Digital Color Printer Operator Manual
SAFETY PRECAUTIONS THIS EQUIPMENT PRESENTS NO PROBLEM WHEN USED PROPERLY. HOWEVER, CERTAIN SAFETY RULES SHOULD BE OBSERVED WHEN OPERATING THE DIGITAL COLOR PRINTER. BEFORE USING THE PRINTER, YOU SHOULD READ THIS MANUAL CAREFULLY AND FOLLOW THE RECOMMENDED PROCEDURES, SAFETY WARNINGS, AND INSTRUCTIONS: Keep hands, hair, and clothing clear of rollers and other moving parts. Avoid touching moving parts or materials while the machine is in use.
TABLE OF CONTENTS Table of Contents Section 1 – Getting Acquainted ..................................................................................... 1 Front View ........................................................................................................................... 1 Rear View ............................................................................................................................. 2 Print Engine Area................................................................
TABLE OF CONTENTS Replacing the Ink Tanks ...................................................................................................... 41 Cleaning Ink Tank Contacts & Prism ..................................................................................................... 41 Ink Tank Storage & Shelf Life ................................................................................................................ 42 Ink Tank Service Life .......................................................
TABLE OF CONTENTS Power Problems ................................................................................................................................... 81 Service Station Problems ...................................................................................................................... 82 Interface Communication Problems ..................................................................................................... 83 Feeding Problems ..........................................
TABLE OF CONTENTS NOTES ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ _______________________________________________
SECTION 1 GETTING ACQUAINTED Section 1 – Getting Acquainted Front View 1. 2. Control Panel – Provides printer controls. See "Control Panel Functions" section 3. Rear Media Support Guide – Provides the proper angle to enhance paper feeding and separation. 4. Media Support Wedge – Allows for adjustments in stack angle, based on media type and length. Helps to force the media against the separation area. Narrow and wide wedges are provided with the printer to accommodate different media widths. 5.
SECTION 1 GETTING ACQUAINTED Rear View Main Power Switch, Receptacle and Fuse – Plug in AC power cord here. Switch turns main power ON/OFF. Fuse provides over-current protection. Fuse rating: 2.5A, 250V, slow blow. CAUTION: Make sure power cord is disconnected from printer before checking/replacing fuse. 1. 2 WARNING: Press the ON/OFF Button, located on the control panel, to properly power-down the print engine. Wait until all control panel lights turn off, before you turn off the main power switch.
SECTION 1 GETTING ACQUAINTED Print Engine Area Print Engine with printhead cartridge installed and printhead latch closed. 1. 2. Antistatic Brush Assembly – Contains an antistatic brush that is used to help reduce static energy and remove paper dust from the media. This assembly also contains pressure rollers and fingers that help guide the paper into the print engine. Printhead Latch – When closed; the Ink Revolver Couplings extend/connect with the Printhead Cartridge.
SECTION 1 GETTING ACQUAINTED Behind the Ink Tank Door 1 4 2 3 Ink Tank Securing Latches – Used to hold the Ink Tanks securely into the slots and against the electrical contacts within the print engine. 1. CAUTION! Before removing/installing Ink Tanks; please be sure to power-down the Print Engine or press the “Replace Ink Tanks” button, in the Toolbox. If this rule is not followed damage to the Ink Tanks may result, rendering them unusable.
SECTION 2 INSTALLING THE PRINTER Section 2 – Installing the Printer Before using the Digital Color Printer the following must be done: Transport Inspection. Upon delivery; inspect packaging and report any issues to the Carrier Gather Tools.
SECTION 2 INSTALLING THE PRINTER Choosing the Location The Digital Color Printer should be placed on a sturdy, level, worktable or cabinet; at least 9 inches from any walls. Protect the Digital Color Printer from excessive heat, dust, and moisture – avoid placing it in direct sunlight. Work-Table Surface Must be Level IMPORTANT! Level the Table, NOT the Printer! The surface that the printer is placed upon must be level, front to back and side to side.
SECTION 2 INSTALLING THE PRINTER Unpacking Please refer to the unpacking sequence, shown below. NOTE: Packaging materials may vary slightly from what is shown below. Please save the packaging in a safe place, for possible future use. Two people will be required to safely lift the printer and place it onto a sturdy, level work table. IMPORTANT: WORK TABLE SURFACE MUST BE LEVEL! Level the Table, NOT the Printer! 1 2 3 4 5 6 Save the Packaging for possible future use.
SECTION 2 INSTALLING THE PRINTER Accessory Box Contents Accessories Box Ink Tank Packaging The following items are included with your printer: Qty [Image Reference] Description 5 [A] Ink Tanks (packed in foam molds) - Cyan, Magenta, Yellow, Black, Black 1 [B] Printhead Cartridge and packaging 1 [C] Rear Media Support Guide - thumb screw attached to printer 1 [D] Service Station (now pre-installed in printer) 1 [E] Wide Media Support Wedge - mounting hardware attached to item C 1 [F] Narrow Medi
SECTION 2 INSTALLING THE PRINTER Removing the cardboard Shipping Insert and Shipping Tape WARNING! To avoid possible damage to the printer; do NOT plug-in, or power-up, the printer until all shipping materials have been removed; as described below. 1. Open the Top Cover. 2. Carefully release both latches (one on either side of the Print Engine), and lift up with both hands, to gently swing open the Print Engine Clamshell.
SECTION 2 INSTALLING THE PRINTER Installing Media Guides The screws needed to attach the side guides to the printer are located under the shipping tape in their respective positions. 10 1. Begin by installing the Media Registration Side Guide using the two screws [1] provided: 2. Next install the Adjustable Media Side Guide using the two screws [2] provided.
SECTION 2 INSTALLING THE PRINTER 3. Attach the Rear Media Support Guide using the Knob [3] and washer provided. Remove the knob and washer from the printer. Position the Rear Media Support Guide against the frame of the printer. The two outer holes in the guide fit over the socket head screws; as shown. Install the washer, then install and tighten the Knob. 4. 3 Install the desired Media Support Wedge using the mounting hardware [4]; as described below.
SECTION 2 INSTALLING THE PRINTER Connecting the Printer Plugging in the Printer Check to make sure the Main Power Switch [1] is in the OFF position. Plug the Power Cord into the receptacle [1] at the rear of the Printer. Connect the other end of the Power Cord to a compatible AC Outlet that supplies 100-240 volts AC, 50/60 Hz and provides earth ground. CAUTION DO NOT USE AN ADAPTER PLUG OR EXTENSION CORD TO CONNECT THE PRINTER TO THE WALL RECEPTACLE. DO NOT USE OUTLETS CONTROLLED BY WALL SWITCHES.
SECTION 2 INSTALLING THE PRINTER Installing the Ink Tanks The Digital Color Printer uses five Ink Tanks (two Black, one Cyan, one Magenta, and one Yellow). The Ink Tank is a delicate, precision device. Handle with extreme care to avoid damage. Ink Tank Anatomy The ink used in this system may be harmful if swallowed. Keep new and used printhead cartridges and ink tanks out of reach of children. Discard unwanted printhead cartridges and empty ink tanks immediately.
SECTION 2 INSTALLING THE PRINTER Procedure (Installing the Ink Tanks): This procedure assumes that you are installing Ink Tanks into a printer that doesn’t have any Ink Tanks installed. If you are replacing an empty Ink Tank, please refer to the “Replacing the Ink Tanks” section. Install the Ink Tanks as follows: 1. Power the Printer ON. Plug in the printer. Turn the printer’s Main Power Switch ON; then press the control panel’s ON/OFF button.
SECTION 2 INSTALLING THE PRINTER 7. Insert the new Ink Tanks (label side up) into their appropriate color slots [B]. CAUTION! Be sure each Tank is installed into the proper color slot. If you force the Ink Tank into the wrong slot, you will contaminate the ink system and professional service will be required. INSTALLATION TIP: To help insure that the Ink Tanks are seat properly. Insert the Ink Tank into the appropriate Ink Station, then pull the Ink Tank back about an inch and push forward firmly.
SECTION 2 INSTALLING THE PRINTER Installing the Printhead Cartridge The Digital Color Printer uses a single Memjet® printhead cartridge. The Printhead Cartridge is a delicate, precision device. Handle with extreme care to avoid damage and issues that could degrade print quality.
SECTION 2 INSTALLING THE PRINTER CAUTION Use electrostatic discharge (ESD) handling precautions. Hold the Printhead Cartridge by the handles ONLY. DO NOT touch the Ink Couplings, nozzle surface or electrical contacts. DO NOT unpack the Printhead Cartridge until the Printer is ready for installation. Once unwrapped, delay in installing the Printhead can compromise print quality due to dehydration. DO NOT place an unwrapped Printhead on any surface before installing.
SECTION 2 INSTALLING THE PRINTER Procedure (Installing the Printhead Cartridge) This procedure assumes that you are installing a Printhead Cartridge into a printer that does NOT have a Printhead Cartridge installed. If your printer already has a Printhead Cartridge installed, and you wish to replace the Printhead Cartridge; please refer to the section titled “Replacing the Printhead Cartridge”. 1. Plug in the printer. Turn the printer’s Main Power Switch ON; then press the control panel’s ON/OFF button.
SECTION 2 INSTALLING THE PRINTER 5. [A] Carefully remove the Printhead Cartridge from the foil packaging. Tear at notch or cut end with scissors. [B] Remove the protective plastic cover. Hold the Printhead by the handle and unclip the cover from the Printhead. [C] Remove protective strip from the Printhead Electrical Contacts. DO NOT allow removed strip to touch the electrical contacts. [D] Remove protective strip from the Printhead Nozzles. Hold the Printhead by the handle.
SECTION 2 INSTALLING THE PRINTER 7. Open the Print Engine Clamshell; using with both hands. 8. Using a lint-free cloth soaked with deionized or distilled water, wet the entire Printhead Nozzle area. Be liberal with the amount of water you leave behind on the nozzles (the thin dark line on bottom of printhead cartridge). See images below. Printhead Nozzle Area WARNING: Be careful not to damage the “star rollers” when wiping the printhead.
SECTION 2 INSTALLING THE PRINTER If ink doesn’t start filling all tubes during the first 5-seconds of the first ink pump cycle: Using deionized or distilled water; re-wet your lint-free cloth generously. Don’t wait for the pump to stop, open the clamshell and wipe along the Nozzles with the cloth, back and forth twice. Immediately after re-wetting the nozzles, carefully close the clamshell. The ink tubes should begin filling.
SECTION 2 INSTALLING THE PRINTER Envelope Printing Attachment Kit The Envelope Printing Attachment Kit (42-900-55) is included with the printer. Kit Includes: Head Media Guide (1) Left-hand (large) PPS Spacer (1) Right-hand (small) PPS Spacer (1) CAUTION: Do NOT use “PPS Spacers” with earlier style Envelope Printing Attachments (Head Media Guides) that did not come with Spacers. If this rule is not followed, significant loss of print quality will result.
SECTION 2 INSTALLING THE PRINTER 3. [A] & [B] Start with the Head Media Guide positioned as shown in “A”, on previous page. Note: The “Tab”, on the end of the Guide, fits over the front side of the metal “Support” plate. While lightly pressing up on the Guide; slide it to the left, until the cutouts in the Guide aligned with the ears on the back side of the metal “Support” plate. This will allow the Guide slide up closer to the printhead surface; as shown in “B”.
SECTION 2 INSTALLING THE PRINTER Installing/Removing the PPS Spacers The PPS Spacers are designed to be used in conjunction with the Head Media Guide. They may come preinstalled in the printer. With the PPS spacers installed and the clamshell closed; the spacers make contact with both ends of the printhead cartridge, which pushes the Platen down a small amount. This creates a larger gap between the printhead and Platen; thereby reducing the chance of contact between the media and the printhead.
SECTION 3 OPERATING THE PRINTER Section 3 – Operating the Printer Control Panel Functions BUTTON FUNCTION(s) Press to power-up or power-down the print engine. Note: The Main Power Switch must be ON, to power-up the print engine. POWERING-UP: After pressing this button; it takes approximately 45 seconds for the print engine to power-up. All lights blink simultaneously during power-up sequence. The ON/OFF button will change to a steady illumination condition, once the print engine is fully powered-up.
SECTION 3 OPERATING THE PRINTER Printer Status Light Indicators Valid with Firmware 20130820 or higher installed. The lights (LED’s), on the three control panel buttons, indicate the status of the printer. Flashing SLOW = 1 time per second Flashing FAST = 3 times per second NOTE: To obtain additional detail about the printer’s condition, please open the Toolbox utility. See “Errors and Warnings” for Additional Troubleshooting information.
SECTION 3 OPERATING THE PRINTER Printer Status Light Indicator Chart (continued) Printer Status corresponding Toolbox message Additional Details, Possible Solution or Action Printing Paused PAUSE button was pressed. Press the RESUME button to continue printing. Job can also be resumed by clicking on the “Clear Error” button in the Toolbox. Press the CANCEL button to cancel the job and clear the job from the computer’s print queue.
SECTION 3 OPERATING THE PRINTER Printer Status Light Indicator Chart (continued) Printer Status corresponding Toolbox message Paper Jam Detected Toolbox = PAPERPATH_PAPERJAM Any of the following conditions could exist: Paperpath: Entry : Yes Exit: Yes or Paperpath: Entry : No Exit: Yes or Paperpath: Entry : Yes Exit: No Printhead Missing Toolbox = PRINTHEAD_MISSING Service Station Movement Error Toolbox= MECH_FAIL_PERMANENT Reason = Sled home failed or Sled lift failed Additional Details, Possible Solu
SECTION 3 OPERATING THE PRINTER Setting up the Feed The Digital Color Printer is equipped with four sheet separators, two side guides, a rear media support guide and two different sized media support wedges. When properly adjusted these items will separate and guide the media so that only one piece of media is fed into the print engine at a time. 1. If not already present; install the appropriate Media Support Wedge onto the Rear Media Support Guide, using the mounting hardware [4] provided.
SECTION 3 OPERATING THE PRINTER 3. Loosen the locking screws, located behind the sheet separators, and raise the separators. Then tighten the locking screws to hold the separators in the up position. 4. Place a single piece of the media, to be run, under the separators. Always place the media against the Media Registration Side Guide. 5. Loosen the separator locking screw and allow the separator to settle onto the media. Then tighten the locking screw. Repeat for each sheet separator.
SECTION 3 OPERATING THE PRINTER 7. Adjust the position of the Rear Media Support Guide, so that it is centered under the width of your media. This guide slides side to side. Tip: The Rear Media Support will slide, without loosening the knob. 8. Adjust the position of the Media Support Wedge to accommodate the length of your media. Place a second piece of media onto the single piece that is already in the hopper. Make sure the second piece of media is against the separators.
SECTION 3 OPERATING THE PRINTER Using the Toolbox Utility Valid for M-Series Printers with Firmware version 20130820 installed. Once the Printer Driver is installed you have access to the Printer Toolbox (Embedded Web Server). The Toolbox lets you monitor the job, ink usage, perform diagnostic checks, print reports and run maintenance tasks on the Printer from your computer. To open the Toolbox: Open the Start Menu and then click on Toolbox.
SECTION 3 OPERATING THE PRINTER Ink Level Status Displays the approximate amount (%) of ink available in each Ink Tank. NOTE: The Ink Level (%) is an estimated value based on ink that has been ejected (printed) from the printhead. Priming/depriming and manually cleaning the printhead can reduce the accuracy of this calculation.
SECTION 3 OPERATING THE PRINTER User Interface Menu [A] User Interface Buttons: Let you perform routine maintenance and operating tasks. You can use these buttons to Clear Errors, Cancel a Job, Reset the Job Counter, and Reset the Page Counter. You can also: Replace Ink Tanks – Disconnects Printer communication with Ink Tanks; allowing for the safe removal or install of Ink Tanks. Previously the printer had to be powered-down before Ink Tanks could be safely removed or installed.
SECTION 3 OPERATING THE PRINTER [B] Basic Printer Settings – Lets you adjust automated service and cleaning intervals, adjust the feed mode, manually set the purge bar location and disable “paper jam” detection. KWS Setting – (Keep Wet Spitting) Incorporates an algorithm to periodically fire all printhead nozzles in order to keep all nozzles wet; thereby reducing nozzle clogging and print quality issues. In general the dots produced on the media by this nozzle firing algorithm are hardly noticeable.
SECTION 3 OPERATING THE PRINTER Purge Bar Position (BoF)* – In operation, the Printhead spits a small amount of ink in the gap between pieces to keep the nozzles refreshed. For irregular-shaped pieces (like an open envelope flap), the sensor may “read” the lower end as the edge and spray (print a purge bar) on the tip of the flap instead of the actual gap. This feature allows you to manually set the purge bar location (bottom of form), to account for the extra length needed to reach the actual gap.
SECTION 3 OPERATING THE PRINTER illuminated) at all times. If you need to turn the printer off; please be sure to power-down the printengine, using the “Shutdown” button in the Toolbox or the ON/OFF button on the control panel. Wait until all the control panel buttons go out, before turning off the Main Power Switch. [D] Display Language – Selects the language the Toolbox information will be displayed in.
SECTION 3 OPERATING THE PRINTER well the nozzles are performing, in each color channel of the Printhead. New: This function can now be accessed by pressing the “Print Ink Channels” button; located on the top, non-operator side, of the Print Engine. Print Color Bars Page – Prints a series of 7 color bars to show how well the Printhead is mixing colors and printing. Ink Usage Menu This tool is provided for the purpose of estimating the amount of ink usage for a particular print job.
SECTION 3 OPERATING THE PRINTER Service Menus For authorized personnel only. Provides access to more advanced Printer control and maintenance menus. A password is required to open the following features. Printer Maint Config Printer Control Config Scan Sensors Commands Help Exit Service Menu Printing Once the printer installation and setup is complete, you are ready to start printing.
SECTION 3 OPERATING THE PRINTER 40 5. Locate the “Circulate Ink” button. Click on this button. While the ink is circulating, tap lightly on the ink tubes, located at the operator side of the printer, and on the printhead cartridge. This will help dislodge air bubbles; allowing them to pass through the printhead and out the non-operator side of the printhead. NOTE: It is normal to see air bubble accumulation in the ink tubes located at the non-operator side of the printer. This is OK.
SECTION 4 MAINTENANCE Section 4 – Operator Maintenance This section covers how to perform routine operator maintenance on the printer; including Ink Tank care, Printhead care, clearing paper jams, replacing Ink Tanks, replacing Printhead Cartridge, replacing sheet separators. If printer maintenance or service is needed beyond the scope of what is covered in this section; please contact your Dealer/Distributor for support.
SECTION 4 MAINTENANCE 5. Clean the Ink Level Prism [A] and QA Chip contacts [B] with a clean, dry, lint-free cloth. NOTE: You can dampen the cloth with distilled water to wipe the Prism, but DO NOT get the QA Chip contacts wet. Tip: A soft pencil eraser can also be used to lightly clean the QA Chip contacts. This can help remove corrosion that is not visible. Wipe the contacts off with a lint-free cloth after cleaning them with an eraser. 6.
SECTION 4 MAINTENANCE Ink Tank Disposal The Ink Tank may be disposed of in a normal manner. Clean up spills with soap and water. Abrasive soap is effective in cleaning ink off your hands. Cleaning the Printhead Cartridge The Printhead Cartridge is cleaned automatically; each time the printer is turned ON, before each job, periodically during the print job, and when a User Maintenance Level routine is performed by the operator.
SECTION 4 MAINTENANCE Manual Printhead Cleaning: NOTE: We recommend the use of nitrile powder-free gloves for this process. As a last resort, if running the built-in “... Clean Printhead” features don’t help improve print quality; the printhead cartridge can be cleaned manually. 1. Carefully open the clamshell. 2. Clean the printhead nozzles. Dampen a lint-free cloth (i.e. Cartridge Wipes, PN 2023), with deionized or distilled water.
SECTION 4 MAINTENANCE Replacing the Printhead Cartridge The following procedure describes how to remove the Printhead Cartridge from the printer. ATTENTION If you experienced fuzzy print quality or an abrupt failure in a particular area of nozzles on the previous printhead; we recommend that you have the service station inspected/cleaned and the wiper roller replaced, before installing the new printhead. If not; the chance of damage to the new printhead is greatly increased.
SECTION 4 MAINTENANCE Printhead Storage & Shelf Life Properly stored, unopened, Printhead Cartridges have a shelf life of up to 1 year. Long Term: 14° F to 86° F (-10° C to 30° C) Humidity Range: Short Term: -11° F to 140° F (-25° C to 60° C) NOTE: Cumulative storage duration above 86° F (30° C) must not exceed 72 hours.
SECTION 4 MAINTENANCE Inspecting & Cleaning the Lip of the Capping Station The Capping Station (Cap) is part of the Service Station. When the printer is idle, the Service Station automatically caps the printhead to keep the nozzles hydrated. Excess ink can accumulate on the Lip of the Cap. This commonly occurs after a printhead cartridge is installed and the system is primed. During the printhead priming process the system performs multiple purges of ink into the Cap.
SECTION 4 MAINTENANCE Inspecting the Wiper Roller The Wiper Roller should be routinely inspected for signs of wear and debris. NOTICE! If you have not been trained or are uncomfortable performing this task, please contact your service support representative. Directions: 48 1. Power ON the printer and power-up the print engine. 2. After the printer has finished performing maintenance, carefully release the Latches and Open the Clamshell. 3. Open the Toolbox and press the “Wipe Printhead” button. 4.
SECTION 4 MAINTENANCE Cleaning/Replacing Service Station Items The Service Station contains separate areas/devices that are used to perform the following tasks. Cleaning. The Wiper Roller cleans the Printhead nozzles of excess ink and debris. Printing/Purging. The Printing Platen acts as a base to support media during printing. It also contains a purging area; which captures and absorbs ink that is purged, to help keep nozzles clear. Capping.
SECTION 4 MAINTENANCE Removing the Service Station 1. Open the Top Cover 2. Open the Ink Tank Door (hinged at bottom) to expose the “Service Station Slot”. Tip: On older units you will need to remove the Exit Roller Cover by removing the four (4) screws. This is not necessary on newer units. Service Station Slot Ink Tank Door 3. Power-up the printer. 4. Open the Printer Toolbox. In the User Interface window, press the “Eject Service Station” button. 5.
SECTION 4 MAINTENANCE 6. If you are replacing or re-installing the Service Station, please see the section titled “Installing the Service Station”. 7. If you are cleaning or replacing items in the service station; please see the next section titled “Cleaning the Service Station”. Cleaning the Service Station Caution: Please be sure that you are using proper cleaning techniques to clean items that come in contact with the printhead. Use only distilled or deionized water and lint free cloths.
SECTION 4 MAINTENANCE Cleaning/Replacement: 1. Using distilled water; immerse for 10 minutes, then remove and pat dry with absorbent lint free towel. WARNING! Do NOT rub the roller, when cleaning or drying it. This will cause damage to the roller fabric. Do NOT use tap/mineral/spring water to clean the wiper roller; doing so will introduce contaminants into the roller. A contaminated roller will cause damage to the printhead and ink system. Allow the roller to dry completely, before re-installing it. 2.
SECTION 4 MAINTENANCE volume, it may be worthwhile to replace the entire Service Station instead of replacing components. 5. Lightly lubricate the Wiper Motor Gears (3) with synthetic PTFE grease (Super Lube 21030 or equivalent). Install: 1. Allow the Wiper Motor Assembly to dry. 2. Re-install in reverse order. NOTE: Make sure the wiper roller is re-installed, wiper roller latches are fully closed/locked and the wiper roller retaining screws are fully tightened (do not over-tighten).
SECTION 4 MAINTENANCE 5. Reinstall the Service Station Printed Circuit Board, Wiper Motor Assembly, Printing Platen and Capping Station, into the Tray; as described on the previous pages. Suggestion for High Volume Users: For printers that are being used at high volumes (over 200,000 pieces per month), we recommend purchasing a second service station to reduce down-time for Service Station Maintenance. The new/clean service station can be swapped with the dirty one.
SECTION 4 MAINTENANCE Installing the Service Station NOTICE: Due to the technical nature of this procedure; it should only be performed by a qualified technical support person or someone that has been properly trained on this procedure. Please contact your technical support representative. Please use nitrile powder-free gloves and have plenty of paper towels onhand for these procedures. The Service Station fits in the slot immediately above the Ink Tank slots. PROCEDURE: 1.
SECTION 4 MAINTENANCE Closed 7. Locate the Ribbon Cable (from within the Service Station Slot). Insert the Ribbon Cable (blue side up) into the space under the Cable Securing Latch [1]. Make sure the ribbon cable is pushed in all the way and is NOT crooked. Then close the Cable Securing Latch [2]. Open 8.
SECTION 4 MAINTENANCE 9. Look down through open area, in the Print Engine, to make sure the Service Station is aligned with the “Bar”; (Service Station Drive Shaft) as shown. If the Printhead Cartridge is not installed (has been removed), you can look down through the top of the Print-Engine, through the Printhead Cartridge opening. If the Printhead Cartridge is still installed, you must open the Clamshell to see into this area; as shown.
SECTION 4 MAINTENANCE 11. Turn the printer’s Main Power Switch ON; then press the control panel’s ON/OFF button. After printer initialization (~45 seconds) the Print Engine will automatically pull the Service Station the rest of the way in. NOTICE: If the Service Station should get jammed during this process (you hear motor stall noise or gear slipping noise); immediately turn OFF the printer’s Main Power Switch.
SECTION 4 MAINTENANCE Inspecting/Replacing the Waste Ink Tray The Waste Ink Tray (123-2487) is filled with an absorbent material, used to capture the waste ink that drains from the Service Station. 1. If the printer is on; press the ON/OFF button to power-down the print engine. Wait about 45 seconds until the system shuts down (all control panel lights will go off). Turn off the Main Power Switch and unplug the printer from the power receptacle.
SECTION 4 MAINTENANCE Replacing the Sheet Separators The sheet separators (90-103-09) insure separation of the pieces as they are being fed. If you experience double sheet feeding and cannot adjust the separators to prevent this, replace the separators. Replacing the sheet separators is not difficult; however if you don’t feel confident about doing this yourself; please contact your technical support person. 1. Turn OFF the printer.
SECTION 4 MAINTENANCE Removing Jammed Media Clearing a jam depends on where the jam occurred. From the Feed Section: Remove media stack. Loosen and lift the sheet separators to clear the jam. Then re-adjust the sheet separators as described in this manual. Under the Antistatic Brush Assembly: If necessary, remove the Antistatic Brush Assembly [A] to access jammed material. Unlatch the two latches (one on either side of the Assembly) and lift the assembly off the four mounting pins as shown.
SECTION 4 MAINTENANCE Cleaning the Printer Body WARNING THE PRINTER IS A PRECISION MACHINE THAT SHOULD BE CLEANED REGULARLY TO INSURE MANY YEARS OF SERVICE. BEFORE PERFORMING ANY MAINTENANCE, DISCONNECT THE MACHINE FROM ITS POWER SOURCE! DO NOT REMOVE SIDE COVERS! HIGH VOLTAGES PRESENT. Clean the Printer regularly to remove accumulated paper dust and ink. Depending on the types of media that are run, paper dust may accumulate inside the printer and on the transport. 1.
SECTION 4 MAINTENANCE Cleaning the Feed Sensor The Feed Sensor is located between the media hopper and the print engine. It has two functions. - It is used to control the delivery of media to the print engine. - It drives the LCD counter; located on the entrance side of the printer. TIP: If the LCD counter is not incrementing with each piece of media, then the sensor is not working properly (dusty/dirty). This can be intermittent. If in doubt; clean the sensor.
SECTION 4 MAINTENANCE Cleaning Other Items inside the Print Engine Areas in the Print Engine can become glazed with a buildup of dust, paper lint and accumulated ink and need to be cleaned regularly. This section covers the procedures for cleaning the following items. Grit Rollers (Media Transport Rollers) Media (Paperpath) Sensors Capping Station Lip Paperpath Surfaces Printing Platen Surface WARNING THE PRINTER IS A PRECISION MACHINE THAT SHOULD BE CLEANED REGULARLY TO INSURE MANY YEARS OF SERVICE.
SECTION 4 MAINTENANCE 5. Use the procedures, as outlined below, to clean the following items. Grit Rollers [A]: Clean as needed using a small stiff-bristled brush (toothbrush), lightly moistened with distilled water. Do NOT use anything other than distilled water to clean the Rollers. Pat the roller dry using a lint-free cloth. Do NOT rub with cloth or this may produce lint. Entry Mark Exit Media (Paperpath) Sensors [B]: Paper lint, dust and ink will buildup on the Media Sensors.
SECTION 4 MAINTENANCE Cleaning the Ink Revolver Couplings This process should be performed just before a printhead cartridge is installed or re-installed; to remove contaminated/dry ink and other debris from the Ink Revolver Couplings. If this step is skipped; the printhead and or ink system could become contaminated resulting in an increase in print quality issues. 66 1. If Printhead Cartridge is installed; follow the procedure for releasing and removing the Printhead Cartridge.
SECTION 4 MAINTENANCE PRINTER MAINTENANCE SCHEDULE General, periodic maintenance is needed to keep the Printer in good working order. Many tasks can be performed by operators with basic supplies, no special tools needed. Other tasks should only be performed by trained service personnel. NOTE: High volume usage may require more frequent maintenance.
SECTION 4 MAINTENANCE NOTES ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ___________________________________________
SECTION 4 MAINTENANCE Preparing Printer for Transport Please use this procedure if you ever need to transport the printer to a new location or ship the printer. Please refer to the appropriate sections in the manual for details on installing/removing items from the printer. Local relocation Transporting the printer from one room to another in the same building is considered a local relocation. Local relocation does not normally require that the printer be repackaged before transportation.
SECTION 4 MAINTENANCE 9. Remove the Printhead Cartridge and install protective covers on printhead. Be careful to avoid ink spills (drips) and stains during this process. Store Printhead Cartridge in a sealed plastic bag with a damp cloth. CAUTION: Make sure the cartridges electrical contacts are dry before re-installing printhead. 10. Remove all five Ink Tanks. Be careful to avoid spills or stains during this process.
SECTION 5 TROUBLESHOOTING Section 5 – Troubleshooting Guide The following troubleshooting guides are provided to assist you in solving any problems that might occur with the Digital Color Printer. We have tried to make them as complete as possible. The best advice we can offer is to make sure that the system is set up properly, plugged in, and that it has an adequate supply of ink before attempting to troubleshoot any problem.
SECTION 5 TROUBLESHOOTING Examples of Print Quality Issues (including possible causes and solutions) The Memjet printhead cartridge contains 70,400 inkjet nozzles. These nozzles are divided into ten rows; two rows of nozzles for each color channel. Due to the high number of nozzles; it is not uncommon for some nozzles to become contaminated, dehydrated or clogged. The following examples were produced using a Five Band Color Purge YKCKM.
SECTION 5 TROUBLESHOOTING Clogged/Damaged/Dead Nozzles: Clogged/damaged/dead/ nozzles will normally show as thin, crisp, vertical lines of missing color. Multiple adjacent nozzles, with same issue, will show as wider, crisp, vertical lines of missing color. Clogged nozzles are normally due to Printhead nozzle dehydration or partial contamination. Damaged nozzles are normally due to improper cleaning or debris on wiper roller causing damage to head.
SECTION 5 TROUBLESHOOTING Color Mixing Issues: Color mixing will show as muddy, mottled or distorted (grainy) colors. Color mixing occurs when the ink from one color channel crosses over into another color channel. Since the inkjet nozzle rows are located very close to one another (ten rows of 7,040 nozzles, located within a 0.8 mm space), it is easy for partials or fibers to create bridges across color channels.
SECTION 5 TROUBLESHOOTING Scuff Marks and Smudging Issues: Scuff Marks occur when the media makes contact with an area of the printhead that has ink on it. Smudging occurs when the wet image, on the media, makes contact with something (most commonly the printhead) before it is dry. This issue will also increase the chance for scuff marks. Scuff Marks: Here is an example of “scuff marks” that occurred when the high points (thicker/puffier areas) on this #10 envelope made contact with the printhead.
SECTION 5 TROUBLESHOOTING Smudging: Here is an example of “smudging” that occurred when an area of this page, with a wet image, made contact with the printhead. Note: There are also scuff marks in this example. As mentioned previously; smudging will increase the chance for scuff marks; by deposition ink onto other areas of the printhead. Direction of transport Possible Solutions to Reduce Smudging: Check to be sure the “Head Media Guide” is properly installed and clean.
SECTION 5 TROUBLESHOOTING Fuzzy/Distorted Print Fuzzy/distorted print can occur for a number of reasons; listed/shown below. Problem: Poor original image quality (less than 300 dpi). Solution: Use high quality images. Problem: Choosing to print image in low resolution from software application. Solution: Set image to highest resolution possible from software application. Problem: Paper is buckling or bowing during the time of printing. Solution: Try removing the PPS spacers.
SECTION 5 TROUBLESHOOTING The Ink Tank(s) CONDITION PROBLEM SOLUTION Installed New Ink Tank and shortly after the related Ink Channel (color) stopped printing and or the related color tube went empty. CAUTION! Do NOT continue printing in this condition. Damage to the Printhead will result. One or more of the “septum needles” didn’t fully puncture the septum seal on the new Ink Tank. Antistatic Brush Assembly was not installed properly. Defective Ink Tank. Septum seal is not being punctured by needle.
SECTION 5 TROUBLESHOOTING The Printhead Cartridge The Memjet printhead cartridge contains over 70,000 inkjet nozzles. These nozzles are divided into ten rows; two rows of nozzles for each color channel. Due to the very tiny size of each nozzle and the high number of nozzles; it is not uncommon for some nozzles to become contaminated or clogged. CONDITION Mixed, mottled, muddy or distorted colors. PROBLEM SOLUTION Ink color channel mixing within the printhead cartridge/nozzles.
SECTION 5 TROUBLESHOOTING The Printhead Cartridge (continued) CONDITION System will not prime the printhead after installing Printhead Cartridge (During the priming process one or more of the ink color tubes are not filling with ink.) PROBLEM Printhead nozzles dry (air pulled through nozzles; not allowing system to create vacuum) Capping station not making good seal against the printhead. Pinched/kinked ink tube(s) SOLUTION Wet the Printhead nozzles using distilled water and a wet, lint-free cloth.
SECTION 5 TROUBLESHOOTING The Printer NOTICE: The printer will not print if any of the five ink tanks are empty or missing. Dots or Lines Printed on Media CONDITION PROBLEM SOLUTION Multiple horizontal black lines are printed down the length of the media. You have exceeded the maximum print width of 8.5”. A thick horizontal black line is printed at or near the trailing edge of the media. Purge Bar is hitting trailing edge of media. Media is hesitating or skewing during transport.
SECTION 5 TROUBLESHOOTING Service Station Problems WARNING! Many of the issues related to Service Station function will require a qualified Service Person, or properly trained person, to diagnose and fix these issues. If you haven’t been properly trained on or don’t feel comfortable performing these procedures; please contact your Service Support Representative. CONDITION Service Station Drive Motor stalls. Wiper Motor doesn’t turn or stalls PROBLEM Service Station was not installed properly.
SECTION 5 TROUBLESHOOTING Interface Communication Problems CONDITION M Series Driver does not respond to printer being connected via USB. Driver shows printer off-line, even with printer connected and powered-up. PROBLEM SOLUTION Wrong USB port selected in “M Series Driver”. Verify that you are selecting the appropriate USB port in the driver Ports Tab. Note: During driver install the USB port was automatically assigned.
SECTION 5 TROUBLESHOOTING Feeding Problems CONDITION Intermittent feeding PROBLEM Media Support Wedge not used. Side Guides set too tight to media. Dirty Feed Rollers. Multiple feeds (double feeding) Failure to feed Paper stuck together. Uneven mail piece. Separator gap not set properly. Media stuck together. Side Guides set too tight to media. No power to Printer. Feed gap too tight. Feed gap too loose. Material is out of specification.
SECTION 5 TROUBLESHOOTING Errors and Warnings Printer Alert Window Messages Messages sent from the driver and displayed on PC screen in a small popup window. MESSAGE Cleaning in Progress Excessive Tilt Error Incompatible Printhead Incorrect … Ink Tank …. Ink Low Example: Black Ink Low ….
SECTION 5 TROUBLESHOOTING Toolbox System Status Messages Displayed, in red, in the M Series Toolbox utility. Valid for printers with firmware version 20130820 or higher installed. SYSTEM STATUS PROBLEM SOLUTION PAPERPATH_FEED_TIME OUT Out of Paper Media is not reaching the print engine. Hesitation in media feed. Load media into printer and press the PAPER/RESUME button. If media is present; check/adjust the guides and separators.
SECTION 5 TROUBLESHOOTING Toolbox System Status Messages (continued) Displayed, in red, in the M Series Toolbox utility. Valid for printers with firmware version 20130820 or higher installed. X_INK_LOW Example: CYAN_ INK_LOW INK_OUT_X Example: INK_OUT_YELLOW X = Color. One or more Ink Tanks are low on ink. X = Color or MULTI One or more Ink Tanks are out of ink NOTE: If the message “INK_OUT_ANY” is displayed; please contact service support and ask them to update the printer’s firmware.
SECTION 5 TROUBLESHOOTING Toolbox System Status Messages (continued) Displayed, in red, in the M Series Toolbox utility. Valid for printers with firmware version 20130820 or higher installed. SYSTEM STATUS PROBLEM SOLUTION TILT_ERROR or EXCESSIVE_TILT_ERROR The printer’s electronics have detected that the print engine is too far out of level. If just powered on, wait a few minutes; error may clear by itself. Once Tilt level drops to 1.
SECTION 5 TROUBLESHOOTING Toolbox System Status Messages (continued) Displayed, in red, in the M Series Toolbox utility. Valid for printers with firmware version 20130820 or higher installed. PRINTHEAD_MISSINGQA Printhead Missing and one or more of the Ink Tanks are also missing. Install Printhead Install Ink Tanks. PRINTHEAD_UNPRIMED Printhead priming process has failed. If just powered on, or Tanks/Printhead just installed, wait a few minutes; error may clear by itself.
APPENDICES Appendix A – Printer Specifications SPEED (color or mono) Page Printing 8.5” x 11” No. 10 Envelopes MEDIA SIZE TECHNOLOGY Up to 3,600 per hour (1600 x 800 dpi @12 ips) Up to 7,500 per hour (1600 x 800 dpi @ 12 ips) Minimum: 3" W X 4.125" L (76.2 mm W x 104.76 mm L) Maximum: 9.5" W x 17" L (241.3 mm W x 431.8 mm L) Minimum: 0.004" (0.102 mm) Maximum: 0.020" (0.
APPENDICES Appendix B – Supplies and Optional Hardware The following supply items and optional hardware are available from Printware LLC: Supplies Description Part # Printhead Cartridge 870100‐001 Cyan Ink Tank (250 ml) 870102‐001 Magenta Ink Tank (250 ml) 870103‐001 Yellow Ink Tank (250 ml) 870104‐001 Black Ink Tank (250 ml) - printer requires two 870101‐001 All Five Ink Tanks (5x 250 ml) 870105‐001 Waste Ink Tray (Tray with Absorbent material) 870116‐001 Obtaining Supplies, Service and S
APPENDICES Appendix C – Quick Reference Info Suggestion: Printout these quick reference sheets and attach to, or near, the printer. Control Panel Light Sequences – Quick Reference Valid with Firmware 20130820 or higher installed. The lights (LED’s), on the three control panel buttons, indicate the status of the printer.
INDEX A Accessory Box Contents ......................................................... 8 Adjustable Media Side Guide ............................................. 1, 8 Air in Nozzles ....................................................................... 72 Antistatic Brush Assembly...................................................... 3 C Cartridge Conditioning ......................................................... 39 Cartridge, Printhead ..............................................................
INDEX Storage .............................................................................. 46 Printhead Cartridge ............................................................. 3, 8 Printhead Cartridge Conditioning ......................................... 39 Printhead Cartridge Protective Packaging ............................ 16 Printhead, Install ................................................................... 18 Q Quick Reference Control Panel Light Sequences .......................................
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