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User Guide for Vortex 851R printer (R13) 28-May-2014

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1. D femm e Bi epii ey s 9 WE cy nr ze d M hleeen GB oriee Prete Senn SD Som Pee ye Tabs Ss Zentren Staten DA PS z S Mech State STANDET Diagnostics Alech fined Di Do 5 i 5 Slee Same Varri Pratbead POY Aleng Sam TANDET Formar da aladi Serial Member MYPAL Smal Number AT FSCADESOSCH Firmware Version D0 4608 Kellon GE Iegbesd BAHTI Fesad lsiera Memory MB Ai Back I 98 es Total Pages L600x 1600 450 Cyan 98 Bessa Beery 8 bor Me Total Pages L it 21 Black 2 55 Slamrtrmance bisdun Ce Magepta G E Swetwerk Status re Ted MAC Addeean 84 97 65 01 23 67 Printer Name DEWO11967 IP Address 192 068 205 PEM DES DES ESA ESA Demain Name Sebari Mask 255 355 2550 Joke Page A DC Dass Delali Gateway 192 168 2244 Total Fagen BOOTb Disabled WIENS Server 05000 AgtelP hid User Interface DACP Lease Time tij 0 Dagmsunecn Ink Usage Fani Samgis Page Ert Cordon Pret Dupain Mesok Ce 4 Mi Prt Dens Page Frei Coe Bare Port isin Chen Stop Be ch Evar Leg History Pages Ereni Description 42 TPS Feni DON 28 Babette 6 LGM Sloe di TPS Peo BO EW dadde TOT TOTS TOT ITH 429 Paien aren 439 Peethead srergeoe fal 429 Prethead coor 429 Presthead enrice Pe 439 Prethead error 420 Pristhead insertice fall LES TPS Reak BOOSTS TOT RTT OT Te H7 Poorer of L TPS Repke BOOST Secce T Ste T L Power of Lf Test page 15 Test page LD Teal page IL Peat page bo Tru page S biman Pectevted Mode Ce
2. Datum Post Septum Wi Ink Level Prism a Product Label Handle Ke e Color Label 219 Handle Internal Rib Filter Picture of Ink Cartridge Cross Section Design Objective Create air path as high as possible in ink cartridge so that ink doesn t get pushed out of cartridge during deprime Picture of Ink Cartridge Cross Section with Air Vent Path Detail 12 2 8 Ink Connection Ports Ink connection ports allow the connection of the external ink supply houses to the print engine Unique zero insertion force ganged connectors allow all 10 ink hoses to be engaged with the printhead in one movement The printhead can be removed or installed without disconnecting any of the ink hoses Ink Cartridges 2 9 Ink Delivery System IDS The Ink Delivery System IDS is a complex system designed to cleanly and reliably deliver ink to the printhead while minimizing color mixing drop weight variation and dehydration The major components of the Ink Delivery System IDS are e The disposable ink cartridges e The printhead e The tubing e The peristaltic pump e The pinch valve assembly e The QA and ink level sensing electronics e The buffer box 2 10 Bulkhead Assembly The bulkhead assembly includes the ink cartridges the septum for connecting to the bulkhead plate ink level PCAs the QAI chip for each ink cartridge and the buffer boxes for each
3. 3 Verify that the printhead to paper spacing PPS is within limits A If within limits continue to the next step If beyond the threshold adjust the spacing If not resolved contact Customer Service and report error code CM01 03 Color misting unresolved 101 Cause CM02 Color Contamination Repeated at Beginning of Every Page CM02 displays as small amounts of color contamination that appear on top of a page The contamination is reduced after a couple of pages Leading Edge of Printi Picture of color Mixing Color Contamination The printhead is covered with ink somewhere and the ink keeps wicking back to the channels This happens most often on printheads with paper guides since ink wicks beneath the paper guide and forms a reservoir of ink that damages future prints Resolution 1 Verify that the defect is beyond the threshold If beyond the threshold continue to the next step 2 Check if the correct maintenance process is applied KWS IPS Use the correct Maintenance profile and re evaluate the performance If not resolved continue to the next step 3 Run the color mixing recovery process maint_clear_color_mix 1 and re evaluate the plots If not resolved continue to the next step 4 Power off the printer remove the printhead and thoroughly clean it manually 5 If there is a paper guide remove it and clean underneath it If not resolved contact Customer Service and report error code CMO
4. This occurs 20mm from the bottom of the page Cause BOFTE results from a change in paper speed when the paper Is released from the grit shaft that precedes the print area Differences in speed between the leading and trailing paper handling drives can make the problem worse as can improper tension settings on the belts and pinch wheels The paper thickness and shape also plays a role Resolution Ensure that all belts are properly tensioned SEE TOFTE 135 Paper Jams and Head Crashes PA09 True Paper Jams The sound of crinkling paper usually precedes the notification of a paper jam PAOY Paper must be cleared to continue printing Cause Causes include debris or objects in the paper path platen out of position bent or curled media prior to entering the printer repeated paper jams are often caused by small pieces of paper that are left behind from a first sheet that ripped Resolution 1 Open clamshell and remove jammed media from the paper path 2 Check for small pieces of paper that may be caught in pinch rollers and other tight places These small pieces need to be removed before continuing printing PA10 False Paper Jams An error message for example Media present in paper path claims that there is a paper jam but there is not In this condition the cap will be unable to cap the printhead The maintenance module Is also be unable to wipe the printhead as the print engine is set as though media is blocking its p
5. colors Can be caused by ink flooding air in the printhead or a dirty printhead Results in no print or crisp blocks of missing drops usually conforming to the printhead die boundaries Cured by recirculation priming or cycles of depriming and repriming Often the bubbles will go away with time Cured by automatic servicing or manual wiping Cured by automated serving or manual wiping Cured by reseating the printhead or replacing the printhead Print quality problems are detailed in the Troubleshooting Guide Please contact Customer Support for further details 89 6 4 Vortex 851R Troubleshooting Guide GENERAL Documents to read before available on ftp Print engine OEM Setup and Operations Guide OEM Troubleshooting Guide OEM Service and Repair Guide Technical Specifications Vortex 851R Training software module Troubleshooting Flowchart SSC Release Notes Checklist before doing any support Firmware is 20140509 version Driver is R13 Print engine serial number USB AB cable is attached to print engine TTL cable is attached to print engine Preventive maintenance is done sensors are clean KWS default 3 NVM pages_per_cut 1 NVM Mpcarev 5 NVM wiper motor E NVM pump motor B NEI 3 5 4 is installed 90 Troubleshooting Tools Serial communication between the NorthStar print engine and the host PC enables detection and analysis of issues You will also need the related softwa
6. not seated properly Debris build up on blade and rollers increasing friction Bad motor Color Mixing Wiper roller microfiber roller MFR is saturated Squeegee doctor blade wedged not seated properly or is bowed Check through each of the possible Causes If possible correct the situation For example re seat the gears and squeegee clean off debris from blade and rollers Re test If motor is still stalled contact Customer Service If wiper roller is saturated replace it If squeegee is not seated properly reseat It If squeegee is bowed contact Customer Service Unable to remove Latches on the Contact Customer Service or maintenance module from the maintenance module your Application Engineer print engine were not completely closed when the MM was Inserted and they are now hooked on the bottom of the paper path 88 6 2 Printhead Troubleshooting Occasionally print quality is affected by minor problems that arise with the printhead The following table provides a list of common printhead issues their symptoms and solutions Air and air bubbles causing bloacked nozzles Debris on printhead Ink mixing Electrical failure or poor electrical connection 6 3 Print quality problems Appear as missing groups of adjacent drops but the shape is often rounded or irregular Shows up as regularly missing or misdirected nozzles or as ink color mixing Appears as mixed or muddy
7. 108 Streaking SR White or grey lines or parabolas running vertically in print jobs as well as white unprinted areas are called streaks Picture of Streaks SR01 Growing Nozzles Out SR1 displays as a region of nozzles out that is nozzles stop working that becomes increasingly worse on the way down the page or when any large gt 1cm wide region of nozzles out moves or changes down the page Cause This print defect indicates a large bubble or the beginning of a deprime where air Is entering through some of the nozzles or the Ink Delivery System IDS and expanding to other nozzles Resolution 1 Run a General Maintenance Process TCL maint_user_recovery 1 TCL maint_user_recovery 2 TCL maint_user_recovery 3 If not resolved continue to the next step 2 Perform a pressure prime recovery 2 TCL ids_light_pressure_prime If not resolved m continue to the next step 3 Inspect system for leakage e g kinked tubes bad fluidic interconnect connections etc If not resolved contact Customer Service and report error code SRO1 04 Unresolved streaks 109 1 SR02 Large Missing Nozzles with Varying Amount SR02 displays as a parabola shaped area in the middle of the page Caused by ink puddling Caused by air bubbles Picture of Streaks Parabolas Cause Bubbles can air block ink from getting to nozzles or a puddle has formed in front of the nozzle Resolution If th
8. 5 1 1 Print Area Print area can be found on the back of the printer where the operator needs to feed the materials Any media type must go through the metal paper guide in order to avoid any movement during printing Picture of Paper guide Printing Area is dedicated with the green bar Left edges of Label Gap Sensor and Blackmark Tickmark Sensor is shown with the blue marks During printing the operator has to align the actual material to these blue marks otherwise the sensors won t be able to recognize the media and the printer could run into an error PRINTING AREA LABEL LEF T EDGE ONE OUT MATERIAL BLACK MARK LEFT EDGE BLACK MARK MATERIAL Picture of Printing Area 3 5 1 2 Load Media Take the paper from the roll and see across under the unwinder s roller Don t forget to do this because this will strain the label media during printing Drag the papar towards and see across the roller of the paper guide under the antistatic brushes Feed the paper in the printer till you feel some resistance ye 3 6 Connect the printer to a computer 3 6 1 Direct connection to a personal computer The printer connect to directly via USB AB cable and a TCP IP cable For the driver installation advice to use the USB AB cable or install that in offline mode and after the installtion seletc the correct port for the USB usage 33 3 7 Installing the Printer Driver Your printer can be installed A online
9. Picture of Rear Ink Tubing Detail Buffer Box Peristaltic ink Pump Tubing into Fluidic Couplings Peristaltic Pump Pinch Valve and Vents x5 Picture of Ink Tubing Connections Use a finger to gently pry both fluicid coupling covers off in order to inspect the ink tube connections underneath 64 Picture of Remove Fluidic Coupling Covers 2 Visually inspect each tubing connection point for leaks If leaks are found escalate to a technician for troubleshooting 3 Follow the exposed length of each tube and visually inspect each ink tube for inks or pinches in the tubing Undo the irregularity to allow ink to flow freely Escalate to a technician if leaks result Re install the fluidic coupling covers 5 Re install any housing removed to access this area 65 Lifter Motor Gear Inspection and Encoder Cleaning The lift motor gear on the right side of the unit must be inspected every month 2 pbe wettest e s e Diere nf tho lift Mantar Accomhly laratinn 1 Inspect the lift motor gear for general wear worn teeth debris etc Remove any debris found If excessive wear is observed escalate to a technician for repair Picture of the Lift Motor 2 Use a lint free wipe damped with DI water to very gently clean exposed encoders Gently rotate the encoder after each wipe to ensure cleaning of the entire surface NOTE On some printer there is a cover on the lift motor encoder that protects it fr
10. Printer Series Driver Properties Vortex Printer Serres Driver Print to the following porttz Documents will print to the first free checked port Port Description Printer E 192 16 Universal TCP IP Port 192 16 Universal TCP IP Port 19216 Universal TCP IP Port IPP_19 Universal TCP IP Port Memyet Office Printer E 1P 127 Universal TCP IP Port IP 192 Universal TCP IP Port dl ID 197 Universal TCP IP Port Vortex Printer Series Driver Configure Port Enable printer pooling Click Apply and OK Printer installation is finished 38 B Installing Printer via direct USB connection For this method make sure Your printer is turned on You have connected your PC to the printer with USB AB cable 1 On the user PC or laptop open folder that contains the printer driver software R13 driver and run WinSetup exe ELE RLA 70140508 eng ris Driver b e ty earch Kla reti lt ER Drgange Inchade in library s Share with e Ram hew inier Fi i wr F i Hame gt D EE Draep CH 5 TE Downioadts Augen i W Recent Places TA WinSetup S kyi si Autodesk 350 Google Drive 2 As the installer starts Windows will prompt for permission Click Yes j 5i Rie bels Ing H H H Fi i Unable te connect to the printer te check the firmware please check connections and chear printer errors De you want te retry ae S
11. Size Custom Resize Resizing Lets you specify the Original Size or Custom Resize lets you resize the original as a of normal size The printer will print the document in the size you selected regardless of the size of the paper selected Print on lets you specify the particular size of paper that you want to print on regardless of the size of the original document Checking Scale to Fit automatically resizes the document to fit on the new page size Multipage per N UP If would like to print more pages on the same sheet My Print Settings Access your custom print settings for various jobs that you uploaded through the Media Profile Upload in the Toolbox 100 Print on Letter 8 1 2 x 11in Scale to fit MultiPage N Up Pages Per Sheet My Print Settings Defaults Multi Page N Up Pages per Sheet 1 2 4 9 16 Arrange Pages e Right then down e Down then right s Left then down e Down then left My Print Settings 43 3 7 1 2 Media Tab as Vortex Printer Series Driver Printing Preferences Ss i General Layout Media Import Export Services Position Adjustment J Horizontal Offset 0 Vertical Offset Inches Millimeters Pixels Media Layout Inter Label Gap Black Mark Cut Sheet Continuous Use Printer Setting Page Cutting Job Cut W Use Printer Setting Sheets per cut V Use Printer Setting memyjet 8 5 by 11 inches S
12. a Spring force or excessively high back tension Resolution 1 Check the feed mechanism for proper operation 2 Read the NVM settings to check that PP_scaling Is set to 0 3 Open clamshell and check for any damaged or non functional pinch rollers PA13 Incorrect Bottom Margin The bottom margin will appear very large or very small or nonexistent as the printed image can run off the edge of the media Cause Paper path scaling incorrect NVM setting Media slip likely resulting from too light a Spring force or excessively high back tension Resolution 1 Check the feed mechanism for proper operation 2 Read the NVM settings to check that PP_scaling Is set to 0 3 Open clamshell and check for any damaged or nonfunctional pinch rollers PA14 Print Image Skewed Printed image appears crooked or skewed when viewed in comparison to the edge of the media Printed image might also run off of the edge of the media on one side and leave white space on the opposite edge Cause This defects results from incorrect feeder alignment and from damaged dirty or broken pinch rollers Resolution 1 Check that the feeder alignment Is straight and of proper height 2 Open the clamshell and look for any damaged or non functional pinch rollers 3 The input system should have paper guides to prevent media from skewing when It is picked 137 Ink Delivery System ID For issues with missing or non recognized ink cartridges a s
13. allow the removed strip to contact the electrical contacts or the printhead nozzles 11 Raise the printhead latch fully until it is upright so you can insert the printhead into the printer at an angle 29 KC E z SCH Ch KN AT VAL eX Ka e 13 Slowly close the printhead latch The fluidic couplings should advance and seal to the printhead cartridge 14 Close the printhead latch When the printhead latch is closed the printer will prime clean and cap the printhead automatically This operation will generally take a minute or two and will be obvious from sounds emanating from the printer NOTE The Printer may take up to 12 minutes to set Itself up during initial startup This is normal The machine will emit a number of chirps whirrs and other noises as it circulates ink and runs systems 3 5 4 Switch on the Printer After the print head and the ink tanks are installed switch on the printer by switching on the main switch on the back of the printer This will power up the print engine and the controllers After few seconds you will hear the ink pump starting to prime the system then the wiper will wipe the print head and starts its first maintenance During this process the software is starting to build up the connection to the print engine This can take up to 10 15 minutes but it is normal so please wait until the GUI for the system indicates that it is in the ready state 31 3 5 5 Media Handling 3
14. and in the background Normally manual print head cleaning is not required Regular checks At regular intervals say at the beginning of a shift or day inspect that the maintenance station is in cap position the cutter is not obstructed the paper path is clean there are no paper clippings present sensors are not covered Check that wires are not loose there is no ink leaking lf the operator detects print quality problems check the troubleshooting part for steps to perform in order to solve the issues Consumable change The main consumables in the printer are the ink and the print head The most frequent user intervention during the life time of the printer is the ink cartridge and print head change When the printer is running out of a particular ink the Toolbox will display a message on the screen specifying which tank is out of ink Remove the empty tank and insert a new one and the printer will operate again as before he printer is working only with all cartridges installed 52 Standard Maintenance General and periodic maintenance procedures are needed to keep the Print Engine in good condition In anticipation of industrial applications an extensive list of service parts are available for the printer Please contact you Reseller for futher details High volume usage and specific use cases configurations may require more frequent maintenance NOTE Repair and replacement tasks are referred to qualified technicians For so
15. ink cartridge KE Ink castndge 5X Bulkhead plate Cartndge Alignment Post 10X QA Chip PCA 5X and Buffer Box 3X bracket Septum Needle 15X Picture of Bulkhead Assembly Other IDS Components Ink cartndge 5X SS Penstaltic Pump Gore Vent and Se Pinch Valve Dual Pinch Valve Bulkhead plate Picture of Other IDS Components 14 2 10 Maintenance Module Aka Service Station SS The multi station maintenance module MM maintains and cleans the printhead by wiping off waste ink and contamination In addition the MM assists with printing by priming the printhead as well as protecting it when not in use and guiding the paper as it passes under the printhead Picture of the Maintenance Module The maintenance module MM is a sled that contains stations for wiper cap spittoon and print zone platen To position the correct station into place a stepper motor moves the sled horizontally and a DC motor moves the sled vertically The maintenance module e Cleans the printhead of excess ink and debris e Keeps the printhead protected and hydrated while not in use e Provides a safe place to spit ink that is used to keep the nozzles clear e Provides a suitable base for supporting the media during printing This is done with the print zone platen station KC Picture of Maintenance Module MM Assembly exploded view The maintenance module
16. on the roller Wash the roller with damp lint free cloth if necesarry 7 Re assemble the wiper module 8 In Toolbox press Home Service Station button to re install the MM into the print engine Ink Tank Latches Inspection 1 Release the three ink tank latches Picture of released ink tank latches Carefully slide all five ink tanks one at a time out of the unit Picture of removed Ink Tanks 74 2 Verify that Toolbox reflects the tank removal 3 Align each ink tank with the rails on the printer and insert Repeat until all five ink tanks are re installed Picture of re installing Ink Tanks 4 Re fasten each ink tank latch to ensure it moves properly and engages fully If not escalate to a technician for replacement Picture of opened and closed Int Tank Latch 75 5 2 4 1 Cutter Inspection and Cleaning 1 Fold a damp lint free cloth and insert it into the groove beneath the cutter Pictures of cleaning the Cutter 2 Wipe back and forth to remove aerosol and debris 3 Remove any media debris from the cutter with tweezers 76 5 2 5 As Needed Maintenance Tasks The following general maintenance tasks should be performed on an as needed basis based upon Inspection during every day use and or when performing other tasks The printhead cartridge should be manually wiped after the following occurrences e after paper jams e before re installing an used printhead cartridge into the print e
17. pause command Clear Pause clear pause state KWS setting 0 default 3 7 IMPORTANT if you change the default settings the printhead will loose its warranty If Keep Wet Spitting function isn t working then the printhead nozzles have bigger chance of drying out what will make printing mistakes Lines This function is a basic defence of the printhead Non Printing Mode In this mode the printer can calculate inkusage from the job Shutdown the Printer this will shut the engine down After this the printer itself also needs to be switched off 4 2 Diagnostics From this screen you can see the current status of your Printer You can also Print Sample Page Prints type and color bands to check print quality Print Configuration Page Shows the current configuration of the Printer including Firmware Version Network Connection Printer Serial Number and more Print Diagnostic Page Shows basic printer information memory Network Settings Event Log and RAM partitions Print Demo Page Prints Memjet Demo Page 50 Print Color Bars Prints 7 color bar page to check color quality Print Ink Channels Prints 5 color bar page YBCBM to check whether all color channels are working properly MAKE SURE YOUR PRINTER IS SET TO CONTIOUS MODE AND YOU ARE USING CONTINOUS MEDIA WHEN YOU ARE PRINTING THESE TEST SAMPLE PAGES aS erp Ey EK age l t HRP a ek trag el ee 4 e iE z m
18. print out the missed jobs again Reset job counter this will reset the job counter Reset Page Counter this will reset the page cuonter Wipe Printhead this is a cleaning service issue It will carry out a light cleaning on the printhead Circulate Ink Purges air from the pipes and primes the system after replacing the Ink Tanks or Printhead Cartridge Release Printhead Performs the same task as the Cover Release Button on the Printer Pumps the ink back into the Ink Tanks and opens the Printhead Cover to remove install the Printhead System Deprime Pumps the ink back into the Ink Tanks prior to replacing the Printhead or transporting the Printer Eject Maintanence Module this will eject the service station If you would like to remove it then use this at first If not possible to use this button still can remove it manually Install Maintane Module this will call home the service station Wiper Inspection sets the service station in wiper state so the wiper roller faces upward and can be inspected Wiper Preemtive Maintenance It enables users to re moisturize the wiper module with ink to recover from the excessive dehydration in the system This algorithm is user initiated only It is recommended that it be run once a week as well as after extended durations of printer idle time Shutdown Turns the Printer off from your computer Pinch Media this will feed the media Retract media this will unfeed the media Request Pause send
19. varies significantly A 1 2 3 4 Picture of Varying Top of Form The print defect may result from dirty sensors or data that has timed out 126 Resolution 1 Evaluate paper path sensors If not resolved contact Customer Service and report error code GEO 02 Varying top of form margin unresolved GE03 Ink on Back Top of Page GEO03 displays as ink tracks on back or front side of the media Sometimes the mark can be seen through the page Picture of Ink on Back or Top of Page This defect indicates that the platen is dirty or an ink puddle is building up on the print engine 127 Resolution 1 Physically wipe the platen If not resolved continue to the next step 2 Evaluate the ink buildup inside the print engine oO If not resolved contact Customer Service and report error code GE03 03 Ink on back top of page unresolved 128 GE04 Bleed Line or text quality looks very fuzzy Edges of each line look ragged Some media may have better performance than others print mode and color profiles are the main ways used to control this behaviour Picture of Examples of Clear Edges and Ragged Edges Bleed Bleed results from ink and media interaction Ink amount media type ink order and dry time can all influence bleed performance Resolution 1 Verify the correct media and media profiles are being used If new media Is being used consider creating a new profile for the media set o
20. via Network B via direct USB connection The preferred installation is over Network since USB installation process may conflict with previously installed USB printer software A Installing Printer online via Network Setup Steps Make sure your printer is turned on and online Your printer is connected to your network via LAN cable Your PC is connected to the same network LAN or WIFI 1 On the user PC or laptop open folder that contains the printer driver software R13 driver and run WinSetup exe G Lei E e RAMANA e RI wer lt lill Sohta arer o Organise Include in library Share with Bum New inider H e z Hame D gr L vordes HE Deeg E w TE Dewentonh o Autorun Y Berent Places T WinSetup S yiri Autodesk 30 AS Google Drive 2 As the installer starts Windows will prompt for permission Click Yes i Unable te connect te the printer te check the firmware please check Z connections and chear printer errors Do you want te retry 34 3 The setup console will start TL Vortex Printer Series Driver Thank you for buying our printer Click the Install Printer Software button to install the printer on your computer User Guide 4 Click Install printer software and accept the terms in the license agreement then click Next Portions of this Software contain copyrighted materials from RTID s suppliers and licensors Term
21. 2 03 Servicing process not effective 102 Cause CMO03 Color Contamination at 1 mm Intervals CMO03 usually displays as color contamination lines that continue at approximately 1 mm intervals after the majority of the color has cleared Lesding Edge of Print d ink is feeding into the properly cleared areas and the contaminated ink takes longer to ciear in the Picture of Color Mixing Color Contamination at 1mm intervals Ink mixing is caused by location of feed holes in the back channel Resolution Check the tubes at the back of the print engine before circulating ink If it is clear in some places 1 Run the servicing process and re evaluate the plots TCL maint_clear_color_mix lt level gt If not resolved continue to the next step 2 Run the servicing process three times and re evaluate the plots If not resolved continue to the next step 3 Take the PH out install the designated golden unit and print the same set of plots report error code CM03 04 PH failure analysis required P P 2 If not resolved further printhead failure analysis is required Contact Customer Service and 103 Cause CM04 Color Mixing in the Middle of the Page CM04 is the printing of mixed colors after long continuous printing or short periods of idle time 5 seconds from a printhead that does not show signs of internal leaks Type test mage A4 inthis cose is blue Close ups in examples below are efter pr
22. 3 Place the foam swab in one of the ink channels on the fluidic coupling and rotate to clean Picture of cleaning the ink channel 14 Use a new moist foam swab and repeat the process for each ink channel on both fluidic couplings until all 10 openings are cleaned pe b Picture of soiled swab for one fluidic Coupling 5 channels 84 15 Remove the cap from the printhead Picture of uncapping the PH 16 Wipe from one end to the other with the damp lint free cloth d Picture of wiping the PH 17 Align the PH cartridge with the pin on the PPCA board and slide it into the print engine PH Alignment Pin Picture of PH alignment Pin 85 n Lk ELETT iia caer 3 wi Eg ga Alignment Pin d y i T ai D D e gp gp we e ww DH Groove Picture of PH alignment pin interface j 18 Tilt the top of the printhead cartridge toward the back of the printer about 20 19 Gently seat the back of the printhead cartridge into the print engine 20 When the back of the printhead is firmly seated gently rotate the printhead cartridge into position against the stops on the printhead connector board until it clicks into place 21 Slowly close the printhead latch The fluidic couplings will advance and seal to the printhead cartridge 22 Close the printhead latch When the printhead latch is closed the printer will prime clean and cap the printhead automatically This operation will general
23. My Print Settings Defaults ok Il Ge _ the engine documentation Printing Adjustments Allows you to make minor positioning changes to the print area in relation to the media if needed NOTE Only works on jobs using less than the full print area less than 8 5 wide Media Layout possible to set what kind of print jobs will arrived Inter Label Gap the media has labels form Blackmark the media has blacmark ont he DOWNSIDE CUTSheet cut after the medium size Continous in this mode the machine will print fluently Use printer setting the engine has some setting what can check with the nvm_getset command For more information about under My Print Settings Access your custom print settings for various jobs that you uploaded through the Media Profile Upload in the Toolbox Position Adjusment offset units Media Layout Page Cutting e Horizontal Offset e Vertical Offset e Inches e Mi llimeters e Pixels e Inter Label Gap e Black Mark e Cut Sheet Continuous Use Printer Setting Job Cut cut at end of job Sheet per cut number of pages before cutting Use Printer Settings My Print Settings 3 7 1 3 Import Export When updating to new Memjet driver the Import Export tab is used to save previously adjusted media sizes and My Print Settings General Layout Media Import Export Services Maintenance You can also use this function to copy prin
24. Re run servicing and print the plots again If not resolved continue to the next step 3 Replace the printhead B If not resolved contact Customer Service and report error code BDO1_94 Initial page startup unresolved 119 BDO2 Optical Density or Color Variation BD02 displays as an area of half tone prints with unexpected color variation or horizontal thin lines with dot placement error Leadina Edae of Pont 60 70 ER light band Picture of Banding Variation of Optical Density or Color This defect results from heat generated while printing the solid black area that creates a sub optimal ejection behavior of the nozzles that later have to print the half tone area Resolution 1 Compare the defect against the acceptability threshold PQ1700 If worse than the threshold run the maintenance algorithm V If not resolved continue to the next step 2 Replace the printhead If not resolved contact Customer Service and report error code BDO2 03 Banding with variation unresolved 120 BD03 Die Boundary Banding BD03 displays as dark light or rainbow bands 0 5 mm to 1 mm wide at die boundaries not caused by dead nozzles or mist Example on Process Gray CMY Area Fills gt 05 men Picture of Die Boundary Banding This defect results from a shift in dot grid from one die to the neighboring die due to a printhead related defect lack of die flatness at die ends or a combination o
25. Remove the ink tanks from the shipping box e Qpen the ink tank latches in the front of the printer by pushing the bottom of the latch upward The latch has a marker for signalling the place of the C M Y and K tanks The reason why K is used for Black in RBG color mode B is reserved for Blue e Locate the place where each tank should go than slowly but firmly push the tank into the tank socket The pressure in the ink tanks and the septums may prevent the cartridge to fully engage for the first insertion 25 To make sure you have a good contact remove the ink tank and re insert twice O Cyan C inserted in the top left slot e Black K two cartridges inserted in the bottom left and bottom right slots e Yellow Y inserted in the top middle slot e Magenta M inserted in the top right slot WARNING The ink 29nt he Ink Tanks may be harmful if swallowed Keep new and used Tanks out or reach of children Discard empty tanks immediately 3 5 3 Installing the Printhead The printhead Is the core of the print engine As sensitive electromechanical equipment it requires careful and special handling to avoid damage and ensure quality printing NOTE The printhead is sensitive to electro static discharge ESD Use ESD protection when handling the printhead Priming the Printhead Before the printhead can be used it must be primed Priming helps purge both the liquid and air in the ink lines to allow reliable printing P
26. TETEG eege 96 We eh rt 96 MAINTENANCE BUSY E 97 POW EO 1G LOG E AE AE E E AAEE E AEEA E 97 Se te E 97 POM LO CLOG GE 97 BVO MO rt 98 FAPERPFATH_ CUTTER ERROR E 98 PAPERPATH FEED Eegeregie 98 Wu rd E DE 98 BEE testis ductsctneaceteaggsmarateomnceraimesenkt 99 Color MIXDO TON eaea gantiadda ae edeustee tiasaaauria A E EE 99 Examples for Color MIXING E 100 SEARO SR ea E A E E sane E A E E N EEA 109 Dot WITS CO TCE EE 115 Bandino BD EE 118 Other General Print Quality Errors DEI 124 PAD Fle MING GE 133 mK D livery System LD EE 138 FO CUr mOPG EE Firmware Error Messages IERT Maimtenance ell EES eege E3 1 Introduction The purpose of this manual is to describe the operation of the Vortex 851R label printer The first section provides and overview of the Memjet print technology to make you familiar with the terms and basics of this new technology that forms the basis of the Vortex 851R printer series The following sections walk you through the installation steps explain the components of the printer and their roles and then teach you how to operate your printer The manual ends with a maintenance and troubleshooting guide 1 1 Introduction to Memjet print technology Memjet Technology is a revolutionary printing technology developed by Silverbrooks Research Sidney Australia The core of this technology is a full paper width printhead capable of printing the entire page width at the same time without head movemen
27. Unresolved white area 111 SR04 Lines Prints Fall In SRO4 text or images become weaker page after page and finally drop out oe e kee Le i Cyan Nozzles are Out Picture of Streaks Lines or Prints Fail Cause The nozzles can dry out over time if there is not enough on page and inter page servicing Harsh environmental conditions e g too dry or hot fast printing speed or some media types can accelerate dehydration Resolution 1 Evaluate maintenance algorithm inter and intra page servicing that is mid page servicing TCL nvm_getset If not resolved continue to the next step _ 2 Run maintenance algorithm wipe If not resolved continue to the next step 3 Consider the environmental conditions Report defect SR04 03 Unresolved lines print fall 112 SRO5 Random Small Streak SR05 displays as random small thin lines that are visible on the print but do not grow along the page Picture of Random Small Streaks Cause Thin streaks can be caused by internal contaminants external contaminants fibers air bubbles or printhead damage Resolution 1 lf the white gap Is persistent from plot to plot print a 5 band plot or a plot that has primary colors If gap is only in one of the primary colors the streak Is likely to be from an air bubble Run the maintenance algorithm pressure prime H If not resolved continue to the next step 2 When neighboring color channels have str
28. Vortex 851R Series Go to Printer Configuration Go to Ports tab Change port from TCP IP to FILE or Print to File og E Print jobs are pre defined printjobs which could be usable in the future The Vortex 851R printer is only working with PRN files which can be generated from the driver of the printer 46 3 9 0 Printers Buttons Power button green LED When push the power button the engine will start and start to priming or will do a little maintance At first start should to wait lot time 10 15mins because the ink delivery system is empty Sometimes it takes more than ten minutes But if the system primed after this time is shorter The green LED always should to light when the machine is ON Cancel button red LED This button can cancel the job under the printing The LED is working only if the button pressed Feed button yellow LED Before printing should to feed the media into the machine Advice to place the the media to the left side of the machine because the print engine has the gap and balcmark sensors also there PRINTING AREA LABEL LEFT EDGE E CUT MATERIAL BLACK MARK LEFT EDGE BLACK MARK MATERIAL Feed Unfeed Cancel Feed Power 47 3 9 1 Buttons and Led signals The first button from the left is the Power button with an integrated Green led The second button Is the Cancel Clear Error with a Red led and the last one Is the Feed Unfeed with a Yellow led The power button only
29. ance module is also known as the service station SS in some contexts and messages MM01 Wiper Not Spinning The wiper roller is not spinning No sound of the wiper motor is heard Other maintenance functions may also be affected Cause The temperature is too high the FW safety cable unplugged a bad motor cable PCA or driver An obstruction Is in drive train The drive train is loose misaligned or broken Resolution 1 First disable the clamshell sensor by sending a CL gt nvm_getset 2 Send a wipe command while the clamshell is open Check that the wiper is installed correctly and the retention clips are properly locked into place If the problem continues you may need a new maintenance module 3 Printer firmware estimated motor temperature and shuts off the motor if it is believed to be too high Waiting a few minutes should resolve this issue 4 Maintenance module wiper assembly could be removed and turned by hand to determine if it is physically able to rotate and not jammed up 5 If itis jammed up replace the maintenance module B If not jammed further troubleshooting is required to determine if problem is the motor cable or PCA See also the sections on servo encoder and sensor failure MM02 Maintenance Module Is Not Going Home The maintenance module is not homing and may or may not be making noises when trying to home Printing and maintenance functions disabled as the MM will not be able find other loc
30. arwheels missing obstruction or debris in paper path platen in maintenance module not properly seated Resolution If itis determined that the media is damaged prior to entering the printer then the damaged media needs to be removed and discarded Check that the feeder is properly adjusted to prevent media damage Check for foreign objects in the printer that can cause the media to strike the printhead or cause a pinch roller to stop functioning Ensure that no starwheels are missing Replace if required 133 PA02 Feeder Marks PA02 displays as tracks on the paper that correspond to the measurements of the sheet feeder s wheels 2 x 1 2 wide roughly 5 in apart Cause This defect results from a dirty feeder assembly possibly from aerosol or an ink spill that contacts media Resolution The media feeders should be cleaned periodically by vacuuming the dust Also use a soft lintfree cloth and some dionized water to clean the rollers of the feeder PA03 Starwheel Marks PA03 presents as small track marks that are visible in printed media The printer has little pointy wheels in the upper clamshell that hold the paper down in the paper path Starwheel marks are usually only visible on glossy media Cause This defect results when starwheels are exerting too much pressure on paper are dirty or are not moving properly Resolution 1 Print a solid area fill plot insert plot here and look for track marks 2 Check t
31. ath Cause Causes of false paper jams include faulty sensor wiring or PCA and debris blocking sensor Resolution 1 First open the clamshell and check for any small pieces of debris that may be blocking the entry or exit sensor causing this error 2 If determined that no foreign object is blocking the sensor use TCL commands or scripts to determine if the sensor is functioning t Query sensor state 1 or 0 Using a piece of media or some other object block or cover the sensor and query again to see is the state has changed 1 or 0 3 Check for voltage at sensor and leaving MPCA 4 Check continuity of wiring from MPCA to sensor end of cable PA11 Wrinkled Paper Paper does not come out flat but also does not jam Any folding marking or ripping on the output media Cause Damaged or incompatible media misadjusted feeder object in paper path Resolution 1 Adjust feeder so as not to cause damage to media 2 Check to ensure that proper media is being used 136 3 Open clamshell check for and remove any foreign objects in paper path causing the problem Margin Defects Margin defects may appear in the top margin in the bottom margin or with the image askew on the page PA12 Incorrect Top Margin The top margin appears very large or very small or nonexistent as the printed image can run off the edge of the media Cause Paper path scaling incorrect NVM setting Media slip likely resulting from too light
32. ath sensors If not resolved continue to the next step 4 Check whether the media being used Is too slippery or too heavy 5 If not resolved contact Customer Service and report error code GE06 04 Print skew unresolved 132 Paper Handling PA Issues with paper handling PA cause a range of defects as detailed in the following sections Page Marking from Paper Handling LA WwW N Page Marking from Paper Handling displays as smudged ink Cause This defect results when the top of the media makes contact shortly after printing Resolution Print a solid area fill plot insert plot name and confirm area of contact Check the area of contact on the upper clamshell features to verify that nothing is hanging down that can contact media 3 Verify that the media entering the print engine is flat and undamaged Verify that the media is not skewed when entering printer Verify that the platen in the maintenance module platen is free to move up fully in its guides to the datum from the printhead Confirm that the printhead is properly seated PA01 Printhead Strikes PA01 Printhead strikes commonly appear as visible smudging on the paper These are due to the printhead striking the paper as it passes underneath If the printhead is dirty then ink transfers to the paper Cause Some common causes of this defect are media bent or curled prior to entering the printer pinch rollers not free to move or st
33. ations Cause Send a home command while the clamshell is open Bad sensor cable or PCA Obstruction in sensor or in path of sled Faulty stepper cable PCA pulley or gear misaligned sled Resolution Eject the sled and then reinstall Be sure to make sure that the sled is not skewed when installing send a home command while the clamshell is open and check that the station can home correctly If the issues continues contact your application engineer for additional assistance Using TCL query the sensor to get the state Block or cover the sensor and query again to see if state changed Check continuity of cable check voltage at sensor and MPCA 143 7 Printer Specifications Printer Technology Drop on Demand Thermal Inkjet printing Printable width is 215 9 mm 8 5 inch 70 400 nozzles 14 080 per color Five channels Cyan Magenta Yellow Black 2x Print Speed 300mm s at 1 600 x 1 600 dpi black 300mm s at 1 600 x 800 dpi color 150mm s at 1 600 x 1 600 dpi black and color 12 inches s 21 6 km day Print Quality Black and color 1 600 dpi native resolution Operating Systems Microsoft Windows XP and Windows 7 and Windows 8 Media Formats Roll Media Fan Fold Media 8 75 wide perforated 500 6 fan fold Media Handling Gap sensing Black mark sensing Continuous roll handling Media Dimensions Max media width 215 9mm 8 5 inch Minimum media width 50mm 2 inch Minimum media length 91 5mm 3 6 inc
34. banda Sinp z Tendar BSF m B Stephen J Sin amp lt a i d ill A 8 Fabanda Sinpi Tendar BSF E Fabanda Sinpi Tendar BSF Picture of Dot Misplacement Text Becomes Fuzzy Over Time Cause Asymmetric wear of the MEMS heaters over time after a few tens of millions of ejections results in the odd and even nozzle rows having different directionality in the Y axis Resolution Run the maintenance algorithm TCL gt maint_user_recovery 1 If not resolved continue to the next step 2 Check the printhead to paper spacing PPS with the PPS tool B If not resolved continue to the next step e 115 3 Replace printhead with a new one or swap with another printhead If not resolved contact Customer Service and report error code DP01 04 Poor text quality unresolved 116 DP02 Graininess Graininess presents as a mottled random pattern in a solid fill area Picture of Dot Misplacement Graininess Cause Excessive printhead to paper spacing or a worn out printhead can cause this printing defect eee cere e eerste Pee ete ee eee eee ee ee eee dE EE AALE a cee AALE Li pen o 26 6S pO SS CONES ES Iessen eRRe Y DEL EKZKAZTKGC HA e neeggeng onde ounesceuen aun Dk MAC r Sep gg eee eee rss ra fe CREP Le eee eee ee eee ee Pete eee ee eee eee eee tee wee ee see TETERE etter hM DEE ECKE Oe oe eee ees Sg eee ee Pw ewe eee ee eee ee ee eee ate et tata tute gp seggggeggeef eee e
35. by a dirty sensor or servo issues Resolution 1 If the encoder is working then check belt tightness 2 If the problem is not resolved contact Customer Service and report ER01 03 ERO2 Servo Error Limit Exceeded ER02 indicates that a servo motor requires more power than Is specified in the firmware code Cause This defect results from any impedance to mechanical motion Alternatively the electric motors may have reached life Resolution EROS Tilt Error In order to protect from situations that could cause ink mixing and possible spillage the printer will not function if it is tilted The print engine needs to be operated ona completely level surface for proper operation Cause Tilt sensors can give bad readings when there Is excess electrical noise or EMF in the vicinity or if the table on which the printer Is sitting is vibrating Resolution 1 Confirm that the printer is level and keep printer on sturdy table away from excess physical vibration and electrical interference 2 If problem persists recalibrate see TCL help for re calibration TCL accel_zero for proper restart use TCL gt shutdown WARMING The print engine must be level when you re calibrate or else the tilt protection system will not work and the printer will suffer from severe ink mixing 141 ERO4 SS Lift Error In order to protect from situations that could cause ink mixing and possible spillage the printer will not function if it is t
36. ck The printhead cartridge dock positions the page wide static high speed Memjet printhead in the correct location to maintain correct position with the print zone 9 Dual Action Fluidic Connector Actuation Lever Output Fluidic Input Fluidic Connector Connector Lever Closed Sensor Retractable Memjet A4 Page Zero Insertion _ irae Force Fluidic artriage Connector Picture of Fluidic Connectors and Memjet Printhead Cartridge 2 5 Print Mechanism During printing the print mechanism moves the paper through the print zone below the static printhead 2 6 Cutter The NorthStar cutter is designed to provide a complete cut of continuous media in the crossweb direction This will provide the ability to singulate labels and enable a break in continuous media to allow servicing of the printhead The cutter has a design target of providing a 400 000 cut life on thin tag media Cuts are expected to execute in 0 4 seconds at up to 80 8 5inch cuts minute The cutter unit can be removed or replaced if necessary without affecting the performance of the NorthStar 10 2 7 Ink Cartridges Vortex 851R Series Printers use a single Printhead Cartridge and five Ink Tanks two Black one Cyan one Magenta and one Yellow During installing the ink cartridges the Printer should be turned off Picture of the ink cartridge Alignment Pin Slot d Septum Septum QAChip di Alignment Pin Slot i V
37. cro sponges to collect ink overspray Picture of Printing platen 17 2 12 3 Capping spittoon station The printhead should not be allowed to dry out after priming The cap station is used when the printer is idle The cap station limits evaporation from the printhead by sealing around the nozzles and maintaining a humid environment The cap is an elastomer seal that fits around and over the printhead nozzles It is held against the printhead by the lift springs on the maintenance module The cap aligns with the printhead by features at each end of the maintenance module The spittoon portion of the station has a waste ink receptacle used to capture ink ejected during maintenance processes The used ink wicks and drains into the waste tank The wicking bar is a plastic frame and channel of absorbent material The absorbent material can be replaced by trained service personnel Picture of Capping spittoon station 2 12 4 Printhead servicing events The printhead requires cleaning after any of the following events occur Anew printhead Is installed and primed The printhead is removed and then replaced The printhead is primed or re primed with ink The printhead is showing signs of contamination Be aware that ink is used by the print engine during printhead maintenance as well as during printing All waste ink from the printhead nozzles is contained by the maintenance carousel either in the spittoon holds waste ink generated by
38. daily to ensure optimal printing lf the operator finds paper debris on a starwheel check to see whether or not it is aligned with the edge of the media If so you may need to adjust the paper guide and margin so that the starwheel no longer rubs the edge of the paper 1 Perform this procedure with the printer powered on so the platen Is raised 2 Pinch the clamshell latches to release as shown on the pictures Open the clamshell and allow the upper portion to rest on the hard stops as wg ti iad W Ben ee E e ae Ak i Picture of the clamshell opening procedure Picture of the opened Clamshell 3 Dampen a lint free cloth with distilled water 4 Wipe the system components and paper path surfaces uppen and lower with a clean damp lint free cloth to remove ink overspray aerosol and debris 57 NOTE Do not wipe the starwheels as they may release and fall out Do not clean the printhead nozzle plate at this time it will be cleaned during another task 5 Use a clean dry lint free cloth dry the inside of the unit Avoid the grit rollers since they can snag on the cloth and create debris wm Grit Rollers Platen Housing Picture of the Wipe Lower Surfaces 58 Aerosol Starwhee Pinch Rollers Picture of the Wipe Upper Surfaces 6 Fold the cloth between wipes to ensure a clean uncontaminated surface Is used each time 7 Use avacuum cleaner if necessary to rem
39. e drive gear and gently pull the module forward until you can disconnect it from the translation motor emm Zei 1 J 7 e p L d J E e el GS eee A ff j l a N l WW 3 a D d D kb fe i H 7 Sen Picture of disconnecting MM from Wiper Motor 5 Use a lint free cloth moistened with DI water to gently remove any ink residue or debris from the Maintenance Module Once the lint free cloth is soiled use a new cloth Picture of Ink Residue removal from the Maintenance Module 6 Inspect both wicks printing platen and cap for warping plugged up sections or to see if it is falling out If fouled escalate to a technician for replacement with new wick s 70 7 Inspect the cap for ink contamination and cracking or permanent deformation of the cap If permanently damaged escalate to a technician for replacement Ae S Picture of wiping the Cap Seal wuth damp lint free cloth 8 Inspect the wiper module components for damage or permanent deformation If permanently damaged escalate to a technician for replacement 9 Remove the paper dust from underneath the maintenance module during the annual cleaning Use a vacuum cleaner for the interior of the unit if necesarry p V 7 We vi a pana n 3 e a Cem ae mm A we ee bung ll mme Picture of using a Vacuum cleaner to remove debris from under the MM Wiper cleaning Wiper cleaning usually means t
40. e are more often caused by air injestion than excess backpressure but pumping rapidly when the ink is low can pull air through the nozzles and result in a deprime Resolution 1 Test with a full and truly empty tank to ensure that the sensor is working 2 Replace the ink cartridge with a full tank to confirm that the printer recovers ID05 Ink Coming Out of the Printer Ink drools or puddles on the surface that the printer is sitting on Cause This can happen if the printer is tilted or the clamshell left open with the valves open or if the printhead is pulled off without depriming This can also happen if firmware commands are run to abuse the system E g spitting more than 10CC into the cap without lowering it to drain The ink could be coming from the maintenance module ink tank fitting tubing printhead or diaper The likeliest cause is an over full maintenance module 139 Resolution 1 Remove the maintenance module and evaluate whether It was the cause 2 Dismantle the printer to locate the source of ink Paper Cutting PC Issues with paper cutting PC cause a range of defects as detailed in the following sections PC01 Cutter Not Operating Cutter is not moving when commanded thus stalling the print job and errors out Cause This defect may also result when the cutter is not at home or has an obstruction Other causes include faulty sensor wiring PCA driver or motor A common cause is that the cutter connect
41. e notch Use scissors if your foil bag does not have a notch or you are finding it difficult to tear the bag Pana ma ech 4 A co t A W fi H GE Made ah we A e i i i 4 d aa j d gt we BR 2 A ie 2 A V ae be E Ga Remove the printhead cartridge from the foil bag Remove the orange protective plastic cover from the printhead cartridge Holding the printhead cartridge by the handle a Release the flaps covering the ink ports 1 and 2 b Release the clip retaining the cover near the center of the printhead cartridge 3 c Carefully remove the protective cover 4 28 9 Remove the protective strip from the electrical contacts While holding the printhead cartridge by the handle with one hand grasp the pull tab with the other hand and slowly and carefully peel back the plastic strip covering the electrical contacts Dispose of the removed strip immediately and do not allow the removed strip to contact the electrical contacts 10 Remove the protective strip from the printhead nozzles While holding the printhead cartridge by the handle with one hand grasp the pull tab with the other hand and slowly and carefully peel back the plastic strip covering the printhead nozzles Maintain an angle of no less than 45 with the printhead surface when pulling on the strip than 45 yen _ T Ben pr j a Di WR Dispose of the removed strip immediately and do not
42. e white gap Is persistent from plot to plot it is likely to be from an air bubble Run Servicing Line Prime Pulse Prime and look for improvement If not resolved continue to the next step 2 lf the white area is shaped like a parabola and the color of printing at the bottom of the page is different it is likely to be from an ink puddle Run Servicing Level 1 to clean the printhead If not resolved contact Customer Service and report error code SRO2 03 Unresolved parabola 110 SR03 Large White Area SRO3 displays as a large white area with almost no nozzle firing and is consistent from page to page Possible Electrical Cause Not an airflow issue only 1 color Picture of Streaks White Areas Not all 5 channels are always e out at the same time Picture of Streaks Single Die Cut Cause This print defect indicates an electrical issue or damage to the printhead Resolution 1 For lines approximately 1 wide print a spit plot If the missing area exactly follows the die boundaries then it is probably caused by an electrical problem Remove the printhead and clean up the contacts Check for the board and make sure there is no damage on the printhead p If not resolved continue to the next step 2 lf all the colors are out there may be a hydration problem Run the dehydration recovery algorythm CL dy_rec If not resolved contact Customer Service a 654 nd report error code SRO3 03
43. eaks at the same location there is an ternal contamination Run the maintenance algorithm wipe If not resolved continue to the next step 3 If the streak is shaped like a parabola and the color of the printing at the bottom of the page Is different it is likely due to an ink puddle Run maintenance algorithm 1 Z not resolved contact Customer Service and report error code SR05 04 Unresolved thin streaks 113 SR06 Weak Chips SRO6 displays as weak chips that result when some dies do not eject properly The issue does not improve by varying pulse width Clogged magenta nozzles Picture of Streaks Weak Chips Example Cause This print defect may result from an electrical failure due to a cracked die or extended periods of nozzle dehydration Resolution 1 Run maintenance algorithm three times TCL dy_rec followed by TCL maint_clear_color_mix B If not resolved continue to the next step 2 If not recoverable after running the service algorithm the streaks are likely to be due to weak chips Replace the printhead and send the old one to the engineering team for further investigation Report this as error code SRO6 02 Weak chips 114 Dot Misplacement DP Dot misplacement can be observed as lines or solid fill areas that are fuzzy Picture of Dot Misplacement Examples DP01 Poor Text Quality In DP01 text becomes fuzzy or unfocused after many thousands of pages have printed Stephen J Sin Fa
44. ed by other noise or imperfections in the paper path Resolution 1 Print a solid area fill plot insert plot here and measure spacing 2 Reset belt tension and rerun diagnostic 1040 plot Check pulleys and bearings for any slop or run out 3 Clean rollers and other paper handling mechanisms adjust belt tightness and ensure that the motor is mounted securely If tuning the system does not solve the problem drive components may need to be replaced PA05 Top of Form Transition Error TOFTE PA05 displays as a set of horizontal lines visible near the top of the page Cause TOFTE results from a change In paper speed as It transitions to the starwheel feeder after the print zone If the transition is not smooth it will result in the horizontal lines The problem can be exacerbated by thick or curved media and can be improved by reducing the starwheel force staggering the starwheels and improving the dive angle of the media as it enters the pinch Any problem with the starwheels sticking jamming or being out of position starwheels Resolution Ensure that all of the starwheels are spinning easily and that the spring force is correct Use thinner media and ensure that the media is curved so that it transitions smoothly into the star wheel pick area For labels use media that does not have the ladder removed PAO6 Bottom of Form Transition Error BOFTE PAO6 displays as a set of horizontal lines visible near the bottom of the page
45. ed including printhead cooling using special fast drying inks feeding paper accurately controlling the operation of the unit etc A unique property of Memjet printing is the special print processor that uses a custom hardware print pipeline processing engine to render images at a very high speed The level of technical standards are reflected by the fact that Silverbrooks Research hold 2500 patents related to Memjet Technology along with another 2000 pending 2 Printer parts and their functions 2 1 Printer The Vortex 851R printer is a state of the art Memjet printer designed for maximum usability and performance The major components of the printer are the print engine the controller and the control panel 2 2 Print engine The print engine is the heart of the Vortex 851R printer It is responsible for the actual print process The major subsystems of the engine are the mechanics paper transport ink delivery system including print head and ink tanks the print controller and a paper cutter The Vortex 851R controller is responsible to control the operation for the print engine You do not need to access and use the print engine directly except when changing print heads and ink tanks Al D E a Ge PO S L l e lt gt P ve weg d by R e d e a gt d H a Wm Ae gw a am eg w d La Picture of the Printdine 2 3 Printhead 2 4 Printhead Cartridge Do
46. ed to the flash the engine need to be restarted The result can be checked via TTL cable during the power up sequence the engine will print the following messages onto the TTL output 1 Custom Intitialization completed 2 Starting ErrorCheckDaemon 3 Starting ButtonHandler Deamon 4 Initialization finished Their sequence is fixed but there can be other messages between them if the TTL connection is established too late to catch the initialization issuing a dbg_replay command will replay the recent outputs from the engine Alternatively sending a checkCustomDaemons command will print the current status of the resident processes to the TTL output The result of this command should be ButtonHandler already running and ErrorCheckDaemon already running this means that the two resident processes are currently running so the initialization of the printer was successful 92 Dead engine EWS Firmware Dead engine When is a print engine dead After Dediprog re flash the putty output is empty or not interpretable green LED Is off EWS How can reach the print engine information page Open the toolbox Firmware How can I burn the firmware All firmware has a Readme file Usually that file has a ddetailed description about the firmware burning The firmware burning is working step by step mech_state of the engine should return STANDBY before running Step 2 and Step 4 If the engine is not starting or the T
47. ee a De vortex SSIR User Guide for Vortex 851R printer R13 28 May 2014 Copyright statement 2013 RTI Digital This document attachments and information contained herein are the confidential and proprietary property of RTI Digital and their suppliers As such this document attached files and information contained herein are subject to all nondisclosure and proprietary information agreements currently in effect with your organization Copies of this document any portion of this document or attachments may not be transmitted or disclosed to any third party without the prior written permission of RTI Digital 2013 RTI Digital All content is the confidential property of or licensed to RTI Digital RTID we or us and is protected under Hungarian and Foreign copyright trademark and other intellectual property laws Contents Copyright statement E 2 L nro Tel E 7 1 1 Introduction to Memjet print Technology 7 2 Printer parts and their Tunctons 9 EE 9 Des UME e TEEN 9 SC MN Glenn EN 9 24 Printhead Cartridge Au 9 2 PENE ORAT E 10 EK ue E 10 SO MVR GAN CEG TE 11 28 Ink C onnection POTES eege EE 13 29 Ink DENY CI System DS E 13 ZNO Bulkhead ASSEmDIy EE 13 210 WINE OT CA lee TC 15 PAZ MV VAD ES aO e a E E E ce mamensoersneeee 17 SEHR o E E O E 17 2 12 3 Capping spittoon Statio EE 18 2 12 4 Printhead servicing events 18 ZISPAR ZONE EE 18 2 14 Onboard Print Engine Contro
48. ee ee eee ee GE o s5 4u 4 2 s sas sseuknus KE NC entree oe upoo ee tee tees ege D LESgggegggegggesgggggrgegg gg G eigegi ee set ege E EEN eee ee ee eee Pewee ee ee povesses e hah anne ee eee pia GEN eg i eg ee ee e SEN eat eee ee REN EN s ween sg gg e gt se S LA Kiel ze eneg eneee L MK rrer ge geg Cues ie de deer Ae EA ch EERSTEN rnanan Picture of Dot Placement Examples Poor and Good Resolution 1 Print a diagnostic plot to evaluate individual dot placement If the individual dot pattern Is irregular evaluate PPS If not resolved continue to the next step 2 Replace the printhead If not resolved contact Customer Service and report error code DP02 03 Unresolved graininess 117 Banding BD Banding defects are shown in the following illustration and detailed in subsequent sections G a A Picture of Banding Examples BD01 Initial Page Startup Defect BD01 displays as color change or poor directionality at the start of nozzle firing m G3IE n Poor Poor Ejection oor Directionaliyat Print Start Directionality at Print Star 1 25 mm spaced color parabolas follow the ink inlets from the backchannel to the die Picture of Initial Page Startup Defect This defect results from dehydration of the ink nozzles 118 Resolution 1 Check the Maintenance Algorithm KWS Inter page spit TCL maint_user_recovery 1 If not resolved continue to the next step 2
49. etect gpio_pin_get SNSR_PWR_B_EN returns 0 How to fix gpio_pin_set SNSR_PWR_B_EN 1 ss_home mech_clear_error Lift sensor dirty Clean lift sensor Service station connection fault Eject service station unconnect connect home Clean service station Replace service station Service station is in wrong position How to fix maint_enable 0 ss_goto cap gpio_pin_get SS_LIFT_UP Se down gpio_pin_get SS_LIFT_UP maint_enable 1 Explanation The state of the lift sensor can be checked by running the following TCL commands after the engine is fully booted 1 maint_enable 0 disables maintenance to prevent the maintenance state machine from overriding commands to position the maintenance module 2 sS_goto cap moves to the capped position and raises the cap 3 gpio_pin_get SS_LIFT_UP should return a 1 indicating that cap is lifted and that the sensor is reading the correct position Verify that the cap Is lifted to the full height if not then there is a problem with the lift mechanism If the cap is lifted then there is a problem with the sensor 4 ss_down lowers the cap 95 5 gpio_pin_get SS_LIFT_UP should return a 0 indicating that the cap is down 6 maint_enable 1 re enable the maintenance state machine Service station position unkown How to detect SS_pos returns unknown unknown How to fix 1 Clean service station 2 Replace lifter arm if broken 3 Clean sensor sled 4 Replace sensor sled Old fir
50. f both Resolution Compare the boundary against the threshold If worse continue to the next step Run the maintenance algorithm CL maint_user_recovery 1 continue to the next step If not resolved 1 Print the spider pattern and inspect to see if anything stands out 2 Replace the printhead If not resolved contact Customer Service and report error code BDO3 04 Die boundary banding unresolved 121 BDO High Frequency Banding BD04 displays as horizontal high frequency dark bands that are visible in solid fill area Picture of High Frequency Banding This defect is caused by a variation in dot placement due to paper path firmware rendering or a combination of both Resolution 1 Evaluate the paper path and note any thing causing disturbance to the media e If not resolved continue to the next step 2 If anew color profile is used consider going back to the old ones and re evaulate the banding e If notresolved contact Customer Service and report error code BD04 03 High Frequency banding unresolved 122 BDO05 Low Frequency Page Advance Banding BD05 displays as a horizontal dark bands visible in solid fill areas mainly close to the top or bottom of the page Picture of Low Frequency Page Advance Banding Cause This defect is caused by a variation in dot placement due to the paper path in the print engine the systems that feed in the paper or a combination of both Resolution 1 C
51. h Media thickness 0 13 to 0 33mm 007 0 13 inch Power Interface 20 AMPS 24VDC Maximum current power supply load Ink Cartridges Dye based inks colors CMYKK Non refillable ink cartridges Cartridge size 250ml 144 Cutter Integrated cutter Operation data Power supply 90 240 V 50 60 Hz PFC Power consumption max 1200 W 5A bizt Operating temperature 15 35 C Humidity 40 range Dimensions Width 61 cm Height 40 cm Depth 40 5 cm Weight 40 kg 145 Print speed quick chart The table below shows the print performance of the printer expressed in printing length and label count for given print time intervals This information is for getting a feel of the volume the printer can print for planning purposes Speed IPS Inch per second RE a EE BEE RE LS EE LEE E Printed lenght Number of labels of labels Number of 150 m Wel inch inch ae en Cem da a w e o e w o i amn Im a nu Im In Im In Ju ma faso 72 na e Im mm Im p ma mm am mu suas 2700 am is J37 thous aew om Im mg um mm 1 E E EE E 24 7 3 628 800 7 251 600 92 172 184 343 907 200 1 314 400 mw y Gi operation week Time to 8 2 print a 150 m roll min 146
52. hat all starwheels are present and free to move both rotationally as well as vertically 3 Vertical force should be the same on all the starwheels 10g per 4 Starwheel points should be sharp and not rounded 5 Clean the starwheels with water and a soft lint free cloth to get rid of any ink debris on the wheels Continue process until marks on media have stopped Paper Feed Inconsistency In general this relates to periodic or random horizontal bands in the printed image PA04 High Frequency Horizontal Banding PA04 displays as horizontal banding at a frequency higher than one cycle per 1 2 inch typically about 1mm spacing The banding occurs all the way down the page with a period of 1cm or less and appears as dark or light horizontal bands across the media Usually spans the entire width of the media but can vary in degrees of severity across the page Cause Causes may include debris on paper path rollers shafts pullies idlers or belt belt damage location and tension loose pullies and or idlers loose motor any interference or touching of the drive system Also can be due to non round or non centered paper drive components Causes can be Identified by the location and spacing between banding A single defect on the encoder wheel would lead to a horizontal bar about every inch and can happen as a result of paper fibers landing on the encoder wheel Higher frequency 134 banding less than an inch between lines can be caus
53. hat the oparator has to change the microfiber roller as it comes to the end of Its lifetime The operator can easily recognize this stage First of all the shape of the roller turns from rounded to ellipse Secondly this chage within the shape will Cause significant noises during maintenance NOTE Lifetime of the wiper roller depends on the usage but should be change at least twice a year 1 Disconnect the wiper motor connector PCB from the mounting clip 71 D om ee GEE ia be Picture of disconnecting wiper PCB from Wiper Housing 2 Disconnect the wiper PCB from the ribbon cable as shown in the figure below Picture of disconnecting Wiper PCD from ribbon cable 3 Route the ribbon cable through the housing to free the wiper as show non the next pictures Picture of routing ribbon cable through housing 4 Flip up the retention tab at each end of the wiper assembly to free the microfiber roller 72 Retention tab Picture of removina the MFR after ovenina retention tabs 73 5 Remove the MFR to access the transfer roller TR that is installed below the MFR in the wiper module assembly de vr b KE d i Wy F aa s E e mm mg e i d H H i 98 el 7 ege gt sf e CR SJ a Picture of Transfer Roller TR 6 Visually inspect the transfer roller TR for unusual ink accumulation The transfer roller is stainless steel Ink may accumulate in scratches
54. he toolboox and press system deprime This command will de prime the system During de priming the printhead latch will release Listen for the latch to click and observe that it is popped up when release is successful i Picture of released PH Latch 79 Latch popped up Ink backs out of tubing during deprime Pictureof released Latch and empty ink tubes 5 Open the latch 80 6 Tiltthe printhead cartridge towards the rear of the unit until it clicks EE Gen Picture of tilting PH towards rear of the unit 7 Slide the printhead cartridge out of the print engine 2 Picture of sliding the PH out of the unit 8 Gently wipe the printhead from one end to the other with a lint free cloth moistened with DI water and then cap the printhead to keep it moist while performing other tasks Picture of wiping PH nozzle strip 81 Picture of capping the PH NOTE Each time the printhead is removed clean the PPCA contacts and fluidic couplings 9 Locate the PPCA contacts PPCA Contacts Picture of PPCA Contacts 10 Use a new lint free cloth dampened with DI water to gently wipe up and down to clean the PPCA contacts 82 Picture of cleaning the PPCA Contacts 11 Locate the fluidic couplings Fluidic Couplings t be af af Picture of Fluidic Coupling with ink residue 12 Moisten a foam swab with DI water 83 Pictured of moisten swab 1
55. iaa a ASA 55 5 2 1 Daily Maintenance Eege 57 5 2 2 Bi Weekly Maintenance Taeks 59 5 2 3 Monthly Maintenance Tastks cc cesssccsecccccceeceeeeeseseececeseesueesesececcceeessaueesansnesses 62 5 2 4 Annual Maintenance Task 68 5 2 5 AS Needed Maintenance Tasks cccccccceeeeesseseseseeseseseeesesseeeseseeseseseesesesessstsneaaaes 77 UCU FE STNG GI EE 88 6 1 Maintenance Module aka Service Station Troubleshooting senccse 88 6 2 Printhead Troubleshooting EN 89 6 3 Print quality EES eege eiert ege 89 6 4 Vortex 851R Troubleshooting Guide cc eeecccececcccceeceseeesseeceeccesueeesesceeeceseessueaeeeesesses 90 Eeer EE 90 Documents to read before available On fm 90 Checklist before doing ANY SUDDOM SE 90 Troubleshooting LL 91 Installing and checking the Custom Firmware routnges 91 Dead engine EWS Seu AD cisoncdintedainsnnceaussiasesaiineln iulesaeanauainsenenieaadiacdadaueleteetecuaiadesmeapaaseesteghe 93 EE 93 4 HOW todetert 93 RONTE a E tees tend E E E E EA 93 ROW OCCU GI Eoria E E E E E E E ce 93 AON O EE 93 PRINT ENGINE ERROR MESSAGES eeneg gege 94 Crit 63 03 phead offline cancelpage E 94 CARTRIDGE MISSING X EEN 94 DATA ae WT OS 17 IC 94 Fatal 7102 offline aie rte 95 MONTO UCIEC oa E E E E E A E E Sees ptuneuieaceaniee 95 HON e aae E E E prs es us os ancy E E E E Sad E OEE annie 95 HON e aoaie E E E ces osc E E E E E E oantinoe 95 A EL eege 95 PONTO UCC E 96 We eh rt 96 POWO
56. ilted Cause Tilt sensors can give bad readings when there Is excess electrical noise or EMF in the vicinity or if the table on which the print engine sits is vibrating Resolution 1 Level the printer and keep printer on sturdy table away from excess physical vibration and electrical interference 2 If problem persists re calibrate see TCL help for re calibration WARMING The print engine must be level when you re calibrate or else the tilt protection system will not work and the printer will suffer from severe ink mixing ERO5 PrintZone Some object is blocking one of the paper path sensors located at either the entrance or exit of the printer Will stop printing and may inhibit some of the maintenance functionality Cause Remove media blocking sensors Resolution 1 Open the clamshell and remove the debris or media 2 Reset mech on top left button ERO6 Paper Path Timeout Paper path motion stops due to no media present at entrance of printer within the set limits after a print job has started Cause Various including media jam or media otherwise not feeding properly Resolution Use the reset button ERO7 Cutter Failure The cutter can fail if it loses track of its position Cause Not being homed Resolution Re home the cutter using 7CL gt cutter home 142 Maintenance Module MM Issues with the maintenance module MM cause a range of defects as detailed in the following sections The mainten
57. ining Cause The primary cause of excess stranded ink Is false early detection from the ink low sensor See Ink Low When Not Low for details There are firmware settings to adjust the allowable ink that can be used after detection This is currently set to zero as of 10 21 2010 On average an additional 2CC can be used but the distribution is not well controlled and using a nonzero number will not completely protect the user from running out of ink while printing This could damage the head so it is avoided at the expense of excess stranded ink Resolution 1 See Low Ink When Not Low CMs have two avenues to adjust what happens between ink low detection and ink out protection First the nvm flag can be set to false so that the printer will only warn about ink out but will not error and prevent printing Second the allowable ink after low ink detection can be set to a nonzero number which will enable most users to print a few more CCs of ink but expose some users to the risk of dry firing the head 138 ID03 Ink Low Indicator When Not Actually Low The printer reports empty ink and refuses to print but the cartridge still has more than 7CCs remaining Cause In order to trigger low ink the low ink sensor must detect low ink in the prism of the cartridge The sensor can return false readings as a result of electrical noise improper cartridge placement or printer tilt The firmware is designed to ignore readings that appea
58. inting 100 megentsa end 100 yetow 4 Stain detection strpos 9 SCPs 4 Picture of Color Mixing Example 2 104 Picture of Color Mixing Example 3 Cause Color mixing results when ink migrates across the printhead surface from heavily printing nozzles into the nearest odd or even nozzle row that is not printing Resolution L Use profile tool loading Printing Preferences Color Tab Color Matching to verify that the correct color profiles are being used This is a possible operator handling issue Use the correct profile and re evaluate the performance 2 If not resolved continue to the next step A Run the servicing process 7CL maint_clear_color_mix lt level gt and re evaluate the plots If not resolved contact Customer Service and report error code CM04 03 Servicing process unresolved 105 CMO05 Color Contamination CM05 Color Contamination is when prints that are supposed to be one color are coming out in a different color Leading Edge of Print wem Picture of Color Contamination Samples Cause Although leaks are possible in the backchannel the most common cause of color contamination is mixing of ink from drool on the nozzle plate Also if the printhead backpressure Is not preserved correctly this type of color mixing may happen more frequently Resolution 1 Run the maintenance algorithm and re evaluate the plots CL maint_clear_color_mix lt level gt B If not resolved co
59. ion Is not plugged in which may be difficult to see in an integrated print engine Resolution Check that the cutter is connected Try the cutter home command followed by a cutter cut command Use cutter stats command to determine the state of the sensors PC02 Partial or Incomplete Cut Cutter stops after a partial or incomplete cut Home sensors will not be made and the other 2 non home sensors will not be made Cause Causes include obstruction Faulty sensor wiring PCA driver or motor Resolution 1 Try the cutter home command followed by a cutter cut command 2 Use cutter stats command to determine the state of the sensors 140 Firmware Error Messages ER Error messages ER may display on the Toolbox indicating a problem The following sections detail some of the more common messages ERO1 PEP Data Underrun The paper path motion stops under this condition Partially printed pages are common as the error only occurs while the paper path is moving This condition can be temporarily reset by pressing the reset button on the PPCA or by rebooting the printer ER01 can be very intermittent in nature Cause Several causes might be behind this issue S A dirty encoder due to paper fibers Vv WwW A damaged encoder cable or board component A bad motor or driver belt tension too high or low excessive drive train friction belt pullies idlers shafts bearings Can be caused
60. istory servo_sensor SSLift 0 SS_LIFT_UP 2 store lift servo history servo_history_store SSLift 3 go to Known position and set start servo position to 0 ss_down servo_pos SSLift 0 4 reset servo history servo_history_reset 5 run lifter servo for 2 rotations servo_move SSLift 50000 150000 6 on PC run this command to download servo history usbemd exe c servo_history gt sslift txt 7 go back to Known position and turn maintenance back on ss_down maint_enable 1 MAINTENANCE BUS Entry exit sensors indicate paper inside the engine How to detect gpio_pin_get PZONE_ENTRY_SNSR returns 1 AND gpio_pin_get PZONE_EXIT_SNSR returns 1 How to fix Check for paper pieces left inside the engine Clean both sensors NVM dropout How to detect nvm_getset mpcarev returns 3 nvm_getset wiper_motor returns none 97 nvm_getset pump_ motor returns 0 How to fix nvm_getset mpcarev 5 nvm_getset wiper_motor E nvm_getset pump_motor B shutdown 1 PAPERPATH_CUTTER_ERROR reset PAPERPATH_FEED_ TIMEOUT clean sensors check paperpath check paper settings amp positioning PAPERPATH_PAPERJAM o D clean entry exit sensors 98 6 5 Print Quality Issues Print quality issues can be grouped into the following categories as explained in subsequent sections Two letter abbreviations are used as the prefix for each category so that they can be reported to the support team and tracked with metrics for further a
61. lf not resolved contact Customer Service and report error code GE04 02 Bleed unresolved 129 GE05 Scrambled Print GEO5 displays as scrambled or garbled print spanning a zone width equal to one die chip 20 mm Print Direction Picture of Scrambled Print This defect generally results from a poor connection between printhead and printer Alternatively it can arise from cracked dies or broken bond wires Resolution Jy Power down the printhead Re install the printhead If not resolved continue to the next step 2 Inspect and clean the printhead and printer contacts B If not resolved continue to the next step 3 Inspect printer connection pins bent missing out of place If not resolved continue to p the next step 4 Check alignment between the printer pins and the printhead pins fa 130 If not resolved as a last resort switch printhead to see if the defect follows the printhead oris still present on the printer If the defect is in the printhead install a new printhead and report error code GE05 05 Scrambled print unresolved 131 GE06 Print Skew GE06 presents as an untended skewing of the body of print l e the print is crooked on the page Cause This defect results from various issues of paper path handling Resolution 1 Remove ay paper jam If not resolved continue to the next step 2 5 Check the media feeder If not resolved continue to the next step 3 Check the paper p
62. ller OmniPEC and Main Board 18 215 the Control EE 19 a MARGE PNE EE 20 McK MOO SO aloca EE 20 Cette IMG and SEUD ME 20 GEMENGE 20 3 4 Connecting the Vortex 851R E 21 39 SECHER 23 3 5 1 Maintenance Module MM u cccccccccssssscecececesesssseeceececesesesseeeeeeeeessasseeeeeeesenaas 23 39 2 Installing Ink CaridgE E 25 3 5 3 Installing the Printhead eeeeeessssseennenesssssssrrrrrrressssssrereesssssrrrrrrresesssrrrrrrrereeeesssserene 26 3 5 5 Media Handling csssccccccccccccecseseesecceccseeceeeesecececceseeeaueeseseeceeecceeeeeasuegnnseseeeeteneegs 32 3 6 Connect the printer to a Computer 33 3 6 1 Direct connection to a personal computer 33 3 7 Installing the Printer Driver se ceeecsaateact cane catece darieseoncnasenscrodennlead antes antes bea eaiiossausescianesaedanaesonnieeane 34 3 7 1 Driver Specifications Printer Preferences cccccccccccsssssssseeeceecceeeeaseenesseeeeeeeeanens 42 3 8 Label printing generating print ol EE 46 3 8 1 Printing Cu Ee Tu 46 3 8 2 Printing labels from print JOS EE 46 SCHT Gd at EC Tt LEE 47 39 1 B ttons and WEE EE 48 E WOON EE 49 BD WS enn 49 AADEL E S E A E A N E E E E 50 A lut Ee 52 4 4 Network configuration ssisisiiascunesacivastnnatdenacsndenadinVeniuntacneuaasesTnnsdsaainidenadeetenstonetacavelsbanieateneedes 53 AD SEVICE ET 54 J AVAIL Ee a ENG e GUE serere E EEEE E 55 5 1 Maintenance Uvervieuw 55 5 2 Standard Maintenant e serce
63. ly take a minute or two and will be apparent from sounds emanating from the print engine If the engine don t start it automaticaly then open the toolbox and press thesystem prime 23 When the system Is primed print a test printjob from Toolbox to make sure the cleaning process was right and the printhead Is working properly 86 Waste Ink Absorber Replacement The waste ink absorber was designed to last the life of the printer under normal printing conditions taking into account evaporation Replace the waste ink absorber when ink is leaking out of the waste ink tray 1 Use fingers to squeeze the waste ink tray latches inwards at the front of the unit to release and slide the tray out Waste Ink Tray Latches Be Waste Ink Absorber 2 Use a gloved hand to pull the waste ink absorber out of the waste ink tray and dispose of It according to local regulations 3 Align a new waste ink absorber with the shape of the waste ink tray and push into place until evenly seated and flush with the tray top edge 4 Slide the waste ink tray back into the frame until it clicks 87 6 Troubleshooting 6 1 Maintenance Module aka Service Station Troubleshooting The following table lists some possible problems related to the maintenance module with possible causes and solutions Possible Causes we Motor stalls e Jammed gear train from 1 broken post or improperly seated gears e Squeegee doctor blade wedged
64. me maintenance tasks it is better to remove the engine from the printer Use the table below to determine which maintenance task inspection cleaning lubrication or replacement etc to perform at a given time period or usage interval The following tasks are to be performed by the operator only with very basic supplies no special tools are needed 55 Printhead manual wipe ee ee PPCA Contact Cleaning Every PH i ee we IDS Fluidic Couplings Every PH ee E E l a Aerosol amp Debris Clean Clean Clean Clean Clean Removal Optical Sensors Paper Path Wiper Inspection Wiper Cleaning Clean Clean a C eee DN KEES NEE EE bio iere ee Seen sp a SEN Moving Parts Motor Test Maintenance Module Ink Tank Latches In order to avoid personal injury always use appropriate personal protection when performing maintenance tasks e Clothing protection e Powder free nitrile gloves e Lint free cloth wipes It Is critical that the wipes used be soft to avoid scratching the prtinhead and lint free to avoid contaminating the printhead e De ionized DI Distilled water electronics grade Use only deionized or distilled water for cleaning the unit Take care to avoid contaminating the printhead with cleaners lubricants or other chemicals 56 5 2 1 Daily Maintenance Tasks Aerosol and debris removal Ink may transfer from printer components into media path Remove excess ink and debris
65. mware Upgrade firmware to at least 20140509 if possible with DediProg Paper sensor connectivity Follow CF07 of OEM Troubleshooting Guide Valve is giving a clicking noise Move the valve to all possible positions by ids_ valve ids_valve openink ids_valve openair ids_valve closed Valve motor problem Valve motor broken or blocked by a particle So engine can t recognize Its position Disassemble and check replace if needed Valve position unknown How to detect gpio_pin_getIDS_VALVE_POS1 returns 1 AND gpio_pin_get IDS_VALVE_POS2 returns 1 How to fix This can be due to misalignment of the disk on the valve shaft and may require replacement of the pinch valve try manually cycling the valve using tcl commands to openink openair amp closed and see if the appropriate position is returned Before attempting to change out the valve de power the engine then remove and reinsert all electrical connectors at the valve If this fails to correct the problem then the valve needs to be replaced Appendix A Capturing the sensor encoder data during lifter arm movement for reporting to Memyet For servo move debounce to work the following settings and their values should be set this is the default on power up 96 TCL gt servo_debounce SSLift 15 TCL gt vars_getset servo_disable_gpio_debounce Instructions for collecting sensor history information 0 turn off maintenance maint_enable 0 1 add lift sensor to servo h
66. nalysis e Color Mixing CM e Streak SR e Dot Misplacement DP e Banding BD e Other print quality General Defects GE Color Mixing CM Color mixing unwanted intrusion of one or more colors in another color s area shows in a range of defects as illustrated here and detailed in issues with the CM prefix Picture of Color Mixing Samples 99 Examples for Color Mixing CM01 Fine Clouds of Ink or Misting Issue CM01 Fine Clouds of Ink or Misting displays as a fine spray of small ink drops from the upstream print area that is falling on the downstream print area of the page Leading Edge of Primi Ca 30pm Cu Test image bas non printing test nozzles every 1cmto funnel mist La Picture of Color Mixing Clouds of Ink Fine mist jends after sold area fi d 2907 d Picture of Color Mixing Fine Misting Fine mist lands after sold eres fi 100 Cause Misting typically results from by the poor break off of the tails of the ejected ink drops which results in very small droplets that have very little momentum Higher pen to paper spacing difficult images or old printheads may amplify this defect To resolve this issue 1 Verify that the defect is beyond the threshold 2 Verify that the correct profiles are being used for the media If so continue to the next step If not use the correct profile s and re evaluate the performance R If not resolved continue to the next step
67. ng on the printer you need to install the MM After module has passed inspection Service Station aka Maintenance Module The Service Station cleans the Printhead Cartridge of excess ink and debris keeps the Printhead hydrated and protected when not in use captures ink used to keep nozzles clear and acts as a base to support media during printing Installation steps e Unpack the Maintenance Module e Check that each part of the station is complete and functional e Open the printer and the ink tank cover e Open the print engine clamshell e Locate the MM ribbon cable e Connect the ribbon cable to the MM connector at the back of the service station e Insert the station into the print engine 23 The Service Station fits in the port immediately above the Ink Tank Station 1 Plug in the white flat flex cable to the motor PCA on the maintenance module Slide the Latch open on the Maintenance Station Circuit Board 3 Slowly turn the gear on the print engine until the maintenance module engages 24 i og eg P i J ai d A a E 4 Close the clamshell gently to avoid causing vibration on the printhead NOTE The MM must be perfectly aligned with bar to prevent misalignment 3 5 2 Installing Ink Cartridges Vortex 851R Series Printers use a single Printhead Cartridge and five Ink Tanks two Black one Cyan one Magenta and one Yellow During installing the ink cartridges the Printer should be turned off e
68. ngine e if print quality is showing signs of contamination e if automated maintenance algorithms prove ineffective for nozzle recovery There are two methods for cleaning the print head cartridge one with it installed and one with it removed from the unit Both methods are listed below When removing and reinstalling an used printhead or when replacing a printhead use the second method Printhead Cartridge Cleaning Manual Wipe While Installed Perform the following steps to ensure proper printhead cleaning without removing it 1 Pinch the clamshell latches to release Open the clamshell and allow the upper portion to rest on the hard stops Picture of opened Clamshell 2 Locate the printhead nozzle strip E 3 Ka E m Picture of Printhead Nozzle Plate Dr ef 3 Dampen a lint free cloth with distilled water 4 Gently wipe the print nozzle plate from one end to the other Picture of wiping the nozzles 5 Fold the cloth and clean the nozzle plate again to remove remaining debris Pictures of soiled lint free cloth Close the clamshell Printhead Cartridge Cleaning Remove Cartridge Preparation 1 Lightly dampen a lint free cloth with DI water 2 Setthe wipe on a clean surface 3 Lightly moisten the cloth strip in a PH shipping cap with a small amount of DI water and set aside 78 Picture of moisten PH Cap Perform the following steps to ensure proper printhead cartridge cleaning 4 Open t
69. ntinue to the next step 2 Evaluate the ink cartridge to ensure there are no leaks out of the ink cartridge snorkel If p there are leaks run the purge algorithm If not resolved continue to the next step 3 Remove the printhead and install the designated golden unit 106 4 Purge the ink and clean the nozzle plate before resuming backpressure Then print the same set of plots 2 If not resolved contact Customer Service and report error code CM05 04 Possible printhead damage 107 CMO6 Vertical Lines Throughout Page Drooling CMO06 displays as vertical white lines followed by a dark dot Leading Edge of Print Picture of Verical Lines with Dark Dot from Drooling Cause A puddle has formed in front of the nozzle possibly due to a particle or fiber on the printhead surface and Is capturing the drops that are fired Eventually the accumulated puddle drops onto the page LA NO Resolution Run printhead servicing i e a wipe TCL wipe_basic f not resolved continue to the next step Run the maintenance algorithm 1 2 TCL gt maint_user_recovery 1 TCL maint_user_recovery 2 If not resolved continue to the next step Remove the printhead and manually wipe the printhead Re insert the printhead to see if this has corrected the problem If Hot resolved continue to the next step Replace the printhead p S al If not resolved contact Customer Service and report error code CM06
70. oane eee Mle E orn Pronin bn rear fives fan ONLINE W Mach Sne STANDBY Aiei Suter ONLINE Meet Siriei STANDEYT Firmaen AO 29tAeEg Network Settings Network Configuration Prmcer Naame DE mht Ter Feit Rei Tomas Nimr Valve Chad dhep Papert Een Ve Et No Mister apde Mhie Cag baup auloip lak p hiers Hi 1 29 pabana mask 255755 2045 ay oats Soh A def pmeeway 152 1682 PA fob 0 Pager Tan Pages WIE ps og Sobel Leet arais lak Usage Nemo Config Serge Memm Stop Be ech 53 4 5 Service Menus For authorized peronnel only Provides acces to more advanced printer control and maintenance menus Under this menu you can find many basic engine settings Very easy to uncalibrate the engine this is the reason of the password protection Here possible change TOF BOF Cut Gap r2r distances Tof2Tof settings The driver also can handle the most of these parameters 54 5 1 5 Maintenance Guide Maintenance Overview To ensure reliable operation and high print quality while using the product the regular inspection and maintenance steps are required to be performed These include mechanical subsystems checks occasional cleanings consumables changing and print head cleaning Cleaning The most essential maintenance operation is automatic cleaning the print head and preventing it from dehydration The print engine performs various maintenance operations before and after print jobs
71. om aerosol and debris No cleaninig is required on these units 66 Picture of cleaning the Lift Motor Encoder Paper Path Grit Roller Inspection The three paper path grit rollers must be inspected every month i IE a T Rui P i yee ee ee CT ee P Ee Grit Rollers Ke Picture of Grit Rollers 67 1 Inspect the print rollers for ink residue and debris If none is found proceed to the next PM task If residue is seen perform the following steps to remove it Picture of Grit Rollers with residue 2 Lightly moisten a toothbrush with a small amount of DI water 3 Gently scrub the grit rollers to remove any ink or paper dust Manually rotate the rollers to ensure that they are completely clean 4 Use a shop towel to dab the rollers and remove any excess moisture Do not rub the towel back and forth or fibers will be left on the grit rollers 5 2 4 Annual Maintenance Tasks Perform the following maintenance procedures once a year Aerosol and debris removal Paper path optical sensor cleaning Wiper cleaning Waste ink absorber inspection Ink tubing inspection Lift motor gear inspection Paper path grit roller inspection Moving parts motor test Maintenance Module sled assembly cleaning Paper dust removal Ink tank latch ink bay inspection Cutter inspection Aerosol and debris removal Paper path optical sensor cleaning Wiper cleaning Waste ink absorber in
72. ompare banding to the acceptability threshold Evaluate the paper path and note anything that is disturbing the media e if not resolved continue to next step 2 Evaluate cleanliness of the encoder and paper path sensors e If notresolved contact Customer Service and report the error code BD05 03 Low frequency page advance banding 123 Other General Print Quality Errors GE This section covers issues that come from mechanical behaviors such as varying distance for top of form smears or dots marks or ink on the paper scrambled or skewed printing 124 GE01 Marks on the Print Paper Dust GEO1 presents as fine detail artifacts on the print that resolve after running maintenance Picture of Dust and Marks on Paper Cause This defect results from paper dust or other particles hanging from the printhead Resolution 1 Run the maintenance algorithm to clean the printhead TCL gt maint_user_recovery 1 e If not resolved try the next level servicing TCL maint_user_recovery 2 TCL maint_user_recovery 3 e If not resolved manually wipe the printhead o If not resolved continue to thenext step 2 Check if the media has substantially more than average dust Replace media o If not resolved contact Customer Service and report error code GE01 03 Dust and marks unresolved 125 GE02 Varying Top of Form Margin GE02 presents as a varying margin from lead edge of paper to top of print form Measurment
73. ompatible 650 MHz CPU gt 40 million transistors USB 2 0 19 3 Installing the Printer 4 3 1 Choose a location The Vortex 851R should be placed on a properly levelled worktable or cabinet which is able to handle the printer s weight and minimum 61 cm 24 inch wide 3 2 Unpacking and Setup The printer is shipped in a strong cardboard or wooden box Before opening the box check that the box is not damaged in any way and was not turned upside down during shipment If signs of damage are found contact your reseller and inspect the box together lf the box is undamaged carefully cut the tape on the box open the box Before taking the printer out of the box make sure a strong and level work surface is prepared for the printer NOTE The printer is heavy Never attempt to lift and take it out of the box on your own as it can cause lasting injuries The printer should always be lifted by two persons Place the printer on the desk and inspect that no damages are found on the unit Unpack the unwinder and the optional rewinder units and place them on the desk next to the printer 3 3 Checking the contents Check the parts list to ensure you have received all required components If the shipment is complete proceed to the next chapter Vortex 851R Printer 1 set of CMYKK ink cartridges 5 cartridges per set 1 printhead 1 service station 1 main power cable 1 paper guide Unwinder Rewinder optional 20 Prin
74. oolbox cant see Engine IP address dropout How to detect net_mylP Engine MAC address dropout How to detect net_MAC_addr does not return 010101010101 How to fix net_MAC_addr 010101010101 Firmware dropout How to detect After starting the engine PulTY returns ABCDGK012LMNPORST BootCode Ver 2010 2 23 v 1 program 28 platform 1 Processor speed 650 Memory Size 67108864 ASIC ID 0x1162620 How to fix Burn the firmware by running Step 3 Step 4 OR Re flash with DediProg than adjust NVM getset IP and MAC address settings 93 PRINT ENGINE ERROR MESSAGES Crit 63 03 phead offline cancelpage 1 Clean printhead contact sensors 2 Replace print head 3 Flash Omnipec 4 Replace Omnipec CARTRIDGE_MISSING X clean cartridge chip with isopropyl alcohol clean chip readers with isopropyl alcohol run cm_ink replace ink cartridge DATA_PATH_UNDERRUN clean the encoder wheel reduce image complexity reduce print speed to 6 IPS check for NVIMG corruption update EEPROM with Step 1 use Adobe Reader 9 good instead of 10 bad for printing 94 Fatal 71 02 offline cancelpage Dongle Please ensure 1 That P2002 on the MPCA has not been lifted from the solder pads on the PCA 2 Thatthere is insulating tape on the dongle covering the solder pads 3 That the wires between the dongle PCA and P2002 are connected to the dongle PCA and to the connector Incorrect NVM settings Interruptioin the sensor power How to d
75. ove debris inside and outside surfaces of the clamshell N hq fl 5 2 2 Bi Weekly Maintenance Tasks Aerosol and debris removal e Paper path optical sensor cleaning e Wiper inspection Aerosol and debris removal see at daily maintenance tasks Optical Sensor Cleaning Clean the four optical sensors in the paper path every two weeks 1 Pinch the clamshell latch to release and open the clamshell CSS E Picture of Paper Path Optical Sensor Locations Bottom 2 Moisten a foam swab with distilled water hh a e 3 Place the damp swab on each sensor and twist back and forth to clean the surface Use a new moist swab on each sensor ON p 4 Repeat cleaning and drying process for all four sensors Wiper Inspection 1 Pinch the clamshell latches to release and opend the clamshell TTT Tt wd NOTE The wiper Is automatically in the up position when the clamshell is open Go to Toolbox and click on Eject Sevice Station button Inspect the wiper to ensure that it is spins freely with no excessive noise Check the surface of the microfiber roller MFR for any irregularities bumps divots etc or delamination peeling of the wiper surface at the seam Iff irregularities are seen escalate to a technician for replacement 5 Use tweezers to remove any large clumps of debris 5 2 3 Monthly Maintenance Tastks e Aerosol and debris removal e Paper path optical sensor cleaning e Wiper inspection e Was
76. priming cleaning or in the platen holds waste ink generated during printing Therefore periodic maintenance will be required to remove the waste ink 2 13 Print Zone The clamshell design allows for accessibility during paper loading and paper jam clearance in the print zone 2 14 Onboard Print Engine Controller OmniPEC and Main Board The OmniPEC controls all electronic aspects of the printing and print engine operation The custom 95 pin WaveTech connector connects the printhead to the printhead board which is 18 connected by cables to the OmniPEC main board The OmniPEC allows connections to paper motors ink level sensors ink pump and additional sensors Dual resolution file format to achieve crisp Print Quality PQ yet reasonable file size 1600 dpi lossless text expansion 800 dpi contone JPEG expansion Two processors 650MHz RISC CPU with customized HW assist image processing focus and 192MHz SPARC CPU dedicated to the printing pipeline Dedicated printing pipeline in HW Real time JPEG compression Color Space conversion Half toning Dead nozzle compensation Printhead data formatting 2 15 The Control System The Printer engine is controlled by the OmniPEC the Quality Assurance Infrastructure QAI and the firmware Full page array printing Calculates 900 million drops sec Drives 70 400 nozzles on the printhead JPEG expansion in hardware On chip memory Extensive motor control and 0 Xscale c
77. ps S15 51 4 3 Ink Usage Allows you to monitor the estimated amount of ink left in each of the five Ink Tanks You can monitor inkusage and consumption and schedule Tank changes saving down time during a print run NOTE Ink Usage only works when you start with a new Tank and leave it in the Printer pope s ME beg SE EE a 0 Gage e teen Hee Mane Sytem Staten Gi Dep 1 k U f Mach Sinir STANDERT H KA Mech tana Cp Do net Sr READY Printed Tak nl Ach Pasai Mode Alada Feme irga EE ien saciid kate Sena Number MEESCH Panhead BMY I Premed W028 93153760 APE IHI I L Noma inima TE Fett Let vahe ymiai Pipapih imm Tea Bi Xe Almira bisd Poi Lok Kik Ki Ke Ke V Heke i Page 3 Total Fagen User Interface OO heon Peetri Mode Oe i IR e Please note that ink usage job history will be lost after turning the printer down 52 4 4 Network configuration On this page you will see the actual engine network configurations The network settings page provides information about the network connectivity Printer name Domain name and IP configuration settings dhcp if its on then the machine will get an ip address from the router This is the basic setting also Manually IP settings turn off the dhcp and autoip and after type the chosen IP into the Paddress line and press SUBMIT Or zs UI D pee n Ip oot F aiaa a hh a D e laa A U
78. py the file contents to an archive location and trim the file back to zero size It is good practice always to keep serial logs for long term reference Use TCL Help to learn about debug levels Setting a higher debugging level will display more information However setting debugging too high can interfere with printer operations since it takes time to write information to the log so finding a debug level that s appropriate is important Installing and checking the Custom Firmware routines The custom Firmware routines used for extending the printers control interface with the buttons are stored in the Engine s flash memory and are non volatile but firmware burning will clear the flash so the custom extensions need to be reapplied after firmware upgrade Adding the custom routines is done by uploading the V851R_CustomFW tcl file to the engine via USB after there is working R13 Firmware on the engine V857R_CustomFW tcl can be send to the engine with the help of the attached Add Custom FW Routines bat batch file Or manually from command prompt by typing usbemd i V851R_CustomFW tc Of course the correct path need to be set for the usbcmd exe as well as the tcl file and the engine need to be 91 under power connected via USB and the firmware in standby mode As long as the tcl file the batch file and the USBcmd exe are in the same folder there should be no issues with the upload After the custom routines are burn
79. r to be due to any of these causes Resolution See Low Ink When Not Low CMs have two avenues to adjust what happens between ink low detection and ink out protection First the nvm flag can be set to FALSE so that the printer will only warn about ink out but will not error and prevent printing Second the allowable ink after low ink detection can be set to a nonzero number which will enable most users to print a few more CCs of ink but expose some users to the risk of dry firing the head ID04 Ink Indicated As Out Without Warning Out of Ink often appears as light printing in a color all the way across the page fading from full color to no printing at all within a few pages Less often the problem can manifest as a deprime which shows up as which streak that expands to cover the whole head often leaving jellyfish patterns on the page Cause A sensor can fail to detect Out of Ink if the sensor is coated with sludge or the cartridge is not properly inserted or the sensor is broken The light printing is caused by excess backpressure When there Is no ink the backpressure gets more negative and the drops get smaller When the backpressure gets to 900 mm H20 the printhead Is no longer able to eject drops and printing of that color will stop Waiting a short time will allow some ink to flow across the filter and a small amount of printing will be possible again Deprimes that start as a white streak and grow to cover the whole pag
80. re for entering commands serial logging More information about it int he next phase Serial Communication and Related Tools The most important troubleshooting tool is serial communication which requires a special serial cable and some software on the PC Recommend using PuTTY a free open source terminal emulator with strong logging capability Once serial communication is set up use serial logging for debugging Issues Using TCL Commands and TCL Help Many of the resolution actions listed in this document do not describe the exact TCL commands used It is critical that any user of TCL be familiar with the self documenting help feature Newer and better TCL commands are often being added and TCL commands can vary from one version of firmware to another Enter the appropriate TCL command to get the latest TCL commands and descriptions currently on the system For example For a complete alphabetical list of TCL command with the description that is the verbose version arranged in an 80 character column enter help For a description of a specific TCL command enter help Exact 2 where lt srch gt is the keyword To read sensor values use GPIO commands for example TCL gt help gpio 2 Serial Logging Serial logging records everything the printer does and keeps it archived Recommend keeping PuTTY running at all times with the logging feature enabled to create an unlimited length file and using some scripts to occasionally co
81. riming can also help to remove air 26 bubbles from a previously primed printhead The priming process is designed to use less than 5ml of ink To prime the printhead manually 1 Fillthe main channels of the printhead Generate a pressure pulse to push out any bubbles Clean and dispose of the ink pushed out onto the nozzle plate Print out color mixed ink Cap the printhead to prevent dehydration U AeA U N Installing the Printhead 1 Ensure your printer is switched on and the Power button is lit and steady 2 Open the cover of your printer to reveal the printhead latch with a screw driver ONLY at first use 27 e Dm If the printhead latch is not raised press the Printhead Eject button for three seconds This will automatically initiate printhead latch opening This process may take several seconds Remove the fluidic cap protectors from the two fluidic couplings Fluidic cap protector ALE i IS W I Fluidic cap protector yo 2 CR Open the end of the printhead package outer box and slide out the foil bag a ve TE mt J Inspect the integrity of the foil vacuum sealing The foil bag should be formed tightly to the contours of the printhead cartridge as shown above If the foil is loose to any degree then the seal has been compromised If a poor seal is suspected DO NOT USE the printhead cartridge Report the issue to your supplier Carefully rip the foil packaging open atth
82. rint 4 L Ip ep CES ier ee ee Treen circ nit rte PR za g meiegim go rh Log opge E WU Bra Paar tee Dia D a Sd im Ee Welcome to reopen Eni Me ba e Northstar isi e ggf D n D n Die Din DES isb Page 3 Total Page i User Interface Dicplay Language Weg wiem TE Stop Bech A benna Pron Uno e Gs Aue CE Mar EE te ee ee TEE bo te a OC Sey nee TT e ag Teater CN pi Ml iia E orte Pestii Sane DA a B Mach Stais STAT User Interface Mach Starner OLDS RE Gees Meng Boun STANDE Gen Ema Paaa baa Famer hia anpa t Pewter id BHT Freed z j Pom Pi Th FE i LBec 3 Reg Jab Courter d Renal Page Comte a Tabe d Wipe ebe Creisse ak bk TENi Pee Sie p PE ee a ee Jake Page B e T ha Mole Total Pages User Interface We bagecme Note Beate opge that the peasperpath is clear md the peter in kie 49 Some Pages Geter Tash Provides access to the Printer User Control screen From this screen you can Clear Errors Cancel a Job Reset the Job Counter and Reset the Page Counter You can also perform some maintenance and operating tasks such as Clear Error If the engine Is in error status it is possible to delete with this button There are some fatal states that are unable to delete Cancel job delete the actual jobs For example if the machine Is in error state and won t delete the jobs after cancel job it will
83. s 39 3 The setup console will start TA Vortex Printer Series Driver Thank you for buying our printer Click the Install Printer Software button to install the printer on your computer User Guide 4 Click Install printer software and accept the terms in the license agreement then click Next Kg x gt i ga T3 Vortex Printer Series Divet gem n x Portions of this Software contain copyrighted matenals from RIID s suppliers and licensors Terms governing use copying and distribution of such third party materials are set out in the Legal Notice accompanying this Software accept the terms in the license agreement 5 When asked select Configure to print using USB F Vortex Printer Series Driver Configure to print using USB E My printer is connected directly to my computer using a USE cable C Configure to print over the Network Wi My printer is connected to the Network 6 When the installation is finished you can set this printer as default and or print test page not necessary Click Finish button and exit the installer Thank you for installing the printer software Print Test Page T Set this printer as the default printer Installation is finished 41 3 7 1 Driver Specifications Printer Preferences 3 7 1 0 General Tab Orientation Portrait default Landscape Rotate 180 and Mirrored Lets you choose the number of copies
84. s governing use copying and distribution of such third party materials are set out in the Legal Notice accompanying this Software accept the terms in the license agreement 35 5 When asked select Configure to print over the Network Configure to print using USB My printer is connected directly to my computer using a USB cable onfigure to print over the Network My printer is connected to the Network 6 The installation will begin and a new window will pop up with the available printers on the network Select your printer and click Next IP Address Printer 192 168 2 21 Vortex DEVV6851R Vortex 49 7oe0 1256 36 7 When the installation is finished you can set this printer as default and or print test page not necessary Click Finish button and exit the installer Thank you for installing the printer software Print Test Page Set this printer as the default printer 8 Open Windows Devices and Printers right click on Vortex Printer Series Driver and select Printer Properties 7 Ga a leer cel P Vortex Printer Series Driver Properties 4 Unspecified 1 E Apple iPhone Model Vortex Printer Series Driver Features Staple No Speed 60 ppm Maximum resolution 1600 dpi vor Color Yes Paper available Double sided No Letter8 1 2x11 in gt d 37 9 Select Ports tab from the top and deselect Enable bidirectional printing de Vortex
85. should be replaced as part of annual maintenance or after printing one million inches NOTE The maintenance module is not intended to be end user serviceable although itis a service part for technicians 16 2 12 1 Wiper station The printhead must be wiped to remove ink cross contamination and particulates The cylindrical wiper rotates to wipe the entire width of the printhead The roller rotates for the duration of the lift dwell lower cycle The intent is not to merely blot the nozzles but to have functionally translational wiping The wiper is programmable and can be rotated numerous times to perform multiple wiping operations Once wiping is complete the station drops back down A metal transfer roller cleaned by a doctor blade helps remove ink from the wiper The removed ink dries or evaporates within the wiper station When the wiper becomes contaminated to such an extent that it is no longer effective the wiper must be replaced by unlatching the two wiper retaining clips These clips can be released while the maintenance module is in the wipe position Picture of the wiperstation 2 12 2 Printing platen The platen provides a smooth writing surface and the correct spacing between the media and the printhead During printing the paper below the printhead Is maintained at a fixed dive angle from the drive roller nip and platen below the nozzles to ensure print quality Along the center of the platen there are four Porex tm mi
86. sorts two GPIO pins so it does not require any kind of software for its operation consequently it can be used to power on the engine during the manufacturing process even if there is no firmware on the machine The other buttons need the custom firmware components added by the V851R_CustomFW tcl to be running The integrated leds in the buttons are used to give further information about the printer s current state these are listed in the Led Table below Led Table Green Led Power Status e Led On Engine ON e Led OFF Engine OFF Red Led Cancel Job Clear Error e Led Off Normal operation gt Button press will Cancel current job e Led On Error detected gt Button press will start the Clear Error procedure further error info can be denoted by the yellow led s status described below e Led Blinking Doing work cancelling or clearing error Yellow Led Feed Unfeed e Button press will initiate Feed or Unfeed process depending on the current paper status of the printer e Led Blinking Doing work feeding on unfeeding e Led On Red Led On Engine in Paperpath related error state denotes Paperjam in 95 of the time e Led Blinking Red Led On Engine in Paperpath_end_of_roll error state so there is no paper in the printer or it is unable to detect it 48 4 Toolbox On the welcome screen you can select your language and on the left side you will find the status panel of the engine If the engine is ONLINE it is ready to p
87. spection Ink tubing inspection Lift motor gear inspection Paper path grit roller inspection see at monthly maintenance tasks Moving Parts Motor Test 1 Activate the media path cutter pump pinch valves and maintenance module and listen for any noises not present when the printer was new 2 Inspect the motion of the media path and the maintenance module to ensure the motion looks smooth and free 68 Maintenance Module Cleanining Clean the Maintenance Module aka Service Station every year 1 Lay absorbent disposable towels under the base of the printer ff Picture of layed towels NOTE it recommended to do a System Deprime before ejecting the Maintenance Module Also it is better to remove the printhead and cap Itt o avoid contamination and adequate moisture 2 Inthe Toolbox push Eject Service Station button to send the Maintenance Module to the eject position The maintenance module moves forward for easy access na a L i cil Maintenance Module in Forward Position 3 Prepare a large absorbent towel to catch any ink which might leak from the maintenance module or the wick to the waste ink reservoir Make sure to fold the towel over 2 or 3 times so that it can absorb lots of ink Be prepared to cover the bottom of the maintenance module with the towel as you pull it out 69 Manually rotate the maintenance module positioning gear until the module disengages from th
88. t The result of this setup is a breakthrough 12 inch 305 mm per second printing speed The printhead is manufactured with state of the art semiconductor technology an A4 head contains 70 400 nozzles delivering 1600 dpi native resolution at full colour The nozzles are arranged in 10 rows having 2 rows for each ink channels The fixed head spans the width of the label and feeds an entire label at a time similar to a laser printer This architecture dramatically improves performance and ink drop placement accuracy during printing while decreasing noise and vibration Figure 1 Printing with a traditional moving head and with the Memjet printhead Printhead aignmert surface PaperPath Prntheed Printhead Encapsulation alignment surface e ed eer SE WO BN ik cullet ports V R dance ral Y alignment tongue e ink inlet ports Peta re Figure 2 The Memjet 8 5 printhead cartidge showing the ink inlet outlet ports various print related parts and the printhead w b 4 a b Figure 3 The Memjet printhead contains 70 400 nozzles in 10 rows brown stripe in Figure a An electron microscope image of a single nozzle Figure b The small size of the nozzles results in very small 1 2 picolitre paint drops approximately 14 micron drop diameter on paper effectively achieving the highest print resolution the human eye can see Printing with this type of precision requires many technical details to be solv
89. tandard good practice Is to remove all ink cartridges then insert them one at a time and run the qa command In this way the actual cartridge can be Identified instead of the confusion that may result with bus contention or an incorrectly chipped cartridge If two identically chipped cartridges are inserted for example chips indicate two magentas one will show as authentic but the incorrectly chipped cartridge will show up as missing 1D01 Ink Cartridge Not Recognized When Inserted The message ink tank missing appears on the screen Querying the QA status may reveal that the cartridge is not authenticated or missing Cause Tanks may not be making contact with the pads that read the chip This happens if the tank is noti inserted fully the pads on the printer are damaged or the chip Is not located properly on the tank Chips can also be faulty and fail to read even when the contact Is good Resolution Shim bottom of tank to make contact 1 If the tank is now seen as present then the contacts on the printer PCA may be damaged 2 If the tank is still reading as missing then the chip on the ink cartridge is nonoperational It is possible for a chip on the tank to be working normally and then not work properly Try replacing with a different ink cartridge ID02 Ink Reported As Out When Not Out Excess Stranded Ink The printer reports empty ink and refuses to print but the cartridge still has more than 7CCs rema
90. te ink absorber inspection e Ink tubing inspection e Lift motor gear inspection e Paper path grit roller inpection Aerosol and debris removal Paper path optical sensor cleaning Wiper inspection see at bi weekly maintenance tasks Waste ink absorber inpection Waste ink absorber must be inspected every month The waste ink absorber was designed to last the life of the printer under normal printing conditions 1 Release the waste ink tray latches at the front of the unit and slide the tray out 62 2 Eventhe absorber is completely darkened with waste ink with no white showing it may still be able to hold additional ink due to evaporation The capacity of the waste ink absorber is 1 6L Visually inspect the waste ink absorber and tray to see if there Is ink leaking out of the tray If yes replace the absorber with a new one a E Weg d ai E 3 Slide the waste ink tray back into the frame until it clicks Ink Tubing Inspection The following ink tubing and connections visible to the operator must be inspected every month e Fluidic coupling aka Revolver Caps e Buffer box e Pinch valve e Peristaltic ink pump Refer to the following pictures to identify the specific harwares 1 Remove any housing or covers positioned around the ink tubing NOTE The clamshell should be closed during this procedure 63 Ink Tubing E gt y _ A mmm Pinch Valve and Vents x5 e Er
91. ter and contents Rewinder Unwinder 3 4 Connecting the Vortex 851R Make sure the printer is used with the mains cable suited to the requirements of the electrical system of your country The internal power supply in the Printer is rated 115 to 240VAC 50 60 Hz Insert the cable into the printer first The cable connector should sit in the socket securely Insert the cable into the mains socket 21 Turning Power On Off Powering Up 1 Turn onthe main switch and 2 Press the Main Power Button on top of the Printer Powering Down Printer 1 Press Main Power button on the top of the Printer and wait until the engine is turned off 2 And turn off the machine with the main switch OR 1 Open the Toolbox and press Shutdown 2 Waitfor the printer to stop processing and the toolbox write out the printer not responding 3 Switch off the mainswitch 22 3 5 Setting up the Printer After the printer has passed inspection install the maintenance module the printhead and the ink cartridges as explained in the following sections To set up the printer you need to do the following 1 Install the Service Station if shipped as a separate unit Install the ink cartridges Install the printhead Turn on the Printer Unwinder setup Load label media Install the printer driver eS eS Se E a 3 5 1 Maintenance Module MM In case your printer is shipped with a MM as a separate unit before switchi
92. ter and media settings from one PC to another When exporting these settings an ini SE file will be generated which can be Wee apf Segen BN connec copied onto another computer where the driver is installed as well and can be imorted simply memyet 3 7 1 4 Services When printer is online Service menu can be used to carry out manual not automated programmed maintenance by simply clicking on CLEAN PRINTHEADS button PRINTING DEMO PAGE will print Windows demo page Make sure you have wide enough 210mm continous media fed into the printer prior using this function PRINT CONFIGURATION PAGE will print printer confguration page IP address etc Make sure you have wide enough 210mm continous media fed into the printer prior using this function 45 3 8 Label printing generating print jobs For printing labels the operator has two options Print label from a labelling graphical or other software Print labels from print jobs 3 8 1 Printing labels from softwares Printing labels from any kind of software is quite easy The operator just needs to set all prefrences within the Vortex 851R Series Driver paper size printing speed number of copies etc 3 8 2 Printing labels from print jobs To help the whole process it is recommended to install the driver on the personal computer then change the following 1 Go to Start Devices and Printer Right click on
93. to be printed If choose the reverse order then the jobs starts Vortex Printer Series Driver Printing Preference Media Import Export Services 1 Job per Copy Reverse Order Collate Color Selection Color General Layout a Orientation Page Stitching 8 5 by 11 inches printing after the last page Is arrived iech a PrintSpeed eet 6IPS is the Best quality mode with 1600 1600 dpi Copies 12IPS is the normal with 1600 800 dpi My Print settings Acces your costum print settings for various jobs memyet aoe arc as that you uploaded through the Media Profile D n pnt Speed Upload int he Toolbox Se a z Media type and media size are defined by the Vortex My Print Settings 851R Series Driver and included during installation Defaults Default SpeedJet Glossy Label SpeedJet Matte Label SpeedJet Standard Label SpeedJet Vellum Letter 8 x 11 in Legal8 x 14 in Statement5 x8 Yin Executive 7 14 x 10 in A4 210 x 297 mm A5 148 x 210 mm A6 105 x 148 mm 4x6in 5x7in 5x8in Color Composite Black only 4x 10 in 4x11 in 4x 12 In 8x 10 in Env Monarch 3 7 8 x7 Yin Env Com 1041 8 x9 Yin Env DL 110 x 220 mm Hagaki 100 x 148 mm 100 x 150 mm 1x 1in 42 3 7 1 1 Layout Tab ems Vortex Printer Series Driver Printing Preferences Resizing 8 5 by 11 inches Original

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