Colordyne | 1600-S | Troubleshooting guide | Colordyne 1600-S Troubleshooting guide

Colordyne 1600S
COLOR PAGE
PRINTER
OPERATOR
MANUAL
SAFETY PRECAUTIONS
THIS EQUIPMENT PRESENTS NO PROBLEM WHEN USED PROPERLY.
HOWEVER, CERTAIN SAFETY RULES SHOULD BE OBSERVED WHEN
OPERATING THE COLORDYNE 1600-S 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. Before clearing a jam, be
sure machine mechanisms come to a stop.

Always turn off the machine before making adjustments, cleaning the machine, or performing any
maintenance covered in this manual.

The power cord and power supply supplied with the machine should be plugged into a properly
grounded, easily accessible wall outlet located near the machine. Failure to properly ground the
machine can result in severe personal injury and/or fire.

The power cord and wall plug is the primary means of disconnecting the machine from the power
supply.

DO NOT use an adapter plug on the line cord or wall outlet.

DO NOT remove the ground pin from the line cord.

DO NOT route the power cord over sharp edges or trap it between furniture.

Avoid using wall outlets that are controlled by wall switches or shared with other equipment.

Make sure there is no strain on the power cord caused by jamming between equipment, walls or
furniture.

DO NOT remove covers. Covers enclose hazardous parts that should only be accessed by a
qualified service representative. Report any cover damage to your service representative.

This machine requires periodic maintenance. Contact your authorized service representative for
required service schedules.

To prevent overheating, do not cover the vent openings.

Use this equipment only for its intended purpose.
In addition, follow any specific occupational safety and health standards for your workplace or area.
This manual is intended solely for the use and information of Colordyne Technologies, LLC, its
designated agents, customers, and their employees. The information in this guide was obtained
from several different sources that are deemed reliable by all industry standards. To the best of
our knowledge, that information is accurate in all respects. However, neither Colordyne
Technologies, LLC nor any of its agents or employees shall be responsible for any inaccuracies
contained herein.
ColordyneTM is a registered trademark of Colordyne Technologies, LLC.
MemjetTM is a registered trademark.
All other trademarks are the property of their respective holders.
All rights reserved. No part of this book may be reproduced or transmitted in any form or by any means, electronic or mechanical,
including photocopying, recording, or any information storage and retrieval system, without permission in writing from the publisher.
TABLE OF CONTENTS
Table of Contents
SECTION 1 – Getting Acquainted
Front View
Rear View
Control Panel Button/LED Indicators:
SECTION 2 – Installing the Printer
Contents of Packaging
Choose a Location
Unpacking and Setup
Hydrating the Printhead Cartridge
Remove Service Station Transport Tab
Assembling the Printer
Connecting the Colordyne 1600-S
Install the Printer Driver
Install the Ink Tanks
Install the Printhead Cartridge
Installing Envelope Printing Attachment
Setting up the Feed
SECTION 3 – Operating the Colordyne 1600-S
Setting Up a Job in MS Word
Printing a Typical Job on 8.5-inch by 5.5-inch Paper
Printer Driver Properties
Using the Printer Toolbox
SECTION 4 – Maintenance
Replacing the Ink Tanks
Cleaning/Replacing the Printhead Cartridge
Replacing the Service Station
Replacing the Ink Waste Tray
Replacing the Sheet Separators
Jams in the Colordyne 1600-S Printer
Cleaning
Shipping or Transporting the 1600-S Printer
SECTION 5 – Troubleshooting Guide
The Memjet Printhead
The Printer
Appendices
Appendix A – Colordyne 1600-S Specifications
Appendix B – Supplies and Optional Hardware
1
1
2
3
5
5
5
5
6
7
7
9
10
12
14
17
18
20
20
21
22
25
32
32
34
38
41
41
42
43
45
48
48
49
50
50
50
Index
51
Printer Maintenance Schedule
53
i
NOTES
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ii
SECTION 1
GETTING ACQUAINTED
SECTION 1 – Getting Acquainted
Front View
1.
2.
3.
4.
5.
Paper LED Button – Press to stop printing, press to restart printing. Press switch
to continue printing.
ON/OFF LED Button -- Use to turn power ON or OFF during idle time and
maintenance.
Rear Guide – Holds the media against the Front Plate.
Rear Guide Support – Supports the paper/media.
6.
Adjustable Media Guide – Adjusts to hold the paper/media against the
Envelope/Paper Register Guide.
7.
Envelope/Paper Media Guide – All printing is registered against this Guide. It
has adjustable positions for envelopes and paper.
8.
9.
1
Cancel LED Button – Press this switch to cancel the job being printed.
Top Cover – Provides access to the Print Engine.
Front Cover – Provides access to the Ink Tanks.
SECTION 1
GETTING ACQUAINTED
Rear View
2
1.
Main Power Switch, Receptacle and Fuse – Plug in power cord here. Switch
turns main power ON/OFF. (Use Control Panel LED Power switch to turn off
machine for cleaning and maintenance). Fuse protects the Printer’s electronic
circuits.
2.
USB Port Connection – The USB cable attaches to the Printer here.
3.
Network Connection – The network cable plugs in here.
4.
Envelope/Paper Media Guide – All printing is registered against this Guide. It
has adjustable positions for envelopes and paper.
5.
Adjustable Media Guide – Adjusts to hold the paper/media against the
Envelope/Paper Media Guide.
6.
Rear Guide– Holds the paper/media against the Front Plate.
7.
Rear Guide Support – Supports the paper/media.
8.
Counter – LCD displays number of pieces run for a given job. Reset button
zeros Counter.
SECTION 1
GETTING ACQUAINTED
Control Panel Button/LED Indicators:
The Control Panel has 3 buttons with LED
indicators.
POWER (ON/OFF) – Turns Printer power
ON and OFF. Turn off power for cleaning
and maintenance.
PAPER (STOP JOB/RESUME) – Stops
Paper Feed or Resumes Printing.

Press to Stop Paper Feed
Immediately. Printer will clear media in Printer and stop.

Press to Resume Printing. Restart printing after a paper feed error (such as a paper jam or
running out of paper).
CANCEL (CANCEL JOB) – Cancels a Job.

Press to Cancel a Job. Once the Printer has stopped, pressing this button clears job from Printer
and Print Queue in Driver. NOTE: Cancelled Jobs must be reloaded before printing can resume.
PRINTER OPERATION INDICATORS – NORMAL
PRINTER
STATUS
3
POWER
PAPER
CANCEL
(ON/OFF)
(STOP/RESUME)
(CANCEL JOB)
Power cord
plugged in, Main
Power Switch ON,
Control Panel
Power Switch OFF.
Unit Powered Up,
No Job Loaded.
LED OFF
N/A – LED OFF
N/A – LED OFF
LED ON, steady
LED OFF
Press and hold for 3 seconds
to feed single piece at 6
inches/second.
N/A – LED OFF
Job Loading
LED ON, steady
Printing
LED ON, steady
LEDs flashing alternately ON/OFF once/second.
Job Loaded,
Printer Stopped.
Maintenance
Running
LED ON, steady
LED ON, flashing ON/OFF
LED OFF.
once/second.
LEDs flashing simultaneously ON/OFF once/second.
Wait until Maintenance stops running.
LED ON, steady
LEDs flashing simultaneously ON/OFF once/second.
SECTION 1
GETTING ACQUAINTED
PRINTER ERROR INDICATORS
PROBLEM
Paper Feed
Times Out/Out
of Paper
POWER
(ON/OFF)
LED ON, steady
PAPER
(STOP/RESUME)
LED ON, flashing about 3
times/second.
CANCEL
(CANCEL JOB)
LED OFF
ACTION:
Press PAPER to pause job. Check/clear paper jams or reload feeder. If OK, press
PAPER to resume printing. If not fixed, press CANCEL to cancel the job.
Sensor(s)
Covered
ACTION:
LED ON, steady
Tilt Error
LED ON, steady
ACTION:
Press PAPER to stop feed. Check that Printer is on a stable, level surface. If OK,
press PAPER to resume printing. If not fixed, press CANCEL to cancel the job.
Ink Tank
Missing
ACTION:
LED ON, steady
Other Errors
LED ON, steady
ACTION:
Press PAPER to stop feed. Try to determine and correct the problem. If OK, press
PAPER to resume printing. If not fixed, press CANCEL to cancel the job.
LED ON, steady
LED OFF
Press PAPER to pause job. Remove media covering Sensor or clean Sensor. If OK,
press PAPER to resume printing. If not fixed, press CANCEL to cancel the job.
LEDs flashing fast alternately
ON/OFF about 3 times/second.
LED OFF
LED ON, steady.
Press POWER to turn off Printer. Install missing Ink Tank(s) (see Replacing Ink
Tanks in Maintenance)
LEDs flashing fast simultaneously
ON/OFF about 3 times/second. .
MORE TROUBLESHOOTING GUIDES ON PAGE 48
4
SECTION 2
INSTALLING THE PRINTER
SECTION 2 – Installing the Printer
Contents of Packaging
1.
Colordyne 1600-S Printer
2.
Ink Tanks – Cyan, Magenta, Yellow, Black, Black
3.
Printhead Cartridge
4.
Media Side Guides: Registration (Fixed) and Adjustable –
mounting screws attached to Printer
5.
Rear Media Support Guide
– thumbscrew attached to Printer
6.
Media Support Wedges: Narrow and Wide
– mounting hardware attached to Rear Media Support Guide
7.
Envelope Printing Attachment
Use when printing large volume envelope jobs)
8.
AC Power Cord
9.
USB Cable
10.
Operator Manual
11.
Driver Software CD
Before using the Colordyne 1600-S Printer the following must be done:

Choose a location for the Printer

Unpack and assemble the Printer

Hydrate the Printhead Cartridge

Remove the Service Station Transport Tab

Plug in the Printer and connect it to the computer

Install the Printer Driver

Install the Ink Tanks

Install the Printhead

Set up the feed on the Printer
Choose a Location
The Colordyne 1600-S should be placed on a sturdy level worktable or cabinet at least 9 inches from
any walls. Protect the Colordyne 1600-S from excessive heat, dust, and moisture – avoid placing it in
direct sunlight.
Unpacking and Setup
Remove the Printer and its parts from the carton. Remove all packing tape. The screws that attach the
various parts of the Guides to the Printer are under the tape in their respective positions.
5
SECTION 2
INSTALLING THE PRINTER
Hydrating the Printhead Cartridge
Before you begin assembling the Printer, it is a good idea to hydrate the Printhead Cartridge.
CAUTION

Use electrostatic discharge (ESD) protection when handling.

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.
Protect the Printhead from scratches, dust, fibers, dirt and other
contaminants at all times.
6
1.
Carefully remove the
Printhead Cartridge
from the foil packaging.
[A] 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
with one hand. Pull the
strip tab with the other hand and slowly peel the strip from the
Printhead. DO NOT pull the strip at any angle less than 45° with the Printhead surface. DO
NOT allow removed strip to touch the Printhead Nozzles.
2.
Pour just enough distilled water into the orange plastic cover you removed in Step 1B to
moisten the bottom strip inside. Carefully reinstall the Printhead back into the plastic cover.
Set the Printhead aside for installation later. This rehydrates Printhead and allows easier
priming once it is installed in the Printer.
SECTION 2
INSTALLING THE PRINTER
Remove Service Station Transport Tab
1.
Open the Top Cover.
2. Release the two latches (one on either side of the
Print Engine). Open the top half of the Print Engine
by lifting both levers at the same time.
CAUTION
OPERATE AND HOLD ONTO BOTH
LATCHES WHEN OPENING AND
CLOSING THE PRINTHEAD
ASSEMBLY TO PREVENT DAMAGE.
DO NOT ALLOW THE ASSEMBLY TO
DROP BY ITSELF WHEN CLOSING.
TO PREVENT DAMAGE TO THE INK
LINES, A STOP LIMITS RAISING THE
ASSEMBLY MORE THAN 60°.
3. Pull up on the two tabs to remove the cardboard
Transport Tab up from the Service Station.
4. Carefully close and relatch the Upper Print Engine.
Then close the Top Cover.
Assembling the Printer
Begin by installing the Adjustable Side Guide with two
screws [1]:
7
SECTION 2
INSTALLING THE PRINTER
Next install the Envelope/Paper Side Guide using the two
screws [2] provided.
Attach the Rear Paper Support using the knob [3] provided.
NOTE: The two outside holes fit over the socket head
screws.
Install the Back Guide using the thumbscrew and washer
[4] provided. The washer goes between the screw and the
Rear Paper Support.
8
SECTION 2
INSTALLING THE PRINTER
Connecting the Colordyne 1600-S
Plugging in the Printer
Connect the power cord to the receptacle [1] at the rear of the Printer. The
internal power supply in the Printer is rated 115 to 240VAC, 50/60 Hz.
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.
DO NOT USE AN OUTLET THAT SHARES THE SAME CIRCUIT
WITH LARGE ELECTRICAL MACHINES OR APPLIANCES.
Connecting to the Computer
The Printer connects to the computer through the USB port [2].
A Network port [3] is provided when operating in a network environment. See
“Network Connection Setup” in the “Using the Printer Toolbox” section.
Turning Power ON and OFF
Powering Up Printer:
1.
Press the Main Power Switch on the Rear Panel.
2.
Press the Power Button on the Control Panel.
Powering Down Printer:
CAUTION
WHENEVER POWERING DOWN UNIT, ALWAYS:
1. PRESS THE POWER BUTTON ON THE CONTROL PANEL.
2. WAIT FOR THE PRINTER TO STOP PROCESSING.
3. THEN PRESS THE MAIN POWER SWITCH ON THE REAR PANEL.
9
SECTION 2
INSTALLING THE PRINTER
Install the Printer Driver
For the Printer software to operate properly check that the computer system meets these minimum
requirements:






Windows XP, Windows Vista, Windows 7. (Supports 32 and 64 bit systems)
You must have administrative privileges on the system.
Microsoft Internet Explorer 6.0 or higher.
Java version 6 or higher
USB 2.0 port (ports will be identified as “USB2” or “Enhanced” in the Device Manager.)
Microsoft .NET Framework 3.5 installed (Even if you have a higher version installed, version
3.5 must also be installed.)
IMPORTANT: Before installing the Printer software (Toolbox and Driver), you should temporarily
disable all antivirus programs and firewalls. In addition, you must be logged onto the system with full
administrative privileges (admin rights).
NOTE: If installing over USB, do not plug in the USB cable until prompted.
10
1.
Make sure the Printer is plugged in and turned OFF.
Disconnect the USB connection if you have plugged it
in already. Install the disk supplied with the Printer in
your CD drive. When the AutoPlay Window opens,
click “Run Setup.exe” to start.
2.
The “Install Printer Software” window opens on
the computer screen. Make sure the computer
system meets the minimum requirements and
you have followed the other instructions on the
screen. Click “Install Printer Software”.
3.
The License Agreement window opens.
Carefully read the “End User Agreement”. If
you agree to the terms, check “I accept…” then
click Next>.
SECTION 2
INSTALLING THE PRINTER
11
4.
After a few moments the “Printer Connections”
window opens. Click “Configure to print using
USB”. Then click Next>.
5.
After a few moments the “M Series Driver”
window opens followed by the “Would you like
to install this device software?” window. Click
“Install” and the driver software will load from
the disk.
6.
The software will start to download and a
second “Would You Like to Install This Device
Software” opens. Click Install.
7.
The “Connect Device Now” window opens.
Switch the Printer on and connect the USB cable.
Don’t click on either button. The software will
then finish installing.
SECTION 2
INSTALLING THE PRINTER
8.
The “Finished software installation” window
opens. Do not print a test page since printer is not
set up yet. Do not check the Print Test Page.
Click Next>.
9.
The M Series Driver welcome window returns.
Note that you can click on the User’s Guide for
installation, document set up and printer
maintenance, cleaning and troubleshooting
information. If you are connected to the Internet
you can click Website. Click Exit to close CD.
10. Restart the computer to complete the installation.
Install the Ink Tanks
M Series Printers use a single Printhead Cartridge and five Ink Tanks (two Black, one Cyan, one Magenta,
and one Yellow). Install the Ink Tanks as follows:
1.
12
Open the Printer Toolbox. Go to All Programs, open
the Colordyne Folder and open the Toolbox. On the
Opening Screen you will see System Status information
in the upper left corner.
SECTION 2
INSTALLING THE PRINTER
2.
Open the Front Cover (hinged at bottom).
Open the three Latches [A].
3.
Remove the new Tank(s) from packaging.
4.
Slide the new Tanks (label up) into their
appropriate color slots [B].
INSTALLATION TIP: Make sure the
Tanks seat properly. Insert the Tank
into the appropriate Ink Station, then
pull the Tank back about an inch and
push forward firmly to insure that the
Ink Nozzles penetrate the seals on the
Tanks.
5.
Watch the Toolbox screen on your computer; you will
see the ink colors fill in as the Tanks are installed. If the
ink color does not fill in after a few seconds, reinstall
the Tank.
6.
Close the three Latches. Close the Front Cover.
WARNING!
The ink in the Ink Tanks may be
harmful if swallowed. Keep new and
used Tanks out or reach of children.
Discard empty tanks immediately.
13
SECTION 2
INSTALLING THE PRINTER
Install the Printhead Cartridge
The Printhead Cartridge is a delicate precision device. Handle with extreme care to avoid damage and
issues that could degrade print quality.
CAUTION
1.

Use electrostatic discharge (ESD) protection when handling.

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. Protect the Printhead from scratches, dust, fibers, dirt and
other contaminants at all times.
With the Printer power ON, open the Top
Cover. Press the Printhead Cover Release
Button [1]. The Printer will run a routine, then
the Cover will pop open [2].
NOTE: Remove the Cap Protectors on the
Ink Nozzles [3]. Be sure to open the Cover
fully to retract the Ink Nozzles.
CAUTION
DO NOT PRY OR MANUALLY LIFT THE PRINTHEAD COVER OR THE COVER
MAY BREAK. ONLY OPEN THE COVER USING THE RELEASE BUTTONS ON
THE PRINTER OR THE PRINTHEAD RELEASE COMMANDS IN THE
SERVICES TAB OR M SERIES TOOLBOX.
14
SECTION 2
INSTALLING THE PRINTER
2.
Take the Printhead
Cartridge you hydrated
and set aside earlier,
remove the orange cover
and proceed to Step 3.
Otherwise, follow the
Steps below:
Carefully remove the
Printhead Cartridge
from the foil packaging.
[A] 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
with one hand. Pull the strip tab with the other hand and slowly peel the strip from the
Printhead. DO NOT pull the strip at any angle less than 45° with the Printhead surface.
DO NOT allow removed strip to touch the Printhead Nozzles.
IMPORTANT! Pour just enough distilled water into the orange plastic cover you removed in
Step 1B to moisten the bottom strip. Carefully reinstall the Printhead back into the plastic
cover. Set the Printhead aside for 15 to 20 minutes. This rehydrates Printhead and allows
easier priming once it is installed in the Printer.
WARNING!
TO AVOID ELECTRICAL SHOCK OR SHORTING:
Before installing Printhead, make sure nozzles are hydrated and contacts are DRY!
3.
15
Carefully insert the Cartridge into the compartment at an angle [4], with the Printhead surface
facing down and the Ink Nozzles facing the Ink Hoses. Once it is seated, gently tilt the Cartridge
back until it snaps into an upright position [5]. DO NOT FORCE the Cartridge into position.
SECTION 2
INSTALLING THE PRINTER
4.
Wet the Printhead Surface. This ensures
that the Printhead will prime correctly.
Open the Top Cover. Release and lift up the
two latches at the same time to raise the
Printhead Assembly. Moisten the Printhead
nozzles using distilled water and a damp,
lint-free cloth, wiping end to end. (Gray
strip located below orange strip.) Close
and relatch the Printhead Assembly.
CAUTION
OPERATE AND HOLD ONTO BOTH
LATCHES WHEN OPENING AND
CLOSING THE PRINTHEAD
ASSEMBLY TO PREVENT DAMAGE.
DO NOT ALLOW THE ASSEMBLY TO
DROP BY ITSELF WHEN CLOSING.
TO PREVENT DAMAGE TO THE INK
LINES, A STOP LIMITS RAISING THE
ASSEMBLY MORE THAN 60°.
5.
Close the Printhead Cover [6]. The Printer will run a
start-up routine and prime ink into the Printhead.
This may take a few minutes. Make sure that ink is
flowing through the ink hoses.
6.
Watch the Toolbox screen on your computer again. Notice
that some of the information is in red. As the Printer
circulates ink and primes the system these fields should all
turn black.
7.
When the Printer stops processing and all the fields in
System Status are black, the Printer is ready for use. Close
the Top Cover.
NOTE: The Printer may take up to 12 minutes to set itself up
during initial startup. This is normal. The machine will emit a
number of chirps, whirrs and other noises as it circulates ink
and runs systems.
16
SECTION 2
INSTALLING THE PRINTER
Installing Envelope Printing Attachment
Use this attachment if you are primarily printing envelopes or running large batches of envelopes. The
attachment flattens the envelope flap for better print consistency.
1.
Open the Top Cover. Press the
Printhead Latch Cover Release Button
(or click the Printhead Release from
the Services Tab or the User Interface
screen in the Toolbox.) The Printer
pumps any ink in the system back into
the Tanks. Wait for the Printhead
Latch Cover to open.
2.
Make sure the Printhead Latch Cover
is fully opened to retract the ink lines.
Tilt the Printhead Cartridge back
toward the ink lines and lift it up
slightly. This will keep the printing
surface out of the way during
installation.
3.
Open the Printhead Clamshell.
4.
[A] Slide the Envelope Printing
Attachment up behind the metal
support.
[B] Push the Attachment to the right
side of the Printer to lock the
Attachment in place.
[C] While the Printhead Clamshell is
still open, snap the Printhead
Cartridge back into place. Make sure
the Attachment is aligned with the
Printhead Cartridge as shown.
5.
Wipe the Printhead Nozzles end to
end using distilled water and a damp
lint-free cloth. Close and relatch the
Printhead Clamshell. Close the
Printhead Latch Cover and Top Cover.
Reprime the system.
NOTE: Remove the Attachment if you are
going to primarily run flat sheets.
17
SECTION 2
INSTALLING THE PRINTER
Setting up the Feed
The Colordyne 1600-S Printer is equipped with four Sheet Separators, two Side Guides and a Rear Media
Guide. The Sheet Separators are adjusted individually as follows:
18
1.
Move the Left-hand Side Guide into position. This Guide has two positions. The position closest
to the Side Frame is for 9.5" media and the position closest to the center of the Printer is for
printing 8.5" wide media edge to edge.
2.
Loosen the locking screws located behind
the Sheet Separators and raise the Paper
Separators, then tighten the locking screws
to hold the Separators in the "Up" position.
3.
Place a single piece of the media to be run
under the Separators. Always place the
media against the Left-hand Paper Guide.
Loosen the separator locking screw and
allow the Paper Separator to settle onto the
media. Then tighten the locking screw.
Repeat for each Paper Separator.
SECTION 2
INSTALLING THE PRINTER
4.
Adjust the Right-hand Side Guide so that it is about
1/32-inch from the sides of the media. Tighten the
locking knob on the Side Guide. Place a stack of
media in the machine. Press and hold the Paper key
to feed one piece through the Separator.
NOTE: To prevent misfeeds and tearing, keep
the Right hand Side Guide at least 1/8" from the
Side Frame.
5.
Adjust the Rear Support Guide by using the knob
to slide the Guide right and left. If you experience
feeding problems, slide the Rear Support Guide
right or left keep the media aligned with the
Media Guides.
6.
Adjust the Rear Media Guide by loosening the
locking screw and moving the Guide to raise the
media approximately 2" above the Feed Table for
paper and about ½" for envelopes.
NOTE: The amount of media that can be stacked
on the Printer is determined by the weight of the
material. The Feeder may not feed larger and
heavier media when the stack is full. If this is the
case, reduce the amount of media in the stack until
the Feeder functions properly.
19
SECTION 3
OPERATING THE COLORDYNE 1600-S
SECTION 3 – Operating the Colordyne 1600-S
Once the Printer Driver is installed on your computer and the Printhead is primed, you are ready to start
printing. Set up your job and send it to the Printer. The Printer will start and print.
This rest of this section is divided into two parts:
1.
How to set up a job to print from Microsoft Word.
2.
Driver properties and the various options available when you run a job.
The Printer Driver that you installed on your computer in Section 2 should be set as the default driver. It
will then be accessible through your applications such as Microsoft Word. Other types of applications and
database management software will work in a similar manner when using this Driver. This Section further
assumes that you have set up the feed and the Printer is connected to your computer.
Setting Up a Job in MS Word
When setting up a job to print in MS Word or any other
application, first determine the print area of the Printer
and the paper sizes it can handle.
Maximum print area for the Printer:
8.5" wide x 17" long.
Maximum paper size Printer can feed:
9.5" wide x 17" long. (See diagram at right.)
Minimum paper size Printer can feed:
3" wide x 4.2" long.
To set up the maximum print area for a 9.5" x 17"
document, set the paper size to 9.5" wide by 17" long in
the "Custom Paper" setting. Set top and bottom margins to
0" or any margin you require. Set right-hand and left hand
margins to 0.5". You can now layout the job and print the
maximum printing area.
For other page sizes such as 8.5" x 11" (standard letter) or
8.5" x 14" (legal size), set the paper size to the exact size
and set the margins as needed.
NOTE: Set the Left-hand Side Guide to the proper
9.5" position when running 9.5" wide media.
Set the Guide to the 8.5" position when
running 8.5" or narrower media.
Envelopes: Select an envelope (example uses a
#10 envelope) from "Page Setup" in MS Word.
Feed the envelope by the 9.5" inch width, (the
fastest way to run envelopes, especially if you
are addressing them with a Mail Merge). Set the
top and bottom margins to 0", the left and right
margins at 0.5" as shown.
20
SECTION 3
OPERATING THE COLORDYNE 1600-S
Printing a Typical Job on 8.5-inch by 5.5-inch Paper
The Colordyne 1600-S can print edge-to-edge on an 8.5" x 5.5"
document. Follow these steps to set up a job:
1.
Go to File, then Page Setup and select 0" margins.
2.
Select the Paper tab, select Paper Size “Custom size” then
set the paper Width to 8.5" and the paper Height to 5.5".
Then click OK.
3.
The screen at right is an example of
a job to be printed. Once the job is
ready for printing, select "Print"
from the file menu and print the job.
For more information about changes that
can be made in the Driver please see the
Printer Driver section.
21
SECTION 3
OPERATING THE COLORDYNE 1600-S
Printer Driver Properties
The Printer Driver for the Colordyne 1600-S works the same as any other Printer Driver for Windows. It
does have some enhancements to help you maximize the ability of the Printer to print variable addressed
pieces quickly and efficiently.
Windows XP, Vista, Windows 7: Once
the job is set up, click File, then Print.
The window on the right will open. Make
sure the M Series Driver is the selected
Printer. Clicking on Properties opens the
“Properties” window.
General Tab
The General tab lets you select:

Orientation – Portrait (Default),
Landscape, Rotate 180° and Mirrored.

Page Buffering – Allows the entire print
job to load before printing starts.

Copies – Lets you choose the number of
copies to be printed.
NOTE: Reverse Order is set as
the default. This means the job
starts printing from the last
page. The entire job will load
into the Printer before printing
starts. Large jobs may take
some time to load.
Unchecking the box prints the
job starting with the first page.
Printing starts as soon as first
page loads.
22
SECTION 3
OPERATING THE COLORDYNE 1600-S

Media – Choose a type of media or different
size media than the document was originally
designed for. Type: Chart at right lists the
media profiles associated with the type of
media chosen. Sizes: 21 sizes are available.
The document is automatically resized to fit
the new media. You can also create and save a
Custom Size to suit your needs. NOTE: Do
not exceed maximum paper size for the
Printer.
MEDIA TYPE
MEDIA PROFILE
Plain Paper
Bright White Paper
Transparency Film
Plain Paper
Premium Photo Paper Glossy
Photo Paper Glossy
Label Glossy
Premium Glossy Label
Photo Greeting Cards Glossy
Photo Paper Semi-gloss
Postcards Glossy
Brochure Glossy
Glossy Label
Photo Paper Matte
Label Matte
Photo Greeting Cards Matte
Brochure Matte
Premium Inkjet Paper
Presentation Paper
Other Inkjet Paper
Postcards Matte
Matte Coated Label

Color Selection – Set Printing for Color or
Monochrome.

Print Quality – Select Normal or Best.
Normal is 1600 x 800 dpi, checking the Half
Speed box slows printing for higher quality on
glossy stock. Best setting is 1600 x 1600 dpi,
for use when high quality images are required.

My Print Settings – Access your saved custom print settings for various jobs.
Layout Tab
Layout allows you change how the document
prints without changing the original document.
23

Resizing – Lets you specify the
Original Size or Custom Resize: lets
you resize the original as a % of normal
size. The Printer will print the document
in the size you selected regardless of the
size of the paper selected. Print on: lets
you specify the particular size of paper
that you want to print on regardless of
the size of the original document.
Checking “Scale to Fit” automatically
resizes the document to fit on the new
page size.

Printing Adjustments – Allows you to
make minor positioning changes to the
print area in relation to the media if
needed.
NOTE: Only works on jobs using less
than the full print area (less than 8.5"
wide).

Watermark – Prints a light background watermark in the paper while printing the original
document. When this option is selected the “First page only” option prints the watermark on the
first page, but not subsequent pages. Unchecking prints the watermark on all pages. The Custom
button lets you create a new watermark or edit an existing watermark, including font selection,
color, size and printing angle.

My Print Settings – Access your saved custom print settings for various jobs.
SECTION 3
OPERATING THE COLORDYNE 1600-S
Services Tab
Services allows you to:
24

Print Configuration Page – Prints out
the current configuration of the Printer
including current Firmware Version,
Network Connection, printer Serial
Number and more.

Print Colorbar Page – Prints type and
color bands to check print quality.

Print Diagnostic Page – Shows basic
Printer information, memory, Network
Settings, Event Log and RAM partitions.

User Maintenance, Levels 1 to 3
Level 1 – Circulates ink, wipes and
cleans the Printhead Cartridge.
Level 2 – Runs cleaning and wiping
routine twice for better flushing and
cleaning.
Level 3 – Runs the cleaning routine
multiple times for the most thorough
flushing and cleaning of the Printhead.
NOTE: If the Printer is connected to a
network and the Driver buttons fail to activate the cleaning process, you can perform the
same functions from the Toolbox User Interface.

Wipe Printhead – Wipes and cleans excess ink from the Printhead Cartridge.

Printhead Release – Performs the same task as the Cover Release button on the Printer. Deprimes
the ink from the system and opens the Printhead Cover for removing/installing the Printhead
Cartridge.

System Deprime – Drains the ink in the lines back into the Ink Tanks before servicing the
Printhead Cartridge or prepping the Printer for storage or transport.
SECTION 3
OPERATING THE COLORDYNE 1600-S
Using the Printer Toolbox
Once the Printer Driver is installed, you have access to the Printer Toolbox. The Toolbox lets you monitor
ink usage, perform diagnostic checks, print reports and run maintenance tasks on the Printer from your
computer.
To open the Toolbox:
Click Start from the Windows taskbar, go to All Programs, open the Colordyne folder, then click on
“Toolbox”. When the “User Interface” window opens you will find a series of Menu Options you can click
on at the lower left of the screen. You can check the Printer Status in the upper left part of the screen.
User Interface
[A] Screen Buttons: Let you perform
maintenance and operating tasks. You can use
the screen buttons to Clear Errors, Cancel a Job,
Reset the Job Counter, and Reset the Page
Counter. You can also:
Wipe Printhead – Activates the Service
Station to wipe the Printhead.
Release the Printhead – Performs the same
task as the Cover Release button on the
Printer. Pumps the ink back into the Ink Tanks
and opens the Printhead Cover to
remove/install the Printhead Cartridge.
Circulate Ink – Purges air from the lines and
primes the system after replacing the Ink
Tanks or Printhead Cartridge.
System Deprime – Pumps the ink back into the Ink Tanks prior to replacing the
Printhead Cartridge or transporting the Printer.
25
SECTION 3
OPERATING THE COLORDYNE 1600-S
Cleaning Buttons: Provide 3 levels of cleaning for the Printhead Cartridge. These work the same way as
the 3 Maintenance Level Buttons in the Printer Driver:
Quick Clean Printhead – Circulates ink, wipes and cleans the Printhead Cartridge.
Normal Clean Printhead – Runs cleaning and wiping routine twice for better flushing and cleaning.
Full Clean Printhead – Runs the cleaning routine multiple times for the most thorough flushing and
cleaning of the Printhead.
Eject Service Station – Releases the Service Station for removal for cleaning, repair or replacement.
Install Service Station – Pulls the Service Station back into place after cleaning, repair or replacement.
[B] Basic Printer Settings – Lets you adjust
automated service and cleaning intervals, adjust
the feeder speed for a job and adjust the Printer
for pre-printed media.
KWS Setting – (Keep Web Spitting) Keeps
Printhead hydrated while running a job. Select
from 3 settings: None, Light (default), Heavy,
to determine how much ink will “spit” from
the Printhead Nozzles. Set in conjunction with
“Mid Job Servicing” which determines the
frequency of the Printer stopping for selfservicing during a job.
Mid Job Servicing – Sets the frequency of
automatic maintenance cycles run during a job
after a set amount of media is run. Settings
are: Default (14m), Level 4 (100m), Level 3
(250m), Level 2 (375m), Level 1 (500m) and Off (. NOTE: Changing the setting from “Default”
may cause print quality issues and reduce Printhead life.
Cutsheet Feeding Mode – Permits you to change how the Printer feeds media depending on the type of
job you are running:
Safe Feed – Leaves a larger gap between pieces to reduce overprinting onto the next piece. This
setting is useful for more intricate printing jobs or jobs requiring the best print quality.
Max_Throughput – Allows fastest printing speed. The Printer works like a stream feeder. This
setting is useful for simple printing jobs. NOTE: A few extra blank pieces may run through at the end
of the job.
NOTE: These two settings can be changed “on the fly” without stopping the job. Example: While
running a job in “Max-Throughput” you find that the media is jamming excessively due to speed.
Open the Toolbox, check “Safe Feed” and click “Submit”. The Printer will automatically adjust
without having to pause or stop the job.
Ignore Exit Sensor – Checking this box turns the Exit Sensor OFF. The Sensor may not “see” the
trailing edge of a piece of pre-printed media if the back of that media is dark or black. (Example: adding
addresses to a pre-printed postcard.) This may “fool” the Sensor into thinking a jam has occurred.
Turning the Sensor OFF prevents these “false jams” from stopping the job.
26
SECTION 3
OPERATING THE COLORDYNE 1600-S
[C] Shutdown – Turns the Printer OFF from
your computer.
[D] Display Language – Selects the language
the Printer will operate in.
[E] Firmware Download – Get the latest version
of firmware for your Printer.
How to download new firmware:
1.
2.
3.
4.
5.
27
When you are notified that new firmware
is available for your Printer, download the
*.fbf file and save it to your desktop.
Open the Toolbox. On the “User
Interface” page, find Firmware
Downloads.
Click the “Browse” button and find the
file you just saved to your desktop.
Click “Submit”. DO NOT touch the
Printer until the firmware is loaded! A
message will appear on your screen
warning you not to unplug or shut off the Printer.
Once the firmware finishes loading (about 5-10 minutes), the Control Panel lights and Printer
shuts OFF. Press the Control Panel Power button to restart the Printer and installation is complete.
SECTION 3
OPERATING THE COLORDYNE 1600-S
Diagnostics
From this screen you can see the current status of
your Printer. You can also:
Print Sample Page – Prints type and color bands
to check print quality.
Print Configuration Page – Shows the current
configuration of the Printer including Firmware
Version, Network Connection, Printer Serial
Number and more.
Print Diagnostic Page – Shows basic Printer
information, memory, Network Settings, Event
Log and RAM partitions.
Print Demo Page – Prints a 4-color sheet.
Print Ink Channels – Prints 5 bars (1 bar from each ink tank) to show how well the Printhead Nozzles are
working.
Print Color Bars Page – Prints a series of 8 color bars to show how well the Printhead is mixing colors
and printing.
Ink Usage
Allows you to monitor the estimated amount of ink left
in each of the five Ink Tanks. You can monitor ink
consumption and schedule Tank changes (saving
down-time during a print run.) NOTE: Ink Usage only
works when you start with a new Ink Tank and
leave it in the Printer.
Ink Estimation Mode – Checking this box lets you
predetermine how much ink a given job may use prior
to printing. This can be useful for determining per
piece costs. The job is sent to the Printer and loads, but
does not print. Once the job is loaded, the chart shows
the amount of ink (by color) that the job will use.
NOTE: The estimating process will take as long as
the job would take to print (i.e., if the job would
take 1 hour to print, the estimate will take 1 hour to display.)
28
SECTION 3
OPERATING THE COLORDYNE 1600-S
Network Configuration
Permits you to view, enter or change settings to connect the Printer to your network.
Network Connection Set Up:
29
1.
The Printer is still connected to the computer via
the USB cable.
To connect the Printer to a network, open the
Toolbox. On the “User Interface” page, click
Network Config.
2.
The “Network Status and Configuration” page
opens. Your IT person can choose the Network
Settings box to enter the correct settings for
your network.
3.
Connect Ethernet cable to Network Port on Rear Panel of Printer.
SECTION 3
OPERATING THE COLORDYNE 1600-S
Service Menu
For authorized personnel only. Provides
access to more advanced Printer control and
maintenance menus.
30
SECTION 3
OPERATING THE COLORDYNE 1600-S
NOTES
______________________________________________________
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______________________________________________________
______________________________________________________
______________________________________________________
______________________________________________________
______________________________________________________
31
SECTION 4
MAINTENANCE
SECTION 4 – Maintenance
This section covers how to care for the Ink Tanks, Printhead Cartridge, Service Station, clear paper jams
and replace the Sheet Separators.
Replacing the Ink Tanks
Replace the Ink Tanks when the ink runs out.
32
1.
Open the Printer Toolbox. Go to All Programs, open
the Colordyne Folder and open the Toolbox. On the
Opening Screen you will see System Status information
in the upper left corner.
2.
Open the Front Cover (hinged at bottom).
Open the three Latches [A] and pull the
Ink Tank(s) out of the Printer.
3.
Remove the new Tank(s) from packaging.
4.
Slide the new Tank (label up) into its
appropriate color slot [B].
INSTALLATION TIP: Make sure the
Tanks seat properly. Insert the Tank
into the appropriate Ink Station, then
pull the Tank back about an inch and
push forward firmly to insure that the
Ink Nozzles penetrate the seals on the
Ink Tanks.
SECTION 4
MAINTENANCE
5.
Watch the Toolbox screen on your computer; you will
see the ink colors fill in as the Ink Tanks are installed.
If the ink color does not fill in after a few seconds,
reinstall the Tank.
6.
Prime the system by running the Circulate Ink routine
from the User Interface window in the Toolbox.
7.
Watch the Toolbox screen on your computer again.
Notice that some of the information is in red. As the
Printer circulates ink and primes the system these
fields should all turn black.
8.
When the Printer stops processing and all the fields in
System Status are black, the Printer is ready for use.
9.
Latch the three Latches. Close the Front Cover.
WARNING!
The ink in the Ink Tanks may be
harmful if swallowed. Keep new and
used Tanks out or reach of children.
Discard empty Tanks immediately.
Storage
New Ink Tanks should be stored in their original packaging and kept away from heat.
Opened Ink Tanks should remain in the Printer.
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.
33
SECTION 4
MAINTENANCE
Cleaning/Replacing the Printhead Cartridge
Cleaning
The Printhead in the Colordyne 1600-S Printer is cleaned automatically each time the machine is turned
ON or when the Level 1 Maintenance routine is performed by the operator. This can be found under the
Service Tab, Level 1 Maintenance in the Printer Driver or the User Maintenance Levels in the Printer
Toolbox. Level 2 and Level 3 Maintenance can be used to more thoroughly clean or clear the Printhead.
If running the automated Maintenance Levels doesn’t help improve print quality, the Printhead Cartridge
can be cleaned manually.
1.
Open the Top Cover.
2.
Release and lift up the two latches at the same time
to raise the Printhead Assembly.
3.
Moisten the Printhead nozzles using
deionized/distilled water (reference ASTM D512790 Type E-II Electronic Grade Water) and a damp,
lint-free cloth, wiping end to end. (Gray strip located
below orange strip.) Take care not to damage the
copper contacts, the metal plate, or the gold
Printhead surface.
4.
Close and relatch the Printhead Assembly.
Generally, when the ink supply is adequate and the print quality remains poor, or when the automated
cleaning processes or manually cleaning the Printhead has not helped the image quality, the Printhead
should be replaced.
CAUTION
34

Use electrostatic discharge (ESD) protection when handling.

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. Protect the Printhead from scratches, dust, fibers, dirt and
other contaminants at all times.
SECTION 4
MAINTENANCE
Replacing the Printhead Cartridge
1.
Open the Printer Toolbox. Go to All Programs,
open the Colordyne Folder and open the Toolbox.
On the Opening Screen you will see information
about the System Status in the upper left corner.
2.
Open the Top Cover. Press the Printhead Cover
Release Button [1]. The Printer pumps any ink in
the system back into the Tanks. Then the Printhead
Cover pops open [2].
NOTE: You can perform this same function
from your computer by clicking Printhead
Release from the Services tab in Print
Properties or the User Interface screen in the
Printer Toolbox.
CAUTION
DO NOT PRY OR MANUALLY LIFT THE
PRINTHEAD COVER OR THE COVER MAY
BREAK. ONLY OPEN THE COVER USING
THE RELEASE BUTTONS ON THE PRINTER
OR THE PRINTHEAD RELEASE COMMANDS
IN THE SERVICES TAB OR M SERIES
TOOLBOX.
3.
35
Make sure the Printhead Cover is fully opened to retract the ink lines. Remove the used Printhead
Cartridge by tilting it toward the ink lines [3], then carefully lifting it out of the Printhead
Compartment.
SECTION 4
MAINTENANCE
4.
Carefully remove the
Printhead Cartridge
from the foil packaging.
[A] 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
with one hand. Pull the
strip tab with the other hand and slowly peel the strip from the
Printhead. DO NOT pull the strip at any angle less than 45° with the Printhead surface. DO
NOT allow removed strip to touch the Printhead Nozzles.
NOTE: Keep foil packaging to store/dispose of old Printhead Cartridge.
IMPORTANT! Pour just enough distilled water into the orange plastic cover you removed in
Step 4B to moisten the bottom strip. Carefully reinstall the Printhead back into the plastic cover.
Set the Printhead aside for 15 to 20 minutes. This rehydrates Printhead and allows easier priming
once it is installed in the Printer.
WARNING!
TO AVOID ELECTRICAL SHOCK OR SHORTING:
Before installing Printhead, make sure nozzles are hydrated and contacts are DRY!
5.
36
Carefully insert the Cartridge into the
compartment at an angle [4], with the
Printhead surface facing down and the
Ink Nozzles facing the ink hoses. Once it
is seated, gently tilt the Cartridge back
until it snaps into an upright position [5].
DO NOT FORCE the Cartridge into
position.
SECTION 4
MAINTENANCE
6.
Wet the Printhead Surface. This
ensures that the Printhead will prime
correctly. Open the Top Cover. Release
and lift up the two latches at the same
time to raise the Printhead Assembly.
Moisten the Printhead nozzles using
distilled water and a damp, lint-free
cloth, wiping end to end. (Gray strip
located below orange strip.) Close and
relatch the Printhead Assembly.
CAUTION
OPERATE AND HOLD ONTO BOTH
LATCHES WHEN OPENING AND
CLOSING THE PRINTHEAD
ASSEMBLY TO PREVENT DAMAGE.
DO NOT ALLOW THE ASSEMBLY
DROP BY ITSELF WHEN CLOSING.
TO PREVENT DAMAGE TO THE INK
LINES, A STOP LIMITS RAISING THE
ASSEMBLY MORE THAN 60°.
7.
Close the Printhead Cover [6]. The Printer will
automatically run a start-up routine and prime the ink
into the Printhead. This may take a few minutes. Make
sure that ink is flowing through the hoses. If air
bubbles appear you may have to tap the lines or run
the Circulate Ink routine to clear them.
8.
Watch the Toolbox screen on your computer again. Notice
that some of the information is in red. As the Printer
circulates ink and primes the system these fields should all
turn black.
9.
When the Printer stops processing and all the fields in
System Status are black, the Printer is ready for use. Close
the Top Cover.
IMPORTANT
CHECK INK TANKS. PRINTER MAY NOT FULLY
REPRIME IF TANKS ARE LESS THAN 1/3 FULL.
NOTE: The Printer may take up to 12 minutes to set itself up
during initial startup. This is normal. The machine will emit a
number of chirps, whirrs and other noises as it circulates ink
and runs systems.
37
SECTION 4
MAINTENANCE
Replacing the Service Station
The Service Station is designed provide a long service life. However, should it need to be replaced, follow
these steps. The Service Station is located above the Ink Tank Station.
1.
Open the Front Cover (hinged at bottom).
Remove the Exit Roller Cover by removing the four
(4) screws. Open the Top Cover.
Release the two latches and open the Clamshell
Cover. The Service Station will not fully eject with
the Cover Closed.
2.
Open the Printer Toolbox. In the
User Interface window, press the
Eject Maintenance Station
button. Once the Printer pushes
the Service Station out, turn the
Printer OFF.
TURN PRINTER POWER OFF.
CAUTION
WHENEVER POWERING DOWN UNIT, ALWAYS:
1. PRESS THE POWER BUTTON ON THE CONTROL PANEL.
2. WAIT FOR THE PRINTER TO STOP PROCESSING.
3. THEN PRESS THE MAIN POWER SWITCH ON THE REAR PANEL.
38
SECTION 4
MAINTENANCE
3.
Slide the Service Station out of the Service Station
port. NOTE: Do not pull Station all the way out
until you disconnect the Ribbon Cable.
NOTE: It is a good idea to place an absorbent towel
under the Service Station as you remove it to prevent
any drips or leaks.
4.
Disconnect the Ribbon Cable. Slide the Latch open on
the Service Station Circuit Board to release the Ribbon
Cable. Remove the Service Station.
5.
Carefully unwrap the new Service Station. NOTE:
Loose parts may fall out. Keep Roller side facing
up when removing packaging.
CAUTION
MAKE SURE THE LATCHES ON THE WIPER
ROLLER ARE FULLY LOCKED BEFORE
INSTALLING THE SERVICE STATION.
6.
39
Slide the Latch open on the Service Station Circuit
Board.
SECTION 4
MAINTENANCE
7.
[1] Plug the Ribbon Connector (blue side up) into the space under the Latch.
[2] Close the Latch.
8.
[1] Slide the Service Station into the Service Station port until it touches the bar. Align with tracks
along sides and Guide on Service Station dock floor.
[2] Look down through the Top Cover to make sure Service Station is aligned with the bar.
IMPORTANT! Service Station must be perfectly aligned with bar to prevent misalignment
and operating problems.
9.
GENTLY push the Service Station while
turning the large Gear on right side of Print
Engine clockwise. Gear should engage
gear on Service Station Roller and pull it
in. Once the Service Station starts moving,
stop turning the gear. Powering up the unit
will pull the Service Station the rest of the
way in. NOTE: Make sure the wick
hanging below the Service Station is inside
the plastic trough inside the Ink Tank
Station to prevent ink seepage.
NOTE: Service Station should operate
smoothly. If it binds or makes irregular
noises, reinstall the Service Station.
Lubricate Side Tracks and Guide if necessary.
10. Close Clamshell Cover. Replace the Exit Roller Door and Close the Front Cover.
CAUTION
OPERATE AND HOLD ONTO BOTH LATCHES WHEN OPENING AND
CLOSING THE CLAMSHELL COVER TO PREVENT DAMAGE. DO NOT
ALLOW THE ASSEMBLY TO DROP BY ITSELF WHEN CLOSING.
40
SECTION 4
MAINTENANCE
Replacing the Ink Waste Tray
The Ink Waste Tray soaks up any excess ink that may drip from the Print Engine during operation. After a
period of time it may become saturated and need replacement.
1.
Open Ink Tank
Door.
2.
Push in on the Tabs
to release the Ink
Waste Tray and
remove it from unit.
3.
Replace with a new
Ink Waste Tray.
Replacing the Sheet Separators
The Sheet Separators insure separation of the pieces as they are being fed. If you experience double sheet
feeding and cannot adjust the Separators to prevent it, replace the Separators. Replacing the Sheet
Separators is not difficult:
1. Turn Printer OFF and unplug it and from the power source.
2. Release the Separator by loosening the
Locking Knob and moving the Paper Side
Guides to their maximum opened position.
3. Lower the Separators so that they touch the
Feed Roller.
4. Remove the screw [A] and the Separator
Cover [B]. Then remove the Separator [C]
by prying it out of the Holder.
5. Install a new Separator in place and replace
the Separator Support and screw.
41
SECTION 4
MAINTENANCE
Jams in the Colordyne 1600-S Printer
If a jam occurs, STOP the Printer.
Some possible causes for jamming are:
1.
2.
3.
4.
Feeding more than one piece of media (double-feeding).
Damaged media, such as dog-eared (turned down corners).
Media that is not stiff enough may not be usable. Media that meets Postal stiffness requirements
for automated feeding is acceptable in the Colordyne 1600S.
Envelopes that are caught under the flap of another envelope or stick to one another.
Removing Jammed Media
Clearing a jam depends on where the jam occurred.
Feed Section: Clear by pulling the paper out of the Separators.
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. Do not bend the brushes! Clear the jam, then
carefully reinstall the Brush Assembly.
CAUTION
DO NOT BEND, PINCH OR CUT THE INK LINES LOCATED
DIRECTLY IN FRONT OF THE BRUSH ASSEMBLY.
NOTE: Make sure Brush Assembly is correctly reinstalled and
aligned before starting to print. Assembly should sit flat on transport
area surface.
Print Engine Area: Open the Top
Cover. Release and lift up the two
latches [B] (one on each side of the
Printhead Assembly) at the same time
to raise the Printhead Assembly [C].
Clear the jam, then carefully lower and
relatch the Printhead Assembly. Close
the Top Cover.
CAUTION
OPERATE AND HOLD ONTO BOTH
LATCHES WHEN OPENING AND
CLOSING THE PRINTHEAD ASSEMBLY
TO PREVENT DAMAGE. DO NOT
ALLOW THE ASSEMBLY TO DROP BY
ITSELF WHEN CLOSING.
Misfeeds
Misfeeds can be corrected by readjusting the Sheet
Separators to the media or replacing them. See
“Replacing the Sheet Separators” on previous page.
42
B
Unlatch the Print Engine Assembly
Raise the Print Engine Assembly
C
SECTION 4
MAINTENANCE
Cleaning
WARNING!
THE PRINTER IS A PRECISION MACHINE. CLEAN 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. Turn the Printer OFF and unplug it from the power receptacle. Then open or remove the Covers.
2. Interior: Use a vacuum with a soft brush attachment or a can of compressed air to help loosen
dust particles. NOTE: Be careful around ink tray and capping station in the Print Engine area
as accumulated ink may splash onto other parts of the printer. Take care not to damage the PC
Boards or electrical wiring.
3. Exterior: Wipe clean with a lint-free cloth using any standard nonabrasive household cleaner that
does not contain plastic-harming solvents.
CAUTION
NEVER SPRAY OR POUR CLEANERS DIRECTLY ON OR INTO THE PRINTER.
EXCESS LIQUID COULD HARM ELECTRONIC PARTS. DAMPEN A LINT-FREE
CLOTH WITH THE CLEANER AND APPLY IT TO THE PARTS TO BE CLEANED.
Feed Rollers and Forwarding Rollers
The Feed and Forwarding Rollers can become glazed with paper lint and ink from the media. They should
be regularly cleaned with a mild abrasive household cleaner on a damp lint-free cloth.
NOTE: Avoid using solvents on the Rubber Rollers.
43
SECTION 4
MAINTENANCE
Print Engine
Areas in the Print Engine can become glazed with a buildup of dust, paper lint and accumulated ink and
have to be cleaned regularly. Open the Top Cover. Open the Clamshell Assembly by releasing the two
latches. Use a vacuum to pick up any loose debris.
NOTE: Be careful around Ink Tray and Capping Station in the Print Engine area as accumulated ink may
splash onto other parts of the Printer. Take care not to damage the PC Boards or electrical wiring.
CAUTION
USE ONLY DEIONIZED/DISTILLED WATER TO CLEAN PRINT ENGINE
COMPONENTS. AVOID CONTAMINATING THE PRINTHEAD WITH CLEANERS,
LUBRICANTS OR OTHER CHEMICALS.
[A] Grit Rollers: Clean as needed by
moistening a small hard-bristled brush
or toothbrush with distilled water. DO
NOT use anything other than distilled
water to clean the Rollers.
[B] Media Sensors: Paper lint and
dust may build up on the Media
Sensors. Use a can of compressed air
or a damp (not wet) foam or lint-free
cotton swab to gently swab the
Sensors. Take care not to drip water
into the Circuit Boards. Use a clean,
dry swab to dab surfaces dry.
Remember to wipe the clear panel over the Sensor Receiver in the
upper Printhead Assembly (see inset).
[C] Capping Station Seal and Squeegee. Clean as needed with
distilled water on a damp, lint-free cloth. Be careful not to splash or
drip ink on other parts of the Printer.
[D] Printing Platen. Wipe with distilled water on a damp, lint-free cloth. Pat dry with a lint-free cloth.
Cleaning the Ink Revolver Couplings
44
1.
First Deprime the system and remove the
Printhead Cartridge.
2.
Moisten a foam swab in distilled water.
3.
Insert the swab into one of the ink channels
and rotate the swab to clean the chamber.
4.
Use a new swab for each of the remaining
ink channels until all 10 openings are clean.
(5 on each side.)
SECTION 4
MAINTENANCE
Shipping or Transporting the 1600-S Printer
If you have to ship or transport the Printer for any reason, the unit will have to be prepared. Once the
Printer is prepared, carefully package the Printer, Printhead Cartridge, Service Station and Ink Tanks in
their original packaging.
Deprime the System
1.
This forces all of the ink to return to the Ink Tanks. You can do this by accessing the Toolbox
User Interface Screen and pressing "System Deprime" or by using the Service Tab in the Printer
Driver and pressing "System Deprime".
Remove the Printhead Cartridge
1.
Open the Top Cover. Press the Printhead Cover
Release Button [1]. The Printer pumps any ink in
the system back into the Tanks. Then the Printhead
Cover pops open [2].
NOTE: You can perform this same function
from your computer by clicking Printhead
Release from the Services tab in Print Properties
or the User Interface screen in the Printer
Toolbox.
CAUTION
DO NOT PRY OR MANUALLY LIFT THE
PRINTHEAD COVER OR THE COVER MAY
BREAK. ONLY OPEN THE COVER USING THE
RELEASE BUTTONS ON THE PRINTER OR
THE PRINTHEAD RELEASE COMMANDS IN
THE SERVICES TAB OR M SERIES TOOLBOX.
45
SECTION 4
MAINTENANCE
2.
Make sure the Printhead Cover is fully opened to retract the ink lines. Remove the Printhead
Cartridge by tilting it toward the ink lines [3], then carefully lift it out of the Printhead
Compartment.
3.
Carefully pack the Cartridge using the original packaging.
Remove the Service Station
1.
Open the Front Cover (hinged at bottom). Remove
the Exit Roller Cover by removing the four (4) screws.
Open the Top Cover.
Release the two latches and open the Clamshell Cover.
The Service Station will not fully eject with the Cover
Closed.
2.
Open the Printer Toolbox. In the
User Interface window, press the
Eject Maintenance Station
button. Once the Printer pushes
the Service Station out, turn the
Printer OFF.
TURN PRINTER POWER OFF.
CAUTION
WHENEVER POWERING DOWN UNIT, ALWAYS:
1. PRESS THE POWER BUTTON ON THE CONTROL PANEL.
2. WAIT FOR THE PRINTER TO STOP PROCESSING.
3. THEN PRESS THE MAIN POWER SWITCH ON THE REAR PANEL.
46
SECTION 4
MAINTENANCE
3.
Slide the Service Station out of the Service Station port.
NOTE: Do not pull Station all the way out until you
disconnect the Ribbon Cable.
NOTE: It is a good idea to place an absorbent towel
under the Service Station as you remove it to prevent any
drips or leaks.
4.
Disconnect the Ribbon Cable. Slide the Latch open on
the Service Station Circuit Board to release the Ribbon
Cable. Remove the Service Station.
Remove the Ink Tanks
47
1.
Open the Front Cover (hinged at bottom).
Unlatch the three Locks [A] and pull the
Ink Tank(s) out of the Printer.
2.
Carefully package the Ink Tanks in the
original packaging.
IMPORTANT: Make sure the ink seals
on the Ink Tanks are facing up to prevent
leakage.
3.
Pack the Ink Tank bays with absorbent towels to catch any ink drips or spills.
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 Colordyne 1600-S 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.
The Memjet Printhead
CONDITION
PROBLEM
SOLUTION
Missing parts of letters or
text.
Air and bubbles blocking Nozzles.
Clean the Printhead using
recirculation, priming or
cycles of depriming and
priming found in the
Maintenance section of the
Driver.
Rehydrate the Printhead
using distilled water and a
wet, clean, lint-free cloth.
Bubbles often disappear with
Printer use.
Print shows regularly
missing or misdirected
nozzles or ink color mixing.
Debris on Printhead.
Ink mixing -- Mixed or
muddy colors.
Causes: Ink flooding, air in the
Printhead or a dirty Printhead.
No print or crisp blocks of
missing drops.
Electrical failure or poor electrical
connection.
System will not reprime ink
after replacing Printhead
Cartridge
Printhead nozzles dry.
Perform the startup routine.
Clean the Printhead using
one of the Maintenance
Levels in the Driver.
Wipe the Printhead manually
with distilled water and a
wet, clean, lint-free cloth.
Replace the Printhead.
Clean the Printhead using
one of the Maintenance
Levels in the Driver.
Wipe the Printhead manually
with distilled water and a
wet, clean, lint-free cloth.
Reseat the Printhead.
Replace the Printhead.
Wipe the Printhead manually
with distilled water and a
wet, clean, lint-free cloth.
Ink Tanks may be 1/3 full or less.
Replace Ink Tanks.
WARNING!
DO NOT REMOVE THE SIDE COVERS OF THE PRINTER!
THERE ARE HIGH VOLTAGES PRESENT BEHIND THE COVERS!
48
SECTION 5
TROUBLESHOOTING
The Printer
CONDITION
PROBLEM
SOLUTION
Extra lines; losing data
Database problem.
Check data in database
program.
Improper output (address
information out of order,
misfeeding, etc.)
Wrong interface settings.
Check software or database
on PC.
Close the software, then
turn Printer OFF and ON.
Clean Media Sensor.
Static electricity.
Dirty Media Sensor.
Media jams
Double feeding.
Media is curled or bent.
Media is too thin.
Unit not receiving power.
Use proper USB cable (see
Operator Manual.)
Check plug connections,
ON/OFF button and fuse on
back panel.
Print too light or missing
character dots
Clogged or dirty Printhead.
Running out of ink.
Check the Printhead.
Check Ink Tanks.
Blurry address
Image is not sharp.
Clean Printhead using one
of the Maintenance Levels.
(See Service Tab in the
Print Driver.)
Clean the Printhead
manually using distilled
water and a wet, clean, lintfree cloth.
Feeding problems
Double sheets.
Misfeeds.
Adjust the Sheet Separators.
Job is sent to print but does not
print.
Printer not turned on.
Printer not connected to
computer.
Check that Printer is ON.
Connect printer cable to
computer and resend the
job.
Open Print Engine and
remove media.
No communication
Improper cabling / connector.
Adjust Sheet Separators on
Feeder.
Uncurl media.
Minimum thickness for
media is 0.004".
Media Sensor is covered in Print
Engine.
49
APPENDICES
Appendix A – Colordyne 1600-S Specifications
PRINT RESOLUTION
Best: 1600 x 1600 DPI
Normal: 1600 x 800 DPI
SPEED (color or mono)
Up to 3600 letter size pages or 9000 envelopes per hour
MEDIA SIZE
Minimum: 3" x 4.2" (76 mm x 107 mm)
Maximum: 9.5" x 17" (241 mm x 431 mm)
PRINT AREA
8.5" x 17" (215 mm x 431 mm)
MEDIA THICKNESS
Minimum: 0.004" (0.102 mm)
Maximum: 0.020" (0.5 mm)
INK
Water-based ink. 5 individual 250 ml ink tanks (CMYKK)
PRINT CARTRIDGE
Memjet®
INTERFACE
USB
DIMENSIONS
20" W x 24" L x 17-1/4" H (50.8 cm x 61 cm x 44.0 cm)
WEIGHT
75 lbs. (34 kg)
DUTY CYCLE
500,000 #10 Envelopes per month
All Specifications Subject To Change Without Notice
Appendix B – Supplies and Optional Hardware
The following supply items and optional hardware are available from your
Colordyne Distributor:
Supplies
Black Ink Tank
Cyan Ink Tank
Magenta Ink Tank
Yellow Ink Tank
Optional Hardware
Conveyor /Stacker
Drop Tray
50
INDEX
INDEX
#10 Envelope Setup
9.5" x 17" Paper Setup
20
20
A
Adjustable Media Guide
Assembling the Printer
1, 2
7
C
Cancel Button
Choose Location
Cleaning
Ink Revolvers
Print Engine
Printer
Printhead
Rollers
Connecting
Computer
Printer
Connection
Network
USB
Control Panel
Cancel Button
Indicators
Paper Button
Power Button
Counter, LCD
1, 3
5
9
9
2
2
1, 3
3
1, 3
1, 3
2
28
33
E
Envelope Printing Attachment
Envelope/Paper Media Guide
17
1, 2
F
Feed Setup
Front Cover
Fuse
18
1
2
G
General Tab
22
H
Hydrating Printhead
Hydrating the Printhead
15, 36
6
I
Ink Revolvers
Ink Tanks
Disposal
Installing
Remove/Replace
Storage
Ink Usage, Toolbox
Ink Waste Tray
51
17
12
5
10
14
J
Jams in Printer
42
L
44
44
43
34
43
D
Diagnostics, Toolbox
Disposal, Ink Tanks
Installing
Envelope Printing Attachment
Ink Tanks
Printer
Printer Driver
Printhead
44
33
12
32, 47
33
28
41
Layout Tab
Location, Choose
23
5
M
Main Fuse
Main Power Switch
Maintenance
Maintenance Schedule
Media Guide
Adjustable
Envelope/Paper
Media Profiles Chart
Minimum Requirements, System
2
2
32
53
1, 2
1, 2
23
10
N
Network Port
2
O
Optional Hardware, Printer
50
P
Paper Button
Power Button
Power Receptacle
Print Engine
Cleaning
Ink Revolvers
Printer
Assembly
Cleaning
Connecting
Installing
Jams
Maintenance
Media Profiles Chart
Operating
Optional Hardware
Setup
Shipping/Transporting
Specifications
Supplies
Troubleshooting
Unpacking
Printer Driver
General Tab
Installing
1, 3
1, 3
2
44
44
7
43
9
5
42
32
23
20
50
5
45
50
50
49
5
22
10
INDEX
Layout Tab
Properties
Services Tab
Printer Toolbox
Diagnostics
Ink Usage
Network Configuration
Service Menu
User Interface
Using
Printhead
Cleaning
Hydrating
Installing
Remove/Replace
Troubleshooting
23
22
24
28
28
29
30
25
25
34
6, 15, 36
14
34, 45
48
R
Rear Guide
Rear Guide Support
Remove/Replace
Ink Tanks
Ink Waste Tray
Printer Jams
Printhead
Service Station
Service Station Transport Tab
Sheet Separators
Rollers, Cleaning
52
1, 2
1, 2
32, 47
41
42
34, 45
38, 46
7
41
43
S
Schedule, Maintenance
Service Menu, Toolbox
Service Station
Remove Transport Tab
Remove/Replace
Services Tab
Setup
#10 Envelope
9.5" x 17" Paper
Feed
Job in MS Word
Sheet Separators, Replacing
Shipping/Transporting Printer
Specifications, Printer
Storage, Ink Tanks
Supplies, Printer
System Requirements, Minimum
53
30
7
38, 46
24
20
20
18
20
41
45
50
33
50
10
T
Top Cover
Troubleshooting
Printer
Printhead
1
48
49
48
U
Unpacking and Setup
USB Port
User Interface, Toolbox
Using the Printer Toolbox
5
2
25
25
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.
Maintenance Supplies & Equipment: Flashlight, small telescoping mirror, hard-bristled toothbrush or
equivalent, powder-free nitrile gloves, protective clothing and eyewear, small flathead screwdriver,
tweezers, vacuum with wand, deionized distilled water, Super Lube 21030 synthetic grease (or equivalent),
Loctite 38650 copper anti-seize (or equivalent), can of compressed air, foam or lint-free cotton swabs, lintfree wipes, disposable shop towels.
COMPONENTS/TASKS
MAINTENANCE TYPE
DAILY
BI-WEEKLY
MONTHLY
YEARLY
AS NEEDED
PERFORMED BY OPERATOR
Printhead (Manual Wiping)
WIPE
Ink Revolver Couplings and
Connections:
Inspection/Cleaning
EVERY
PRINTHEAD
REMOVAL
Residue and Debris Removal
CLEAN
CLEAN
CLEAN
CLEAN
Optical Sensors
(Media Path)
CLEAN
CLEAN
CLEAN
Wiper Assembly:
Inspection
INSPECT
INSPECT
INSPECT
INSPECT
CLEAN
Grit Rollers (Media Path)
Ink Tank Latches/Ink Bay
CLEAN
INSPECT
Ink Tubing, Couplings,
Components
INSPECT
INSPECT
Ink Waste Tray
INSPECT
INSPECT
Lift Motor Gear
INSPECT
INSPECT
REPLACE
PERFORMED BY SERVICE TECHNICIAN
Lubrication
APPLY
EVERY
PRINTHEAD
REMOVAL
Pen Driver PCA Contacts:
Cleaning
Moving Parts/Motor
TEST
Service Station Sled Assembly
CLEAN
Wiper Assembly:
Cleaning
CLEAN
WARNING!
ALWAYS POWER DOWN THE PRINTER BEFORE CONNECTING OR DISCONNECTING ANY
WIRING HARNESSES OR CABLE CONNECTIONS TO AVOID SERIOUS SHOCK OR INJURY.
CAUTION
 ALWAYS USE APPROPRIATE PERSONAL PROTECTION EQUIPMENT (PPE).
 USE ELECTROSTATIC DISCHARGE (ESD) PROTECTION WHEN MAINTAINING EQUIPMENT.
 DISPOSE OF ALL MAINTENANCE WASTE IN ACCORDANCE WITH LOCAL REGULATIONS.
NOTES
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Copyright © 2012 COLORDYNE TECHNOLOGIES LLC.
04/17/2012
Part Number: 200-CDT1600S, Rev. O
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