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HP 72SI User's Manual

1. Fig 3 2 Ink box with supply connector Loading Ink Loading Ink Connect the ink supply tube to the ink box Grasp and squeeze the ink tube connector as shown engage the connector to the ink box and release the connector Ensure that the connectors are firmly engaged before pro ceeding Fig 3 3 Connecting the ink tube to the ink box Invert and install the ink box into position in the holder The position for each ink color is shown on a label below the ink box holder on the pump cover and on the profiler docking station Install the profiler in the corresponding docking station slot 3 12 Pause Swapping Ink You can replace one or more ink boxes during a print by pausing the printer ds 2 On the printer control panel press the Pause key Remove the old profiler This signals to the printer that the ink box is being replaced Disconnect and remove the old ink box Install and connect the new ink box Install the profiler that was included with the new ink box The LED above the protiler blinks slowly while the printer reads and verifies the profiler The LED goes out after the profiler has been verified as a valid protiler with ink remain ing Repeat steps 2 through 5 for any other ink boxes you want to replace On the printer control panel press the Resume key Loading Ink Capping the Printheads Cap the Printheads 63 B D Offline amp Ink ea 38 E e goes
2. Media Handling Automatic color calibration uses an onboard photodiode to linearize output over the entire density range with print server or RIP support Color profiling with print server or RIP support the onboard photodiode can be used to create custom ColorMark and ICC color profiles for third party media Tensioned roll to roll media handler supply and takeup spools are tensioned to manage vinyl medias on heated sur faces Tensioning is automatically maintained consistently on the supply and takeup as the roll diameters change during printing Optionally the supply or takeup motors can be idled during printing In roll fed mode the supply must be loaded but the media can optionally be left off the takeup Releasable pinch rollers ease the loading of roll fed media and enable the loading of rigid cut sheet media The pinch roller force is adjustable to feed the media without marking or damaging it Steel media spools the takeup supports up to 7 5 inch 190 5 mm diameter rolls of vinyl media on 3 inch cores The supply can also accept 2 inch cores with the supplied 2 inch collets On the 98 inch model spool supports and a reinforcement sleeve support the weight of longer rolls of media less than 72 inches wide Rigid cut sheet printing supports printing on rigid cut sheet media up to 1 4 inch 6 mm thick Media width sensing automatically detects the width and position of the media loaded
3. Backward DisplayMaker Gator Advance Fig 3 17 Load Reload key Load New Media press this key to re enter the Media Wiz ard and select a new media to load either roll fed or rigid cut sheet See Loading Roll Fed Media on page 3 16 or Loading Rigid Media on page 3 29 for instructions Reload Media press this key to re load the same media type for example to print multiple copies of an image on the same media 3 36 Reloading Rigid Media When you press the Reload Media key the control panel displays this screen Load a sheet of media onto the printer Place the front of the sheet under the pinch rollers and align the right side with the fence Set the pinch rollers to slot 2 Press Reload when ready gt 5 gt ro Eo Reload Reload Sheet amp Print Reloading Media Type Sheet Fed Fig 3 18 Reload media See Loading Rigid Media on page 3 29 for instructions Then press one of the following keys Reload amp Print the printer locates the edges of the media as specified in Measure Media Type see Printer Settings on page 2 10 then switches online and receives the next print job Reload Sheet the printer locates the edges of the media as specified in Measure Media Type see Printer Settings on page 2 10 then displays the Front Page screen so you can print Prime Bars or make adjustments When you are ready to print press the Online Of
4. Input MFN enter the Media Feed Number that was displayed after a previous media feed calibration to return to that setting without performing the calibration again 4 7 Manual Calibrations 3 B ex Offline amp Ink Em amp c3 Em et Bas amp Sleep aa 1 Ta Gea co Access Media Load Heads Yard Media When you run the calibrations from this menu you evaluate the calibration test patterns visually and enter the calibration values via the control panel Note The manual BiDi and X head calibrations are time consuming and can be error prone but is necessary when calibrating transparent media or other media that the printer s digital image sensor cannot cali brate Before calibrating the printer first clean the printhead jets See Loading Roll Fed Media on page 3 16 for tips on detecting and recovering missing jets 1 Pressthe Menu key from the Front Page screen on the control panel to display the menus 2 Press the Y Menu In key display the Calibrate Printer menu Press the V key to highlight Manual Calibrations 4 Press the X Menu In key The Manual Calibration menu consists of these options Manual BiDi Registration page 4 11 the manual ver sion of AutoBiDi Calibration Manual X Head Registration page 4 9 the manual version of AutoH2H Calibration Manual Jet Mapping page 4 13 the manual version of Autojet Jet Stat
5. Registration successful Manual Calibrations Manual BiDi Registration Bidirectional registration is a method to align each of the print heads so that dot placement is accurate in both directions along the X axis along the direction of printhead travel The bidirectional registration pattern consists of a series of verti cal lines Half the pixels in this pattern are printed in one direc tion half of them in the other direction When the pixels are accurately aligned the pattern is clear When the dots are not aligned the pattern appears fuzzy and ill defined Note AutoBiDi Calibration is the automatic version of this calibration Try AutoBiDi first before running this manual calibration see Auto Calibrations on page 4 20 for details 1 On the Manual Calibrations menu press the Y key repeat edly to highlight Manual BiDi Registration Press the X Menu In key to select the option Press P Proceed The control panel displays this prompt Print a manual bidi registration page 4 Press gt Proceed The printer prints the calibration pattern you selected 5 When the calibration page has printed the control panel dis plays this prompt Bidi registration Head 1 0 6 Examine the BiDi Registration pattern for the current head and determine which pattern is the closest to perfectly aligned Manual Calibrations 4 11 Use a printer s loupe to select the pattern since the lines in the patterns may be dif
6. Wizard Media Advance The filter s label has an arrow that indicates the direction of flow Install the filter with the arrow pointing up Tighten the filter clamp The filter should be secure but do not overtighten the screw Connect the hoses to the top and bottom of the filter and tighten the connectors Reconnect the ink tube to the ink box See Loading Ink on page 3 10 for instructions Replace the ink box On the Front Page screen press the Menu key to enter the menu system Press the V key repeatedly to highlight Maintenance Press the X Menu In key display the Maintenance menu Press the V key repeatedly to highlight Reset Reservoir Filters Press the X Menu In key Select the filter s you want to reset Replace Ink Filters Extended Power Down and Restart Power Down Extended Power Down and Restart UNDER NORMAL OPERATION DO NOT POWER DOWN THE PRINTER Constant vacuum at the printheads is required to pre vent ink from running out of the printheads If the power must be removed for a brief period of time you can leave the carriage over the service station not the capping sta tion to allow the ink which will no longer be held inside the printheads by the vacuum pressure system to drain into the excess ink reservoir Power up the printer as soon as possible and cap the printheads if the printer will be idle for four hours or more Optionally you can
7. on page 3 44 for details 3 19 3 20 13 Select the media type that most closely matches the media you are loading or create a new media type The control panel displays the current settings for the media type you chose Media Smooth Banner Vinyl not loaded Thickness 0 074 in Feed Method Roll Stiff Media Handling Ltt Print Mode Production Quality Tension Takeup 7 Supply Idle Heater Temps Setting 7 Platen Vacuum 5 0 Drying Delay 0 0 sec Fig 3 8 Media settings Loading Roll Fed Media Media Serm Banner Winyl Thickness 0 075 in Media Feed Number 2792 Feed Method Roll Stiff Media Handling Of Measure width Automatically Fage 1 of 2 Print Mode Production Quality Dryers On Takeup Tension 5 Dryers OFf Dryers Un BOO 300 600600 600 300 Heaters Custom Setting Custom Vacuum 5 0 Dry Delay 0 0 sec cow Media Settings Fig 3 9 Media settings roll fed 14 Press one of the change keys to change any of the settings print mode or media type press the LI key to see page 2 or press the key to continue Ifyou do not have the optional auxiliary dryer enabled page 2 will only show the Dryers Off column Ifyou press one of the change keys a screen appears to allow you to change any of the settings Then press the Loading Roll Fed Media 3 21 gt key to continue See Media Wizard on page 3 44 for information about these settin
8. 5 9 Manual lot WIDE sus 5 9 Cleaning Solvelit Sodksntetelseuei e eteboutstp eot a abbe quada al Ente d tel cata debe 5 10 Cleaning the Service Station Doctor Blade 5 11 Set the Printhead and Camera Height seeeeeesssss 5 12 Set ng the Head Fl CIM usa 5 13 xi xii Setting the Camera Heights ass 5 15 Calibrate the Service StatloN suis 5 17 Replace nk FIM S dete ine ame pem utes doom aaa 5 19 Extended Power Down and ReStalt ccccccecsecsecsececenceeceeceseeseecees 5 21 POWER DOWN Eee TT 5 21 Restart oos wb e eios mte usa uti a Mi n d ute Dd ett E eae oe 5 22 Technical Specifications SPEEINICAlIONS etm aes A 2 S pplies and Accessories nie A 6 Troubleshooting THOUDIESIIOOLING Checks au ren B 2 Waranty Caisse ae B 5 Bitrepretid eset T B 7 MacDermid ColorSpan Technical Services eseeeeeees B 14 HelpsErotm Your Reseller sn B 14 Help FroM COl0fSPaNn un ueneen aa B 14 NENNEN cipere B 14 Index Table of Contents CHAPTER 1 NS Getting Started This chapter shows you how to get started using your printer It includes these topics Operating Requirements page 1 2 Unpacking and Assembly page 1 7 Workflow Overview page 1 8 Parts Overview page 1 10 so Special Features page 1 15 Getting Started 1 1 Operating Requirements 1 2 Electrical Environmental Choose
9. LS Image Sensor W LS 1 Image Sensor Is Not Operat The image sensor shutter cable is dis Connect the image sensor shutter ing connected cable and restart the printer W LS 2 Image Sensor Is Not Operat The image sensor cable is discon Connect the image sensor cable and ing nected restart the printer MD Media Drive A MD 1 Media Advance Stalled The media drive motor has stalled Check supply spool for binding and motor for failure MS Media Sensing A MS 3 Media Too Far Left Right Media is loaded too far to the left or Reload the media closer to the center right of the platen A MS 4 Media Out There is no media loaded Load media A MS 5 Media Too Narrow Media loaded is not wide enough for Load media that is at least 24 inches printing wide W MS 1 Media Low Less than 10 feet 3 meters of media Monitor printing and reload media to remains roll fed or less than 1 foot avoid running out of media during 30 cm of media remains sheet printing fed W MS 2 Media loaded may cause head strike Continue printing or replace media Media Non Standard Width W MS 4 Media Advance Switch on back of Press the Load or Unload button on Media Advance Switch Detected printer was depressed the control panel to ensure proper tensioning of the supply and takeup W MS 6 Media loaded is too wide to be Replace media See Appendix A Media Too Wide printed on Specifications for supported widths PC Printing Calibration
10. Printing can be paused and resumed at the control panel enabling you to purge the printheads to recover jets or make other adjustments During the pause the carriage goes to the service station and idle spits 600x300 Printing The default printing resolution is 600x600 dpi To print a docu ment at 600x300 dpi configure the third party RIP or Color Span print server to rasterize print jobs at this resolution Refer to the Print Server amp Driver Setup Guide or third party RIP docu mentation for instructions 1 Cap the printheads for instructions see Capping the Print heads on page 3 13 2 DONOT POWER DOWN THE PRINTER If the printheads will be capped longer than overnight follow the instructions under Daily Startup twice a week to prevent excessive ink clogging then recap the printheads If this is not possible or impractical or if the printer must be shipped see Extended Power Down and Restart on page 5 21 for instruc tions For further idle maintenance tips see Idle Jet Maintenance on page 3 3 Parts Overview Fig 1 1 Front view Xj CIR 4 d poc c i Fig 1 2 Rear view 1 10 Parts Overview Parts Overview Index Description 1 10 Encoder strip allows precise positioning of the print head carriage across the length of the platen Main carriage drive belt moves the carriage across the length of the platen Transport chain not show
11. JOE Maintenance een 3 3 Selectingra Print Mode emm P 3 4 General Printing TDS asus aoswlacalaruacwdnceas 3 6 Checking Jet Health 3 7 PRE PRONG Bai Sreser anae R e E een 3 8 P rgesnsWiIpe Printheads ass 3 8 Print Jet OUEb INS See rear 3 9 Maps OUCIMISSING GUS anana 3 9 Loading INK 3 10 VV MEO LOA ia qe NT 3 10 Unloading an Empty Ink Box esee 3 10 Eoadirdjs Full dnk Borstel 3 10 Pause SwabDIDO IHR ete aov R P viol a oa uoo Use 3 12 Capping the Printheads ss 3 13 Cap tne Printheads RER 3 13 Uncap thie Phipntlieadsissesonsoss atu end Cubs E RU pep tube R Robe E uu oa to baN END 3 14 Loading ROMER SE Median 3 16 Support for Large Narrow Media Rolls 3 17 Loading Wide Media a m a Ca eA Ee edu 3 24 Unloading and Cutting Roll Fed Media eese 3 25 Takeup Spool PIN Reledse as er 3 26 Respooling Media nn 3 27 Loading Rigid Isto ir m 3 29 Releasing a PiniecbiRellerias ie e oe RR mine EON DIN u 3 33 Reloading Rigid Media nn 3 36 Edge tosEdge PBIPITITTO o oec conos e ost ete eo edo o edd Lo eumd La oed 3 38 Document Application and RIP Settings eeeeeesssse 3 38 Media Properties ueni e PROP are 3 39 Printer SetU she 3 39 Loading and Squaring the Media cessere 3 40 EX INI BI Sessel russ 3 41 Docultnent Deslafiss ede DU c e Ot rede den eb
12. for precise image placement AutoEdge automatically aids the loading of rigid sheets by detecting right left and leading edges and warns the user if the sheet is skewed Integrated contact heaters preheater and platen heater maintain uniform surface temperature across the printing area to control dot gain on various media Heated drying surface allows prints to dry before being rolled onto the take up spool results may vary based on media and color profile characteristics Optional auxiliary dryer the available auxiliary dryer pro vides extra drying power to both roll fed and sheet fed out put Special Features Performance and Media Wizard stores and recalls a set of operating param Ease of Use eters by media type and print mode for optimal printing performance Includes a set of predefined settings for stan dard media user may add settings for other media Speed quality print modes multiple print modes and res olutions provided to meet job and customer requirements for speed and quality Simplified control panel interface Front Page screen pre sents frequently used functions with recommended preset configurations A menu provides access to less frequently used functions and troubleshooting help User assistance control panel features online help interac tive procedures and diagnostics to assist the user on the fly reducing training and troubleshooting time Integrate
13. locking wall receptacle wall receptacle North America Japan Europe North America If your building receives power from a standard three phase supply note that the printer will use only two of the three phases This means that your building s three phase power transformer may have an unbal anced load Check with your electrician to verify that your building has sufficient capacity for this unbalanced load Optional auxiliary power for vacuum system Supplied 24 volt DC power supply with univer sal adapters connected from the 24 VDC jack on the vacuum pressure assembly to either of two options 1 UPS customer supplied uninterruptible power supply output 100 240 VAC 50 60 Hz minimum of 15 watts of power provides bat tery backup to the vacuum system in the event of a power failure 2 Wall outlet 100 240 VAC 50 60 Hz pro vides temporary power to the vacuum system when it is necessary to power down the printer for service Ld d Ta Specifications A 3 Power cord Ventilation Operating Conditions Approvals Required power cord supplied with printer North American UL CSA approved length 8 2 feet 2 5 m OR European Harmonized length 8 2 feet 2 5 m The printer uses solvent based inks The printer does not include an integrated exhaust hood or shielding for collecting the volatile organic com pound VOC emissions from the inks and cleaning solvent The owner is responsible for
14. AutoTune to run Purge Wipe Purge Wipe amp AutoJet AutoJet Purge Wipe takes the least amount of time Purge Wipe amp AutoJet takes the greatest amount of time Select Purge Wipe amp AutoSet only if Purge Wipe does not produce satisfactory results Select an AutoTune option to run Press the W key then the Menu Out key The control panel displays a confirmation message Setting completed Press the X Menu Out key repeatedly until the Front Page screen is displayed Press the Online Offline button to return the printer to the Ready state Note When AutoTune is enabled the selected operations will be executed as scheduled regardless of whether you initiate them manually from the control panel AutoTune Quality Check When you run AutoJet manually the software notifies you if there are any jet or alignment problems so that they can be addressed When AutoTune runs AutoJet at scheduled intervals you can use the Quality Check feature to handle AutoJet errors When Quality Check is enabled if any missing jets are found that are not substituted by a working jet the operator can be alerted by the control panel or the job can be routed to the Attention queue on the ColorSpan print server 1 Onthe Front Page screen press the Menu key to enter the menu system teL Boral Oeo hh rire edia rint Offline amp Ink Kode Backward DisplayMaker Gator Advance 2 Press the V key repeatedly to highl
15. Bearings Clean the Rail and Bearings 3 4 Wipe the entire length of the rail with a lint free cloth or wipe moistened with isopropyl alcohol The rail surfaces that must be clean are the surfaces that touch the carriage bearings These are the top surface including the front and back of the front lip and the side surface behind the belt Move the carriage manually or press the Carriage key on the control panel Front Page so you can access and clean the entire rail Top of the rail Side of the rail behind the belt E Fig 5 2 Cleaning the rail From the control panel Front Page screen press the Access Heads key The carriage moves out of the service station to the access carriage position The bearings are on the back of the car riage There are four bearings that should be kept clean one pair on each end of the carriage Each pair of bearings rolls along the front and back of the lip on the top of the rail If any buildup occurs on one of these bearings banding or other artifacts could appear in printed output This buildup can range from a fine dust to visible particles The fifth bearing rolls along the lower edge of the rail behind the belt Cleaning this bearing is not necessary since it usually does not get dirty 5 5 5 6 Cleaning the Encoder Strip Outside bearing Inside bearing Cleaning window Fig 5 3 Carriage bearings left pair shown Clean the left and right outside bea
16. Bearings on page 5 4 See Checking Jet Health on page 3 7 To recover jets that are unrecoverable with the automated Purge n Wipe see Cleaning Clogged Ink Jets on page 5 9 Carefully wipe ink from the platen with a cloth moistened with SolaChrome HR Cleaning Sol vent especially near the right and left edges Inspect the service station wipers for ink buildup If found clean the wipers with a lint free cloth moistened with SolaChrome HR Cleaning Solvent Compensates for the reduced effectiveness of the wipers after they have been exposed to inks and cleaning solvent for an extended period Aligns the service station wipers to the centers of the printheads With the printheads uncapped the capping station assembly can be pulled straight for ward and out of its tracks Clean the capping pad with cleaning solvent Clean the embossed postheater cover only with an ammonia free deionized cleaner such as Sparkle http www glasscleaner com Other cleaners may leave a sticky residue that increases the possibility of head strikes Clean with cleaning solvent and lint free cloth Maintenance Schedule Task Interval At control panel warning Empty excess ink page 5 7 Replace ink filters page 5 19 Maintenance Schedule Description The excess ink containers on the printer stand legs should be emptied when half full When the container under the service station is full the control panel displ
17. Menu In key The Jet Out Lines pattern prints Substituted jets are marked with a black square If the Jet Out Lines above reveal an blank or wavy lines the corresponding jets should be mapped out For instructions see AutoJet on page 4 3 or Manual Jet Mapping on page 4 13 When all missing jets have been substituted printed output will appear as if all jets are working Loading Ink When to Load Ink The amount of ink in the ink box is tracked by the printer soft ware and recorded on its corresponding profiler When the ink box is almost empty the LED above the corresponding profiler will blink You should replace the ink box with a full ink box of the same color ink as soon as possible The status of each ink box and profiler is indicated by the LEDs as follows Unloading an Empty Ink 1 Box gt Loading a Full Ink Box 1 3 10 Off OK Slow Blink profiler is being verified after insertion Fast Blink low ink warning 300 ml remaining On ink system action ink empty ink pump failure pro filer error or other see control panel Remove the profiler Lift the box out of its holder and turn the box upside down so the ink tube is pointing up Lift the retaining clip on the ink tube connector and disen gage the tube from the ink box Remove and dispose of the ink box refer to the MSDS for proper disposal procedures Open the new ink box and locate the supply connector
18. bidi calibration Press V to perform a bidi calibration or X to continue Observe a Purge n Wipe cycle to ensure that the service sta tion wipers are centered and properly deflected during a wipe Ifthe wipers are not centered see Calibrate the Service Station on page 5 17 for instructions Ifthe wipers do not touch the service station or are over deflected see Calibrate the Service Station on page 5 17 for instructions Calibrate the position of the camera image sensor by peforming an Image Sensor Calibration see Image Sensor Calibration on page 4 23 Set the Printhead and Camera Height Calibrate the Service Service station calibration enables you to properly align the ser Station vice station wipers to the printheads When properly aligned the service station wipers should be centered on the printheads Setting the service station height should not be necessary unless the printhead height is changed by a large amount or you notice that the service station wipers are not wiping the print heads adequately a RATE ET EEE OC UN CR EN Poe Eee Pee eee tte tee tee ee Oo a o is e ERE a E EN Fig 5 6 Service station cover removed for clarity 1 Onthe Front Page screen press the Menu key to enter Seo M a the menu system KA B a Backward BQ Gator Advance M zoe Ce tw Prime ene Aubol et Bars Purge Press the V key repeatedly to highlight Service Printer Press
19. end of the printer over the capping station Engage the capping station by pulling forward on both levers simultaneously until the capping pad touches the printheads and the carriage just begins to move up Do not raise the capping pad beyond this point Press Proceed The control panel displays the Front Page screen Note that all but a few functions are disabled until you uncap the printheads 3 13 Uncap the Printheads Uncapping the printheads is one component of the Wake func tion which reverses the Sleep function The printer leaves standby mode the heaters are switched on and the supply amp takeup system is tensioned loaded The OHS is enabled which turns on power to the pumps When you manually disengage the capping levers the cap ping pad sensor is detected and the control panel enables all functions and displays the Sleep key ping station wear latex gloves to prevent staining Tip Since some ink may spill from the film wrapped cap your hands during this procedure 1 Press the Wake key on the Front Page screen on the control panel P is The control panel asks you to confirm that you want to E E wt Te hh one MI Neds Pe Bless uncap the printheads DisplayMaker Gator Advance 2 Press the B gt Proceed key to uncap the printheads The control panel prompts you to disengage the capping sta tion pad 3 Disengage the capping station Have a paper towel ready to blot any cle
20. fan speed and observe the media as the fan speed changes If the media is lifting off the platen increase the fan speed If the media is sticking to the platen decrease the fan speed Drying Delay press the A and Y keys on the control panel to increase or decrease the drying delay seconds per print swath To increase throughput decrease the drying delay If prints are not drying increase the dry ing delay When you select Create Media Type the Media Wizard dis plays a series of screens that enable you to enter each of the Media Wizard settings The current settings as shown on the Media Settings screen are used as default values Change the defaults to suit the new media for each print mode When you select Delete Media Type the Media Wizard shows a list of currently defined media You can delete any user defined media type When you select View Media Types the Media Wizard allows you to browse through the settings for each of the media types and print modes Media Wizard Setting Heater Temperatures 63 B e Offline amp Ink sere 38 e e pce e et m e T A b A 3 E Heads Wizard Media Setting Heater Temperatures The are three heaters a preheater a platen heater and post heater The postheater s top and bottom zones can be set to dif ferent temperatures Optionally the postheater can be turned off The heater temperatures can be set during the media load pro cess see Load
21. for Profile Creation cut sheet printing only causes all calibration prints to print on the same cut sheet rather than ejecting the sheet after each calibration print Automatically disabled after all calibration prints are fin ished when a print job is received from the RIP or when roll fed media is loaded Also allows you to configure a dry time before calibration readings are taken Printer Settings enables you to set many options that control how the printer operates Settings saved by the Media Wizard are indicated by MEDIA WIZARD in the margin Takeup Tension adjusts the media takeup tension which is required for proper media feeding Insufficient takeup ten sion could result in inaccurate media feed and media buck ling Supply Out Detection for roll fed media the printer usu ally monitors the supply spool to detect when it runs out of media You can use this menu option to disable media out detection when you keep the takeup spool pin release tool part number 05043234 see Takeup Spool Pin Release on page 3 26 for instructions installed for printing rather than to freely pull media from the supply Heater Temp Settings selects one of several pre defined temperatures plus one custom user defined setting Exces sively high heat could cause the media to deform or stick to the platen while not enough heat could result in partially dried prints For instructions see Setting Heater Tempera tures o
22. for fastest throughput with media in per fect condition Maximal for greatest precision and skew detection when printing edge to edge Menu Menu MEDIA WIZARD Quality Check determines how AutoTune errors are han dled see Auto Calibrations on page 4 20 for information about AutoTune Print Position when the printed image does not span the entire width of the media positions the printed image flush right nearest the control panel flush left nearest the cap ping station or centered on the media Stiff Roll Fed Media Handling when enabled detensions then retensions the takeup system before every print job for more accurate feeding of adhesive backed and other stiffer roll fed media types Standby Wait sets the period of time to wait for a print job before going into standby mode which turns off the heat ers and detensions the supply and takeup system Expert Novice Messages Novice mode presents Warn ings alerts that do not prohibit printing and Actions con ditions that require user intervention before printing can proceed Expert mode presents Actions only presents fewer press Proceed prompts after an Action has been addressed The default is Novice mode When in Expert mode active Warnings and Actions can be displayed by selecting Warnings amp Actions from the menu since Warnings will not cause the ATTN icon will appear in Expert mode See User Assistance on page 2 3 f
23. further action from you After the calibration completes load or reload media and begin printing 4 23 Linearization 4 24 O As the density of an image varies from highlights to shadows or from lighter tints to darker tints the printer should accurately reproduce these areas in a predictable or linear fashion The process of linearization or color calibration involves printing and reading color test patches and calibrating the printer to ensure that the expected and printed densities will match This in turn will ensure optimal color matching You should perform a color calibration when You notice a shift change in color output First loading a new media type that you have never cali brated Changing print mode only if the most precise color match ing is required The piezo printing technology used by the printer is much less prone to changes in ink drop size over time than thermal inkjet technology therefore each media type should only have to be linearized once Color calibration is a feature of the print server or RIP con nected to the printer Refer to the documentation that accompa nies the print server for further information Tip For best results be sure that the color calibration patches are dry before taking readings Tip Changing the head height and camera height will affect linearization results Be sure that the head height and camera height are set to their desired positions with
24. height Auto Bidirectional page 4 20 or Head calibration run Manual when Manual Bidirectional page 4 11 calibrating transparent or other media that the onboard digital image sensor cannot calibrate When loading a new media but not Color calibration page 4 24 or Linearization of colors when loading a new roll of the same third party RIP manual media 4 2 When to Calibrate Autojet ili n Online Media Offline amp Ink DisplavMaker Gator sive PI mu ME aot Auto et pe Purge u Ga coe Access Media Load Heads wizard Media AutoJet he Backward Advance Media AutoJet detects individual ink jets that are misfiring or not firing at all During subsequent printing the printer compensates for these jets by using other jets in their place ensuring maximum print quality without reducing print speed You can also identify and map missing jets manually from the Manual Calibrations menu see Manual Jet Mapping on page 4 13 You may want to manually map weak or misdirected jets that AutoJet does not detect and substitute To run AutoJet Press the AutoJet button on the control panel Front Page screen see page 2 4 or Select AutoJet Calibration from the Auto Calibrations menu see Auto Calibrations on page 4 20 or Run AutoJet automatically with the AutoTune scheduler see Auto Calibrations on page 4 20 Note AutoJet does not work with transparent media nor with many translucent media In
25. maintain power to the vacuum system for a brief period of time by using the auxiliary 24 volt power supply included in the printer accessory kit This will prevent ink from running out of the printheads but may not prevent the print heads from drying out If the printer will be powered down for an extended period follow the procedure below If it is necessary to power down the printer for an extended period for example in order to store or ship it empty the ink from the printheads and cap the heads Note This process takes approximately 2 1 2 hours and 1 liter of SolaChrome HR Cleaning Solvent to per form Make sure that there is a sufficient amount of Cleaning Solvent in the reservoir before performing this procedure 1 Unload media if any is loaded see Unloading and Cutting Roll Fed Media on page 3 25 2 On the Front Page screen press the Menu key to enter the menu system Press the V key repeatedly to highlight Maintenance Press the X Menu In key display the Maintenance menu Press the V key repeatedly to highlight Prep for Storage Shipping 6 Press the X Menu In key 5 21 7 Cap the printheads See Cap the Printheads on page 3 13 for instructions 8 Switch the power switch to the off position Restart To restart the printer follow the procedure below 1 Switch the power switch to the on position 2 Uncap the printheads See Uncap the Printheads on page 3 14 for instruct
26. note about Prep for Storage Ship ping requirements Appendix A Specifications for DisplayMaker 9881 added Maximum media thickness corrected Regulatory Statements FCC A DOC Canada This equipment has been tested and found to comply with the limits for a Class A digital device pursuant to Part 15 of the FCC Rules These limits are designed to provide reasonable protec tion against harmful interference when the equipment is oper ated in a commercial environment This equipment generates uses and can radiate radio frequency energy and if not installed and used in accordance with the instruction manual may cause harmful interference to radio communications Operation of this equipment in a residential area is likely to cause harmful inter ference in which case the user will be required to correct the interference at his or her own expense This equipment must be installed exactly as instructed in this manual using only the components supplied If a supplied com ponent ever needs to be replaced it must be replaced with the same part supplied by the manufacturer It is your responsibility to follow these instructions in order to maintain compliance with the FCC regulations Changes or modifications not expressly approved by ColorSpan Corporation could void your authority to operate this equipment In particular this device must be operated with shielded cables to maintain FCC compliance A booklet is available from the Federa
27. or damaged sheets with parallel opposite edges and 90 corners 1 Onthe Front Page screen of the control panel press the Load Media key Oins a poe Backward hd v The control panel presents a list of media types You can DisplayMaker Gator 53 select a ColorSpan media from the list or select Custom at e i mae Dry the end of the list to specify a new media The printer s Autol et zur p y p dius Media Wizard feature stores a set of parameters for each media type which can be recalled and applied whenever T ie you change media types See Media Wizard on page 3 44 Heats ieee Media for details 2 Select the media type that most closely matches the media you are loading or create a new media type The control panel displays the current settings for the media type you choose Loading Rigid Media 3 29 Media Sheet Fed Feed Method Cut Sheet Pinch Rollers Slot Media Out Sensor Enabled Print Mode Production Quality Platen Vacuum Maximum Drying Delay 0 0 sec eec BE I Oso bk Media Frint Select Settings Mode Media Proceed Fig 3 13 Media settings 3 30 Loading Rigid Media Loading Rigid Media Media Sheetfed Media Feed Number 2 709 Feed Method Cut Sheet Pinch Rollers Slot 2 Media Out Sensor Enabled Measure width Automatically Page 1 of 2 i Select Settings Media Print Mode Production Quality Dryers On Dryers OFf Dryers On 600600 60
28. room wipe DO NOT USE ISOPROPYL ALCOHOL ON THE PRINTHEADS Ensure the functioning or substitution of all inkjets for instructions see Checking Jet Health on page 3 7 Print Prime Bars Run Purge n Wipe Repeat once or twice to recover missing inkjets Map out missing jets see AutoJet on page 4 3 or Manual Jet Mapping on page 4 13 Under normal circumstances these procedures should ade quately prepare the printer to print For instructions on recover ing stubbornly clogged printheads see Cleaning Clogged Ink Jets on page 5 9 Workflow Overview Printing Daily Shutdown Workflow Overview When the printer is connected to a ColorMark Pro print server here is how a typical print job progresses from the client work station to the printer If you are using a non ColorSpan RIP refer to the documentation that accompanies it for details 1 The operator sends a file to be printed from a client workstation 2 The print job is received by the print server Once it reaches the print server the print job may be reprior itized combined with other jobs re routed or otherwise manipulated Refer to the print server online help or manual for instructions 3 The print server RIPs the job The raster image processing RIP process translates the PostScript language data that comprises the print job into the data required by the printer 4 The server sends the image to the printer for printing
29. the X Menu In key display the Service Printer menu Press the V key repeatedly to highlight Service Station 8 Press the Menu In key t j T Fi te i gend MPE 28 ooo Media The control panel prompts you to confirm that you want to calibrate the service station U A W N Calibrate the Service Station 5 17 5 18 Press gt Proceed The control panel displays a message asking whether you want to calibrate the service station position If you choose to do so the control panel walks you through the proce dure Shine a flashlight through the carriage cutouts see Fig 5 6 on page 5 17 for location to see how the wiper at the left and right ends aligns with the printhead above it Aligned Not Aligned Fig 5 10 Service station alignment Press gt Proceed The control panel displays a message asking whether you want to change the height of the service station If you choose to do so the control panel displays a message that explains how to set the service station height Use the sup plied hex wrenches to turn the adjustment screws on the left and right sides of the carriage simultaneously to ensure that the service station remains level When properly adjusted the wipers would just touch the pin plate between the printheads It may be necessary to misalign the carriage as shown below to precisely measure this distance At this height after the carriage is realigned to the service station the wipers wil
30. the gauges provided before lineariz Ing Linearization Maintaining the Printer CHAPTER 5 LLLLLLLLL AXE Maintaining the Printer This chapter describes how to maintain the printer Maintenance Schedule page 5 2 Clean the Rail and Bearings page 5 4 Empty Excess Ink page 5 7 Printhead Maintenance page 5 8 Cleaning Clogged Ink Jets page 5 9 Set the Printhead and Camera Height page 5 12 Calibrate the Service Station page 5 17 Replace Ink Filters page 5 19 99 99 9 HF Extended Power Down and Restart page 5 21 5 1 Maintenance Schedule The printer is designed for low maintenance operation Most operator performed maintenance is performed on the print heads Task Interval Weekly or as needed Clean pinch rollers Clean carriage rail and bearings page 5 4 Clean printheads Clean platen area Inspect service station wipers for ink buildup and clean as needed Interval As needed Adjust service station height page 5 17 Calibrate the service station page 5 17 Clean capping station Clean postheater cover Clean spittoons Description Inspect for ink and dust buildup if necessary wipe with lint free cloth moistened with SolaChrome HR Cleaning Solvent Use the Maintenance gt Clean Grit Rollers function to rotate the grit rollers for cleaning Inspect for ink and dust buildup clean if nec essary see Clean the Rail and
31. the grit rollers continuously so they can be cleaned with no media loaded Capping Purge enables you to disable or enable the purge that is automatically performed prior to capping Menu Menu Service Printer User Diagnostics Printheads Procedures see Printhead Maintenance on page 5 8 for instructions on using the following options Cleaning Solvent Soak empties the printheads of all ink fills all heads with cleaning solvent and prompts you to cap the printheads Prep for Storage Shipping empties the printheads of all ink fills all heads with cleaning solvent then empties the printheads in preparation for long term storage or ship ping Load Ink in All Heads runs the following three opera tions in sequence Fill Heads with Solvent fills the printheads with clean ing solvent Fill Heads with Ink fills the printheads with ink Empty Heads Fill With Air fills the printheads with air These tests are for factory service and technical support use User Diagnostics presents an interactive troubleshooting pro gram to diagnose problems before calling MacDermid Color Span Technical Services It walks you through a series of tests and checks for certain printer functions The printer asks you to make observations or run simple tests to help it diagnose prob lems and suggest corrective actions It has the following sec tions 99 999 Prin
32. the jets in the spittoon only if the media is less than 40 inches wide Off for Media lt 71 In Wide fires the jets only if the media is less than 71 inches wide Platen Gutter Spits sets the amount of ink used by the maintenance spits to High Medium and Low To con serve ink use the lowest setting that keeps the jets open The default High Margin Settings Space Between Prints roll fed sets the blank space between print jobs between O and 10 inches 25 cm Right and Left Margin sets the amount of blank space for the right and left margins between O and 5 inches 13 cm Optionally on rigid media only you can print up to or past the right and left edges see Edge to Edge Printing on page 3 38 Leading Margin cut sheet sets the amount of blank space at the leading edge of cut sheet media Trailing Margin cut sheet sets the amount of blank space at the trailing edge of cut sheet media Media Measure Type for cut sheet media you can choose one of three levels of precision for finding the left right and front edges of the media Minimal measures the width of the media once and finds the front right edge Standard measures the width of the media once and finds the right and left front edges to estimate skew Maximal measures the width of the media in two places and finds the right and left front edges to esti mate skew Choose Minimal
33. the printer warranty The maximum diameter allowed on the takeup spool is 7 5 inches 190 5 mm on a 3 inch core When the takeup spool has a diameter of 6 5 7 5 inches 165 0 190 5 mm the con trol panel displays a warning about possible print quality issues The media supply may be wound either printed side out or printed side in but the takeup if used must be loaded printed side in The printer includes three gauges a minimum gauge 0 085 inches above the media a maximum gauge 0 115 inches above the media and a camera height gauge Set ting the height above the maximum may result in excessive overspray Setting the height below the minimum may result in the carriage striking the media See Set the Printhead and Camera Height on page 5 12 for instructions The Media Wizard stores a set of operational parameters for predefined and user defined media types When you load a new media type select an existing Media Wizard set or cre ate a custom set Media Wizard parameter sets can be selected at any time from the control panel See Media Wizard on page 3 44 for details After calibrating the media feed advance record the Media Feed Number MFN from the control panel in a notebook The next time you load the same media you can recall the media feed settings by entering the MFN instead of per forming the calibration again Enable AutoTune during long periods of unattended print ing AutoTun
34. type for subsequent recall Specifications A 5 Supplies and Consult MacDermid ColorSpan or your MacDermid ColorSpan Accessories representative for an updated listing of supported ink and media Use only genuine ColorSpan SolaChrome inks and cleaning sol vent in the printer Use of any other inks or cleaning fluids could damage the printer and will void the warranty Supplies and accessories are available from MacDermid ColorSpan by calling MacDermid ColorSpan Supplies Sales North America 800 723 3002 or 952 943 3636 Europe 31 23 5622000 Asia 952 943 3300 Latin America 800 664 7242 or 952 943 3600 A 6 Supplies and Accessories Troubleshooting APPENDIX B Te Troubleshooting This appendix explains how to prevent and diagnose printing problems and provides information about getting help from ColorSpan For other software specific troubleshooting procedures refer to your application software documentation or the other ColorSpan documenta tion listed on page vi of this manual If your printer is connected to a non ColorSpan RIP or print server refer to the accompanying third party documentation Troubleshooting Checklist page B 2 Warranty Claims page B 5 Diagnostics page B 7 MacDermid ColorSpan Technical Services page B 14 B 1 Troubleshooting Checklist Before you troubleshoot your printer make sure that it is prop erly installed as described in Chapter 1 Getting
35. you enter O zero you can also Tip specify an amount of overprint printing past the edge of the media This enables you to achieve an edge to edge printing effect without an unprinted border espe cially if the media is skewed or not a perfect rectangle Protect the platen with tape or a strip of media to catch the overprinted ink Leading margin Trailing margin 6 50 inches 165 mm minimum to allow the pinch rollers to feed the media If you set the Trailing Margin to O and want to print to the trailing edge you must attach a trailer of the same media to the trailing edge so the pinch rollers can feed the media all the way past the print zone For tips on printing edge to edge see Edge to Edge Printing on page 3 38 16 To change the margin settings press the Margin Settings key otherwise press Proceed The printer moves the media to the proper position for printing 17 Press the Online key to receive a print job from the print server or RIP After a print job has finished printing the media is automat ically advanced ejected from the pinch rollers Note Loading Rigid Media Before a print job is received you can unload the media at any time by pressing the Unload key on the Front Page screen of the control panel 3 35 Reloading Rigid Media After printing the first copy of a multiple copy job onto a sheet of rigid media the Front Page screen displays a special Load Reload key hr
36. 0x300 600x600 600300 Vacuum Masimum Mas mur Mas mar M asimum Dry Delay 0 0 sec Page 2 of 2 Settings Fig 3 14 Media settings cut sheet rigid Press one of the change keys to change any of the settings print mode or media type press the key to see page 2 or press the key to continue If you do not have the optional auxiliary dryers enabled page 2 will only show the Dryers Off column If you press one of the change keys a screen appears to allow you to change any of the settings Then press the key to continue See Media Wizard on page 3 44 for information about these settings If you press B the control panel displays a numeric keypad so you can enter the length of the media 3 31 4 Enter the length of the media The printer will use the value you enter here for subsequent calculations so be as accurate as possible 5 Press the gt key The control panel displays the prompt Load a sheet of media onto the printer Unload any roll fed media from the printer Insert the pins of the media alignment tool into two platen vacuum holes in the same row Fig 3 15 Media alignment tool Release the pinch rollers Slide a sheet of media onto the platen and center it on the pinch rollers It is not necessary to align the media to the left or right edge of the platen If possible avoid positioning the left or right edge of the media under a pinch roller If th
37. 2 14 Actions and warnings B 7 B 8 Adjustable pinch rollers 1 12 Advance Media 2 6 ATIN key 1 17 2 7 Auto Calibrations 2 9 2 10 4 20 AutoBiDi Calibration 4 20 AutoH2H Calibration 4 20 AutoJet Calibration 2 6 4 3 4 20 AutoRecover 2 10 AutoSet 4 20 AutoSet summary 4 21 AutoTune scheduling 1 15 2 10 4 4 quality check mode 4 5 Auxiliary dryer 1 14 software setting 2 11 3 4 Auxiliary power specifications A 3 Bidirectional print modes 3 4 Billboard mode 3 4 C Calibration 2 9 4 1 Index 2 Auto BiDi 4 20 Auto Calibrations 4 20 Auto H2H 4 20 AutoJet 2 6 4 3 4 20 AutoSet 4 20 AutoTune scheduling 1 15 2 10 4 4 bidirectional 4 11 color 1 16 color calibration 4 24 Manual Jet Mapping 4 13 Manual X Head Registration 4 9 Media Feed 4 6 quality check mode 4 5 when to calibrate 4 2 Calibration Summary 2 10 4 21 Camera height 5 12 Cap printheads 3 13 Capping Purge 2 14 Capping Station Sensor 2 11 Carriage 1 11 Clean Grit Rollers 2 14 Cleaning solvent 3 2 3 3 Cleaning Solvent Soak 2 15 Color calibration 1 16 Control panel actions 1 17 2 3 ATTN key 1 17 2 3 Calibrate Printer 2 9 Front Page screen 2 2 2 4 Maintenance 2 14 menu 2 2 menu tree 2 17 navigation keys 2 8 Printer Settings 2 10 Ready screen 2 2 Service Printer 2 15 user assistance 2 3 User Diagnostics 2 15 warnings 1 17 2 3 Warnings and Actions 2 16 Cutting media 3 25 Default Registration Data 4 19 Diagnostics B 7 Doctor blade 5 11 Dryer
38. 45 Tips 3 6 Trailing Margin 2 12 Troubleshooting B 1 U Uncap printheads 3 14 Unidirectional print modes 3 4 Unload media 2 7 3 25 Unpacking and assembly 1 7 V Vacuum pressure system 1 3 auxiliary power A 3 specifications A 5 Ventilation A 4 VOCs A 4 W Wake function 2 7 3 14 Warnings 1 5 Warnings amp Actions 2 16 Warranty claims B 5 Workflow overview 1 8 Index 5 Index 6
39. A 2 B 9 Code Message A IS 80 81 82 83 color Heads Not Loaded with Ink A IS 84 85 86 87 color Ink Sensor Disconnected A IS 88 89 8A 8B color Air Sensor Disconnected A IS 90 91 92 93 94 color Pump Disconnected A IS 100 Excess Ink Bucket Full Table B 1 Actions and Warnings Cause Printheads for color s indicated do not have ink loaded K 80 C 81 M 82 or Y 83 The on head ink sensor for the color s indicated is disconnected The on head air sensor for the color s indicated is disconnected The pump indicated is disconnected The excess ink and solvent reservoir below the supply reservoirs is full A IS 706 Ink Counting Not Working The ink counting mechanism has failed A IS 70C Ink Counting Not Working The ink counting mechanism has A 1S 120 OHS Read Write Failure W IS 7 2 3 4 color Low Ink W IS 5 Cleaning Solvent Low W IS 6 Cleaning Solvent Missing Profiler W IS 7 Out Of Cleaning Solvent W IS 8 Replace Ink Filters W IS 9 Incorrect Cleaning Solvent Profiler WS IS A Invalid Cleaning Solvent Profiler failed Failed to communicate with OHS board The ink box indicated is low on ink The cleaning solvent box is almost out of cleaning solvent The cleaning solvent profiler is not detected The cleaning Solvent reservoir is empty The reservoir filters need to be replaced The profiler in the cleaning solven
40. After the carriage has moved over the capping station remove the capping station pad by pulling it forward and out of the printer 3 Wipe the printheads and any areas of the carriage that have collected ink 4 Press Proceed on the control panel to return the carriage to the service station 5 Replace the capping station pad If it appears that the service station is not wiping the printhead properly it may be misaligned or too low see Calibrate the Ser vice Station on page 5 17 5 9 Cleaning Solvent Soak If a manual cloth wipe fails to recover enough jets you can soak the thin foam pad that ships with the printer with SolaChrome HR cleaning fluid then cap the printheads with this pad over night as shown Fig 5 4 on page 5 10 DO NOT USE ISOPROPYL ALCOHOL ON THE PRINTHEADS From the menu select Maintenance Printhead Procedures Cleaning Solvent Soak This process empties the printheads of ink fills them with cleaning solvent and prompts you to cap the heads After several hours overnight uncap the printheads and the process is reversed Carriage AA A 90lvent soaked 4 cleaning pad Capping film Drip tray Capping station pad Fig 5 4 Using the cleaning foam pad on the service station Cleaning Clogged Ink Jets Cleaning the Service With use over time the doctor blade that cleans excess ink from Station Doctor Blade the service station wiper blades will accumulate
41. DisplayMaker Legacy 72Sl 98S User Guide Part Number 0700048 O Legal notices Copyright 2008 Hewlett Packard Development Company L P The information contained herein is subject to change without notice The only warranties for HP products and services are set forth in the express warranty statements accompanying such products and services Nothing herein should be construed as constituting an additional warranty HP shall not be liable for technical or editorial errors or omissions contained herein Printed in the US For additional technical support and user documentation please refer to www hp com go graphicarts Revision Log The following is a list of major changes and additions that have been made to this manual since it was first released See the accompanying Release Notes for specific changes to the software and hardware between manual updates Revision Description Revision B Chapter 2 Updated Ready screen image Menu items added Clean Grit Rollers Capping Purge Printer Name Localization Print Menu Tree Menu tree updated Chapter 3 Added Fine Text mode Added Media Feed Number prompts to the end of the roll fed media load process Added media alignment bar to the rigid media load process Set Sort Method added to the Media Wiz ard Chapter 4 Fig 4 5 showing AutoSet Summary updated with new All Jets Replaced row headings Chapter 5 Added cleaning procedure for the post heater cover Added
42. E et m e cha EN j Access Media Load 5 i Heads wizard Media Capping the Printheads Capping the printheads prevents the ink from drying out and clogging the ink jets Since the ink jets are automatically exer cised a small amount of ink is expelled when idle capping is only necessary if the printer will be idle for a long period over night or longer Capping the printheads is one component of Sleep Mode The printer enters standby mode which also occurs after the printer has been idle the heaters are switched off and the supply amp takeup system is detensioned The OHS is disabled which turns off power to the pumps When you manually engage the capping levers the capping station sensor is detected and the control panel disables most functions except for Wake Prepare the capping station by placing a sheet of SolaChrome Printhead Capping Film over the capping station pad Fold the capping film underneath the capping pad to allow any ink that escapes the printheads to flow into the drip tray Caution To cap the printheads use only SolaChrome Print head Capping Film Damage to printheads resulting from the use of poorly performing plastic films is not covered by the printer warranty Press the Sleep key on the Front Page screen The control panel asks you to confirm that you want to cap the printheads Press the Proceed key to cap the printheads The printhead carriage moves quickly to the left
43. Fans 2 11 Drying Delay 2 11 Edge to edge printing 3 38 Electrical requirements 1 2 Empty Heads 2 15 Environmental requirements 1 2 Error messages B 7 B 8 Excess Ink Sensor 2 11 F Fill Heads With Ink 2 15 Fill Heads With Solvent 2 15 Fill Service Station 2 14 Filters 5 19 Fine Text 3 4 A 2 Front Page screen 2 2 2 4 Full AutoSet 4 20 G Gutters 2 11 Head Height 2 13 5 17 Heater Temp Settings 2 10 3 47 Heaters 1 16 High Quality mode 3 4 Idle jet maintenance 3 3 Image sensor calibration 4 23 Ink 3 2 3 3 loading 3 10 pause swapping 3 12 Ink filters 5 19 Ink system overview 3 2 Inkjet health 3 7 Installation printer 1 7 rigid sheet fed media 3 29 roll fed media 3 16 Jet health 3 7 Jet maintenance 3 3 Jet replacement 3 4 Jet Status Lines 4 19 L Leading Margin 2 12 Linearization 1 16 4 24 Load Ink In All Heads 2 15 Load media 2 7 3 16 Loading ink 3 10 Localization 2 13 Log Head Registration Data 4 21 Log Jet Data 4 21 Low Ink Warning 2 14 Index 3 Maintenance carriage rail and bearings 5 4 cleaning clogged ink jets 5 9 empty excess ink 5 7 Prep for Storage Shipping 5 21 Printhead Procedures 5 8 replace ink filters 5 19 service station 5 17 Manual BiDi Registration 4 11 Manual Calibrations 2 9 4 8 Manual Jet Mapping 4 13 Manual X Head Registration 4 9 Margins 2 12 Media cutting 3 25 loading 2 7 3 16 3 29 reloading 2 7 3 36 unloading 2 7 3 25 Media amp ink s
44. Menu key from the Front Page screen on the control panel to display the menus From the control panel menu press the Y key to highlight Maintenance Press the X Menu In key From the Maintenance menu press the Y key to highlight Respool Media Press the X Menu In key 3 27 10 Press the P gt Proceed key to respool the media The media is pulled from the supply spool onto the takeup spool When the printer detects the end of the media the respool function stops automatically 3 28 Respooling Media Loading Rigid Media The printer has two media load states Unloaded the printer is ready to accept either roll fed or rigid cut sheet media Loaded the Media Wizard has stored parameters for the currently loaded cut sheet media allowing you to reload multiple cut sheets without reentering the Media Wizard C Tip If you are printing multiple copies of the same image on rigid cut sheet media you can skip much of the load process by using the Reload Media function for the second and subsequent prints See Reloading Rigid Media on page 3 36 for details For optimal results when printing on rigid cut sheet media Ensure that the printer has been correctly assembled and lev eled and operates on a flat stable floor Ensure that the media input and output tables have been correctly assembled are level left to right and are at the same height as the printer platen Use only flat unwarped
45. Settings gt Left amp Right Margin O inches Overprint Distance 0 25 inches Menu gt Printer Settings gt Margin Settings gt Leading Margin O inches Menu gt Printer Settings gt Margin Settings gt Trailing Margin 6 5 inches Menu gt Printer Settings gt Print Position Center Menu gt Printer Settings gt Media Measure Type Maximal Media length entered during Load Media 102 5 inches 96 0 inch media length 6 5 inch trailer PE Right overprint Media feed direction Fig 3 23 Edge to edge printing terminology Edge to Edge Printing Edge to Edge Printing During Load Media the printer locates two points on Note Tip each of the leading left and right edges of the media The printer uses these data points and assumes 90 degree corners and parallel sides to determine the skew of the media If the media is skewed enough that an unprinted left or right edge may result even with a mar gin of O and the amount of overprinting specified the control panel displays a message with the skew amount The media sheet may be skewed causing the print to drift off the sheet approximately 0 1 inches 0 7 cm to the LEFT Would you like to reposition the sheet of media Loading Media Type Fome Lor Fig 3 24 Skew message Correct the skew by nudging the trailing edge of the media by the distance left or right as reported by the control panel without releasing the pinch roll
46. Started Follow the steps in this checklist to isolate and resolve printing problems 1 Does the printer s power come ON YES Go to question 2 NO The following could be the problem The power cable may not be plugged into an electrical outlet Ifthe printer is plugged into a surge protector the surge protector may not be connected to power or it may be switched off Did the start up sequence of the control panel end by dis playing a Ready status screen similar to the one shown in Fig 2 1 on page 2 2 YES Go to question 3 NO The following could be the problem There may be a hardware problem with the printer s internal components Follow the diagnostic routine on the control panel to determine the problem Call Mac Dermid ColorSpan Technical Services as directed by the control panel Can you send a file from the print server to the printer YES Go to question 4 NO The following could be the problem The cable may not be securely connected between the print server and the printer Refer to the server s docu mentation for more information The cable may be connected to the wrong port on the print server Refer to the server s documentation for more information Can you send print or download a document from a client computer to the server YES Go to question 5 NO The following could be the problem The connection from the client to the local area network may not be co
47. Thickness for user defined media use the numeric keyboard displayed on the control panel to enter the media thickness caliper Standard media thickness cannot be changed Thickness is used for reference only so this can be left blank for custom media Media Feed Method Roll or Cut Sheet Stiff Media Handling roll fed when enabled deten sions then retensions the takeup system before every print job for more accurate feeding of adhesive backed and other stiffer roll fed media types Pinch Rollers cut sheet adjustable pinch roller set ting from 1 lowest force to 8 highest force Select the lowest pressure that results in good media advance without leaving pinch roller marks on the media Media Out Sensor cut sheet detects when rigid cut sheet media is out Normally enabled disable only if the sensor is malfunctioning Measure Media Width select whether to have the printer measure the media width automatically works for most media or manually by the operator only nec essary for clear media that cannot be detected with the printer s image sensor In the latter case the control panel prompts the user through the process Takeup Tension roll fed select a tension setting from 1 low to 5 high or select O for idle no tension Takeup tension is used to ensure that the media web feeds straight from supply and takeup and lies flat on the platen Use the lowest tension settings that a
48. User Guides shows you how to print and RIP files through the ColorSpan print server If the printer is connected to a non ColorSpan print server RIP refer to the documentation that accompanies the server ColorSpan web site http www colorspan com Conventions gt IN This manual uses the following informational conventions Note A special technique or information that may help you perform a task or understand a process Hinweis Ein Hinweis beschreibt eine spezielle technik zur L sung einer Aufgabe oder enth llt Informationen die Ihnen eine Prozedur n her erl utert Caution Alerts you to something that has the potential to cause damage to hardware software or data Vorsicht Dieses Feld weist auf einen Umstand hin der einen Hardware oder Software Schaden oder Datenverlust verursachen k nnte WARNING Alerts you to something that has the potential to cause physical harm to you or others around you WARNUNG Eine Warnung auf weist auf einen Umstand hin durch den Ihnen und anderen Personen ein phy sischer Schaden erwachsen k nnte Other WARNING symbols used Electrical Hazard Vorsicht steht unter Spannung Lifting Hazard Vorsicht beim Anheben Hot Surface Hei nicht ber hren Moving Parts Bewegliche Teile Verletzungsgefahr vii viii Table of Contents TABLE OF CONTENTS REVISION LOG oett eier iii Regulatory Statermie DI5s ans IV ge er EP IV DOCE IAI a T ee T IV Telecommun
49. a Width Tension Supply amp Takeup Measure Platen Width Zero Platen Width Printhead Y Calibration Image Sensor Calibration Replace Printhead Fill Replaced Printhead Turn On Off Heaters Enhanced Drying Print Info Pages User Diagnostics Printhead Jet Statistics VideoNet Status VideoNet Connection Carriage Motion Calibration Vacuum Pressure Warnings and Actions List Error History Log Error History Warnings amp Actions Expert mode only Print Menu Tree Menu Tree Ink and Media CHAPTER 3 Te ee ee Ink and Media This chapter describes how to use ink and media with the printer Ink Ink System Overview page 3 2 Idle Jet Maintenance page 3 3 Selecting a Print Mode page 3 4 General Printing Tips page 3 6 Checking Jet Health page 3 7 Loading Ink page 3 10 Capping the Printheads page 3 13 Media 9 999 99 Loading Roll Fed Media page 3 16 Unloading and Cutting Roll Fed Media page 3 25 Respooling Media page 3 27 Loading Rigid Media page 3 29 Reloading Rigid Media page 3 36 Edge to Edge Printing page 3 38 Media Wizard page 3 44 Setting Heater Temperatures page 3 47 3 1 Ink System Overview The printer s ink system consists of the following components Ink boxes four 3 liter boxes of SolaChrome HR solvent pig mented ink CMYK plus SolaChrome cleaning solvent Ink tubes carry ink and cleaning solvent to the print heads and cleaning solvent to th
50. a buildup of ink This will reduce the cleaning effectiveness of the doctor blade resulting in dirtier wiper blades and more clogged printhead jets To keep the inkjets clear regularly inspect and clean the doctor blade with SolaChrome HR Cleaning Solvent Dirty doctor blade Clean doctor blade Fig 5 5 Cleaning the doctor blade Cleaning Clogged Ink Jets 5 11 Set the Printhead and Camera Height 5 12 The correct head height above the media is critical to output quality Lower head heights reduce overspray increasing image quality but also increase the chance of the printheads strik ing the media Printhead strikes are most likely with adhe sive backed vinyls and rigid cut sheet media that is not perfectly flat Higher head heights increase overspray slightly decreasing image quality but also decrease the chance of printhead strikes The correct camera digital imaging sensor height above the media is critical so that its lens can focus accurately for optimal linearization printer calibrations and print quality The printer includes three gauges a minimum head height gauge 0 085 inches above the media a maximum head height gauge 0 115 inches above the media and a camera height gauge If you change the head height above the media use the camera height gauge to reset the height of the camera The camera is attached to the carriage in a separate enclosure that can be raised and lower
51. a list of media feed numbers by media type or by media type and full half and nearly empty supply rolls job is printing Repeatedly press the increase advance or decrease advance button shown on the control panel to eliminate blank spaces or overlap between print swaths When you do this the media feed number displayed on the control panel changes accordingly A 1 Press the Menu key from the Front Page screen on the BO control panel to display the menus Offline amp Ink Mode DisplayMaker Gator Advance 2 Press the Y Menu In key display the Calibrate Printer menu highlighted by default f z E g ts T e 3 Press the X Menu In key to select Media Feed highlighted by default C 4 Press the X Menu In key to select an option Sleeps Headz wizard Media 10 inch calibration prints a 10 inch test pattern so you can verify its length with an accurate metal ruler This is not as precise as the 34 inch calibration but it uses less media Measure and adjust the media advance as needed until the pattern is exactly 10 inches long Tip You can also adjust the media advance while a print Tip To avoid cutting the 10 inch pattern from the media web copy the marks from the 10 inch calibration to the long edge of a letter size or A4 sheet of paper Then measure the transferred marks and adjust the media advance as needed until the marks are exactly 10 inches apart 4 6 Media Feed Media Feed
52. a location for the printer before you unpack it Keep the following requirements in mind Use the supplied power cord Plug it directly into a grounded electrical outlet Do not lengthen the power cord with an extension cord the resulting voltage drop could damage the printer Make sure the line voltage meets the requirements 220 VAC 10 single phase 20 Amps with NEMA L6 20R locking wall receptacle North America and Japan or 16 Amps with IEC 60309 wall receptacle Europe Install a voltage regula tor or similar device if the power source is not stable within these specifications See Appendix A Technical Specifica tions for details To maintain vacuum to the printheads during printer power down use the auxiliary 24 volt power supply included in the accessory kit with universal power adapters Connect the 24 VDC jack on the vacuum pressure assembly to either of two options 1 UPS customer supplied uninterruptable power sup ply output 100 240 VAC 50 60 Hz minimum of 15 watts of power provides battery backup to the vacuum sys tem in the event of a power failure 2 Wall outlet 100 240 VAC 50 60 Hz provides tem porary power to the vacuum system when it is neces sary to power down the printer for service See Appendix A Technical Specifications for details Connect the print server or RIP to a separate electrical circuit from the printer Make sure the room is well ventilated with a tempe
53. al Calibrations Manual Bidi Registration Manual X Head Registration Manual Jet Mapping Jet Status Lines Default Registration Data Auto Calibrations Auto Bidi Calibration Auto H2H Calibration AutoJet Calibration Full AutoSet AutoTune AutoRecover Calibration Summary AutoSet Summary Log Head Registration Data Log Jet Data Configure for Profile Creation Printer Settings Takeup Tension Supply Out Detection Heater Temp Settings Platen Vacuum Control Drying Delay Dryer Fans Excess Ink Sensor Capping Station Sensor Media Out Sensor Gutter Settings Top Gutters Side Gutters Left Platen Gutter Platen Gutter Spits Margin Settings Space Between Prints roll fed media Right and Left Margin Leading Margin Trailing Margin Measure Media Type Quality Check Print Position Stiff Roll Fed Media Handling Standby Wait Expert Novice Messages Audible Alarm Localization Head Height Service Station Automatic Eject Idle Spits Low Ink Warning Printer Name Restore All Defaults Maintenance Access Printheads Purge A Color Print Jet Out Lines Print Media Skew Lines Fill Service Station Reset Reservoir Filters Respool Media Clean Grit Rollers Capping Purge Printheads Procedures Cleaning Solvent Soak Prep for Storage Shipping Load Ink In All Heads Fill Heads with Solvent Fill Heads with Ink Empty Heads Fill With Air Service Printer Device Tests Print Tests Ink System Tests Home Head Home Service Wipers Measure Medi
54. aning fluid that has escaped from the printheads during capping If the capping film was applied as directed most of the fluid should run off the capping film into the drip tray Grasp the two capping pad levers and simultaneously push them toward the back of the printer to lower the capping sta tion 4 Remove and discard the capping film Carefully remove the wrap to avoid spilling ink on the floor or yourself 5 To access the heads for cleaning remove the capping station assembly by pulling it forward and out of the printer 3 14 Capping the Printheads 6 Wipe the printheads with SolaChrome HR Cleaning Solvent using a 100 polyester Class 100 cleanroom wipe DO NOT USE ISOPROPYL ALCOHOL ON THE PRINTHEADS Remove ink buildup on the printheads and lower surfaces of the carriage 7 Replace the capping station assembly by aligning it with and pushing it into its tracks in the printer The capping station assembly is keyed so that it can be inserted all the way in the correct orientation If you cannot push the capping station all the way into place turn it around and try installing it again 8 Press the gt Proceed key The printhead carriage moves quickly to the right end of the printer to the service station 9 Press the gt Proceed key The control panel displays the Front Page screen 10 Print the prime bars See Print Prime Bars on page 3 8 for instructions After the printheads have been cappe
55. appearance of the top and side gutters Top Gutters allows you to turn On or Off the gutter pattern at the top edge of the print which shows data about the print such as date and time printed and print mode plus write in blanks for other data Job Test Job Ink SolaChrome HR Media UltraSmooth Date Time 2002 11 19 10 52 11 Printmode Production Quality Printer DisplayMaker Gator Version Transform C Calibrated Y Printed By Fig 2 5 Top gutter data Side Gutters sets the side gutter pattern to Narrow Medium or Wide sizes or turns them Off Side gutter patterns help keep the ink jets open by firing ink through them in a pattern outside the printed image area You can print gutters on the left side only of the media closest to the capping station or both sides MEDIA WIZARD Printing on the left side only reduces ink usage while printing on both sides can keep the inkjets clearer Using this feature decreases the width available for printing the job Left Platen Gutter determines when the jets will fire in the left spittoon to keep all jets firing correctly Turning off this function may speed throughput with narrower media since it allows the carriage to turn around before reaching the end of the platen but it may also necessi tate more frequent Purge n Wipe operations to clear clogged jets Always On fires the jets in the spittoon with all media widths Off for Media lt 40 In Wide fires
56. asonably square and unskewed From Menu gt Printer Settings gt Print Position center the image on the media When loading the media report the length as the total length of the media plus trailer 3 39 Loading and Squaring the 3 40 Media Under Menu gt Printer Settings gt Media Measure Type choose Maximal for greatest precision and skew detection when printing edge to edge It measures the width of the media in two places and finds the front edge in two places to estimate skew and detect non rectangular sheets The printer will report if the media appears to be skewed and therefore will not feed straight through the print zone If the media is not actually skewed one or more of its edges may not be parallel to each other Load the media as described in Loading Rigid Media earlier in this chapter If the printer discovers that the media is skewed you can reposition most media without releasing the pinch rollers by nudging the trailing edge right or left to correct the skew Fig 3 21 Skewed left and non square right sheets Edge to Edge Printing Example Edge to Edge Printing If the printer reports that the media is skewed but you can not correct the skew the sheet may not be perfectly square 90 degree corners with parallel sides In this case ensure that the right edge of the media closest to the control panel is parallel to the direction of media feed You ca
57. ays an Action message and no further Purge n Wipes and idle spits will occur until the container is emptied Replace all five filters as a set to prevent ink pump failure The control panel will display a Warning message when 20 liters of ink have passed through the set of filters You may con tinue printing past this point but printhead fill errors may occur 5 3 Clean the Rail and Bearings Bearings back of carriage p Pinch rollers ai Fig 5 1 Location of rollers bearings and rail The carriage rail carries the printhead carriage across the width of the platen As dust and ink accumulates on the rail the mate rial could accumulate on the carriage bearings wheels and cause banding in printed output or noisy click click click carriage motion Pinch Rollers 1 Wipe the pinch rollers with a lint free cloth or wipe moist ened with isopropyl alcohol THE PRINTHEADS especially the inkjet orifice plates Contact with the ink could cause the ink to coagu late rendering the printhead unusable and requiring it to be replaced Be sure that cleaned surfaces have dried before printing T Caution DO NOT ALLOW ISOPROPYL ALCOHOL TO TOUCH 2 Clean the grit rollers Select Maintenance gt Clean Grit Rollers from the menu This advances the grit rollers continuously so they can be cleaned with a lint free cloth or wipe moistened with iso propyl alcohol 5 4 Clean the Rail and Bearings Rail Carriage
58. buff them out with a fine grade of sandpaper Scratches in the platen can cause media feed incon sistencies which can lead to head strikes and arti facts in printed output 6 Take the single print or the entire takeup spool with printed output to your finishing area and re load the takeup system To re load the takeup from the menu press the Load key on the control panel Unloading and Cutting Roll Fed Media 3 25 Takeup Spool Pin Release 3 26 To quickly unspool a large amount of media from the takeup without damaging the takeup tension spring you must first dis engage the spool from the takeup system The spool is normally engaged to the takeup motor with a tab at the end of the spool To disengage this tab press the Unload key to detension the supply amp takeup system then insert the takeup spool pin release tool supplied part number 0504334 between the spool and the bracket that holds the spool This allows the spool to spin independently from the takeup as you pull media from it When you are ready to begin printing remove the pin release tool and press the Load key on the control panel Fig 3 11 Takeup spool pin release tool Tip Alternatively you can disengage the takeup spool pin by installing the spool backwards with the pin pointing away from the takeup motor Tip You can reduce the back tension of the media supply motor by installing the takeup spool pin release tool and disabling the
59. cessary to ensure the maximum number of working jets See Checking Jet Health on page 3 7 for instructions 1 On the Manual Calibrations menu press the Y key repeat edly to highlight Manual Jet Mapping 2 Press the X Menu In key to select the option The control panel displays this message Print Jet Map If you have a calibration pattern from a recent print you can use it to calibrate the heads Press X Cancel and go to the next step Otherwise press gt Manual Calibrations 4 13 The printer prints a jet map test pattern Fig 4 3 Sample jet mapping pattern Head 1 of 16 Ifa line segment is missing or broken the jet number shown next to it is out Ifa line segment is marked with a code letter R no replacement S user disqualified soft jetout H user disqualified hard jetout D disqualified and replaced by AutoJet 4 14 Manual Calibrations Manual Calibrations 3 When the calibration pattern has printed the control panel displays a menu with the following options Report individual soft bad jets enables you to report a soft bad jet which can be automatically reenabled if AutoJet finds it working Report individual hard bad jets enables you to report a hard bad jet which will not be checked or reen abled by AutoJet Clear individual bad jets enables you to clear mark as good a jet View current bad jets lists the bad jets on a g
60. cleared Press gt When you have finished mapping jets the following sum mary appears on the control panel x soft jets currently reported bad x hard jets currently reported bad x new soft bad jets reported x new hard bad jets reported x previous soft bad jets cleared x previous hard bad jets cleared where x is the number of jets Manual Calibrations Jet Status Lines Default Registration Data Manual Calibrations This option prints the Manual Jet Mapping test pattern see Fig 4 3 on page 4 14 that shows which jets are working and which jets are out but does not run the Manual Jet Mapping calibra tion see Manual Jet Mapping on page 4 13 for information This option resets all registration data Since there is no registra tion data after running this option all calibration values must be reestablished by running the calibrations Auto Calibrations The printer s piezo printheads are aligned at the factory and should only occasionally require you to run an automatic bidi rectional or head to head calibration 1 On the Front Page screen press the Menu key to enter dii Lae w S ceo MI a the menu system ortine MENS Sink Mode MEME ent DisplayMaker Gator Advance 2 Press the Y Menu In key display the Calibrate Printer menu re E TN a w Se WD 3 Highlight Auto Calibrations and press the X Menu In key p 4 Select one of the Auto Calibrations JE NU UC AutoBiDi bidirect
61. contrast adjust ment lever and audio feedback Electronics module contains the printer s power supply and control electronics Postheater helps to dry the output prior to the takeup Incorporates turnbuckles that can be adjusted to straighten the media path Index Description 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 Pinch rollers grip the media during loading and printing Pinch roller adjustment lever allows you to adjust the force or release the pinch rollers to feed rigid cut sheet media Rigid media sensor detects whether rigid media is loaded Capping station protects the printheads from drying out while idle not printing for extended periods Handle for pulling the printer on its casters and lift ing the end of the printer Stand supports the printer Casters four places enables easy relocation of the printer can be locked in place Leveling pads four places allows the printer to be stabilized and leveled for consistent media feeding Docking station holds the profilers one for each ink box that track ink and cleaning solvent usage and identify ink characteristics for the RIP Off Head System OHS ink boxes electronics vac uum to maintain negative head pressure and pres sure for purging the printheads that provide ink and cleaning solvent for cleaning the printheads Ink filters user rep
62. d the prime bars will reveal sev eral missing jets 11 Purge the printheads See Purge n Wipe Printheads on page 3 8 for instructions 12 Repeat steps 10 through 13 until no unreplaced missing jets are revealed by the prime bars 13 Run AutoJet or Manual Jet Mapping See page 3 9 for instructions Capping the Printheads 3 15 Loading Roll Fed The printer includes a tensioned supply and takeup system Media designed to handle vinyl and other heavier media on three inch cores The media handling system automatically detects the size of the supply and takeup rolls and provides consistent tension as the rolls change size during printing With the corresponding collets media on 2 inch cores can be loaded onto the supply but only 3 inch collets can be used on the takeup Tip Wear cotton gloves when loading media or handle the media only by its very outside edges This will prevent skin oils from being deposited on the media which could be visible on printed output Locking pin allen head 3 inch moveable collet 2 inch moveable collet 2 inch fixed collet supply only supply only Fig 3 4 3 inch and 2 inch collets 3 16 Loading Roll Fed Media Support for Large Narrow For printing with large rolls of narrow media less than 72 Media Rolls inches wide the printer includes spool support accessories to prevent the spools from bowing under the weight Spool support attaches to the stand crossbar sup
63. d Media 3 8 Checking Jet Health Q B e Offline amp Ink P 38 E e 4 c E H b cn co Access Media Load we en Heads Wizard Media Print Jet Out Lines 63 B e Offline amp Ink ee 38 E e E m Bars e Media Load ale ens Headz wizard Media Map Out Missing Jets Checking Jet Health To purge n wipe a color four printheads 1 From the control panel Front Page screen press the Menu key 2 Press the V key to highlight Maintenance 3 Press the X Menu In key 4 Press Vto highlight Purge a Color 5 Press the X Menu In key 6 Press the gt Proceed key to continue The control panel displays a list of ink colors 7 Press V repeatedly to select an ink color to purge 8 Press Proceed to continue The printer purges the printheads with air pressure then wipes them with the service station wipers Approximately 1 7 milliliters of ink per color are expelled by this purge and the purges triggered by AutoTune and AutoRecover Note Purging a single color is more effective because more pressure is applied to each printhead but a possible side effect of repeated single color purges is clogged jets in other colors Repeated single color purges should be followed by a purge of all printheads 1 From the control panel Front Page screen press the Menu key 2 Press the V key to highlight Maintenance 3 Press the X Menu In key 4 Press Vto highlight Print Jet Out Lines 5 Press the X
64. d Warning Action system the ATTN Atten tion key blinks on the control panel when the printer detects an error condition potential error condition or when you make a change that suggests recalibration or other action to ensure best print quality There are two types of ATTN messages Actions the printer has detected an error condition that stopped printing or will prevent printing from start ing You must correct the error before the printer will be ready to print When the printer senses that the error condition has been addressed the Action will be deleted the next time the ATTN key is pressed Warnings the printer has detected a condition that if left unaddressed could result in substandard prints or a condition that will require an action before printing can continue Any action on your part is optional printing is not interrupted for a Warning message Special Features 1 17 Special Features CHAPTER 2 EEE ee Using the Control Panel This chapter describes the functions of the control panel oo Using the Control Panel Overview page 2 2 Front Page page 2 4 Navigation Keys page 2 8 Menu page 2 9 Menu Tree page 2 17 2 1 Overview 2 2 Ready Screen Front Page Menu The touch screen control panel shows you the printer s current status and enables you to interact with the printer when chang ing media and ink respond to an error condition or configure options T
65. d media types If you are not using a standard media type select the standard media type that most closely matches the media you are using Then only if necessary create a new media type using the standard type you selected as a start ing point and adjust it as needed From the Front Page screen press the Media Wizard key The Media Wizard menu appears It contains the following Options Media Settings displays the settings currently stored in the Media Wizard Create Media Type creates a new media type using settings you specify Delete Media Type deletes a user created media type View Media Types allows you to view each of the media types stored in the Media Wizard Set Sort Method allows you to sort the list of media names Alphabetically by Most Used Recently Used Sheet fed First Roll fed First or None preserves the cur rent order When you select Media Settings the control panel displays the current settings To change the current settings press the Media Settings key Media Wizard Media Wizard To return to the Media Wizard menu press the Proceed key For each media type the Media Wizard stores the following settings The settings stored vary depending on whether the media is roll fed or cut sheet Name for user defined media use the alphabetic key board displayed on the control panel to enter the media name Standard media names cannot be changed
66. ds the print heads could be damaged permanently and require replacement Turn the head height adjustment screw clockwise just until the end of the gauge slides under the carriage Remove the gauge and repeat steps 7 through 9 at the other side of the carriage Verify the heights at both sides of the carriage and adjust if necessary Set the Printhead and Camera Height Setting the Camera 1 Remove the carriage cover Height The carriage cover is attached to the carriage with two screws on each side see Fig 5 7 below Fig 5 7 Location of carriage cover screws 2 Loosen the three camera enclosure mounting screws see Fig 5 8 below recessed Fig 5 8 Camera enclosure mounting screws Set the Printhead and Camera Height 5 15 Set the camera height Insert the camera height gauge as shown in Fig 5 9 below Raise or lower the camera enclosure so that it touches the top of the gauge Camera enclosure Fig 5 9 Camera height measurement point 10 Tighten the camera enclosure mounting screws Replace carriage cover and screws Press to return the carriage to the service station The control panel displays a message asking whether you want to calibrate the service station See Calibrate the Ser vice Station on page 5 17 for instructions Press 4 to calibrate the service station or X to continue The control panel displays a message asking whether you want to perform a bidirectional
67. dvises you that it may take several min utes for heaters to reach the new temperature settings 3 48 Setting Heater Temperatures Calibrating the Printer CHAPTER 4 Calibrating the Printer This chapter explains how to calibrate the printer for the best possible output When to Calibrate page 4 2 AutoJet page 4 3 AutoTune page 4 4 Media Feed page 4 6 Manual Calibrations page 4 8 Manual BiDi Registration Manual X Head Registration Manual Jet Mapping Jet Status Lines Default Registration Data Auto Calibrations page 4 20 AutoBiDi Calibration AutoH2H Head to Head Calibration AutoJet Calibration Full AutoSet Auto Calibrations page 4 20 Straightening the Media Path page 4 22 Image Sensor Calibration page 4 23 Linearization page 4 24 4 1 When to Calibrate The printer features several types of calibrations Some should be run routinely others only when necessary When to run Calibration Function When Purge n Wipe does not AutoJet page 4 3 To identify and map out non recover all missing jets or Manual Jet Mapping page 4 13 working jets When printing a large group of print AutoTune page 4 4 Automatic jet maintenance during jobs extended printing periods When loading a new media but not Media Feed or media feed adjust Media advance accuracy when loading a new roll of the same ment during printing page 4 6 media after changing the head
68. e and payment Software whether embedded in ROMs or other hardware or contained on diskettes or other media including related manuals and documentation its quality performance mer chantability or fitness for any particular purpose Warranty Claims Diagnostics Diagnostics The printer includes a series of self diagnostic tests designed to help MacDermid ColorSpan Technical Services solve printer hardware problems If one of the tests encounters an error and error message appears which includes Error code always write down this code for future refer ence by MacDermid ColorSpan Technical Services Brief description of the error A series of buttons that allow you to respond to the error In some cases you can ignore the error or enter a further diag nostic routine In other cases you must restart the printer During the course of operating the printer another class of error messages may appear on the control panel The ATTN Atten tion key blinks on the Ready or Front Page screen when the printer detects an error condition or potential error condition When you press this button the panel displays one or more messages of the following types Warnings the printer has detected a condition that if left unaddressed could result in substandard prints or a condi tion that will require an action before printing can continue Any action on your part is optional Actions the printer has d
69. e media alignment tool Set the pinch rollers as specified in the Media Wizard Remove the media alignment tool from the platen Press the B gt key to continue The control panel asks whether you want to adjust the head height If the thickness of the media you are loading is sig nificantly different from the previously loaded media then adjust the head height for optimal print quality and to pre vent the carriage from striking the media Ifyou press Yes the control panel enters the head height service station height and bidi calibration proce dures See Chapters 4 and 5 for instructions Ifyou press No the media load procedure continues The printhead carriage moves out of the service station and uses the onboard digital imaging sensor camera to locate the right front and left edges of the media and to deter mine whether the sheet was loaded squarely into the printer If the media is skewed the control panel asks whether you want to adjust it Ifyou press Yes you can release the pinch rollers adjust the media lower the pinch rollers and press the Pro ceed key to continue Ifyou press No the media load procedure continues The control panel briefly displays the measured width of the media Loading Rigid Media 15 Press the key to continue The control panel displays a screen that shows the following information Media size Print area Right amp left margins if
70. e of pattern 3 Press the gt key The control panel displays this message X Direction Registration Head 2 0 4 Examine the X direction pattern in the left hand group of patterns for the current head and determine which pattern of colored and black lines are the closest to perfectly aligned Manual Calibrations 4 9 4 10 Use a printer s loupe or magnifying glass if the patterns are difficult to see I LPPPETI Ii bul PEEL Fig 4 1 Sample head calibration patterns In this example pattern 1 is aligned the closest so 1 would be entered Press the or Y control panel keys repeatedly until the num ber next to the pattern that is closest to aligned perfectly is displayed For example if pattern 1 is the closest aligned press the A key to change the display to X REG HEAD 1 1 If a printhead is extremely out of alignment there may be no pattern in alignment Since the black vertical bars are five pixels apart you can add 5 or 5 to a pattern number to shift the colored bars up or down by one black bar Alter natively you can repeatedly perform the X calibration which will move the head in smaller increments until the head is aligned Press P Proceed The control panel message increments the head number by one Repeat steps 4 through 6 for each of the heads When you have entered registration values for all of the pat terns the control panel displays this message
71. e platen Position either the minimum or maximum head height gauge as shown in Fig 5 6 Do not measure the head height from the surface of the postheater Carriage Platen Fig Set the Printhead and Camera Height 5 6 Head height measurement points A and B To lower or raise the printheads without the gauge use two hex wrenches to turn the head height adjust ment screws at the top of the carriage simulta neously and by the same amount Three quarters of a turn of the screws moves the carriage approxi mately 0 03 inches or approximately the distance between the min and max head height gauges Then go to step 1 to set the camera height Use the supplied hex wrench to turn one of the head height adjustment screws counterclockwise until the end of the gauge will not fit under the carriage as shown in Fig 5 6 The head height adjustment screws can be accessed from the top of the carriage The access holes are labeled with a white circular label 5 13 5 14 10 11 The carriage must be lowered below the height of the gauge and then raised If the carriage is simply lowered on top of the gauge the carriage will tend to settle lower during print ing changing the head height and invalidating the calibra tions Caution Do not allow any part of the gauge to touch the printheads and do not leave the gauge on the platen after setting the head height If the gauge is allowed to touch or strike the printhea
72. e runs AutoJet at user defined intervals to ensure that all jets are either working or substituted with working jets See AutoTune on page 4 4 for instructions Wear cotton gloves when loading media to prevent finger prints that could show after printing DO NOT rest or store a media roll on end or you could cause edge creases that could strike the printheads during printing DO NOT clean the printhead surfaces with a dry cloth or paper towel DO NOT reprint over any output that has not completely dried The rubber pinch rollers could be damaged by wet Operating Requirements Safety Warnings Operating Requirements ink If ink does get onto the pinch rollers clean them with SolaChrome HR Cleaning Solvent and dry them thoroughly before printing DO NOT set heavy objects on the power cord or printer cable do not bend the cables or force them into contorted positions DO NOT place heavy objects anywhere on the printer DO NOT lean on or place objects on the optional auxiliary dryer if installed WARNING WARNUNG WARNING WARNUNG WITH THE POWER SWITCH IN THE OFF POSITION POWER MAY STILL BE SUPPLIED TO THE PRINTER COMPONENTS To completely cut power from the printer you must unplug the power cords from the power outlets WENN DER NETZSCHALTER IN OFF POSITION STEHT WIRD DEN KOMPONENTEN TROTZDEM STROM ZUGEFUHRT Um den Drucker komplett stromfrei zu machen m ssen Sie den Netzstecker ziehen The pr
73. e service station Printheads permanent piezo based printheads Vacuum Pressure VP System provides vacuum to main tain negative pressure at the printheads and pressure to purge the ink tubes and printheads Profilers provided with each ink box they contain infor mation about the ink and must be installed together with their corresponding box Profiler data are used to track ink levels and to help ensure optimal output quality and com patibility with printer components LEDs the LED next to each profiler illuminates when the box is almost empty to alert the operator to exchange the box for a full one vent in the printer Use of any other inks or cleaning fluids COULD DAMAGE THE PRINTER AND WILL VOID THE WARRANTY N Caution Use only genuine ColorSpan inks and cleaning sol 3 2 Ink System Overview Idle Jet Maintenance Due to the evaporation of the solvents in solvent based inks the Time Period 1 hour Momentary Power Down 2 hours to 4 days 4 14 days ink jets in solvent printers are susceptible to clogging To mini mize jet outs keep the printer printing and clean and use the printer s jet maintenance features The following table shows the recommended maintenance schedule while the printer is idle See Chapter 5 Maintaining the Printer for a complete listing of recommended maintenance to keep the printer operating well and covered by the manufac turer s warranty Reco
74. eads Empty Heads Fill With Air empties all printheads by purging the ink and cleaning solvent with air Printhead Maintenance Cleaning Clogged Ink Jets Purge n Wipe Manual Cloth Wipe 63 B e Offline amp Ink ea 38 E e T E et c3 e 4 ee Access Media Load Heads wizard Media Cleaning Clogged Ink Jets All printers that use solvent based inks are susceptible to print head clogging This is caused by the solvent evaporating and leaving behind the pigments which is desirable on printed out put but not in the printheads The printer incorporates many automatic features and manual procedures for preventing clogs from occurring and for recover ing ink jets that do become clogged Purge n Wipe Manual Cloth Wipe Cleaning Solvent Soak Cleaning the Service Station Doctor Blade All sixteen heads can be purged at once or one color set four heads can be purged for increased pressure See Checking Jet Health on page 3 7 for instructions If repeated Purge n Wipes fail to recover enough jets you can wipe them manually with a 10096 polyester Class 100 clean room cloth soaked with SolaChrome HR cleaning solvent A manual wipe is also recommended after uncapping the print heads see Uncap the Printheads on page 3 14 for instructions DO NOT USE ISOPROPYL ALCOHOL ON THE PRINTHEADS 1 To access the heads for cleaning select Access Heads from the control panel Front Page 2
75. eben de 3 41 Table of Contents Table of Contents Media Properties naeh 3 41 unici ibo TU 3 42 Media WVIZAIG er 3 44 Setting Heater Temperatures ss bi 3 47 Calibrating the Printer When to Calibrate ss penso eh ee 4 2 AOJO T IT TIU 4 3 AULO TUNG soaron 4 4 Quality Check anne 4 5 Media Feed iS 4 6 Man al C alibrationsaun ssesee ea 4 8 Manual X Head Registration neuen at nena quae 4 9 Manual BID I Registration ersehen 4 11 ManualjJet MappiNg2ee u e2 ee 4 13 Report INGIVIOUaliBad VOUS essen ns ke 4 15 Clear Individual Bad Jets treat ren E e essen us erase osea Ns 4 16 View Current Bad Jets cccccceecceccecceceeccsceseesececenceeceecenseeeees 4 17 Clear ABA 655 3 testet eat ot e utes setatis een 4 17 Jet Stat Hs DINE eder saedced ee da adu Ma odd ipod UE 4 19 Default Registration Data una aa ae 4 19 AUO CaliDrationses dr 4 20 Calibration SUR May nn Da ie 4 2 Straightening the Medid Pan use 4 22 Image Sensor Callpralion en iani che dme eB RM ERU dtes tiu 4 23 Lineari zdu oN a eier 4 24 Maintaining the Printer Maintenance schedule rue 5 2 Clean tne Rail and Bearings nase ae 5 4 PincmRollerses sans 5 4 Balls er ee 5 5 Carriage Bearings au ae 5 5 Cleaning the Encoder SI leere 5 6 EMPU EXCESS INK een a 5 7 Printhead Maintenance 25 2 boc tti to eben e n ie 5 8 Cleaning Clogged Tnk Gels pope d hup a Sep esie a aito ten 5 9 Purge mujer
76. ed independently of the printheads For example if you set the head height above a certain media with the minimum gauge then switch to a thicker media and again set the head height with the minimum gauge the camera will remain at the correct height above the media without adjustment If you instead reset the head height with the maxi mum gauge changing the head height above the media then you should reset the camera height To ensure good automatic printhead wiping check the service station height and recalibrate if necessary after changing the printhead height for instructions see Calibrate the Service Sta tion on page 5 17 Tip If you notice an unacceptable change in color quality after changing the head height perform a ColorMark color calibration linearization on a third party RIP or create a new profile Set the Printhead and Camera Height Setting the Head Height 1 Q B Offline So 3 ag Gator E e o e 5 e Access Media Load welt en amp wizard Media 6 Load the media that you want to calibrate For instructions see Loading Roll Fed Media on page 3 16 On the Front Page screen press the Menu key to enter the menu system From the control panel menu press the Y key to highlight Printer Settings Press the X Menu In key From the Settings menu press the Y key repeatedly until Head Height is highlighted Press the X Menu In key The carriage moves out over th
77. el displays a numeric keypad E 1 LUNI 2 8 9 9 11 11 ase J Eales Fig 3 10 Numeric entry screen 18 Enter the length of the media roll if it is a new roll or the length remaining if it is a partially used roll and press the Enter key to continue To skip this step press Esc or Enter without entering a value The printer will use a value of undefined and will not track media usage The control panel displays the Media Feed Number 19 Accept the displayed Media Feed Number enter a new num ber or perform a Media Feed Calibration to generate a new Media Feed Number see Media Feed on page 4 6 for instructions You are now ready to begin printing 3 23 Loading Wide Media A roll of 72 inch and wider media is impossible to load it by grasping its left and right edges at the same time Follow this procedure to more easily load wider media the media only by its very outside edges This will prevent skin oils from being deposited on the media which could be visible on printed output Y Tip Wear cotton gloves when loading media or handle 1 With one hand grasp the media at the center of its leading edge and pull it forward into the center grit rollers 2 While continuing to hold the center of the leading edge of the media in place grasp the left edge of the media with your left hand Pull the left edge of the media into the leftmost grit rollers Hold the media in place with your le
78. en the containers fill with ink they should be emptied The excess ink container near the service station will need to be emptied when it is full or near full This can be determined by visual inspection or when the float sensor reports a full condi tion via the control panel The ink in the excess ink container near the capping station may evaporate at or near the same rate as it is collected so it may never fill the container Visually check the amount of ink peri odically and empty the container as needed Have a paper towel ready to catch the small amount of ink and cleaning solvent that will spill out of the drain tube as you dis connect it The excess ink container s tray is designed to catch these spills for easier cleanup You may also want to wear protec tive gloves during this procedure 1 Close the stopcock valve on the drain tube This prevents ink from continuing to flow out the end of the tube Disconnect the drain tube from the excess ink container Service station reservoir only disconnect the sensor cable from the float sensor Lift the container out of its tray Empty the excess ink and cleaning solvent into a solvent dis posal container Note Dispose of ink and cleaning solvent only according to the Material Safety Data Sheet MSDS and applica ble laws and regulations The MSDS is available on the MacDermid ColorSpan web site www color span com Replace the container in its tray Reconnect
79. en pages To change an option go to the Printer Con figuration section of the menu Model DisplayMaker Gator Version Company ColorSpan Total RAM Vacuum Pressure 4 80 H20 Ethernet Address 00 07 E9 43 18 6E Link 100 Mb sec Up Fig 2 4 Status page 1 Print Mode sets print quality mode See Selecting a Print Mode on page 3 4 for instructions Advance Media press the Y key to advance the media for ward When you press and hold the Y key the media moves faster Press the A key to reverse the media back onto the supply spool When you press and hold the A key the media moves faster You can also press the Media Advance rocker switch mounted on the OHS near the postheater to move the media in either direction Menu displays the complete printer menu for access to advanced configuration options see Menu on page 2 9 for instructions AutoJet detects deflected and non firing jets and substi tutes working jets for them in Production and Quality modes Prime Bars fires all jets by drawing a set of lines called prime bars This is a good way to inspect and prepare the jets for printing after they have been idle see Print Prime Bars on page 3 8 You can also print a similar pattern called Print Jet Out Lines which shows which jets have been detected and replaced by AutoJet see page 2 14 for details Front Page Front Page Purge performs a Purge n Wipe which purges the prin
80. er Ann herung von Gesetzen von Mitgliedstaaten besch ftigt betreffend Tele kommuniktionsanlagen und die gegenseitige Anerkennung ihrer Konformit t About This Manual vi This manual contains the following topics Chapter 1 Getting Started shows you how to unpack and assemble the printer and introduces you to its main fea tures Chapter 2 Using the Control Panel shows you how to use the control panel to specify printer options Chapter 3 Ink and Media shows you how to install ink and media Chapter 4 Calibrating the Printer shows you how to cali brate the printer for optimal print quality Chapter 5 Maintaining the Printer explains scheduled maintenance how to recover clogged printheads how to prepare the printer for extended power down such as for shipping or storage and more Appendix A Technical Specifications lists the printer s technical specifications Appendix B Troubleshooting shows you how to trouble shoot common printing problems and interpret Action and Warning messages For further information refer to the following ColorSpan documentation Site Preparation Guide explains how to prepare your site for the printer s arrival and installation Release Notes late breaking information update descrip tions and update instructions ColorSpan Print Server Documentation the System Control User Guide Print Server amp Driver Setup Guide and Printing Tools
81. ers Allow the printer to measure the media again Repeat until the skew is within tolerance LEFT and RIGHT are defined as if facing the front of the printer RIGHT is toward the control panel LEFT is toward the opposite end If you set the overprint distance to a smaller number there will be less skew tolerance before the printer reports too much skew If you set a larger overprint distance the printer will permit a greater amount of media skew before displaying the error message 3 43 Media Wizard ame I Iw TE ELA nine edla rint offline Sink Mada Backward d DisplayMaker Gator gee a i E ME i P Frime ua Bars Purge Cc en S i Access f Media Load Sleep g Headz Wizard Media d i Media Settings 3 44 The Media Wizard software feature stores a set of printing parameters by media type enabling you to instantly optimize the printer whenever you change media The Media Wizard includes standard sets of parameters for popular media types and allows you to define new settings for media types you define The Media Wizard can store a different set of settings for each of the print modes Billboard Production High or use the same settings for all three modes The Media Wizard is accessible during the media load process see Loading Roll Fed Media on page 3 16 and from the Front Page screen as follows Tip To use the Media Wizard most efficiently start by using one of the standar
82. etected an error condition that stopped printing or will prevent printing from starting You must correct the error before the printer will be ready to print The following table describes the Actions and Warnings in detail The cross referenced page numbers refer to this manual B 7 Code Message Table B 1 Actions and Warnings Cause What to Do CS Capping Station Capping station is raised and the car Lower the capping station to allow A CS 1 Capping Station riage is not at the capping station the printheads to be capped and to prevent the carriage from crashing into it A CS 2 Capping Station Printheads are capped Uncap the printheads The Capping Station Sensor has been W CS 1 Capping Switch Disabled disabled Enable the Capping Station Sensor in the Printer Settings menu El Excess Ink Sensor Enable the Excess Ink Sensor in the The Excess Ink Sensor has been dis W EI 1 Excess Ink Sensor Disabled abled The Excess Ink Sensor is discon Printer Settings menu Ensure that the Excess Ink reservoir is W El 2 Excess Ink Sensor Disconnected HT Heater W HT 7 23456789 10 11 nected installed and the sensor is connected Call your service provider to check Heater Not Warming W HT 21 22 23 24 25 26 27 28 29 30 A heater or thermistor may be not functioning on the middle platen heater 1 3 middle platen zone 4 right platen heater 5 right pla
83. ficult to see 6 4 2 O x Fig 4 2 BiDi Registration pattern 7 Press the A or V control panel keys repeatedly until the num ber next to the pattern that is closest to aligned perfectly is displayed For example if pattern 2 0 is the closest aligned press the A key to change the display to HEAD 1 2 0 If a printhead is extremely out of alignment there may be no pattern in alignment Since the black vertical bars are nominally five pixels apart you can add 5 or 5 to a pattern number to shift the colored bars right or left by one black bar Alternatively you can perform the BiDi Registration repeatedly which will move the head in smaller increments until the head is aligned 8 Press gt Proceed The control panel message increments the head number by one 9 Repeat steps 6 through 8 for each of the twelve heads When you have entered registration values for all heads the control panel displays this message Registration Successful 4 12 Manual Calibrations Manual Jet Mapping _ Jets that are missing or misfiring are usually detected by the AutoJet calibration Alternatively you can map out jets manually using the Manual Jet Mapping function You may want to manu ally map weak or misdirected jets that AutoJet does not substi tute a Tip AutoJet is the automatic version of this calibration see AutoJet on page 4 3 for details Tip For best results print the prime bars and purge the printheads as ne
84. fline key to switch the printer online Reloading Rigid Media 3 37 Edge to Edge Printing The printer can print up to or past the edges of rigid media This provides the look of a full bleed print without trimming the media For best results follow these guidelines set of tips and techniques for printing on rigid media including edge to edge and double sided printing See the MacDermid ColorSpan web site or Contact Technical Services at 800 925 0563 or 952 944 4040 and ask for Tech Note 2730 Straight Through Paper Path A Handbook for Users BE c UI Document Application To ensure that the printer will print past the edges of the and RIP Settings media design or enlarge the job slightly larger than the media For example if the media is 32 inches wide set an Overprint distance of 0 125 inches see Menu gt Printer Set tings gt Margin Settings and size the document to 32 25 inches wide For images with a special detail at the edge of the page such as a border make the border line thicker than usual to extend past the edges of the page V4 Media edge Erasmus B Dracon s Erasmus B DRAGON MANAGEMENT n zi L NOW LEASING Fig 3 19 Laying out a full bleed document shown with bleeds off three sides 3 38 Edge to Edge Printing Media Properties Printer Setup Edge to Edge Printing Printable area 24 x 41 5 Follow the g
85. ft hand Grasp the right edge of the media with your right hand and pull it into the rightmost grit rollers 6 With both hands feed the media web evenly into all grit rollers 7 With your right hand hold the media spool at the collet to prevent the spool from moving 8 With your left hand press the Media Advance button for 2 3 seconds The grit rollers will spin beneath the stationary media thus equalizing the tension on the roll 9 Press the Media Advance button to finish loading the media 10 Verify that the media web is even and unwrinkled across its width 11 When loading the media onto the takeup spool ensure that the media is tightly wound onto the spool across its width 12 Return to step 12 on page 3 19 to finish loading the media 3 24 Loading Roll Fed Media Unloading and 1 Press the V key on the Front Page screen to advance the Cutting Roll Fed printed portion of the media past the postheater Media 2 Onthe Front Page screen of the control panel press the Unload key 3 The control panel prompts you to press B to unload media or X to cancel 4 Press to continue This detensions the supply and takeup spools 5 Cutthrough the media with a utility knife along the cutting channel in the platen or below the postheater As you cut the media from the printer hold it to prevent it from falling to the floor and possibly damaging it Note If you scratch the platen while cutting media be sure to
86. gn the printer in a single plane Securely tighten the two silver screws that attach the printer to the stand For rigid cut sheet media the input and output tables must be leveled with the printer platen 4 22 Straightening the Media Path Image Sensor Calibration ae w er a Online Media Biffline Ink node Backward DisplayMaker Gator en e BE m BE eo Prime a Autodet Ears Purge Ci gt a EN 3 Access Media Load SEED Heads wizard Media Image Sensor Calibration The precise location of the image sensor camera relative to the printheads is critical for edge to edge printing on rigid cut sheet media The Image Sensor Calibration determines this distance with precision Run this calibration after installing the printer for the first time and whenever the camera height is changed Setting the Cam era Height on page 5 15 or the camera is replaced To calibrate the location of the image sensor ee Load media Load enough media either roll fed or cut sheet to print the small calibration pattern On the Front Page screen press the Menu key to enter the menu system From the control panel menu press the Y key repeatedly to highlight Service Printer Press the X Menu In key From the Service Printer menu press the Y key repeatedly until Image Sensor Calibration is highlighted Press the X Menu In key Press the v key to begin the calibration The calibration runs with no
87. gs Ifyou press P the control panel displays the prompt Advance media to takeup 15 To advance the media press V Yes otherwise press x No and go to the next step Ifyou press V Yes the media advances to the takeup spool You can press Stop if necessary to stop the media advance at any time Ifyou press x No go to step 18 16 Grasp the middle of the media web pull straight back route the media underneath the takeup core and tape it to the takeup core as shown in Fig 3 7 on page 3 19 If necessary you can use the arrow keys on the control panel screen to move the media forward or backward Note With the fixed collets securely pinned to the supply and takeup spools see Fig 3 4 position the media on the takeup core in the same relative position as it is wound on the supply core For example if the media is positioned 0 125 inches from the left end of the supply core it should be positioned the same dis tance from the left end of the takeup core If neces sary the 3 inch collets on the takeup spool can be loosened so that the core can be moved to the right or left 17 Press the B gt key to continue The printer tensions the supply and takeup system turns on the platen vacuum fans and measures the width of the media by locating the right and left edges with the digital image sensor camera on the printhead carriage 3 22 Loading Roll Fed Media Loading Roll Fed Media The control pan
88. h color has its own filter 20 liter life and pump Inkjet Maintenance On demand head cleaning Automatic and on demand jet recovery On demand solvent cleaner purge and ink refill Manually actuated capping station available off printer cleaning station Vacuum Pressure System Maintains negative relative pressure at the print heads and provides air pressure for purging Nominal relative vacuum 4 80 inches H O 8 97 mm Hg Since relative pressure is maintained the printer can be operated at various altitudes above or below sea level without adjustments to the system Media Handler Supply and takeup for roll to roll handling use of takeup is optional Supply accepts 3 inch or 2 inch cores takeup accepts 3 inch cores only The media supply roll can be loaded and unspooled in either direction for printing on either side Releasable pinch rollers ease roll fed media loading and enables rigid cut sheet media loading DisplayMaker 98SI Spool supports and reinforce ment sleeve supports the weight of longer rolls of media less than 72 inches wide Drying System Contact preheater platen heater and postheater with user selectable settings not used for rigid cut sheets Optional auxiliary dryer fans speed drying for high coverage and high speed prints Software Features Touch screen LCD with graphical interface Automatic calibration and detection substitution of missing jets Media Wizard stores operational parameter sets by media
89. he Printheads on page 3 13 14 30 days 30 days or more Idle Jet Maintenance Fill the printheads with cleaning solvent and cap the printheads with a sol vent soaked pad See Cleaning Solvent Soak on page 5 8 for instructions Flush the printheads with cleaning solvent empty the printheads and cap See Extended Power Down and Restart on page 5 21 for instructions 3 3 Selecting a Print Mode The bidirectional print modes printing occurs in both direc tions enable you to select the combination of print speed and quality required Speed or throughput depends on the mode selected and by other factors such as the width of the image The unidirectional modes are available for rigid cut sheet printing only Unidirectional printing eliminates the bidirec tional misalignment that occurs when printing on media that is not perfectly flat The printer automatically accepts and prints jobs from the RIP at either 600x600 or 600x300 dpi Jet replacement refers to the printer s ability to locate and replace ink jets that are clogged or misfiring High Quality mode has the best jet replacement Billboard Quality mode has the highest speed The software will turn on the optional auxiliary dryer fans automatically during printing and increase media advance speeds accordingly if the fans are installed and enabled Menu gt Printer Settings gt Dryer Fans 1 On the Front Page screen of the control panel press the Pri
90. he printhead indicated is not receiving ink An error in ink system at startup was detected Ambient room temp is out of range for operation for K 76 C 77 M 78 or Y 79 What to Do The thermister is bad or the heater board or I O board is malfunctioning or there is a cable problem Wait for the heaters to reach their operational temperatures Wait for the heaters to reach their operational temperatures Allow heaters to cool and restart the printer If it will not cool unplug the printer If problem persists contact your Authorized Service Provider or Technical Services Replace the ink box indicated Install the profiler indicated Replace the profiler with the correct profiler Install the profilers into the correct positions in the docking station Replace the profiler indicated with a valid profiler Call your service provider to reposi tion or replace the air sensor Call your service provider to reposi tion or replace the ink sensor Check the ink level in the correspond ing reservoir If its LED is illuminated replace the ink box Check the ink tubing for leaks or blockage Check Attention messages for a failed ink thermister Check whether the ink filter is full Call your service provider to check the corresponding ink pump Fix the error and restart printer Raise or lower the ambient tempera ture until it is within operating range see Specifications on page
91. hecking jet health and recovering jets Checking Jet Health 3 7 Print Prime Bars 1 From the control panel Front Page screen press the Prime Bars key mh amp ee The control panel displays a prompt asking you to enter the 63 63 B bo es total width of the prime bar pattern you wish to print BQ Gator 2 Enter a width for the prime bar pattern by pressing the Y TILL 3 Press the gt Proceed key to continue 3 i ce te The printer prints the prime bar pattern The prime bars will sen Ne NE show correctly working jets with a solid line and missing jets with no line Purge n Wipe Printheads When prime bars indicate missing or deflected jets automatic jet maintenance should be supplemented by a Purge n Wipe operation air pressure forces ink through the inkjets then the service station dips the wipers in cleaning solvent and wipes the inkjet orifice plate You can purge all sixteen printheads at once or purge a single color four printheads To purge n wipe all sixteen printheads 1 From the control panel Front Page screen press the Purge key The control panel prompts you to press the P Proceed key a B D to continue a 38 2 Press the gt Proceed key to continue e e 88 gt The printer purges the printheads with air pressure then wipes them with the service station wipers Approximately 1 milliliter of ink per color is expelled by this purge mr tme iin Heads wizar
92. here are three main control panel screens Ready Status Screen Front Page Menu When you press the Online Offline button from the Front Page screen the printer goes online and the Ready screen appears The Ready screen displays the current status of the printer and any currently printing job It displays when the printer is online communicating with the print server and either ready to print or printing Online Offline Ready Media Width 10 00 in Length Undefined Mode Production Quality Heaters At temp Vacuum Pressure 3 70 H O Fig 2 1 Ready screen When you press the Online Offline button from the Ready Screen the printer goes offline and the Front Page screen appears This screen is the top level of the printer s menu sys tem It provides access to the most frequently used offline func tions For details see Front Page on page 2 4 When you press the Menu key on the Front Page screen the Menu appears The Menu provides access to advanced configura tion options For details see Menu on page 2 9 Overview User Assistance The control panel provides various forms of online user assistance The button provides an explanation of the current function with some guidance for what to do next The ATTN Attention key blinks on the control panel when the printer detects an error condition potential error condition or when you make a change that suggests recalibration or other ac
93. ications Network Statement uussssssnnesssnnnneneenennnn V ADOUL Dhis IManudlisssenestoi nested euouto le een vi CONVENON aaa vii Getting Started Operating ReguiremenB nn 1 2 BLO CUP Cal een 1 2 Environmental sooren D 1 2 Important Operating NOLES vacasascacsatneeancnntrontaie staid wate ran 1 3 Sately WarniNgs sense 1 5 Unpacking ana ASSembmly seit aa katusksculbeauueenes 1 7 WorktloWw OVervieW na oen ool RO EN dE 1 8 Power A Tier PEIUS cuoio conchae cas es tut a a a acad 1 8 Daily Startup 1 8 Muiniuigro tH 1 9 BGOOX30D REINUN Os er 1 9 Daily SNULOOWN E P Rr RR 1 9 Parts eleg 1 10 Auxilary Divers ae 1 14 Special Features are eines 1 15 Printneads anna 1 15 IHK System m 1 15 e lrlerecinre lam rc 1 15 MOC aE AGING eet TE ERE 1 16 l erfortmarice and Ease o PUSE iiceoe A E 1 17 Using the Control Panel Gul einlesen 2 2 Redely SCE Meenemen een 2 2 pesce ee 2 2 Men euere 2 2 User Assistance ara 2 3 FLOM Age ea ee ne nee nein nes 2 4 Navigation Keys T ee ee ei 2 8 MENU ar ee 2 9 Caliprate Printer een 2 9 Printer iral 2 10 MAIM ENa Gesa aaa aa oained oe Pp e uL Pub ee uel 2 14 SEIVICE Printer eto E M ME 2 15 User DAG INOS CICS au ie 2 15 WY Abilis SA CUOINS See 2 16 PhptclvienUu be E ene ts es er us E ees SI bee RR 2 16 Menur eC RT UU UN UN 2 17 POMC Tage sian cian RR NM RUM RU RUE m EIER DI MIRI I MUR einsehen 2 17 ME T T Em 2 18 Ink and Media Ik System Overview 3 2 VCH
94. iezo printheads are designed to remain in service for the life of the printer All printers that use solvent based inks are susceptible to print head clogging This is caused by the solvent evaporating and leaving behind the pigments The printer incorporates many automatic and manual features for preventing clogs from occur ring and for recovering ink jets that do become clogged see Cleaning Clogged Ink Jets on page 5 9 The warranty terms require that the maintenance procedures contained in this User Manual are followed prior to classifying a printhead anomaly as a printhead failure A printhead failure is defined as any printhead that develops one or more individual jets that do not fire and that cannot be recov ered or replaced mapped out by the AutoJet or Manual Jet Mapping software when printing in Production Mode If the jet s can be mapped out by the software in Production Mode the printhead is deemed to be working satisfactorily and is not considered to have a failure In the event of a printhead failure as defined above the cause and or circumstances that lead to the failure must be identified The following is a list of causes and or circumstances that may lead to printhead failure This list is not considered comprehen sive and any causes and or circumstances that are not identified in this list will be evaluated on a case by case basis All printheads submitted for warranty claims will be subjected t
95. ight Printer Settings EO 3 3 Press the W Menu In key display the Printer Settings Autalet Bur Purae menu pu 4 Press the V key repeatedly to highlight Quality Check EA wizard E 5 Press gt Proceed The control panel displays the Quality Check options Attended Mode user must press P Proceed to acknowledge the error and print the job if one is pend ing or x Cancel to cancel printing Unattended Mode no user acknowledgment of errors is required When a quality check fails print jobs are sent to the ColorSpan print server s Attention queue with a disposition of Uncalibrated Printer this feature may not be supported by non ColorSpan RIPs OFF no quality check is performed all jobs will print Select a Quality Check option Press the X Menu Out key repeatedly until the Front Page screen is displayed Press the Online Offline button to return the printer to the Ready state AutoTune 4 5 Media Feed This calibration allows you to calibrate the accuracy of the media advance Inaccurate media advance can result in blank spaces between print swaths too much advance or overlapping swaths too little advance The Media Wizard stores this value by media type and displays a media feed number MFN which you can record for subsequent entry The media feed number enables you to quickly specify a known good media feed setting without recalibration For example you could keep
96. ing Roll Fed Media on page 3 16 from the Media Wizard see Media Wizard on page 3 44 or from the menu see the following procedure 1 From the control panel Front Page screen press the Menu key 2 Press the V key repeatedly to highlight Printer Settings Press the X Menu In key Press the V key repeatedly to highlight Heater Temps Setting 5 Press the X Menu In key The control panel displays a list of heater settings num bered from 0 to 10 and Custom 6 Press the A or Y keys repeatedly to select a setting As you scroll through the settings the temperature settings for each zone are shown at the bottom of the screen 7 Press P to selecta setting or X to cancel Ifyou selected Custom a list of heaters appears so you can change the settings for each of the heater zones Ifyou selected any other setting go to step 9 8 Select a heater zone and set a new temperature If a Media Wizard type is currently loaded the control panel asks whether to save the new setting in the Media Wizard for the currently loaded media 3 47 9 Press W to save the new settings in the Media Wizard or x to not save them Settings can be saved only for user defined media not for factory defined media The settings will be applied whether or not you save them in the Media Wizard If you do not save them they will be lost when you load a different media type or restart the printer The control panel a
97. ings Changed settings will remain in effect until media is loaded when the settings saved in the Media Wizard will be restored While printing is paused you can also pause swap ink see Pause Swap ping Ink on page 3 12 for instructions General Printing Tips Checking Jet Health The printer s automatic jet maintenance features gutter print ing spits service station wipes are designed to keep the inkjets from clogging In addition when AutoJet detects a missing jet it attempts to replace it with a working jet on the same or another printhead in Production and High Quality modes In this way printing occurs with all jets for maximum quality When you notice a decrease in print quality one or more inkjets may be clogged To recover clogged jets 1 Print a Prime Bars pattern to determine whether there are any missing jets see page 3 8 2 If there are any missing jets Purge n Wipe the printheads see page 3 8 or Print Jet Out Lines page 3 8 Run AutoJet page 4 3 or Manual Jet Mapping page 4 13 Repeat this process until all jets are working or substituted for another jet This process is summarized in Fig 3 1 below j Inspect Prime Purge n Wipe Print Prime Bars for missing all printheads or Bars lines jets single color Menu gt All Maintenance gt missing Jets Print Jet Out replaced Lines to view Map Out Missing Jets replaced jets Ei OR MANUAL JET MAPPING AutoJet Fig 3 1 C
98. inter is too heavy to be lifted safely by one person At least five persons are required to lift the printer Der Drucker ist zu schwer f r eine Person Mindestens 5 Personen sind erforderlich um den Drucker anzuheben 1 5 1 6 IUM BATTERY DEVICE THERE IS A DANGER OF EXPLOSION IF THE BATTERY IS INCORRECTLY REPLACED The battery must be replaced only by ColorSpan authorized personnel and must be replaced only with the same or equivalent type Dispose of this lithium battery device in accordance with local state or province and Federal or country solid waste requirements N WARNING THE PRINTER ELECTRONICS ASSEMBLY CONTAINS A LITH WARNUNG DIE ELEKTRONIK DES DRUCKERS ENTH LT EINE LITHIUM BATTERIE ES BESTEHT EXPLOSIONSGEFAHR WENN DIESE UNSACHGEM SS AUSGEWECHSELT WIRD Die Batterie darf nur durch einen ColorSpan authorisierten Technicker ausgewechselt werden und muss mit dem gleichen oder einem gleichwertigen Typ Batterie ersetzt werden Bitte entsorgen Sie die Lithium Batterie gem ss Ihren Landes oder Bundesgesetzen M WARNING Hotsurface Donottouch nn WARNUNG Hei nicht ber hren WARNING Moving parts Keep fingers away from media path WARNUNG Bewegliche Teile Verletzungsgefahr Operating Requirements Unpacking and Assembly Unpacking and Assembly AN This printer must be unpacked and installed only by a MacDermid ColorSpan Authorized Service Provider ASP If you need to relocate ship or store a
99. ional Calibration ensures that every working jet fires a pixel at precisely the same loca tion regardless of the carriage direction of travel AutoH2H head to head Calibration ensures that the printheads are in alignment relative to each other AutoJet Calibration locates and substitutes missing jets for working jets This is the same calibration per formed as when you press the AutoJet button on the Front Page screen see AutoJet on page 4 3 Full AutoSet runs AutoJet and Auto BiDi Calibration in sequence The minimum media width allowed for AutoSet is 18 inches 46 cm When you select a calibration the control panel prompts whether you want to perform a Purge n Wipe before con tinuing 5 Choose whether to perform a Purge n Wipe By recovering clogged printheads you reduce the number of jet substitutions required Press to initiate a Purge n Wipe The printheads are purged then wiped Press X to skip the Purge n Wipe Then the printer prints a test pattern then reads it and makes the necessary adjustments or jet substitutions 4 20 Auto Calibrations Calibration Summary These options allow you to print a summary of the Full AutoSet calibration or transmit calibration data to a log file on the print server AutoSet Summary when enabled a table of the results of the Full AutoSet calibration is printed after the AutoSet test patterns When you enable the AutoSet S
100. ions 3 On the Front Page screen press the Menu key to enter the menu system Press the V key repeatedly to highlight Maintenance Press the Y Menu In key display the Maintenance menu Press the V key repeatedly to highlight Load Ink in All Heads Press the X Menu In key Load media See Loading Roll Fed Media on page 3 16 for instructions 9 Recover missing jets See Checking Jet Health on page 3 7 for instructions 5 22 Extended Power Down and Restart APPENDIX A A C C X A A SSS Technical Specifications This chapter lists the printer s specifications and information about ordering supplies Technical Specifications A 1 Specifications Dimensions Assembled Weight Assembled Supported Media Widths Maximum Media Thickness Supported Printing Resolutions deter mined by RIP Maximum Print Speeds Bidirectional A 2 General DisplayMaker 7281 Without Tables Height 52 5 inches 133 4 cm Depth 33 0 inches 83 8 cm Width 135 7 inches 344 7 cm With One Input and One Output Table Height 52 5 inches 133 4 cm Depth 87 7 inches 222 8 cm Width 135 7 inches 344 7 cm Without Tables 380 pounds 172 kg With One Input and One Output Table 505 pounds 229 kg 24 73 inches 61 185 cm 0 25 inch 6 35 mm 600 x 600 dpi 600 x 300 dpi Billboard 600x300 650 ft 60 4 m hr Billboard 600x600 400 ft 37 2
101. is is unavoid able see Releasing a Pinch Roller on the next page 3 32 Loading Rigid Media Releasing a Pinch Roller Follow these steps to raise a single pinch roller if the edge of the media must be located under the roller or if the roller is unusable Raise the pinch rollers using the release lever Install the release block from the front of the printer into the desired pinch roller assembly One of the block s two indents should rest on the pivot Push the block back to the second indent to engage the back of the rail as shown below Lower the rollers to the desired tension The block can be stored in the disengaged position by raising the pinch rollers then pulling the block forward so that its first indent rests in the pivot Disengaged Stored Fig 3 16 Using the pinch roller release block Loading Rigid Media 3 33 3 34 10 11 12 13 14 Push the media up against the media alignment tool Make sure that the media is centered under the pinch rollers Avoid positioning either the left or right edge of the media under a pinch roller The printer will automatically locate the left and right edges Note If the media is not square opposite edges parallel with 90 degree corners you can align it with the fence on the input rear table First ensure that the fence is exactly perpendicular with at 90 degrees to the platen with a large framing carpenter s square and th
102. ither unspools from the bottom or the top of the roll see Fig 3 7 Loading Roll Fed Media dE ww er Online Media Offline amp Ink DisplayMaker Gator e Mm M es Autol et zur Purge 48 H Access Media Load Heads Wizard Media Loading Roll Fed Media Backward Ad Juance Media 10 11 12 below This enables you to print on either side of the media Fig 3 7 Media path from supply to takeup Ensure that the media is rolled onto the supply spool evenly without telescoping to one side Release the pinch rollers so that media can be fed through them freely Feed the media through the pinch rollers and onto the platen From the front of the printer pull the media web taut so that the media feeds in a straight line from the supply with no wrinkles This is easier with two persons If loading with one person first lower the pinch rollers walk around to the front of the printer release the pinch rollers then straighten the media Lower the pinch rollers onto the media On the Front Page screen of the control panel press the Load Media key The control panel presents a list of media types You can select a ColorSpan media from the list or select Custom at the end of the list to specify a new media The printer s Media Wizard feature stores a set of parameters for each media type which can be recalled and applied whenever you change media types See Media Wizard
103. iven printhead Clear all bad jets clears marks as good all jets cur rently marked as unusable Select an option and follow the corresponding procedure below Report Individual Bad Jets When you select Report Individual Bad Jets the control panel displays the following prompt Head 1 Press Proceed to report a bad jet 4 Press A and Y to select a head number then press Proceed The control panel displays a numeric keyboard that you can use to enter the number of the bad jet m JUINIsjeje A 1 15 lase El alela Fig 4 4 Numeric entry screen Enter the jet number then press the Enter key When you are finished entering jet numbers press the Esc key The control panel displays the head selection message again Press A and Y to select the next head number then press gt Proceed Repeat steps 5 through 7 for each head containing bad jets you want to report When you are finished reporting bad jets press x The control panel displays the previous menu Clear Individual Bad Jets When you select Clear Individual Bad Jets the control panel displays the following prompt Head 1 Press Proceed to clear a bad jet 10 Press A and Y to select a head number then press gt Proceed The control panel displays a numeric keyboard that you can use to enter the number of the bad jet Enter the jet number then press the Enter key Manual Calibrations Manual Calibratio
104. l Communications Com mission entitled How to Identify and Resolve Radio TV Interfer ence Problems 004 000 00345 4 Write to the U S Government Printing Office Washington DC 20402 This digital apparatus does not exceed the Class A limits for radio noise for digital apparatus set out in the Radio Interfer ence Regulations of the Canadian Department of Communica tions Normes de S curit Canada Le pr sent appariel num rique n met pas de bruits radio lec triques d passant les limites applicables aux appareils num riques de la Classe A prescrites dans le r glements sur le brouillage radio lectrique dict s par le Minist re des Communications du Canada Telecommunications Network Statement The ColorSpan VideoNet port on this device is not intended to be connected to a public telecommunications network Connec tion of this device to a public telecommunications network in a European Community Member State will be in violation of national law implementing Directive 91 263 EEC on the approx imation of laws of the Member States concerning telecommuni cation terminal equipment including the mutual recognition of their conformity Der VideoNet port ist nicht daf r vorgesehen an ein ffentliches Telefonnetz angeschlossen zu werden Der Anschlu dieses Ger tes an ein ffentliches Telefonnetz in einem Mitgliedstaat der EU verst t gegen nationale Gesetze zur Ausf hrung der Direktive 91 263 EEC die sich mit d
105. l contact the printheads with the correct amount of deflection See Fig 5 7 below Pin plate Printhead Fig 5 7 Service station height measured by wiper contact with the pin plate Calibrate the Service Station Replace Ink Filters Replace Ink Filters The control panel displays a Warning message on the control panel when 20 liters of ink has passed through the filters Replace all five the filters as a set Failure to replace the filters when recommended will eventually cause the filters to clog and prevent ink from reaching the printheads Have a paper towel ready to catch the small amount of ink or cleaning solvent that will spill out of some of the tubes and the filter itself as you disconnect them The reservoir shelf is designed to catch these spills for easier cleanup You may also want to wear protective gloves during this procedure 1 Disconnect the tube from the ink box 2 Remove the ink box from the shelf Use a Phillips screwdriver to loosen the filter clamp See Fig 5 11 for location Connector Filter Clamp Connector TA 3i DII E Fig 5 11 Filter connections 4 Unscrew the hose connectors from filter See Fig 5 11 for location Remove the old filter Install the new filter into the filter clamp 5 19 a w Ee Online Media Offline amp Ink Mode DisplayMaker Gator zire es Abo et Zur Purge i3 5 20 Sleep Ta Dan ee Access Media Load Heads
106. laceable one for each ink supply filters out impurities from the ink or cleaning solvent prior to being sent to the printheads Ink boxes each box holds 3 liters of ink or solvent cleaning solution Power connection inlet connects the printer to elec trical power Power outlet provides power to the optional auxiliary dryer Standby power switch places printer in standby mode to disconnect from power remove the power cord VideoNet port connects printer to print server Vacuum Pressure VP assembly provides vacuum and pressure to the OHS and printheads Parts Overview Parts Overview Index Description 27 28 29 30 31 Auxiliary 24 volt power jack to vacuum system accepts the supplied 24 volt DC power supply to the vacuum system which can be connected to a user sup plied UPS for temporary battery backup power in the event of a power failure or to a wall outlet for tempo rary power during maintenance that requires the rest of the printer to be powered down See Appendix A Tech nical Specifications for details Media supply and takeup system drives and pro vides tension to the media supply and takeup spools Media advance switch enables user to advance media forward or backward during loading Preheater warms the media for optimal printing Excess ink containers collects ink from the spittoons and service station The stopcock valve on the drain tube enables
107. llow cor rect media feed When the takeup tension is set to idle printed output is not automatically wound onto the takeup spool In this mode however a key appears on the control panel that enables you to wind the takeup spool manually If the end of the media is taped to the takeup core you can 3 45 3 46 use this key to control how tightly the media is wound onto the core Supply Out Detection roll fed for roll fed media the printer usually monitors the supply spool to detect when it runs out of media You can use this menu option to disable media out detection when you install the takeup spool pin release tool part number 0504334 see Takeup Spool Pin Release on page 3 26 for instruc tions for printing rather than to freely pull media from the supply Heater Temp Settings roll fed select a postheater setting from O to 10 or Custom to specify custom set tings Setting O sets all heaters to 85 F 30 C The preheater and platen heater maintain uniform sur face temperature across the printing area to control dot gain on various media The postheater dries prints before being rolled onto the take up spool If prints are not dry ing increase the postheater temperature if media is deforming or sticking to the postheater lower or turn off the postheater Platen Vacuum Control this To turns on the vac uum fans and T A and Y keys on the control panel Press A and Y to raise or lower the
108. m hr Production 600x300 400 ft 37 2 m hr Production 600x600 200 ft 18 6 m hr High Quality 600x300 200 ft 18 6 m hr High Quality 600x600 100 ft 9 3 m hr DisplayMaker 988I Without Tables Height 52 5 inches 133 4 cm Depth 33 0 inches 83 8 cm Width 159 inches 403 9 cm With One Input and One Output Table Height 52 5 inches 133 4 cm Depth 87 7 inches 222 8 cm Width 159 inches 403 9 cm Without Tables 430 pounds 195 kg With One Input and One Output Table 555 pounds 252 kg 24 98 5 inches 61 250 cm 0 25 inch 6 35 mm 600 x 600 dpi 600 x 300 dpi Billboard 600x300 700 ft 65 0 m hr Billboard 600x600 438 ft 40 7 m hr Production 600x300 438 ft 40 7 m hr Production 600x600 225 ft 20 9 m hr High Quality 600x300 225 ft 20 9 m hr High Quality 600x600 112 ft 10 4 m hr Unidirectional print speeds rigid medias only Approximately 1 2 the speed of the corresponding bidirectional modes Fine Text mode Approximately 1 2 the speed of the corresponding normal printing modes avail able in Production and High Quality modes at 600x600 dpi Specifications Electrical Power Power used 200 240VAC 50 60 Hz 14 8 Amps Required electrical circuit 220 VAC 20 Amps with NEMA L6 20R locking wall receptacle North America and Japan OR 220 VAC 16 Amps single phase with IEC 60309 wall receptacle Europe yy 5 F NEMA L6 20R IEC 60309
109. mmended Maintenance When not printing while the printheads are uncapped a small amount of ink is expelled spit periodically into the spittoons which drain into the excess ink containers See Checking Jet Health on page 3 7 for instructions on using Purge n Wipe and AutoJet See AutoTune on page 4 4 for instructions on schedul ing Purge n Wipe and AutoJet to run automatically If the power must be removed for a brief period of time leave the carriage over the service station not the capping station to allow the ink which will no longer be held inside the printheads by the vacuum pressure system to drain into the excess ink reservoir Power up the printer as soon as possible and cap the printheads if the printer will be idle for 4 hours or more Cap the printheads to prevent drying and conserve ink idle spit is sus pended during capping See Capping the Printheads on page 3 13 for instructions This capping period can successfully extended if every four days the print heads are uncapped purged to recover missing jets prime bars or other print is made and recapped For best results do not allow the printer to remain capped for more than 4 days oth erwise extensive cleaning of the printheads may be required If the printer must remain capped longer than four days such as during a long holiday weekend for shipping or storage follow the applicable procedure below Cap the printheads as described in Capping t
110. n supports the ink sup ply tubes that carry ink from the ink supplies to the printheads power and electrical signal cables Platen supports the media under the printheads during printing warms the media in the print zone includes vacuum to hold the media against the platen Printhead carriage carries the printheads digital imaging sensor and photodiode across the length of the platen Digital image sensor on carriage not shown detects the location of printed pixels for precise align ment of the printheads enables the automatic replace ment of poorly printing ink jets with substitute jets Photodiode on carriage not shown enables the creation of color transforms without an external spec trophotometer requires print server support and the linearization of existing transforms Spittoons located at both ends of the platen receives ink spits that keep the printheads at their optimal performance AutoClean Service station catches purged ink from the printheads wipes the printheads with clean ing solvent Wipers are automatically cleaned and cleaning solvent applied before wiping Ink is periodi cally spit when idle to keep the inkjets working Ready for Refill LEDs an LED illuminates when its corresponding profiler indicates that the ink box should be replaced with a full one Control panel displays messages and allows control of certain printer operations Includes a
111. n installed printer contact your reseller or MacDermid ColorSpan Technical Services for assis tance Caution To avoid damaging the carriage bearings when mov ing the printer move the carriage away from the rail by reinstalling the shipping blocks This is recom mended even if moving the printer down the hall or between rooms To ship or relocate the printer a longer distance contact MacDermid ColorSpan Technical Services for instructions 1 7 Workflow Overview Power Up the Printer Daily Startup DisplayMaker Gator Media amp Ink DisplayMaker Gator 1 8 Turn on the power switch to observe the typical power up sequence The control panel backlight illuminates Move the contrast lever located to the right of the control panel screen up and down until the control panel graphics and messages are eas ily visible The printer runs a series of self tests and reports any errors it finds The printhead carriage moves to the service station The control panel prompts you to load media You may load media or skip loading media for now See Loading Roll Fed Media on page 3 16 for instructions The control panel displays the status screen Uncap the printheads for instructions see Uncap the Print heads on page 3 14 This procedure includes while the carriage is still at the cap ping station wiping the printheads with SolaChrome HR Cleaning Solvent using a 100 polyester Class 100 clean
112. n page 3 47 Platen Vacuum Control turns on the vacuum fans then allows you to raise or lower the fan speed Raise the speed if the media is rising off the platen lower the speed if the Menu Menu MEDIA WIZARD MEDIA WIZARD media is buckling or wrinkling Turn off the vacuum for light weight media such as paper or fabrics Drying Delay a drying delay slows throughput media advance speed to allow prints to dry more thoroughly Select the shortest delay that permits complete drying Dryer Fans specifies whether the optional auxiliary dryer fans will run during printing Excess Ink Sensor enables you to disable the excess ink sensor if it is malfunctioning or enable it after it has been replaced When the sensor in the excess ink reservoir under the OHS indicates that the reservoir is full it generates an Action message on the control panel and printing cannot proceed Do not disable the sensor unless a malfunction erroneously prevents printing Capping Station Sensor allows you to disable the cap ping station sensor if it is malfunctioning or enable it after it has been replaced Media Out Sensor allows you to disable the input table s media out sensor if it is malfunctioning or enable it after it has been replaced Use care when printing with this sensor disabled to avoid printing on the platen or striking the car riage against the media Gutter Settings determines the
113. n use the fence on the input rear table as a guide after squaring it to the platen Then use the procedures described previ ously to ensure enough overprinting to account for the shape of the sheet If insufficient overprinting occurs the sheet may need to be trimmed for a bleed effect Fig 3 22 Feeding a non square sheet Document Design Media size 48x96 inches 4x8 feet Bleeds Full bleed Document size in application software 48 5 inches x 96 0 inches to include an overprint of 0 25 inches on the left and right edges the printer will not overprint the leading edge to avoid feeding the media over wet ink on the platen Media Properties The operator selects a flat sheet of 4x8 foot media with opposite sides parallel and all four corners at 90 degree angles The operator attaches a trailer that is 6 5 inches 16 5 cm long and 48 inches wide to the trailing edge of the media applying the adhesive tape to the back side 3 41 3 42 Printer Setup The operator applies colored masking tape to the platen where the right and left edges of the media will feed to pre vent overprinting onto the platen The operator sets the head height over the media The operator configures the following options on the printer control panel Trailing edge 3J 9 Trailer ee Left overprint p e Leading edge Nominallprint area Menu gt Printer Settings gt Margin
114. nfigured correctly See your system admin istrator for assistance Troubleshooting Checklist The cable between your computer or network and the print server may not be securely connected at both ends Refer to the print server manual for more information Your computer may not be working properly Run an application that you know works correctly and print to be sure The computer s port may not be working properly Print to another output device that you know works correctly and is not connected to the print server to check this There may be another error condition reported by the print server 5 Is the print quality good YES Then the problem is not covered in this checklist Contact MacDermid ColorSpan Technical Services NO The following could be the problem Banding or general poor image quality the print heads may need to be calibrated see Chapter 4 Cali brating the Printer One or more ink jets may be clogged or not firing see Loading Roll Fed Media on page 3 16 The media advance may need to be recali brated see Media Feed on page 4 6 Verify that the printhead carriage is at the proper height see Set the Printhead and Camera Height on page 5 12 Verify that the service station is calibrated see page 5 17 Inaccurate color or under or over saturated output the wrong color profile may be selected at the print server or RIP Refer to the documentation that accom
115. ns 12 13 14 15 When you are finished entering jet numbers press the Esc key The control panel displays the head selection message again Press A and Y to select the next head number then press gt Proceed Repeat steps 11 through 13 for each head containing bad jets you want to clear When you are finished clearing bad jets press x The control panel displays the previous menu View Current Bad Jets 16 17 18 19 When you select View Current Bad Jets the control panel displays the following prompt Head 1 Press Proceed to view bad jets Press A and Y to select a head number then press gt Proceed The control panel displays a message that lists the bad jets by number Press to return to the head selection screen Repeat steps 16 and 17 for each head you want to check for bad jets When you are finished clearing bad jets press X The control panel displays the previous menu Clear All Bad Jets When you select Clear All Bad Jets the control panel dis plays the following prompt Are you sure you want to clear ALL reported bad jets Press X to cancel this function or Press gt Proceed The control panel displays this message Do you want to clear the hard bad jets Press No to clear the soft bad jets only Press Yes to clear both the hard and soft jets 4 18 20 The control panel displays this message All reported bad jets have been
116. nt Mode key eo OG ress gt The print mode menu appears with these options Q B E e Offline amp Ink eg Gator Mode Jet Replacement Be e Billboard None Be aJ nme urge FE a a A XE a Production Standard og E m gt ue d When configured for rigid printing these unidirectional print modes are also available Mode Jet Replacement Billboard Unidirectional None Production Unidirectional Standard High Quality Unidirectional Maximum Fine Text mode is also available in Production and High Quality modes Fine Text prints at half the normal head speed to improve the output quality of fine text and line art 3 4 Selecting a Print Mode Selecting a Print Mode 2 3 Press the A and Y and keys to highlight a print mode Press the V Set key to select the print mode 3 5 General Printing Tips 3 6 See Important Operating Notes on page 1 3 for impor tant information on operating the printer Before printing on vinyl media that has been loaded on an idle printer overnight or longer advance the portion of the media that has been resting on the preheater prior to the platen past the print zone In this situation the vinyl tends to retain the shape of the preheater making it more likely that the printheads or carriage will strike the media To pause printing press the Pause button on the control panel While printing is paused you can change the Heat ers Vacuum and Dry Delay sett
117. o failure analysis to confirm the cause of failure The final determination of warranty applicability will be provided by this analysis For more information about warranty claims contact ColorSpan Technical Services see page ii for contact information Warranty Claims B 5 B 6 Causes that are covered by the manufacturer s warranty Manufacturing defect when a flaw in materials or work manship causes a printhead to fail the failure will be cov ered by the manufacturer s warranty Causes and or circumstances that are not covered by the manufacturer s warranty Third party hardware or software Damage caused by accident abuse misuse including dam age resulting from head strikes or use of non approved sup plies misapplication relocation of product without approved procedures failure to perform user maintenance as defined in the User Manual or contamination of the ink sup ply due to improper handling of the ink or ink system Printheads which have not been properly maintained as defined in the User Manual and printheads with jet outs that AutoJet is able to substitute in Production print mode Service including upgrades and expansions performed by anyone who is not a ColorSpan Authorized Service Provider Modification of the product without the written permission of ColorSpan Product on which the ColorSpan serial number has been removed or defaced or for which you cannot provide proof of purchas
118. ob before printing if a Purge n Wipe has not been performed for a specified amount of time Automated printhead maintenance to keep individual inkjets from drying out the printer periodically spits a small amount of ink and performs a Purge n Wipe cycle Capping station manually operated capping station pre vents drying out of printheads when idle The printer senses the position of the capping pad to prevent carriage move ment while capped or to prevent the carriage from moving to the capping station if the pad is raised Off Head System OHS 3 liter bulk ink boxes with profil ers supply the printheads The printer displays an alert when an ink box should be replaced Onboard vacuum pressure VP system provides vac uum to maintain negative printhead pressure and air pres sure to purge the printheads or ink tubes without removing them from the printer AutoSet M calibration uses a high resolution digital imag ing sensor to automatically align printheads bidirectionally for precise positioning of ink jet pixels and runs AutoJet AutoJet calibration compensates for lost or misfiring jets by locating them and using substitute jets without slowing printing speed AutoTune scheduling runs Purge n Wipe and or Auto Jet at user defined intervals for highest quality during unat tended printing Optionally if unsubstituted non working jets are found printing stops until the problem is corrected
119. or further information about Actions and Warnings See Warnings amp Actions on page 2 16 for further information about this menu option Audible Alarm enables and disables the audible alarm beep that sounds with Warning and Action messages Localization allows you to select units of measure metric or English time format 12 hour or 24 hour and date for mat YYYY MM DD MM DD YYYY and DD MM YYYY Head Height moves the printhead carriage over the platen so you can adjust the head height See Set the Printhead and Camera Height on page 5 12 for instructions Service Station allows you to set the alignment and height of the service station wipers For instructions see Calibrate the Service Station on page 5 17 Automatic Eject cut sheet printing only when enabled the sheet is automatically ejected at the end of the print job When disabled the next job s will print on the same sheet until there is no more room to print 2 14 Maintenance Idle Spits when the printer is idle it automatically spits a small amount of ink into the service station to keep the ink jets open and working To reduce the amount of ink con sumed during idle spitting you can set the operation to Medium or Low To ensure that the printheads are always at maximum readiness use the High setting Low Ink Warning defines the amount of ink remaining in the ink box supply at which the printer will dis
120. pa nies the print server or RIP Inaccurate color or lack of detail one or more ink jets may be clogged or not firing see Loading Roll Fed Media on page 3 16 Media buckling or media feed problems the wrong media could be selected in the Media Wizard see Media Wizard on page 3 44 The printer may not have been installed squarely or securely on the stand see Unpacking and Assembly on page 1 7 The media may not have been loaded squarely see Load ing Roll Fed Media on page 3 16 Troubleshooting Checklist B 3 Head strike if the printhead is striking the media check how the media is tracking from the supply spool to the takeup spool The sides of the media should be parallel to the sides of the printer with no wrinkling or buckling If necessary reload the media See Loading Roll Fed Media on page 3 16 for instructions Also check the Media Wizard to see whether the correct media is selected see Media Wizard on page 3 44 Head strikes may indicate that the printhead height is too low see Set the Printhead and Camera Height on page 5 12 for instructions If head strikes become a recur frequently contact MacDermid ColorSpan Technical Ser vices for an edge retainer that can be attached to the printer Troubleshooting Checklist Warra nty Claims The printer is covered by a manufacturer s limited warranty part number 0700025 which includes the printheads The p
121. play a low ink message on the control panel Printer Name displays a keypad to change the printer name displayed on the control panel and RIP or ColorSpan Print Server Alternatively the printer name can be changed from the ColorSpan Print Server Restore All Defaults restores all Printer Configuration set tings to their factory default values and zeroes all registra tion data After running this option all calibration values must be reestablished by running AutoSet or manual calibra tions Access Printheads moves the printhead carriage out from the service station to the capping station This is the same functionality as the Access Heads button on the Front Page Purge A Color purges the four printheads of a single color rather than all sixteen printheads This is helpful when recov ering stubborn jet outs Print Jet Out Lines prints a version of the prime bars see page 2 6 in which missing jets that are replaced are marked with a black square Fill Service Station fills the service station reservoir with cleaning solvent Reset Reservoir Filters after you replace the ink reservoir filters select this option to reset the ink counts to zero See Replace Ink Filters on page 5 19 for instructions Respool Media this option enables you to respool media from the supply directly to the takeup in either direction without passing over the heaters or platen Clean Grit Rollers advances
122. pool and reload media supply and or takeup page 3 8 The printer cannot detect a print Connect cable turn on server add ser ver printer to server The vacuum pressure of the heads is Call your Authorized Service Provider too low Diagnostics Code Message Table B 1 Actions and Warnings Cause W VS 2 Vacuum Pressure Too High The vacuum pressure of the heads is too high W VS 3 Vacuum Pressure Not Recov The vacuum pressure of the heads is ering Diagnostics not recovering after an air purge What to Do Call your Authorized Service Provider Check vacuum pressure system to ensure it is working properly and check vacuum tubing for leaks You can obtain help using your MacDermid ColorSpan product from a variety of sources This section shows you where to seek help and introduces you to the support available to registered MacDermid ColorSpan customers World Wide Web http www colorspan com E mail support colorspan com If All Else Fails Call MacDermid ColorSpan Technical Services directly Be ready to supply the technician with details about your system s config uration and details about the problem including the exact word ing of any error messages that appear The Technical Services telephone numbers appear on page ii the copyright page of this manual Index Index 1 600x300 printing 1 9 600x300 resolution 3 4 600x600 resolution 3 4 A Access Heads 2 7 5 9 Access Printheads
123. ports the supply and takekup spools Fig 3 5 Spool support Spool sleeve slides over the spool with locking collets Fig 3 6 Spool sleeve Loading Roll Fed Media 3 17 3 18 2 Ensure that the fixed collet is properly located with the screw tightened into the inner hole on the supply spool using the outer hole would prevent the spool from being installed The side of the spool with the fixed collet is the home side closest to the printer s electronics box Remove the moveable collet from the spool Note The 3 inch collets have left handed threads that self tighten during printing Turn the locking ring clock wise to loosen and counterclockwise to tighten Optionally if using large rolls of narrower media install the spool support and or sleeve see Fig 3 5 and Fig 3 6 Load the media roll onto the spool Load and secure the moveable collet against the end of the media roll The moveable collet does not have a metal pin Push the col let into the media core and on 3 inch collets turn the locking ring counterclockwise to secure it in place From the rear of the printer load the media and spool into the printer s supply spool holder Press the home side of the supply spool into the home side holder on the left from the rear of the printer then swing the far side of the supply spool into the far side holder on the right You can load the supply spool so that the media e
124. properly tensions the system See Loading Roll Fed Media on page 3 16 for instructions Unload visible when the supply and takeup are loaded detensions and enables you to unload the supply and takeup system See Unloading and Cutting Roll Fed Media on page 3 25 for instructions Reload visible when printer was loaded with media enables you to load another roll or sheet of the previously printed media with the same settings without stepping through the media load process ATTN Attention blinks on the control panel when the printer detects an error condition potential error condition or when you make a change that requires recalibration or other action to ensure best print quality See User Assis tance on page 2 3 for further details 2 7 Navigation Keys 2 8 The following table shows you how to move through the menu system and perform printer control functions Key gt Vi Bile C gt gt X Ca Rag ME Y v gt Description Display Menu displays the printer menu Menu Up Down moves the menu highlight up and down the menu Menu Top Bottom moves the menu highlight to the top or bottom for the menu Menu Out moves to the next higher menu in the hierarchy Menu In selects the highlighted menu option Back Forward moves between pages or screens or selects between other options Proceed initiates the selected function Help di
125. r is bad or the heater Bad thermister reading detected on the preheat heater board or I O board is malfunctioning or there is a cable problem B 8 Diagnostics Code Message W HT 49 50 Heater Bad Reading W HT 100 Heater Warming W HT 101 Heater Cooling W HT 102 103 Heaters Disabled IS Ink Sensing A IS 1 2 3 4 color Out of Ink A IS 25 26 27 28 color Missing Ink Profiler A IS 31 32 33 34 Incorrect color Profiler A 1S 38 Profiler Setup Error A IS 43 44 45 46 47 Invalid color Profiler A IS 61 62 63 64 color Air Sensor Failed A IS 65 66 67 68 color Ink Sensor Failed A IS 71 72 73 74 color Printheads Out of Ink A IS 75 Ink System Disabled A IS 76 77 78 79 Ink System Disabled Diagnostics Table B 1 Actions and Warnings Cause Bad thermister reading detected on the postheat 1 heater 49 or postheat 2 heater 50 The heaters are warming The heaters are cooling The printer is unable to control heater temperatures The ink box indicated is out of ink The ink color indicated is missing its profiler The profiler in the indicated slot is the wrong color or ink type Ink profilers are installed in the wrong docking station positions The profiler indicated is invalid The air sensor on the printhead indi cated may be not functioning The ink sensor on the printhead indi cated may be not functioning T
126. rature and relative humidity within specifications see Specifica tions on page A 2 Optimal printing and drying occurs within these ranges The newly received printer ink and media should be allowed to stabilize for several hours in its operating environment prior to unpacking installation and assembly especially during seasons of hot or cold weather Failure to do so could result in printing problems The printer uses solvent based inks The printer does not include an integrated exhaust hood or shielding for collect ing the volatile organic compound VOC emissions from the inks and cleaning solvent The owner is responsible for venti lation and VOC recovery as required by local regulations Operating Requirements Important Operating Operating Requirements Notes Connection kits are available from MacDermid ColorSpan to vent VOC emissions to the customer s exhaust system or VOC recovery equipment Consult your MacDermid ColorSpan reseller for details Store media and ink in an area with similar temperature and humidity conditions as the printer Locate the printer close enough to the print server RIP so that they can be connected with the required cable Locate the printer on a flat level floor Locate the printer where its normal operating noise will not disturb quiet work areas DO NOT install the printer near humidifiers refrigerators fans water faucets heaters or similar equipment DO NOT install
127. rings Moisten a cotton swab with isopropyl alcohol or water place it against the left side of the bearing and manually push the carriage to the left Then place the swab against the right side of the bearing and manually push the carriage to the right Repeat once or twice Remove any large dust particles you see Clean the left and right inside bearings Insert a moistened cotton swab into the bearing cleaning window and clean the bearing by manually pushing the car riage to the left and right Repeat once or twice Remove any large dust particles you see Press the Proceed key to return the carriage to the home position The top surface of the encoder strip should be cleaned as needed approximately monthly under typical service with a lint free cloth moistened with SolaChrome HR cleaning fluid After cleaning wipe the top surface of the encoder strip with a new lint free cloth moistened with isopropyl alcohol To check the condition of the encoder view it with a piece of white paper held underneath it The encoder strip should be cleaned if the encoder index marks fine black lines that are perpendicular to the length of the encoder strip are not clearly visible Clean the Rail and Bearings Empty Excess Ink Empty Excess Ink Ink or cleaning solvent that has been expelled spit for ink jet maintenance or from a purge operation drains from the spit toons and service station areas to excess ink containers Wh
128. rnings Cause What to Do Defective software Call Authorized Service Provider for updated software Defective electronics assembly Call Authorized Service Provider for replacement electronics More than eight heads have default Call Authorized Service Provider to voltages set voltages The diameter of the media supply is Set the supply tension to idle and too small The printer supports a min continue printing imum diameter of 3 inches under ten sion The diameter of the media supply is Reload the supply with a smaller too large for the capacity of the sup amount of media see page A 2 for ply amp takeup motors maximum diameter Media out detection using the supply Re enable Supply Media Out Detec roll is disabled tion under Printer Settings Service wipers were not able to move Use Home Service Wipers in the to their home position or the service Service menu to move the wipers wiper home sensor is not working home If the problem persists con tact your service provider The media takeup spool is full Unload the takeup spool and reload media page 3 25 The takeup motor has stalled Check for mechanical interference or binding overloaded spool out of balance spool or failure in electronics or motor The takeup core is too small Only Unload the takeup replace the core 3 inch cores can be used and collets with 3 inch size core and collets The media takeup spool is almost full Unload the takeup s
129. s W PC 2 Media Replaced Media advance accuracy may need to Run Media Feed Calibration if media Recalibrate be recalibrated type was changed page 4 6 W PC 3 Head Height Changed Change in head height has invali Run AutoSet page 4 20 Recalibrate dated calibration W PC 4 Jets Not Replaced Not all missing jets could be replaced Prime clean printheads or choose a in the current print mode higher quality print mode page 3 4 W PC 6 Uncalibrated Pass Mode Print mode selected has media Run Media Feed Calibration advance rate different from the cali page 4 6 brated advance rate which may cause banding WC PC 7 Platen Width Not Known Measurement was reset or not per Restart printer to measure platen formed width SM System A SM 1 Printer Not Personalized Defective electronics assembly Call Authorized Service Provider for replacement electronics Diagnostics B 11 Code Message A SM 2 Invalid Software W SM 1 Printer Not Reset For Shipping W SM 2 Head Voltages Not Set SP Supply A SP 1 Supply Too Small A SP 2 Supply Too Large W SP 1 Supply Media Out Detection Off SS Service Station A SS 2 Could Not Move Wipers Home TU Take Up A TU 1 Takeup Full A TU 2 Takeup Stall A TU 4 Takeup Too Small W TU 1 Takeup Too Large VN VideoNet W VN 1 VideoNet Connection Not Detected VS Vacuum Sensing W VS 1 Vacuum Pressure Too Low Table B 1 Actions and Wa
130. s by the operator during these tests could result in substandard output See Manual Calibrations on page 4 8 for instructions Manual Bidi Registration Manual X Head Registration Manual Jet Mapping the manual version of AutoJet 999 Jet Status Lines prints the Manual Jet Mapping pat tern without running the calibration Default Registration Data Auto Calibrations see Auto Calibrations on page 4 20 for instructions Auto Bidi Calibration ensures that every working jet fires a pixel at precisely the same location in both direc tions of travel Auto H2H Calibration aligns the printheads relative to each other AutoJet Calibration locates and substitutes missing jets for working jets Full AutoSet runs AutoJet and AutoBiDi in sequence Menu 2 9 Printer Settings MEDIA WIZARD MEDIA WIZARD MEDIA WIZARD MEDIA WIZARD AutoTune schedules jet maintenance to run automatically after a certain number of prints have printed See Auto Tune on page 4 4 for instructions AutoRecover performs a Purge n Wipe at the start of a print job before printing if a Purge n Wipe has not been performed for a specified amount of time Calibration Summary prints summary information with the AutoSet calibration test patterns or transmits registra tion or jet data to a log file on the print server Auto Cali brations on page 4 20 for details Configure
131. splays a summary description of the high lighted menu options Pause Resume pauses or resumes printing during a calibration Cancel cancels the current menu function or choice Yes No indicates a Yes or No Continue error screen proceeds to the next step in a troubleshooting dialog Ignore error screen specifies ignore in a trouble shooting dialog Retry error screen specifies retry in a trouble shooting dialog Reboot Printer error screen specifies restart printer in a troubleshooting dialog Information error screen displays further informa tion about the error Navigation Keys Menu The menu has these main sections Calibrate Printer see below Printer Settings page 2 10 Maintenance page 2 14 Service Printer page 2 15 User Diagnostics page 2 15 999 Warnings amp Actions page 2 16 shown in Expert Messages Mode only This section explains each of the functions on the printer menu See Menu Tree on page 2 17 for a listing of all menu options Calibrate Printer For details on these options see Chapter 4 Calibrating the Printer Media Feed eliminates banding between print swaths stitch banding by calibrating media advance See Media Feed on page 4 6 for instructions Manual Calibrations allows you to calibrate the printer visually without the printer s digital imaging sensor Inaccu rate judgment
132. supply out detection feature Menu gt Printer Settings gt Supply Out Detection You may want to do this if back tension is causing the media to buckle or causing other media feed prob lems Unloading and Cutting Roll Fed Media Respooling Media Ja I Iw ww Ee Oeo Online Media Print Offline amp Ink Mode DisplayMaker Gator sive M mx M eo Autol et un Purge Su gt en Co Access Media Load x leen Heads wizard Media Respooling Media FN Backward Advance edia Me The printer can respool media from one cardboard core to another You may want to do this if The media was not taped to its core by the media vendor which makes tensioning impossible You want to change the direction that the media unwinds from the core printed side out vs printed side in Supply Takeup Fig 3 12 Respooling load options Load media on the supply Load an empty cardboard core on the takeup Slowly pull media from the supply spool to the takeup Do not pull the media faster than the supply motor releases it Route the media directly to the takeup Do not route it over the platen and heaters Ensure that the right and left edges of the media web are perpendicular to the sides of the printer that the tension appears uniform across the media web and that the media is not unrolling unevenly telescoping from the supply spool Tape the end of the media to the takeup core Press the Z
133. t heads then wipes them in the service station to help recover missing jets Print a prime bars pattern to verify jet recovery See Checking Jet Health on page 3 7 for instructions Sleep visible when heads are not capped verifies that the Capping pad is disengaged in the lower position the printer turns off the heaters detensions the media and dis ables the OHS When you manually engage the capping levers the capping pad sensor is detected and the control panel disables most functions except for Wake See Cap the Printheads on page 3 13 for instructions Wake visible when the printheads are capped the opera tor lowers the capping pad then selects this option to restore the printer from standby mode enable the OHS and move the printhead carriage back to the service station at the far right end of the printer When the printheads are uncapped the control panel is fully functional See Uncap the Print heads on page 3 14 for instructions Access Heads moves the printhead carriage out from the service station to the capping station This is the same func tionality as the Access Printheads option on the Mainte nance menu Media Wizard provides direct access to the printing parameters stored for the currently loaded media see Media Wizard on page 3 44 for details Load visible when the supply and takeup are unloaded enables you to load media on the supply and or takeup and
134. t slot is not a cleaning solvent profiler or is the wrong type Cleaning solvent profiler is not valid What to Do Fill the affected printheads with ink See Set the Printhead and Camera Height on page 5 12 Reconnect the ink sensor Contact your Authorized Service Provider or MacDermid ColorSpan Technical Support for instructions Reconnect the air sensor Contact your Authorized Service Provider or MacDermid ColorSpan Technical Support for instructions Reconnect the pump and restart the printer Empty and dispose of the excess ink and solvent according to local regula tions Check docking station cables Restart the printer If the problem persists contact your Authorized Ser vice Provider or Technical Services Reseat the profilers and ensure they are inserted correctly Check OHS board cable connections If the prob lem continues after resetting this error contact your Authorized Ser vice Provider or MacDermid Color Span Technical Support Replace the ink box soon Replace the cleaning solvent box soon Install the cleaning solvent profiler Purging will be disabled until you replace the cleaning solvent box Replace the reservoir filters See Replace Ink Filters on page 5 19 for instructions Replace the profiler with appropriate cleaning solvent profiler Replace cleaning solvent profiler Diagnostics Table B 1 Actions and Warnings Code Message Cause What to Do
135. tatus 2 5 Media Feed 4 6 Media feed number 4 6 4 7 Media Measure Type 2 12 Media path 4 22 Media spool 3 16 Media width 1 16 Media Wizard 2 7 3 44 Menu 2 2 2 6 Menu tree 2 17 MFN 4 6 4 7 O Off head system OHS 1 15 Online offline button 2 4 Ordering supplies A 6 Index 4 P Parts overview 1 10 Pause printing 3 6 Pause swapping ink 3 12 Periodic maintenance 5 2 Pinch rollers 1 12 releasing 3 33 Platen Vacuum Control 2 10 Power down and restart 5 21 Prep for Storage Shipping 2 15 5 21 Prime bars 2 6 3 8 Priming 3 8 Print Jet Out Lines 2 14 Print Menu Tree 2 16 Print Mode 2 6 3 4 Print Position 2 13 Printheads capping 3 13 setting height 5 12 uncapping 3 14 Printheads Procedures 2 15 Printing 600x300 printing 1 9 Printing tips 3 6 Production mode 3 4 Purge A Color 2 14 Purge n Wipe 2 7 3 8 Q Quality Check 2 13 4 5 Ready screen 2 2 Reload media 2 7 3 36 Reset Reservoir Filters 2 14 Resolution 3 4 Respool Media 2 14 3 27 Restore All Defaults 2 14 S Safety warnings 1 5 Service Station doctor blade cleaning 5 11 Service station 2 13 calibration 5 17 Sleep mode 2 7 3 13 SolaChrome HR Cleaning Solvent 3 2 3 3 SolaChrome HR Solvent Ink 3 2 3 3 Space Between Prints 2 12 Specifications A 1 Standby Wait 2 13 Status media amp ink 2 5 Status screen 2 6 Stiff Roll Fed Media Handling 2 13 Supplies and accessories A 6 T Takeup spool pin release 3 26 Takeup Tension 2 10 3
136. ten zone 6 left platen heater 7 left platen zone 8 preheat heater 9 postheater 1 10 or postheater 2 11 A heater has been turned off because wiring heater thermistors Wait for the heater to cool If the tem 31 Heater Too Hot W HT 40 47 42 43 Heater Bad Reading its temperature has exceeded its operational specification middle platen heater 21 23 middle platen zone 24 right platen heater 25 right platen zone 26 left platen haeter 27 left platen zone 28 preheat heater 29 postheater 1 30 or postheater 2 31 Bad thermister reading detected on the middle platen heater 40 42 or middle platen zone 43 perature does not decrease unplug the printer then restart it and lower its temperature setting page 3 47 Call your service provider to check wiring heater thermistors The thermister is bad or the heater board or I O board is malfunctioning or there is a cable problem W HT 44 45 Heater Bad Reading Bad thermister reading detected on the right platen heater 44 or zone 45 The thermister is bad or the heater board or I O board is malfunctioning or there is a cable problem W HT 46 47 Heater Bad Reading W HT 48 Heater Bad Reading Bad thermister reading detected on the left platen heater 46 or zone 47 The thermister is bad or the heater board or I O board is malfunctioning or there is a cable problem The thermiste
137. the drain tube to the container Open the stopcock valve on the drain tube S 09 oe ee Service station reservoir only reconnect the sensor cable to the float sensor 5 7 Printhead Maintenance 5 8 The printer uses air pressure to both fill and evacuate ink and cleaning solvent from the printheads The following functions are available from the menu at Maintenance Printhead Procedures Cleaning Solvent Soak empties the printheads of all ink fills all heads with cleaning solvent and prompts you to cap the printheads Reverses this process after the printheads have soaked for example overnight See page 5 10 for instructions Prep for Storage Shipping empties the printheads of all ink fills all heads with cleaning solvent then empties the printheads See Extended Power Down and Restart on page 5 21 for instructions Load Ink In All Heads when installing ink for the first time or when restarting the printer after an extended power down period this function fills the empty printheads with cleaning solvent empties the printheads and fills the heads with ink See Extended Power Down and Restart on page 5 21 for instructions Fill Heads with Solvent fills the printheads with cleaning solvent one color set of four printheads at a time Should only be done with empty printheads Fill Heads with Ink fills the printheads with ink one color at a time Should only be done with empty printh
138. the printer in areas where the temperature changes abruptly such as near air conditioners or in the path of direct sunlight DO NOT expose the printer to flames or dust DO NOT POWER DOWN THE PRINTER Constant vacuum at the printheads is required to prevent ink from flowing from the printheads when not printing even when the printheads are capped If the printer must be powered down for ship ping empty and cap the printheads See Extended Power Down and Restart on page 5 21 or apply auxiliary 24 volt power If the printer has been idle for more than several minutes press the Prime Bars button on the printer control panel to check for missing inkjets To recover missing inkjets see Checking Jet Health on page 3 7 If the printer will be idle for more than one hour cap the printheads to conserve ink When the printheads are uncapped and the printer is not printing the printheads periodically expel a small amount of ink into the excess ink reservoir to keep them working Capping the Printheads on page 3 13 for instructions To wipe the printheads use only ColorSpan cleaning solvent applied with a 100 polyester Class 100 cleanroom wipe See Cleaning Clogged Ink Jets on page 5 9 for instruc tions DO NOT USE ISOPROYPL ALCOHOL 1 3 1 4 To cap the printheads use only SolaChrome Printhead Cap ping Film Damage to printheads resulting from the use of poorly performing plastic films is not covered by
139. the removal of the container for ink dis posal while preventing ink from draining from the tube Caution Open the valve after replacing the con tainer or waste ink will eventually over flow into the printer Auxiliary Dryer The available auxiliary dryer option is an array of fans mounted on a swivel for use during rigid sheet fed and roll fed printing It provides enhanced drying performance for heavy coverage and high speed printing It receives power from a power outlet on the printer s electronics box and is switched on and off auto matically by the printer s software Refer to the Auxiliary Dryer Installation and Operation Instruc tions part number 0700051 for installation and usage instruc tions Roll fed to takeup Fig 1 3 Dryer fan positions 1 14 Parts Overview Special Features Special Features Printheads Ink System Calibration The printer has many advanced features to help you produce the best printed output with the least effort Micro Quad printheads sixteen 600 dpi 25 picoliter piezoelectric printheads four per color AutoClean service station a motorized service station that wipes the printheads with cleaning solvent automati cally to keep all jets firing properly Purge n Wipe combines an air pressure purge with a cleaning solvent wipe of the printheads to recover clogged jets AutoRecover performs a Purge n Wipe at the start of a print j
140. thead Jet Statistics VideoNet Status VideoNet Connection Carriage Motion Calibration Vacuum Pressure Warnings and Actions List table of all actions and warn ings with cause and recovery This is an abbreviated version of the table Actions and Warnings on page B 8 Error History Log Error History Warnings amp Actions Print Menu Tree When in Expert mode active Warnings Changes and Actions can be displayed by selecting Warnings amp Actions from the menu since Warnings will not cause the ATTN icon will appear in Expert mode This option does not appear in Novice mode See User Assistance on page 2 3 for further information about Actions and Warnings and the table beginning on page B 8 for a list of recovery procedures See page 2 13 for a description of the Expert Novice Messages mode This option prints all of the menu options in a hierarchical tree format Menu Menu Tree Front Page Print Media amp Ink SEI Status Select Print Mode Online Offline now Backward Menu DisplayMaker Gator OEC he ix N a au us Purge Autojet Sleep Wake Load Access Heads Media Unload Wizard REDAN Pad Menu Tree Advance Media Print Prime Bars Purge Printheads Attention Load M ew Media Reload Media Menu This menu tree reflects version 3 11 of the embedded printer software Refer to the Release Notes for more recent versions Calibrate Printer Media Feed Manu
141. this case run Man ual Jet Mapping 1 Press the AutoJet button from the Front Page screen or select AutoJet from the Auto Calibrations menu The printer asks whether you want the service station to per form a Purge n Wipe operation By recovering clogged printheads you reduce the number of jet substitutions required Press to initiate a Purge n Wipe The printheads are purged then wiped Press X to skip the Purge n Wipe 2 The printer prints the AutoJet test pattern The printer reads the AutoJet test pattern and maps any miss ing jets to available working jets The control panel shows the progress of this operation as the percentage completed 4 The printer prints an AutoJet report AutoTune Q e es Offline amp Ink re 18 ea amp c3 ea et Bars amp 9 Sleep Ta Gan co Access Media Load Heads wizard Media AutoTune runs jet maintenance automatically at intervals you specify You can use the Quality Check Mode feature to handle AutoJet errors with or without user intervention Tip On the Front Page screen press the Menu key to enter the menu system Press the X Menu In key display the Calibrate Printer menu Press the V key to highlight AutoTune Press the X Menu In key The control panel displays the AutoTune status off or cur rent interval Press A or V to set the AutoTune interval Press P Proceed The control panel displays a list of services for
142. tion to ensure best print quality There are two types of ATTN messages Actions the printer has detected an error condition that stopped printing or will prevent printing from starting You must correct the error before the printer will be ready to print When the printer senses that the error condition has been addressed the Action will be deleted the next time the ATTN key is pressed Warnings the printer has detected a condition that if left unaddressed could result in substandard prints or a condi tion that will require an action before printing can continue Any action on your part is optional printing is not inter rupted for a Warning message When the printer issues one of these messages the ATTN key will blink and an alert beep will sound unless disabled see page 2 13 Press the ATTN key to display a list of message titles and select a title to display a detailed cause and recovery screen If you choose to not correct a Warning condition and resume printing the ATTN key will remain displayed but will not blink until the printer issues a new Warning or Action message The messages can be dismissed by correcting the condition or by pressing the applicable key on the detail screen or Novice mode for displaying these messages Expert mode routes most messages to the Actions amp Warnings menu and for disabling or enabling the audible alarm See the table beginning on page B 8 for a list of errors and reco
143. uidelines in this chapter for printing on rigid media The media should have parallel opposite edges with 90 degree corners Media that is not exactly square with itself can be used but will require extra attention when loading see Loading and Squaring the Media below To print to the trailing edge attach a 6 5 inch 16 5 cm or longer trailer of the same media to the trailing edge so the pinch rollers can feed the media all the way past the print zone 24 x 48 Sheet with trailer Printable area 24 x 48 24 x 48 Sheet Unprintable Trailing Margin g Direction of media feed Fig 3 20 Attaching a trailer Tape the platen under the left and right edges of the media to catch any oversprayed ink Use a colored tape to allow the printer to find the media edges A piece of media printed with a solid color also works for this purpose Do not use white tape or media the printer uses the contrast between the media and the platen to find the media edges Use the supplied head height gauge to set the printhead height over the media From Menu gt Printer Settings gt Margin Settings set the Right and Left Margin and Leading Margin to O as desired Set the Trailing Margin to 6 5 inches which is the mini mum Optionally you can set an Overprint distance between 0 and 0 5 inches to print past the left and right edges 0 125 inches to 0 25 inches is usually sufficient if the media is re
144. ummary you can show or hide the detailed calibration data Calibration Results Date Software Version Printer DisplayMaker Gator Head All Jets Replaced in Billboard Quality Mode All Jets Replaced in Production Quality Mode All Jets Replaced in High Quality Mode Fig 4 5 AutoSet Summary Log Head Registration Data sends head registration data to a log file on the print server Log Jet Data sends jet data to a log file on the print server Calibration Summary 4 21 Straightening the For optimal print quality the media must feed in as straight a i line as possible from the supply to the takeup This can be Media Path accomplished by aligning the sides of the media as straight as possible from supply to takeup before engaging the pinch roll ers and by smoothing the media web as much as possible before attaching it to the takeup See Loading Roll Fed Media on page 3 16 instructions Printer assembly also affects the media path If the printer is not assembled to the stand precisely according to the instructions in Chapter 1 they could be misaligned This could lead to the media steering to the right and left as it is wound onto the takeup spool Leveling and stabilizing the stand also helps to straighten the media path Locate the printer on a flat level surface Ensure that all four leveling feet contact the floor and adjust them as necessary to level the printer or ali
145. us Lines page 4 19 prints a quick test pat tern that shows which jets are out Default Registration Data page 4 19 sets all regis tration data to zero After calibration and jet mapping perform a linearization or color calibration as supported by your print server or RIP For further information see Linearization on page 4 24 Manual Calibrations Manual X Head Precise positioning of each drop of ink is essential for optimal Registration print quality This is possible only if you register all printheads in the printhead assembly to each other in the X along the length of the platen direction This is a two part process Print a registration pattern Enter the X registration data for each head Note This is the manual version of AutoH2H Calibration see Auto Calibrations on page 4 20 for details 1 On the Manual Calibrations menu press the Y key repeat edly to highlight Manual X Head Registration 2 Press the X Menu In key to select the option The control panel asks whether you want to print a manual head to head calibration page If you have a calibration pattern from a recent print you can use it to calibrate the heads Press X Cancel and go to the next step If you need to print a new calibration pattern press P Proceed The printer prints a calibration page When the calibration page has printed the control panel displays this prompt Take readings from left sid
146. ventilation and VOC recovery as required by local regulations Connection kits are available from MacDermid ColorSpan to vent VOC emis sions to the customer s exhaust system or VOC recovery equipment Consult your MacDermid ColorSpan reseller for details The air surrounding the printer should be changed every 1 3 minutes or as desired to reduce or remove the solvent odor The greater the amount of printing and the larger the room in which the printer is located the larger the fan required to change the air at a given rate The space volume can be reduced with an enclosure around the printer or by moving the printer to a smaller room Examples Cubic feet per minute CFM typical to change the air in 3 minutes 1 minute Enclosure 4x10x6 feet 80 240 CFM Small Room 10x12x8 feet 320 960 CFM Medium Room 10x20x8 feet 533 1600 CFM Select a fan with a CFM rating at or greater than the calculated CFM The actual CFM required will vary with local building and airflow condi tions 68 85 F 20 30 C 20 8096 non condensing Safety UL c UL CE Emissions FCC A CE Immunity CE Specifications Performance Printing Technology 16 piezo electric inkjet printheads utilizing Micro Quad Jet Technology Drop size approxi mately 25 picoliters Ink and Cleaning Solution SolaChrome HR 4 color CMYK solvent pig mented inks SolaChrome HR head cleaning solvent solution two 3 5 liter excess ink solvent containers Eac
147. very procedures V Tip See page 2 13 for instructions for choosing an Expert Overview 2 3 Front Page The Front Page provides access to the most frequently used printing and maintenance functions For advanced configura tion options press the Menu key see Menu on page 2 9 for instructions Backward DisplayMaker Gator Adwance Ey Ce cn Auta et Alle Purge Fig 2 2 Front Page Printer Name displays the name of the printer as defined on the print server Online Offline returns the printer to the Ready screen when it is online and ready to receive print jobs 2 4 Front Page Front Page Media amp Ink displays a listing of the media and ink cur rently installed in the printer Press the V and A keys to highlight Media or one of the inks then press B gt Pro ceed to display information about the selection From this screen you can press the and keys to scroll between screens Press P Proceed to return to the list then Menu Out to display the Front Page screen Media Type Smooth Banner Vinyl Width 36 0 in Length Undefined Thickness 0 014 in Position on Platen good Position 1 Color Black Type SolaChrome HR Profiler remaining 7 Reservoir 650 ml Contents Ink Fig 2 3 Media Info Ink Info screens 2 5 2 6 Status displays system parameters and the status of all user configurable options Press the and keys to scroll betwe

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