color IIs / Stylus 820 Operating Principles 720 dpi Printing Mode The Stylus Color IIs has a special printing mode, called “720 dpi Printing Mode,” which also can be selected from the custom printer driver. In this mode, the printer prints dots as follows: 1/360"...

  • Page 38: Carriage Drive Mechanism

    Operating Principles Stylus Color IIs / Stylus 820 2.2.3 Carriage Drive Mechanism The timing belt attached to the base of the carriage unit is driven by the carriage motor, which moves the carriage unit along the carriage guide shaft left to right, or vice versa. The carriage motor for this printer is a 4-phase, 48-pole, hybrid-type stepping motor mechanism, allowing the printer to stop the carriage or change carriage movement in any position.

  • Page 39: Table 2-3. Drive Terms

    Stylus Color IIs / Stylus 820 Operating Principles Table 2-3. Drive Terms CR Speed Frequency Acceleration/ Phase Drive Method (cps) (pps) Deceleration Step SPD1 (170) 3264 1W1-2 phase 88 (22) SPD2 (125) 2400 1W1-2 phase 88 (22) SPD3 (20) 1W1-2 phase 8 (2) SPD41 (20) 1W1-2 phase...

  • Page 40: Platen Gap Adjust Laver

    Operating Principles Stylus Color IIs / Stylus 820 2.2.3.1 Platen Gap Adjust Lever The platen gap adjust lever, which is attached to the left side of the printer mechanism, needs to be set to an appropriate position for the paper type. To change the platen gap (PG), put the printer in the pause state;...

  • Page 41: Paper Select Lever

    Stylus Color IIs / Stylus 820 Operating Principles 2.2.3.2 Paper Select Lever The paper select lever, which is attached to the upper case, needs to be set to an appropriate position for paper-feed reliability. Change the paper select lever before transmitting data from the host computer. Paper Select Lever Manual Feed Auto Feed...

  • Page 42: Paper Feed Mechanism

    Operating Principles Stylus Color IIs / Stylus 820 2.2.4 Paper Feed Mechanism This printer’s paper feed mechanism can feed paper only from the built-in ASF (auto sheet feeder). The paper feed drive motor is a 2-phase, 96-pole, hybrid-type stepping motor that directly drives the paper feed mechanism (paper advancing operation, paper pickup operation).

  • Page 43: Ink System

    Stylus Color IIs / Stylus 820 Operating Principles 2.2.5 Ink System This printer’s ink system is composed of the following mechanisms: Ink cartridge Pump mechanism Cap mechanism Waste ink drain tank Wiping mechanism Carriage lock mechanism The figure below gives a diagram of the ink system. Ink Cartridge Platen Roller Unit Printhead...

  • Page 44: Pump Mechanism

    Operating Principles Stylus Color IIs / Stylus 820 2.2.6 Pump Mechanism The paper feed motor drives the pump mechanism when the transmission gear is moved to the position where the paper feed motor engages the pump mechanism gear trains, when the carriage unit is at the ink system home position.

  • Page 45: Figure 2-13. Trigger Lever Reset

    Stylus Color IIs / Stylus 820 Operating Principles Drive: Trigger Lever Reset Pump Off Trigger Sus Plate Carriage Lever Pump On Trigger Paper Pickup Trigger Sus Plate Figure 2-13. Trigger Lever Reset Drive: Gear Transmission Return the pin to base position Pump Off Trigger Pump On Trigger To Pump Off State...

  • Page 46: Table 2-8. Pump Mechanism Operation

    Operating Principles Stylus Color IIs / Stylus 820 Table 2-8. Pump Mechanism Operation PF Motor Rotational Direction Operation o Absorption Clockwise (CW) o False absorption Forward rotation o Drive transmission change o Absorption Counterclockwise (CCW) o False absorption Backward rotation o Cleaner set o Drive transmission change The pump draws ink from the printhead nozzles and drains it to the waste ink drain tank.

  • Page 47: Cap Mechanism

    Stylus Color IIs / Stylus 820 Operating Principles 2.2.7 Cap Mechanism The cap mechanism prevents printhead nozzles from drying and keeps bubbles from forming inside the nozzles while the printer is not in use. The printer performs this operation automatically when print data is not received.

  • Page 48: Carriage Lock Mechanism

    Operating Principles Stylus Color IIs / Stylus 820 2.2.9 Carriage Lock Mechanism The carriage lock mechanism locks the carriage unit when the printer is in the pause state or while it is not used. The Stylus Color IIs does not use an exclusive mechanism as the carriage lock. (The carriage lock position is on the engage / disengage rail as shown in the figure below.) Carriage Lock Position...

  • Page 49: Operating Principles Of The Electrical Circuits

    Stylus Color IIs / Stylus 820 Operating Principles 2.3 OPERATING PRINCIPLES OF THE CIRCUITS The Stylus Color IIs contains the following circuit board units: C160 MAIN Board (main control circuit board) C160 PSB/PSE Board (power supply circuit board) C160 I/F (exclusive interface board) In addition to the circuit boards above, part of the printhead drive circuit is built on a separate circuit board installed in the printhead unit;...

  • Page 50: Operating Principles Of The Power Supply Circuit

    Operating Principles Stylus Color IIs / Stylus 820 2.3.1 Operating Principles of the Power Supply Circuit The power supply circuitry for this printer is provided either by the C160 PSB Board (120 VAC) or the C160 PSE Board (220-240 VAC). Both boards are identical in design and functionality, except for components in the primary circuit that accommodate the specified input voltage.
  • Page 51 Stylus Color IIs / Stylus 820 Operating Principles 1. +5 VDC line over voltage protection circuit The output voltage level of +5 V line is monitored by Zener diode ZD53. If the voltage level exceeds +6 V, the status is fed back to the primary switching circuit through photocoupler PC1 to stop the +42 V generation. 2.

  • Page 52: Operating Principles Of The Main Control Circuit

    Operating Principles Stylus Color IIs / Stylus 820 2.3.2 Operating Principles of the Main Control Circuit The main control circuit for this printer is the C160 MAIN Board, which is controlled by the 16-bit CPU M3772 (IC2), running at 16 MHz. This CPU has a unique architecture capable of handling data on the data bus at either an 8-bit or 16-bit bus width.

  • Page 53: Reset Circuits

    Stylus Color IIs / Stylus 820 Operating Principles 2.3.2.1 Reset Circuits The C160 MAIN Board contains 2 reset circuits: the +5 V monitor reset circuit and the +42 V monitor reset circuit. The +5 V monitor reset circuit checks the voltage level of the +5 V line, using reset IC PST592D (IC13), and outputs a reset signal to the E05B08 gate array (IC1) when the voltage level drops below +4.2 V.

  • Page 54: Sensor Circuits

    Operating Principles Stylus Color IIs / Stylus 820 2.3.2.2 Sensor Circuits The following sensor circuits enable the C162 MAIN Board to monitor printer mechanism status: HP sensor The photocoupler-type home position (HP) sensor is attached to the surface of the printer mechanism to detect the carriage home position.

  • Page 55: Carriage Motor Driver Circuit

    Stylus Color IIs / Stylus 820 Operating Principles 2.3.2.3 Carriage Motor Driver Circuit Carriage motor driver IC A2919 (IC12) outputs a constant current to drive the carriage motor. Gate array E05B08 (IC1) decides the motor phase and speed, and then sends a signal to the carriage motor driver IC using a 2-bit signal transmission line.
  • Page 56 Operating Principles Stylus Color IIs / Stylus 820 The figure below shows a block diagram of the carriage motor, and the Table 2-12 lists the connection between current control value and output current. +5 V IC1 (GA) VREF0 VREF1 VREF2 A2919 PHASE2 IC2 (CPU)

  • Page 57: Paper Feed Motor Driver Circuit

    Stylus Color IIs / Stylus 820 Operating Principles 2.3.2.4 Paper Feed Motor Driver Circuit The paper feed motor for this printer drives the following mechanisms: Paper feed mechanism Paper pickup mechanism Pump mechanism Driver IC A2919 (IC16) drives the paper feed motor by constant current. Its principle of operation is the same as for the carriage motor driver circuit.

  • Page 58: Printhead Driver Circuit

    Operating Principles Stylus Color IIs / Stylus 820 2.3.2.5 Printhead Driver Circuit The printhead driver circuit for this printer is composed of the following: Common driver circuit (trapezoidal drive pulse generation) Head driver circuit (nozzle control built on the printhead) SED5619D, the 64-bit thermal head driver in the head drive circuit on the carriage, is used as a nozzle selector to drive printhead nozzles selectively.

  • Page 59: Figure 2-29. Printhead Electrical Pole Configuration

    Stylus Color IIs / Stylus 820 Operating Principles The electrical pole configuration on the printhead unit is as follows: GND2 GND2 Figure 2-29. Printhead Electrical Pole Configuration SI Signal: For transmitting 64-bit serial data to the SED5619D LAT: The latch trigger for 64-bit serial data in the driver IC (SED5619D) CLK: The standard trigger for driving serial transmission Note:...
  • Page 60 Chapter 3 Disassembly and Assembly Table of Contents 3.1 OVERVIEW 3.1.1 Precautions for Disassembling the Printer ..... . 3-1 3.2 DISASSEMBLY AND ASSEMBLY 3.2.1 Upper Case Removal .

  • Page 61: List Of Figures

    LIST OF FIGURES Figure 3-1. Upper Housing Removal ....... . 3-2 Figure 3-2.

  • Page 62: Overview

    Stylus Color IIs / Stylus 820 Disassembly and Assembly 3.1 OVERVIEW This section describes procedures for disassembling the main components of the printer. Unless otherwise specified, disassembled units or components can be reassembled by reversing the disassembly procedure. Therefore, no assembly procedures are included. Precautions for any disassembly or assembly procedure are described under the heading “Disassembly/Assembly Points.”...

  • Page 63: Disassembly And Assembly

    Disassembly and Assembly Stylus Color IIs / Stylus 820 START Upper Case C160 Main Board C160 I/F Board C160 PS Board Removal Removal Removal Removal 3.2.1 Page 3-2 3.2.2 Page 3-3 3.2.3 Page 3-4 3.2.4 Page 3-5 PE Sensor ASF Unit Carriage Unit M-4C10 Mechanism Removal...
  • Page 64 Stylus Color IIs / Stylus 820 Disassembly and Assembly 3.2.2 C160 MAIN Control Board and ASF Sensor Removal Remove the upper case (see Section 3.2.1). Remove 4CBB (M3 6) screws attaching the shield frame to the C160 MAIN Board. Remove 7 connectors (CN1, CN8, CN7, CN4, CN3, CN5, CN6) on the main board. (Push CN6 down to release cable on main board.) Then remove the C160 Main Control Board.

  • Page 65: C160 I/F Board Removal

    Disassembly and Assembly Stylus Color IIs / Stylus 820 Remove 3 CPS (M3 6) screws fixing the board frame to the mechanism and 1 CPS (M3x6) screw fixing the metal stay between the board frame and the side(right) frame. Then remove the metal stay. Remove 2 CPS (M3 6) screws fixing the transpearency plate, then remove it.

  • Page 66: C160 Psb/Pse Board Removal

    Stylus Color IIs / Stylus 820 Disassembly and Assembly 3.2.4 C160 PSB/PSE Board Removal Remove the upper case (see Section 3.2.1). Remove 1 CBB (M3 10) screw securing the power supply board to the lower case, 1 CPS (M3 6) screw securing the board frame to the grounding plate, 1 CBB (M3x10) screw fixing the board frame and 1 big screw securing the board frame to the lower case via the grounding plate.

  • Page 67: M-4C10 Printer Mechanism Removal

    Disassembly and Assembly Stylus Color IIs / Stylus 820 3.2.5 M-4C10 Printer Mechanism Removal Remove the upper case (see Section 3.2.1). Remove the C160 MAIN Board (see Section 3.2.2). Remove the C160 I/F Board (see Section 3.2.3). Remove the C160 power supply board (see Section 3.2.4). Remove 4 CBB (M4x11) screws securing the printer mechanism to the lower case.

  • Page 68: Printer Mechanism Disassembly

    Stylus Color IIs / Stylus 820 Disassembly and Assembly 3.2.6 Printer Mechanism Disassembly The procedures described in this section explain how to remove components within the printer mechanism. 3.2.6.1 Carriage Unit Removal Remove the printer mechanism (see Section 3.2.6). Remove the blue PG lever. Remove the tension coil securing the parallelism bushing to the side frame.

  • Page 69: Figure 3-9. Parallelism Adjust Lever Removal

    Disassembly and Assembly Stylus Color IIs / Stylus 820 Remove the parallelism adjust lever by rotating it toward front while pulling the lever knob. Lever Knob Parallelism Adjust Lever Figure 3-9. Parallelism Adjust Lever Removal Remove the timing belt while pressing the pulley holder; then remove the carriage unit along with the carriage guide shaft.

  • Page 70: Asf Unit Removal

    Stylus Color IIs / Stylus 820 Disassembly and Assembly 3.2.6.2 ASF Unit Removal Remove the printer mechanism (see Section 3.2.5). Press down the tab on the left side; then pull the ASF unit toward you. Press the tab on the right side; then remove the ASF unit. When you remove the ASF, be extremely careful of the PE sensor.

  • Page 71: Pickup Roller Unit Removal

    Disassembly and Assembly Stylus Color IIs / Stylus 820 3.2.6.4 Pickup Roller Unit Removal Remove the printer mechanism (see Section 3.2.5). Remove the ASF unit (see Section 3.2.6.2). Remove the PE sensor (see Section 3.2.6.3). By rotating it, remove 1 shaft holder securing the roller shaft to the frame. Remove the pickup roller unit, referring the following illustration.

  • Page 72: Paper Feed Roller Unit Removal

    Stylus Color IIs / Stylus 820 Disassembly and Assembly 3.2.6.6 Paper Feed Roller Unit Removal Remove the printer mechanism (see Section 3.2.5). Remove the carriage unit (see Section 3.2.6.1). Remove the carriage home position sensor (see Section 3.2.6.5). Remove the tension spring holding the tension roller assembly to the sub frame. Remove 2 CPS (M3x6) screws securing the front frame to the printer mechanism.

  • Page 73: Head Cleaner Replacement Removal

    Disassembly and Assembly Stylus Color IIs / Stylus 820 3.2.6.8 Head Cleaner Replacement Remove the printer mechanism (see Section 3.2.5). Remove the front frame (see Section 3.2.6.6). Use tweezers to unhook the head cleaner. Head Cleaner Platen Hook Figure 3-17. Head Cleaner Replacement o Never touch the head cleaner with your bare hands.
  • Page 74 Stylus Color IIs / Stylus 820 Disassembly and Assembly 3.2.6.9 Cap Unit Removal Remove the printer mechanism (see Section 3.2.5). Remove the front frame (see Section 3.2.6.6). Remove 1 CPS (M3x6) screw securing the cap unit to the lower frame. CPS(M3x6) White Tube Figure 3-18.

  • Page 75: Paper Feed Motor Removal

    Disassembly and Assembly Stylus Color IIs / Stylus 820 Pin Holder HOLE Pump Unit Figure 3-20. Pin Position 3.2.6.10 Paper Feed Motor Removal Remove the printer mechanism (see Section 3.2.5). Remove the pump unit. (see Section 3.2.6.9). Remove the 2 CBB (M3x10) screws securing the paper feed motor to the motor frame. Pump Unit CBB(M3x10) PF Motor...
  • Page 76 Chapter 4 Adjustment Table of Contents 4.1 OVERVIEW 4.1.1 Destination Data Writing Operation......4-2 4.1.2 Bi-D (Bidirectional Printing) Alignment Adjustment .

  • Page 77: Table 4-1. Required Adjustments

    Stylus Color IIs / Stylus 820 Adjustments 4.1 OVERVIEW This section describes adjustments required when the printer is disassembled and assembled after repair. oAfter removing an ink cartridge, always install a new cartridge immediately. During adjustments and testing, use cartridges designed exclusively for service (Monochrome: 1023206, CMY: 1023207).

  • Page 78: Destination Data Writing Operation

    Adjustments Stylus Color IIs / Stylus 820 4.1.1 Destination Data Writing Operation The setup value that specifies the printer destination (for character generation and panel default settings) is stored in the EEPROM on the C160 MAIN Board. Therefore, this setup value must be written into the EEPROM when the main board or EEPROM chip is replaced.

  • Page 79: Bi-D (Bidirectional Printing) Alignment Adjustment

    Stylus Color IIs / Stylus 820 Adjustments 4.1.2 Bi-D (Bidirectional Printing) Alignment Adjustment Bidirectional alignment is required when the printer mechanism, main board, or printhead (board) is replaced. Performing this adjustment determines a compensation value to rectify any deviation in the print position. This deviation could be caused by the different print speeds, which are due to tolerances in the mechanical components, or to differences in print timing between odd-numbered lines and even-numbered lines in bidirectional printing.
  • Page 80 Adjustments Stylus Color IIs / Stylus 820 If the sample print does not vertically align both odd- and even-numbered lines, enter a compensation value in the range from 36 to +36. Positive compensation value: Shifts the 2nd line to the left Negative compensation value: Shifts the 2nd line to the right When the sample print becomes vertically aligned for both lines, press Y and E N T E R ;...
  • Page 81 Stylus Color IIs / Stylus 820 Adjustments 4.1.3 Head Gap Adjustment (Black and Color Head) The head gap adjustment is required when the printer mechanism, main board, or printhead (board) is replaced or diassembled. This adjustment calibrates the head drive timing between the black and color head. If this adjustment is not made, the vertical alignment will not be completed.

  • Page 82: Figure 4-4. Angle Lever Operation

    Adjustments Stylus Color IIs / Stylus 820 Change the angle lever, referring to the description below. Rear Rear Black Angle Lever Front Front Figure 4-4. Angle Lever Operation Note: You can change the angle lever without removing the upper case. To confirm the head angle, then press the space key to print the modified pattern.

  • Page 83: Platen Gap Adjustment

    Stylus Color IIs / Stylus 820 Adjustments 4.1.4 Platen Gap Adjustment This adjustment is required when the carriage unit is removed from the main unit or replaced. Adjust the distance between the printhead nose and the paper surface to 1.18 mm. Remove the upper case, and place a thickness gauge (commercially available) on the paper guide plate at the adjustment position on the left side of the printer , as shown in the figure below: Move the carriage unit manually onto the thickness gauge.

  • Page 84: Eeprom Reset Procedure

    Adjustments Stylus Color IIs / Stylus 820 4.1.5 EEPROM Reset Procedure This operation is required when the C160 MAIN Board is replaced, when the waste ink drain pad is replaced, or to recover from printer malfunction. There are two reset methods for this printer. (Reset All and Reset Maintenance Error Only) Reset All Turn printer power on while pressing the ALT and Load / Eject buttons.
  • Page 85 Chapter 5 Troubleshooting Table of Contents 5.1 OVERVIEW 5.2 Repair the Power Supply Board 5.3 Repair the C160 Main Board 5.4 Repair of PRINTER MECHANISM (M-4C10) LIST OF FIGURES Figure 5-1. Troubleshooting Construction ......5-1 Figure 5-2.
  • Page 86 This section describes troubleshooting at the unit level and for abnormal printing(missing-aligned dots). The EPSON Stylus Color IIs/Stylus 820 uses a new print head that is different than the previous Stylus Color print head. Because of its designs, indicating that the cartridge is low or out of ink. If you remove or even partially remove a cartridge unit before it is out of ink, air invades the print head nozzle(s) and the ink cartridge.
  • Page 87 Troubleshooting Stylus Color IIs / Stylus 820 Table 5-2. Sensor Status Sensor Point Signal Level Status H (5 V) Paper exists PE Sensor Pin 1 (PE) to Pin 2 L (GND) No paper (paper end) (GND) L (GND) Cartridge exists CO Sensor Pin 3 (CO) to H (5 V)
  • Page 88 Stylus Color IIs / Stylus 820 Troubleshooting 5.2 Unit-Repair - C160 Power Supply Board This section describes how to repair the C160 power supply board and main board. The table below provides various symptoms, likely causes, and check points. The checkpoints refer to waveforms, resistances, and other values to check to evaluate the operation of each component.
  • Page 89 Troubleshooting Stylus Color IIs / Stylus 820 5.3 Unit Repair - C160 Main Control Board This section describes the problems related to the main controller board (C160 MAIN). The table below provides various symptoms, likely causes, and checkpoints. The checkpoints refer to waveforms, resistance, and other values to be checked to evaluate the operation of each component.

  • Page 90: Troubleshooting

    Stylus Color IIs / Stylus 820 Troubleshooting Table 5-4. Repair of C160 MAIN(Cont.) Phenomenon Condition Cause Checkpoints Solution Carriage does Drive pulse CPU is Does the wave-form correct? Replace CPU. not operate does not defective. (Check pin either at 9 and 10.) normally.
  • Page 91 Troubleshooting Stylus Color IIs / Stylus 820 5.4 Repair of PRINTER MECHANISM (M-4C10) Any problems related to the printer mechanism should be repaired according to the troubleshooting procedures in Table 5-7. Table 5-5. Repair of the Printer Mechanism Symptom Condition Cause Checkpoint Solution...
  • Page 92 Stylus Color IIs / Stylus 820 Troubleshooting 5.5 Dot missing Trouble shooting Guide This section describes how to recover the clogged nozzle when you receive the dot-missing printer. Since the print head of this printer is the new system, it is very difficut to eliminate the invaded air bubble from the print head unit or the ink cartridge so that, never use again if you remove once a ink cartridge from the main unit.
  • Page 93 Troubleshooting Stylus Color IIs / Stylus 820 5.5.1 How to recover the dot-missing with the brand-new ink cartridge The under flow-chart shows the way of the recovering a clogged nozzle with the ink cartridge. The section that is indicated the out of each items shows the additional explanation when you want to help a detail contents.
  • Page 94 Stylus Color IIs / Stylus 820 Troubleshooting 5.5.1.1 How to Perform the 360-DPI Printing It is possible to confirm the any problems with the 360-DPI check pattern printing. Also, if you receive the white banding problem, you can confirm the wrong condition quickly. Please perform the proper repir referring under explanations.
  • Page 95 Troubleshooting Stylus Color IIs / Stylus 820 [Step 8] Select the option 5 or option 6 depending on your printer head. Then the display indicates the “MC ? ”_" [Step 9] Press the return key. Then the printer automatically prints a check pattern. First, the TOF line is printed, then the 360-DPI full duty pattern will be appeared.
  • Page 96 Stylus Color IIs / Stylus 820 Troubleshooting 5.5.1.3 Performing the CL operation for 2 ~ 3 times This section describes the cleaning operation if you find a print missing on the 360-DPI check pattern. You need a confirmation either the CL opeartion is correctly performed or not in this function.. [Step 1] Remove the upper case.
  • Page 97 Troubleshooting Stylus Color IIs / Stylus 820 5.5.1.4 Does the Head angle correct? This section describes either the head angle condition is correct or not. Refer to Section 4.1.3 in the acrual adjustment. [Step 1] Perform the head angle adjustment. (Refer to Section 4.1.3.) Note: If the head angle condition is wrong, white or color banding problem will be appeared on the graphic pattern.
  • Page 98 Chapter 6 Maintenance Table of Contents 6.1 PREVENTIVE MAINTENANCE 6.1.1 Printhead Cleaning......... . 6-1 6.1.2 Waste Ink Drain Tank Replacement .

  • Page 99: Preventive Maintenance

    Stylus Color IIs / Stylus 820 Maintenance 6.1 PREVENTIVE MAINTENANCE This printer must be lubricated only O9 when you need a lubrication for carriage guide shaft. If you lubricate with another oil, it could permanently damage the print head unit.. Although this printer requires no specific maintenance on a regular basis, recommends that you clean the following thoroughly whenever you get a chance.: Outer case...

  • Page 100: Lubrication And Adhesives

    The printer must be lubricated properly when it is disassembled for component replacement, or if mechanical noise exceeds a certain level. EPSON recommends only the lubricants listed in table below for this printer. They have been tested extensively and found to comply with the requirements of this printer mechanism.
  • Page 101 Stylus Color IIs / Stylus 820 Maintenance Figure 6-1. Lubrication and Adhesive Point Rev. A...
  • Page 102 Appendix Table of Contents A.1 CONNECTOR SUMMARY A.1.1 Detail of Connector Summary ....... A-2 A.2 CIRCUIT DIAGRAMS A.3 CIRCUIT BOARD COMPONENTS A.4 EXPLODED DIAGRAMS...
  • Page 103 Stylus Color IIs / Stylus 820 Appendix A.1 CONNECTOR SUMMARY The figure below shows the interconnection between the major components of the Stylus Color IIs / Stylus 820. C160PSB C160MAIN AC INLET Centronics PF MOTOR CR MOTOR HEAD Thermistor No Head Sensor No I/C Sensor Head Drive Voltage Select (3-bit ID Code)
  • Page 104 Appendix Stylus Color IIs / Stylus 820 A.1.1 Connector Summary This section describes the connector summary. The table A-1 lists the connoctor summary for every connectors on the C160 main and the C160 power supply board. Also, the table A-2 to table A-10 lists the detail signals for every connectors.
  • Page 105 Stylus Color IIs / Stylus 820 Appendix Table A-3. Connector Pin Assignments — CN2 Name Description Not connected (Serial I/F) —- —- —- Table A-4. Connector Pin Assignments — CN3 Name Description Bi-poler drive phase A CR-A Bi-poler drive phase -A Bi-poler drive phase B CR-B Bi-poler drive phase -B...
  • Page 106 Appendix Stylus Color IIs / Stylus 820 Table A-6. Connector Pin Assignments — CN5 Name Description Bi-poler drive phase A PF-A Bi-poler drive phase -A Bi-poler drive phase B CR-B Bi-poler drive phase -B Table A-7. Connector Pin Assignments — CN6 Name Description +42VDC...
  • Page 107 Stylus Color IIs / Stylus 820 Appendix A.2 CIRCUIT DIAGRAM Figure A-2. C160 PSB Board Circuit Diagram Rev. A...
  • Page 108 Appendix Stylus Color IIs / Stylus 820 Figure A-3. C160 PSE Board Circuit Diagram Rev. A...
  • Page 109 Stylus Color IIs / Stylus 820 Appendix Figure A-4. C160 Main Control Board Circuit Diagram Rev. A...
  • Page 110 Appendix Stylus Color IIs / Stylus 820 Rev. A...
  • Page 111 Stylus Color IIs / Stylus 820 Appendix A.3 Circuit Board Component Layout Figure A-5. C160 PSB Board Component Layout Rev. A...
  • Page 112 Appendix Stylus Color IIs / Stylus 820 Figure A-6. C160 PSE Board Component Layout A-10 Rev. A...
  • Page 113 Stylus Color IIs / Stylus 820 Appendix Figure A-7. C160 Main Control Board Component Layout Rev. A A-11...
  • Page 114 Appendix Stylus Color IIs / Stylus 820 Figure A-8. C160 I/F Board Component Layout A-12 Rev. A...
  • Page 115 Stylus Color IIs / Stylus 820 Appendix A.4 Exploded Diagram Figure A-9. Stylus Color IIs(820) Exploded Diagram (1) Rev. A A-13...
  • Page 116 Appendix Stylus Color IIs / Stylus 820 Figure A-10. Stylus Color IIs(820) Exploded Diagram (2) Note: A part of #136 and #134 are only used in Japan. A-14 Rev. A...
  • Page 117 Stylus Color IIs / Stylus 820 Appendix Figure A-11. Stylus Color IIs(820) Exploded Diagram (3) Rev. A A-15...

  • Page 118: August

    REVISION SHEET Revision Issue Date Contents 1st issue Rev.-A August 25,1995 Rev.-B October 31,1995 Add the parts list into Appendix Page Detail Position I 1-3 I Input buffer: (64 KBto15KB) \ 1 - 1 2 \ T a b l e l - 1 2 : AddtheEEPR0Mclear I I 2-20 I M o d i f y t h e 2 n d p a r a g r a p h &...
  • Page 119 - EPSON Saris Serif 10.5 points, 8-32 points (in units of 2 points) - EPSON Roman T - EPSON Saris Serif H 10.5 points, 8 -32 points (in units of 2 points) ESC/P 2 and expanded raster graphics codes Control codes: 0.5KB or 15KB(Depending on the installed printhead unit)
  • Page 120 Stylus Color 11s /Stylus 820 Product Description Table 1-12. Built-in Functions on the Panel Button Function Demonstration printing I Self-test Load/Eject Default setting mode (with printing) Pause Non-smear printing Alt + Load/Eject I Data dump mode (Hex mode) Load/Eject + Pause 1) Default setting mode (without printing) Pause + Alt 2) EEPROM reset mode (Refer to 4.1.5 in detail)
  • Page 121 Stylus Color 1!s /Stylus 820 Operating Principles 2.3.2 Operating Principles of the Main Control Circuit The main control circuit for this printer is the C160 MAIN Board, which is controlled by the 16-bit CPU M3772 (IC2), running at 16 MHz. This CPU has a unique architecture capable of handling data on the data bus at either an 8-bit or 16-bit bus width.

  • Page 122: Pump Unit Removal

    Disassembly and Assembly Stylus Color 1/s /Stylus 820 Pump Unit Removal 3.2.6.9 Remove the printer mechanism (see Section 3.2.5). 2. Remove the front frame (see Section 3.2.6.6). 3. Remove 1 CPS (M3x6) screw securing the cap unit to the lower frame. Figure 3-18.
  • Page 123 Stylus Color 11s /Stylus 820 Adjustments 4.1.1 Destination Data Writing Operation The setup value that specifies the printer destination (for character generation and panel default settings) is stored in the EEPROM on the C160 MAIN Board. Therefore, this setup value must be written into the EEPROM when the main board or EEPROM chip is replaced.
  • Page 124 Adjustments Stylus Color 1/s /Stylus 820 4.1.3 Head Angle Adjustment (Black and Color Head) The head kmgle adjustment is required when the printer mechanism, main board, or printhead (board) is replaced or disassembled. This adjustment calibrates the head drive timing between the black and color head.
  • Page 125 Stylus Color 11s /Stylus 820 Adjustments 4.1.5 EEPROM Reset Procedure This operation is required when the C160 MAIN Board is replaced, when the waste ink drain pad is replaced, or to recover from printer malfunction. There are two reset methods for this printer. (Reset All and Reset Maintenance Error Only) Reset All Turn printer power on while pressing the ALT and Pause buttons.
  • Page 126 Troubleshooting Stylus Color 11s /Stylus 820 5.2 Unit-Repair - C160 Power Supply Board This section describes how to repair the C160 power supply board and main board. The table below provides various symptoms, likely causes, and check points. The checkpoints refer to waveforms, resistances, and other values to check to evaluate the operation of each component.
  • Page 127 Maintenance Stylus Color IIs /Stylus 820 6.1 PREVENTIVE MAINTENANCE This printer must be lubricated only 09 when you need a lubrication for carriage guide shaft. If you lubricate with another oil, it could permanently damage the print head unit.. Although this printer requires no specific maintenance on a regular basis,’ recommends that you clean the following thoroughly whenever you get a chance.: Outer case Use a soft, clean cloth, dampened with mild detergent, if necessary.
  • Page 128 The printer must be lubricated properly when it is disassembled for component replacement, or if mechanical noise exceeds a certain level. EPSON recommends only the lubricants Iisted in table below for this printer. They have been tested extensively and found to comply with the requirements of this printer mechanism.
  • Page 129 EPSON OVERSEAS MARKETING LOCATIONS EPSON AMERICA INC. EPSON DEUTSCHLAND GmbH 20770 Madrona Avenue, Zülpicher Straße 6, 40549 Düsseldorf P.O. Box 2842 F.R. Germany Torrance, CA 90509-2842 Phone: 0211-56030 Phone: (800) 922-8911 Fax : 0211-504-7787 Fax: (310) 782-5220 EPSON UK LTD.

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