Kodak VERSAMARK DP5120, Operator'S Manual

Page 1: ...KODAK VERSAMARK DS5110 Printer Operator s Manual Kodak Versamark Inc ...

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Page 3: ...KODAK VERSAMARK DS5110 Printer Operator s Guide ...

Page 4: ... Marking Warning This is a Class A product In a domestic environment this product may cause radio interference in which case the user may be required to take adequate measures KODAK VERSAMARK DS5110 Printer Operator s Guide Eastman Kodak Company 2004 All rights reserved This document contains proprietary information of Kodak Versamark Inc or its licensors and is their exclusive property It may not...

Page 5: ...der is the operator who is responsible for printing jobs troubleshooting common printing problems and performing routine maintenance The reader should have a basic knowledge of computers and the printing environment in which the printer is being used When other system components or system software programs are required to complete a procedure appropriate manuals are referenced ...

Page 6: ...ard that will result in serious injury or death This style Refers to Ready Text displayed by the software go Anything you type exactly as it appears whether referenced in text or at a prompt ENTER Special keys on the keyboard such as enter alt and spacebar NEXT Buttons and lights on the printer operator panel Save Software command buttons and sections of dialog boxes such as group boxes text boxes...

Page 7: ...or telephone or on site technical support to order parts or supplies to request documentation or product information Phone Fax U S A Canada and worldwide 1 800 472 4839 1 937 259 3739 1 937 259 3808 Europe 41 21 806 0404 41 21 806 1920 Asia Pacific Rim 65 6744 6400 65 6744 6700 Japan 81 3 3256 2613 81 3 3256 2616 Updated service information http www kodakversamark com Customer support customer kod...

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Page 9: ...termining Cue Distance and Cue Delay 1 10 Tach Encoder 1 10 Cue Sensor 1 11 Cue Distance 1 11 Cue Delay 1 12 Document and Image Lengths 1 13 Chapter 2 Basic Operation Operator Panel Functions 2 2 Panel Buttons 2 2 Panel Lights 2 4 Operating Procedures 2 5 Turning On the Printer 2 5 Bypassing the POC Test and Fluid System 2 6 Turning On the Fluid System When Idle 2 6 Turning On the Fluid System Whe...

Page 10: ...efects 3 5 Dirty Printhead Components 3 6 Miscellaneous Problems 3 9 Chapter 4 Maintenance Required Tools and Supplies 4 1 Daily Maintenance 4 2 Cleaning the Printhead Bottom Cover 4 2 Cleaning the Printhead 4 3 Periodic Maintenance 4 4 Cleaning the Air Filter 4 4 Replacing the Mist Filter 4 5 Corrective Maintenance 4 7 Cleaning the Printhead Catcher Bottom Plate 4 7 Swabbing the Printhead 4 8 Glo...

Page 11: ...nd cue delay 1 12 Figure 1 10 Document parameters 1 13 Figure 2 1 Operator panel buttons and lights 2 2 Figure 2 2 Ink and replenisher bottles 2 8 Figure 2 3 Printer rear view 2 10 Figure 3 1 Test pattern 3 1 Figure 3 2 Test print example 3 2 Figure 4 1 Removing the printhead bottom cover 4 2 Figure 4 2 Cleaning the printhead bottom cover 4 3 Figure 4 3 Removing the air filter 4 4 Figure 4 4 Remov...

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Page 13: ... Resolution is measured in dots per inch dpi The DS5110 is capable of printing 100 percent variable data at a print speed of up to 1000 fpm After installation basic setup procedures must be performed before printing can begin Along with a brief overview of the system components this chapter describes the required setup procedures which include supporting the printhead setting up the printhead prin...

Page 14: ...er components Printer The printer which includes all of the components within the printer cabinet accepts print data and commands that determine job setup and control printer functions The printer receives this information from a controller and translates it into a bitmapped format that is sent to the printhead through the umbilical Umbilical Printhead Operator panel Replenisher bottle Ink bottle ...

Page 15: ...t grounding strap when handling these components also handle circuit boards only by edges free of connectors The printhead contains the print array a row of holes orifices from which the jets of ink are formed The printhead provides a 1 06 inch 2 69 cm print width A covering called the eyelid protects the print array from damage and dust and keeps fluids from leaking during printer startup and shu...

Page 16: ...e relative concentration of ink to water A light on the operator panel comes on when a fluid bottle or external ink container is depleted and needs to be replaced The printer has quick release couplings in the lines to the ink and replenisher bottles to allow you to connect larger containers located outside of the cabinet See Chapter 2 for fluid bottle and external container replacement procedures...

Page 17: ...nthead and umbilical Printhead height restrictions vary from model to model Maximum printhead height is 1 0 inch 2 54 cm Two support options are available the printhead mount and the printhead mount stand Refer to the installation instructions shipped with the supports for assembly and installation instructions The supports for the one inch and two inch printheads vary only slightly The printhead ...

Page 18: ... Supporting the Printhead The printhead mount stand consists of an extendable arm mounted on a steel base with casters The printhead mount stand provides a stable mobile printhead support Figure 1 3 Figure 1 3 Printhead mount stand ...

Page 19: ...etermining Substrate Movement The printhead has a series of dot indentations appearing on the sides of the printhead cover to indicate the direction of normal substrate movement These dots decrease in size in the direction of normal substrate movement Locating the Print Array The printhead has a dot indentation on the seam of the printhead cover which is the largest dot indentation The seam indica...

Page 20: ...multiple printheads as closely together as possible The most downstream printhead the last printhead to print must finish printing before the next substrate passes under the cue sensor See the section Determining Cue Distance and Cue Delay in this chapter The following dimensions shown in Figure 1 6 need to be considered Feedstroke the substrate length plus the distance between substrates Cue dist...

Page 21: ...o be used for the job must be selected to print and must be configured according to the system software being used See your system software operator s manual for details Figure 1 6 Multiple printer dimensions Synchronization Cue Checking options must be enabled for all printers and all printers must be set for the same cue error response See your system software manual for details on setting this ...

Page 22: ...rmines when printing occurs Tach and cue installation are application specific See the Installation Guide for general installation guidelines Tach Encoder The tach encoder generates pulses that indicate the travel distance and speed of the transport Figure 1 7 The tach rate must match or be a multiple of the print resolution being used See your system software operator s manual for details on sele...

Page 23: ...cue sensor used with the printers Figure 1 8 Cue sensor example Cue Distance Cue distance is the distance from the cue sensor to the print array Figure 1 9 The minimum cue distance is 1 0 inch 2 54 cm The maximum cue distance is dependent on the print resolution in the direction of substrate movement and is shown in Table 1 1 on page 1 14 To determine cue distance slowly move the substrate under t...

Page 24: ...ate The maximum value allowed for cue delay depends on the print resolution in the direction of substrate movement See Table 1 1 on page 1 14 Enter the cue distance and cue delay values at job setup using the procedures described in your systems software Operator s Guide Adding the cue distance and cue delay tells the printer how long to wait before starting to print after the leading edge of the ...

Page 25: ...iling edges of the substrate and in effect provides a start of document and an end of document signal In this case the document length could be specified as being shorter than the substrate length to make sure that printing stops before a sensitive area such as a preprinted area is reached If printing on a web the start of document signal may come from a cue mark on the web or from a mechanical cu...

Page 26: ... distance and cue delay in Table 1 1 Enter the values for document length sometimes called substrate length and image length at job setup using the procedures described in your systems software Operator s Guide Table 1 1 Maximum distances Horizontal Resolution Maximum Cue Distance Cue Delay and Document Length 120 dpi 120 inches 304 8 cm 240 dpi 60 inches 152 4 cm ...

Page 27: ...c Operation This chapter describes basic operating procedures for the printer Operating procedures include turning the printer on and off bringing the printer online and replacing fluids Moving and idle time guidelines are also described ...

Page 28: ...PRINT OPEN EYELID and PRINTER ON buttons provide more than one function When you initially press one of these four buttons the printer performs the function associated with the name of the button The light above the button comes on to indicate the button is the On position If you press the button again the printer reverses the function and the light goes off For example when you press OPEN EYELID ...

Page 29: ...RINT Starts printing test patterns Light is on Stops printing test patterns Light is off OPEN EYELID Opens the eyelid 1 Light is on 1 OPEN EYELID is also used to clear errors and to turn the printer on with the fluid system and power on confidence POC test bypassed See the operating procedures section of this chapter for the POC test bypass procedure Closes the eyelid Light is off CLEAN PRINTHEAD ...

Page 30: ...EPLENISHER Flashes when replenisher is low ADD INK Flashes when ink is low ERROR Flashes for an inkjet or printhead short error remains lit for any other type of error See your system software operator s manual for details on error messages DATA READY Lights up when data is available for printing TACH Lights up each time a tach pulse is received CUE Lights up each time the cue changes state Cue si...

Page 31: ... has electrical power connected before turning on the printer The POWER light is lit Turn on the printer and the fluid system by pressing PRINTER ON During the power on cycle various operator panel lights come on or flash When the cycle is complete the PRINTER ON and STANDBY lights remain lit indicating the fluid system is on Under normal operating conditions 70 F 21 C and 50 relative humidity the...

Page 32: ...EN EYELID The PRINTER ON light remains lit Turning On the Fluid System When Idle To bring the fluid system out of idle press STANDBY The STANDBY light flashes while the fluid system powers up and remains lit when the fluid system is completely powered up See Idle Time Guidelines on page 2 7 Turning On the Fluid System When Bypassed To turn on the fluid system when it has been bypassed press CLEAN ...

Page 33: ...r and the Fluid System To turn off the printer and the fluid system press PRINTER ON The PRINTER ON and STANDBY lights flash rapidly and go off when power off is complete approximately 5 minutes Clearing Errors When an error is detected the ERROR light comes on If the error is an inkjet short IJ 42 error the ERROR light flashes To clear an error press OPEN EYELID The status of the eyelid remains t...

Page 34: ... occurs and the ERROR light comes on The fluid bottles can also be replaced while the printer is on or printing To replace an ink or a replenisher bottle perform the following procedure 1 Open the fluid compartment door 2 Unscrew the ink cap from the empty bottle and set the bottle aside Note Before installing the replacement bottle verify that the sticker on the replacement bottle matches the emb...

Page 35: ...accordance with governmental regulations Moving the Printer When moving the printer refer to the following procedure and Figure 2 3 to prevent damage to the printhead and umbilical Caution To avoid fluid leakage that could cause an inkjet or printhead short ensure the printer and the fluid system are turned off before moving the printer 1 If the printer is on turn it off by pressing PRINTER ON 2 P...

Page 36: ...ration During a complete power loss the eyelid closes to prevent ink spills Setup parameters are saved When power is restored the printer does not automatically power back on To turn on the printer and the fluid system press PRINTER ON The power on cycle is performed See your system software operator s manual for information on restarting a job Umbilical hanger Circuit breaker switch ...

Page 37: ...erns and text prints Test patterns can be printed by pressing TEST PRINT on the operator panel A test pattern consists of a pattern of lines designed to verify print quality or to reveal specific print problems Figure 3 1 provides an example of a test pattern Figure 3 1 Test pattern By comparing the print quality of the test patterns you print with the test pattern examples provided in this chapte...

Page 38: ... the following procedure to print test patterns from the printer operator panel 1 Turn on the printer and the fluid system by pressing PRINTER ON 2 Open the eyelid by pressing OPEN EYELID 3 Press TEST PRINT The TEST PRINT light comes on The DATA READY light comes on indicating data is available for printing 4 Start the document transport The TEST PRINT light flashes indicating test patterns are pr...

Page 39: ...ribed After completing each corrective action print test patterns or run the job examine the print quality of the output If necessary repeat the corrective action until the problem is corrected The following printing problems are caused by incorrect voltage settings See your system software operator s manual for details on adjusting printhead voltage settings Voltage Defects Missing or Misdirected...

Page 40: ... of a test pattern when the charge voltage is too low At the highest voltages an inkjet or printhead short may occur When this error occurs the ERROR light flashes See your system software operator s manual for details on error messages Voltage defects appear on test prints as extra dots of ink that appear near the center of the printed image or across the bottom the image 2 3 ...

Page 41: ...m persists repeat the printhead cleaning procedure 8 When all other corrective actions fail perform the printhead swabbing procedure described in Chapter 4 Phase Defects To correct a printing problem caused by phase defects perform the following steps 1 Verify that the problem is not caused by interference by cleaning the catcher plate as described in Chapter 4 2 Record the current phase setting 3...

Page 42: ...high voltage settings light streakers appear near the sixth bar of a test pattern low voltage settings cause more solid streakers To correct printing problems caused by streakers perform the following steps 1 Perform the printhead cleaning procedure described in Chapter 4 2 If the problem persists repeat the printhead cleaning procedure 3 If the problem still persists clean the printhead bottom co...

Page 43: ...ht of drops also known as drop interference This condition is the most common print problem and is usually caused by particles of dust adhering to the printhead bottom cover Drop interference can also be caused by dust on the eyelid or inside the printhead assembly To correct a printing problem caused by interference perform the following steps 1 Clean the printhead bottom cover and the eyelid See...

Page 44: ...bubbles or ink concentration See Chapter 4 for printhead cleaning procedures Irregular gaps may also appear when the voltage or phase setting is incorrect however always perform a printhead clean before attempting to adjust the printhead voltage level See your system software operator s manual for details on adjusting printhead voltage and phase levels A Single Line of Dots A single line of dots i...

Page 45: ...e caused by improper printhead height Printhead height is the distance between the bottom of the printhead and the substrate See Chapter 1 for details on printhead height 1 Make sure there is clearance between the substrate and the printhead bottom cover 2 Verify that the software parameter for printhead height matches the actual physical printhead height adjust the printhead height parameter to m...

Page 46: ...required See your system software operator s manual for details on adjusting printhead height Elongation Elongation appears on test prints as a consistent widening of characters To correct elongated characters perform the following steps 1 Verify that the parameter settings defined for tach and cue are correct See your system software operator s manual for details on adjusting tach and cue 2 If th...

Page 47: ...e Narrow Print Narrow print appears on text prints as a consistent narrowing of characters To correct printing problems with narrow print perform the following procedure 1 Adjust the parameter settings defined for tach and cue See your system software operator s manual for details on adjusting tach and cue 2 If the substrate flow appears to be hindered check the document transport for proper opera...

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Page 49: ... types of routine maintenance on the printer daily and periodic Corrective maintenance procedures are performed to correct printing problems as directed by the troubleshooting procedures described in Chapter 3 Required Tools and Supplies The following tools are required to perform the maintenance procedures described in this chapter Compressed air Mist filter Spare printhead bottom cover Kodak Ver...

Page 50: ...re less than 10 minutes to perform Cleaning the Printhead Bottom Cover To clean the printhead bottom cover perform the following procedure 1 Turn off the printer by pressing PRINTER ON 2 Position the printhead so that the bottom cover is easily accessible insert an index finger into the slot on the bottom cover and carefully pull the cover off Figure 4 1 illustrates the printhead position used whe...

Page 51: ...ed at installation be sure to align the slot on the bottom cover with the print array 5 Let the replaced bottom cover air dry Cleaning the Printhead The printhead may be cleaned at any time during printer operations The printhead should be cleaned under the following circumstances Before printing when the POC is bypassed After every 8 hours of run time When the printhead bottom cover is cleaned Wh...

Page 52: ...appears dirty Perform the following steps to clean the filter 1 Grasp the sides of the air filter and press down to free the top of the air filter from the upper bracket lift the air filter out of the bottom bracket Figure 4 3 Figure 4 3 Removing the air filter 2 Rinse the air filter in tap water shaking out the excess water 3 Air dry or use compressed air to dry the air filter 4 When the air filt...

Page 53: ...ilter perform the following steps Note Because the mist filter is clogged with ink wear gloves when performing this procedure 1 Open the fluid compartment door and locate the mist filter assembly which is centered above the ink and replenisher bottles 2 Press the release button on the left side of the filter fitting to release the mist filter assembly from its mount Figure 4 4 3 Pull the filter fi...

Page 54: ...4 6 Chapter 4 Maintenance Periodic Maintenance Figure 4 4 Removing the mist filter fitting Figure 4 5 Replacing the mist filter Release button Mist filter Filter fitting Mist filter Filter fitting ...

Page 55: ...rinthead To prevent damage to the printhead and printed circuit board components follow anti static safety precautions and use the KODAK VERSAMARK supplied wrist grounding strap when handling the printhead and circuit boards Handle circuit boards only by edges free of connectors 1 Press STANDBY 2 Press OPEN EYELID 3 Position the printhead at a 90 angle 4 Remove the printhead bottom cover by insert...

Page 56: ...andling the printhead and circuit boards Handle circuit boards only by edges free of connectors 1 Exit any system software program 2 Turn the printer off by pressing PRINTER ON PRINTER ON goes off while POWER remains on 3 Remove the printhead bottom cover from the printhead housing assembly 4 Loosen the captive screw on the printhead front cover and remove the cover 5 Remove the eyelid assembly as...

Page 57: ...otion two or three times using both sides of the swab Caution To avoid damaging the orifice plate or charge leads do not scrub the printhead with the swab or drag the swab past the ends of the orifice plate 8 Re install the eyelid assembly as described in the following procedure c Set eyelid springs into holes inside the printhead frame d Align the pin holes and slide the eyelid pivot shaft throug...

Page 58: ...the printhead bottom cover on the printhead housing verify that the opening on the bottom cover is aligned with the print array opening on the printhead assembly 11 Return the printhead to its normal operating position 12 Turn the printer on by pressing PRINTER ON ...

Page 59: ...ermines when the charge voltage is applied to the printhead Charge phase is measured in counts Also called printhead phase or phase cue A signal that represents the start of a document A cue signal occurs each time the cue sensor detects the leading edge of a piece of substrate or a pre printed cue mark on the substrate cue delay The distance from the leading edge of a piece to the start of the im...

Page 60: ...Drop interference is usually caused by particles of dust adhering to the printhead bottom cover Drop interference may also be caused by dust adhering to the eyelid or to the inside of the printhead assembly elongation A printing problem characterized by elongated characters that occurs when the parameters set for tach and cue are incorrect or the tach encoder is incorrectly tracking the substrate ...

Page 61: ...g problem that usually occurs at powerup and is characterized by missing areas of print These gaps are caused by air trapped within the printhead missing jet A white line that appears where ink should be caused by high charge voltage contamination of the eyelid or an open circuit online A term used to indicate that the printer is ready to print the printer and fluid station are on and the eyelid i...

Page 62: ... the area that can be printed by the printhead usually provided in inches or dots printhead height The distance between the bottom of the printhead and the substrate replenisher A fluid contained within a plastic bottle mounted inside the fluid compartment that maintains the proper concentration of ink resolution The degree of sharpness of an image measured in dpi shrunken print A printing problem...

Page 63: ...printed by the printer operator repeatedly to examine print quality test print A series of printed characters that the printer operator compares against the text produced by the printer to troubleshoot printing problems umbilical The part of the printer that transfers the fluids and signals between the fluid system and the printhead through an assembly of hoses and wiring encased within a flexible...

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