Go to table of contents Maintenance and Troubleshooting DCS_Direct_Jet_1024UVHS_Maintenance_Troubleshooting_Guide_1.2.
Notices The information in this document is subject to change without notice. NO WARRANTY OF ANY KIND IS MADE WITH REGARD TO THIS MATERIAL, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. No liability is assumed for errors contained herein or for incidental damages in connection with the furnishing, performance, or use of this material. This document contains proprietary information which is protected by copyright. All rights are reserved.
Equipment Certificate of Compliance Printing History Edition 1.2 – February 2013 Addition to FAQs Printed in the USA © Copyright 2013, Direct Color, LLC. All rights reserved. DCS_Direct_Jet_1024UVHS_Maintenance_Troubleshooting_Guide_1.2.
Go to table of contents Table of Contents SAFETY AND PRECAUTIONS………………………………………………………………………………………6 MAINTENANCE and CLEANING……………………………………………………………………………………8 Daily Maintenance and Cleaning…………………………………………………………………………9 Weekly Maintenance and Cleaning……………………………………………………………………9 Monthly or Periodic Maintenance………………………………………………………………………13 Correcting a Bad Nozzle Check Condition……………………………………………………………15 The Capping Station……………………………………………………………………………………16 Replacing a Direct Jet Print Head…………………………………………………………
Go to table of contents Direct Jet 1024UVHS Maintenance and Troubleshooting Guide Thank You... …for choosing the Direct Color Systems® Direct Jet UVHS printer. Your printer is designed to provide you with exceptional output quality on a variety of substrates. The Direct Jet's ability to print to many different materials without the need for surface pre-coating or undercoating represents a sound investment in time and productivity that will put you ahead of your competition.
Go to table of contents SAFETY AND PRECAUTIONS • • • • • • • • • • • • • • Please read these guidelines before operating your Direct Jet printer. Keep all inks, solvents and lubricants out of the reach of children. Use only approved cleaning agents and solvents and then only for the purposes specified in this guide. Use only genuine Multisolve™ UV-LED inks. Keep inks in a cool, dark and dry location. Inks must be used in opaque cartridges only. This printer produces potentially harmful UV light.
Go to table of contents Below you will find diagrams of the printer and its parts. Be sure to familiarize yourself with all the individual parts and descriptions of printer as they will be referred to later in this guide. DCS_Direct_Jet_1024UVHS_Maintenance_Troubleshooting_Guide_1.2.
Go to table of contents MAINTENANCE and CLEANING When powering the printer back on, remember to turn on the main power then wait 5 seconds before powering up the print engine. This is to allow time for the LED light to calibrate its distance from the print head. Although your Direct Jet printer is engineered to provide many years of trouble-free operation, regular cleaning and periodic maintenance are required to keep your machine running smoothly.
Go to table of contents 1. Turn on main power. Power on the printer with the main power switch. Do not turn on the print engine (green power button) unless specifically instructed. 2. Inspect Spit Tray. The spit tray should be cleaned of dried ink regularly. Failure to do so will lead to a buildup of ink that could eventually hit the bottom of the head and cause a head strike. Remove the ink by wiping with a dry cloth. 3. Shake the white ink. Cover the bottom of the ink cartridge with a gloved finger.
Go to table of contents 11. Clean and lubricate print station X-axis shafts and rails. Due to the additional heat and dryness created by the UV lamp and its fans, it is necessary to clean and lubricate the rails of the printer often. DCS recommends this be done weekly for moderate users. Heavy users (48 hours/day, 5-6 days/week) should perform this maintenance daily. Use your discretion and perform this maintenance as needed. Use a 3-in-1 oil or a light sewing machine oil on the shafts and rails.
Go to table of contents The outside of the print head bushings on both sides. It is critical that the area between the print head bushings be lubricated. Apply the 3-in-1 oil and then, using a gloved finger, apply lithium grease to the same locations. Upper and lower rail and car on both sides of the UV lamp carriage. Do not use WD-40 on the UV lamp rails. Clean with an IPA wipe when needed.
Go to table of contents Clean the UV lamp after you've cleaned and lubricated the rails. The print head carriage is already in place. Skip right to step b! a. Press to unlock the print head carriage. When it has stopped moving, manually move it to the center of the shaft. b. Turn off the printer by the main power switch. c. Spray a general purpose glass cleaner onto a soft lint-free cloth and wipe the glass covering the UV light. Do not spray cleaner directly onto the lamp.
Go to table of contents Both sides of the encoder strip used by the print head should be wiped gently with an IPA wipe (included in the cleaning kit) in order to remove any debris that may have fallen on to it during the lubrication process or from ink residue. 14. Clean the wiper blade. Clean the wiper in the capping station to avoid streaking in your finished images and/or if drops of ink on the bottom of the head are not being wiped off after a cleaning cycle. Monthly or Periodic Maintenance 15.
Go to table of contents Discard the old filter. 4. Clean the retainer and fan guard with a dry cloth if needed. Maintenance 3. Fan guard Retainer 5. Place the new filter over the fan guard and secure with the retainer and 4 screws. 16. Replace syringes and filling needles every 28 days. No more than every 28 days, discard all filling syringes and filling needles. Begin using new ones. 17. Clean encoder wheel for Y-axis every 84 days. Clean with an IPA wipe. 18.
Go to table of contents 1. If you are unsatisfied with a nozzle check, first run a head clean. Perform a head clean from the device properties dialog box in the Queue or to perform the head clean from the printer, hold 2. for 5 seconds. After the head clean, run another nozzle check. Check for weeping ink. Look at the bottom of the Print Head to determine if either there is ink weeping (dripping) from the print head or if no ink is flowing.
Go to table of contents Maintenance The Capping Station Clean the wiper blade 1. Press . Manually move the capping station away from the print head. 2. Pull back on the tab as shown below and then flip up the wiper. Do not remove the capping station. The picture is for demonstration purposes only. Wiper Tab 3. Wearing gloves, wipe the blade clean with an IPA wipe (provided in your cleaning kit).
Go to table of contents Replace a Capping Station if: a. The gaskets no longer form a tight seal around the print heads, and the cleaning cycle does not perform properly. b. Some type of physical damage has occurred to the unit. c. There is an electrical failure of the pump motor. d. It is more than 90 days old. Tools Required Long magnetized Philips head screwdriver Needle-nose pliers 1. Time Required Approximately 20 minutes Press the up arrow button until the print engine is at its maximum height.
Go to table of contents Remove the locking bracket holding the unit to the side plate. Use pliers to remove the bracket from the side of the print engine. Maintenance 4. Disconnect orange ground wire. 5. Disconnect the electrical cable that goes to the motor. Do not leave the gender changer connected to the capping station. Leave it connected to the wire that is attached to the printer. 6. Carefully remove the unit. 7. Reverse procedure to install the replacement unit. 8.
Go to table of contents This procedure is used for adjusting the X and Y "0" point of the printer to be equal to the Color Byte software "0" point. Tools Required 1/16" hex head wrench 3/32" hex head wrench Time Required Approximately 20 minutes 1. Make sure the print engine power is ON ( 2. Load a piece of 8.5" x 11" (or A4) paper or a white substrate of similar size. Use the edge guides to align it on the left edge of the table. 3. Open the Color Byte Rip Pro Queue. Select the Color Only queue. 4.
Go to table of contents To adjust the print home sensor, look carefully at the printed picture. Verify that the black line across the top of the page is parallel and is .500" (12.7mm) thick. Verify that the vertical line is exactly 1.000" (25.4mm) thick. See below if any of these conditions is not met. Not Parallel If the black line across the top is not parallel with the edge of the paper then the Photo Paper may not have been aligned properly, go back to step 2 and reprint the picture.
Go to table of contents There is a white gap before the vertical line If there is a white gap before the 1.000" thick line then an adjustment must be made to close this gap. Measure the gap and record the resulting value without decimals. For example, if the gap is 0.003" thick, record a value of 3. 1. Click on Printer Status and Settings 2. Select "Read First Dot" and record this value 3. Click Yes to change the value 4. Subtract your value from the First Dot value and enter the new value.
Go to table of contents Read all of the instructions prior to execution When powering the printer back on, remember to turn on the main power then wait 5 seconds before powering up the print engine. This is to allow time for the LED light to calibrate its distance from the print head. Tools Required T-15 Torx driver .050" Hex Head Driver 3/32" Hex Head Driver # 1 Philips head screwdriver (customer supplied) Head Height Gauge (.
Go to table of contents Close the Device Properties dialogue box, and go to your Nozzle Check queue. Click on the preloaded file and print. The print head will move to the far side. As it returns, turn OFF the printer main AC power switch when it is approximately halfway. Wait 10 seconds. Turn the power main AC power switch ON. This will bring power to the printer but not move the Print Head (amber light is displayed on the green button of the front panel). DO NOT turn print engine on.
Go to table of contents Remove the tool. Press the down arrow button and hold it until the elevator stops, then release it. This sets the print head height. Using head. and the arrow buttons once again, move the table until it is under the print Slide the DCS Head Height Gauge between the Print Head and the Media Table. It should fit all the way under the head, with very little gap (just enough to slide a piece of paper in between. Move the head to another point on the axis and check again.
Go to table of contents If the LED sensors aren't level, use these instructions but only adjust one of the blocks Manually move the print head carriage toward the capping station. Move the media table to the far right. Press and hold the down arrow button until the elevator stops moving. Press and hold then press to move the media table toward the print engine until the front edge of the table is past the LED sensor on the print head assembly. See picture below.
Go to table of contents Maintenance UV Lamp Height Adjustment Always check the head height before the UV lamp height! If you have performed and are satisfied with the head height adjustment, place two shims on the media table in front of the UV lamp. Press and hold then use the arrow keys to move the media table so the shims are under the lamp. The lamp should be only slightly above the shims (enough so that a piece of copier paper can fit).
Go to table of contents Replace a Print Head if: 1) Some type of physical damage has occurred to the Print Head unit. 2) Some electrical problem has occurred with the Print Head unit. 3) There is a clog in the head that prevents the correct nozzle check pattern to be printed, and after all attempts at clearing the head, the head will not properly print the correct nozzle check. Contact Direct Color Systems for the print head replacement instructions and special tools needed for replacing the print head.
Go to table of contents If you have difficulty operating the printer, the troubleshooting procedures in this section should, in most cases, solve the problem. Turning the printer off and back on and rebooting the P.C. (cold booting the system) may also clear the error. If you still have difficulty after trying the following procedures, the Direct Jet printer often uses the lights on the Control Panel buttons to indicate various error conditions.
Go to table of contents There are a number of conditions that will cause a fatal error. The most common is that the print engine, media table or head assembly was not in the correct position when the print engine was powered on and tried to perform its self test. Power the print engine off and the main power supply off. Turn on the main power supply, wait 5 seconds and then power on the print engine normally to clear this error.
Go to table of contents Use the following table to indentify and fix Mechanical and Electrical faults Symptoms The UV light is not lit. Check The light will automatically shut off when the temperature exceeds 104°F (40°C). It will turn back on automatically when the operating temperature has returned to an acceptable value. The filter. If it is dirty, it will reduce air flow and can cause high temperature leading to automatic shut down. Switch AC main power on.
Go to table of contents Check Check and verify print home (table control lock) has not been pressed (See Print Home Description). Press Pressing Control Panel buttons: Left Arrow, Right Arrow, or Print Home doesn't move the media table. . Replace Replace 42 VDC 2 Amp Fuse. Check and reseat cable connected to CN3 on the YACB board. Replace 5 VDC 1 Amp. Fuse. Check and reseat cable connected to CN11 on the YACB board. Replace YACB Board. Check F1, 42 VDC fuse on the YACB board.
Go to table of contents Check Replace If you have shut the printer down abnormally, you will need to press the green button again to clear the fatal error. The amber light should light on the green button. Make sure the table is all the way to the right and then press the green button. You may have to do this up to 3 times to clear this error. If the fatal error continues to occur check the following: 1.
Go to table of contents Capping Station Pump motor. Note: Loud grinding noise will occur in addition to flashing lights. When pressing the green button with the amber light lit, after a short time #1 & #2 LED's turn on and flash at a 1 second rate. This is a fatal error. 5. 6. A. Check Pump motor connector. B. Check gear train position in capping station. Replace capping station. Paper Width sensor A. Check and or clean Width Sensor. B. Check for strong overhead light reflecting into sensor.
Go to table of contents Check Replace Check Print Head Height (See Head Height Adjustment) Check that all items on the table are of a similar height. Check for Static on Substrate (Use Novus Cleaner) Over Spray on the print Check Nozzle Check Pattern for Correct spray Check Print Head for drips on the bottom of the Print Head Replace Small Waste Pad. Replace Print Head. Check for Small Waste Pad touching the Print Head Check Print Head ID# to be the same on Print Head as read from the software.
Go to table of contents Troubleshooting During Normal Operation the capping station should last 3 months on average. Normal operation is running the printer 8 hours a day, 5 days a week. Why does the capping station fail? The reason the capping station fails is because the solvents in the ink and cleaning solutions dry out the rubber gasket that is used to seal against the print head. This gasket is used to create a vacuum that pulls air and dried ink from the print head nozzles.
Go to table of contents The printed image is faint or has gaps Possible Cause Solution 1. The gap between the head and substrate is too large 1. Press the down button until the Z axis sensor touches the substrate; release the button when you hear a clicking noise and the stepper motor stops. The Print Head Assembly goes up again automatically. 2. Nozzles are clogged 2. Run a nozzle check to confirm if ink is flowing. If output is faulty, perform a cleaning operation.
PRINTING - INFO SHEET AND FAQs Q: Why do I have shadows or halos around my image? A: The print head is too high or there is too much static electricity. Make sure the print head height is set correctly and that you have cleaned the substrate with an alcohol wipe prior to printing.
Q: Do the inks have a "use by" date? Q: How do I refill the inks? Q: How often do I refill the inks? Q: What substrates can I print to? Are there any made specifically for the UV printer? A: A: A: Inks are viable for 12 months from DOM and 6 months after opening. See section Filling Ink Cartridges, in the Getting Started Guide. Inks will need to be refilled depending on the amount of printing you do and the print modes that you use. On average, you will need to refill every day or two.
Q: Can the UV inks cure without being exposed to the LED light? Q: How do I properly sense the height of clear materials? Q: How do I properly store my filling needles and syringes? Q: Should I use a new filling needle and syringe every time I fill my ink cartridges? Q: What do I do if I run out of ink during a print job? A: A: A: A: A: They can over a long period of time. This is why it is important to swap out your syringes every 28 days and cartridges every 84 days.
Direct Jet UV Printer Maintenance Log DCS_Direct_Jet_UV_Printer_Maintenance_Log_REVB021413
Properly Using Your Maintenance Log Introduction to the Log: This maintenance log has been provided to you by Direct Color Systems to ensure proper operational function of your UV printer. It will also provide DCS technical support with a history to refer to when assessing any issues. About the Log: The log is set up on a 3 month cycle (12 weeks).
Week 1 Start Date:_____________ Pre Production: Day 1 Shake White Ink Power up Print Engine Reset Ink Pad Counter and Re-Cycle Power Clean UV Lamp Lens Clean and Lubricate X-Axis shaft and rails Day 2 Day 3 Day 4 Shake White Ink Shake White Ink Achieve Correct Nozzle Check Achieve Correct Nozzle Check Empty ink waste bottle Empty ink waste bottle Power up Print Engine Achieve Correct Nozzle Check Power up Print Engine Achieve Correct Nozzle Check Day 5 Day 6 Day 7 Shake White Ink Shake
Week 2 Start Date:_____________ Pre Production: Day 8 Shake White Ink Power up Print Engine Reset Ink Pad Counter and Re-Cycle Power Clean UV Lamp Lens Clean and Lubricate X-Axis shaft and rails Day 9 Day 10 Shake White Ink Shake White Ink Achieve Correct Nozzle Check Achieve Correct Nozzle Check Empty ink waste bottle Empty ink waste bottle Power up Print Engine Achieve Correct Nozzle Check Power up Print Engine Achieve Correct Nozzle Check Day 11 Day 12 Day 13 Day 14 Shake White Ink
Week 3 Start Date:_____________ Pre Production: Day 15 Shake White Ink Power up Print Engine Reset Ink Pad Counter and Re-Cycle Power Clean UV Lamp Lens Clean and Lubricate X-Axis shaft and rails Day 16 Day 17 Shake White Ink Shake White Ink Achieve Correct Nozzle Check Achieve Correct Nozzle Check Empty ink waste bottle Empty ink waste bottle Power up Print Engine Achieve Correct Nozzle Check Power up Print Engine Achieve Correct Nozzle Check Day 18 Day 19 Day 20 Day 21 Shake White Ink
Week 4 Start Date:_____________ Pre Production: Day 22 Shake White Ink Power up Print Engine Reset Ink Pad Counter and Re-Cycle Power Clean UV Lamp Lens Clean and Lubricate X-Axis shaft and rails Day 23 Day 24 Shake White Ink Shake White Ink Achieve Correct Nozzle Check Achieve Correct Nozzle Check Empty ink waste bottle Empty ink waste bottle Power up Print Engine Achieve Correct Nozzle Check Power up Print Engine Achieve Correct Nozzle Check Day 25 Day 26 Day 27 Day 28 Shake White Ink
Week 5 Start Date:_____________ Pre Production: Day 29 Day 30 Shake White Ink Shake White Ink Clean UV Lamp Lens Replace Syringes and Filling Needles Power up Print Engine Reset Ink Pad Counter and Re-Cycle Power Clean and Lubricate X-Axis shaft and rails Power up Print Engine Achieve Correct Nozzle Check Day 31 Shake White Ink Power up Print Engine Achieve Correct Nozzle Check Day 32 Day 33 Shake White Ink Power up Print Engine Achieve Correct Nozzle Check Day 34 Day 35 Shake White Ink
Week 6 Start Date:_____________ Pre Production: Day 36 Shake White Ink Power up Print Engine Reset Ink Pad Counter and Re-Cycle Power Clean UV Lamp Lens Clean and Lubricate X-Axis shaft and rails Day 37 Day 38 Shake White Ink Shake White Ink Achieve Correct Nozzle Check Achieve Correct Nozzle Check Empty ink waste bottle Empty ink waste bottle Power up Print Engine Achieve Correct Nozzle Check Power up Print Engine Achieve Correct Nozzle Check Day 39 Day 40 Day 41 Day 42 Shake White Ink
Week 7 Start Date:_____________ Pre Production: Day 43 Shake White Ink Power up Print Engine Reset Ink Pad Counter and Re-Cycle Power Clean UV Lamp Lens Clean and Lubricate X-Axis shaft and rails Day 44 Day 45 Shake White Ink Shake White Ink Achieve Correct Nozzle Check Achieve Correct Nozzle Check Empty ink waste bottle Empty ink waste bottle Power up Print Engine Achieve Correct Nozzle Check Power up Print Engine Achieve Correct Nozzle Check Day 46 Day 47 Day 48 Day 49 Shake White Ink
Week 8 Start Date:_____________ Pre Production: Day 50 Shake White Ink Power up Print Engine Reset Ink Pad Counter and Re-Cycle Power Clean UV Lamp Lens Clean and Lubricate X-Axis shaft and rails Day 51 Day 52 Shake White Ink Shake White Ink Achieve Correct Nozzle Check Achieve Correct Nozzle Check Empty ink waste bottle Empty ink waste bottle Power up Print Engine Achieve Correct Nozzle Check Power up Print Engine Achieve Correct Nozzle Check Day 53 Day 54 Day 55 Day 56 Shake White Ink
Week 9 Start Date:_____________ Pre Production: Day 57 Day 58 Shake White Ink Shake White Ink Clean UV Lamp Lens Replace Syringes and Filling Needles Power up Print Engine Reset Ink Pad Counter and Re-Cycle Power Clean and Lubricate X-Axis shaft and rails Power up Print Engine Achieve Correct Nozzle Check Day 59 Shake White Ink Power up Print Engine Achieve Correct Nozzle Check Day 60 Day 61 Shake White Ink Power up Print Engine Achieve Correct Nozzle Check Day 62 Day 63 Shake White Ink
Week 10 Start Date:_____________ Pre Production: Day 64 Shake White Ink Power up Print Engine Reset Ink Pad Counter and Re-Cycle Power Clean UV Lamp Lens Clean and Lubricate X-Axis shaft and rails Day 65 Day 66 Shake White Ink Shake White Ink Achieve Correct Nozzle Check Achieve Correct Nozzle Check Empty ink waste bottle Empty ink waste bottle Power up Print Engine Achieve Correct Nozzle Check Power up Print Engine Achieve Correct Nozzle Check Day 67 Day 68 Day 69 Day 70 Shake White In
Week 11 Start Date:_____________ Pre Production: Day 71 Shake White Ink Power up Print Engine Reset Ink Pad Counter and Re-Cycle Power Clean UV Lamp Lens Clean and Lubricate X-Axis shaft and rails Day 72 Day 73 Shake White Ink Shake White Ink Achieve Correct Nozzle Check Achieve Correct Nozzle Check Empty ink waste bottle Empty ink waste bottle Power up Print Engine Achieve Correct Nozzle Check Power up Print Engine Achieve Correct Nozzle Check Day 74 Day 75 Day 76 Day 77 Shake White In
Week 12 Start Date:_____________ Pre Production: Day 78 Shake White Ink Power up Print Engine Reset Ink Pad Counter and Re-Cycle Power Clean UV Lamp Lens Clean and Lubricate X-Axis shaft and rails Day 79 Shake White Ink Power up Print Engine Achieve Correct Nozzle Check Lubricate Y-Axis rails Clean X-Axis encoder strip Clean Wiper Blade Day 80 Day 81 Shake White Ink Shake White Ink Inspect UV Light Exhaust Filter (model specific) Change Capping Station Power up Print Engine Achieve Correct
