HP ColorSpan Legacy Printers User's Manual

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HP ColorSpan Legacy Printers User's Manual | Manualzz
DisplayMaker Legacy X-12+
User Manual
Part Number 0706248 Rev C
1
Legal notices
© Copyright 2008 Hewlett-Packard Development Company, L.P.
The information contained herein is subject to change without notice. The only warranties for HP
products and services are set forth in the express warranty statements accompanying such
products and services. Nothing herein should be construed as constituting an additional warranty.
HP shall not be liable for technical or editorial errors or omissions contained herein.
Printed in the US
For additional technical support and user documentation please refer to:
www.hp.com/go/graphicarts
2
Caution
SEVERE DAMAGE TO THE PRINTHEAD
CARRIAGE CIRCUIT BOARD AND PRINTHEAD WILL OCCUR IF A PRINTHEAD IS
REMOVED WHILE POWER IS SUPPLIED TO
THE PRINTHEAD. Repairing this damage will
require a service call and replacement of the printhead carriage circuit board and printhead at customer expense.
To avoid electrical damage to the printhead carriage
circuit board and printhead:
Follow the instructions in this manual to replace
printheads.
DO NOT remove any printhead without first pressing
the Carriage key on the Front Page screen or selecting Prime Pens from the menu. Pressing the Carriage
key will move the printhead carriage to the center of
the platen; selecting Prime Pens will move the carriage out of the service station to the manual prime
position. Pressing either key will cut power to the
printheads, allowing you to safely remove and
replace printheads.
DO NOT disable the “cover open” switches on the
top cover or prime access door. When the printer
detects that either of these doors is open, it cuts
power to the printheads, making it safe to remove
and replace printheads. If these switches are disabled, the printer can no longer detect whether the
doors are open, making electrical damage more
likely.
iii
Revision Log
The following is a list of major changes and additions that have
been made to this manual since it was first released.
See the accompanying Release Notes for specific changes to the
software and hardware between manual updates.
Release Date Description
May 2004
iv
Manual first released.
Regulatory Statements
FCC-A
This equipment has been tested and found to comply with the
limits for a Class A digital device, pursuant to Part 15 of the FCC
Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates,
uses, and can radiate radio frequency energy and, if not installed
and used in accordance with the instruction manual, may cause
harmful interference to radio communications. Operation of this
equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the
interference at his or her own expense.
This equipment must be installed exactly as instructed in this
manual using only the components supplied. If a supplied component ever needs to be replaced, it must be replaced with the
same part supplied by the manufacturer. It is your responsibility
to follow these instructions in order to maintain compliance
with the FCC regulations. Changes or modifications not
expressly approved by ColorSpan Corporation could void your
authority to operate this equipment. In particular, this device
must be operated with shielded cables to maintain FCC
compliance.
A booklet is available from the Federal Communications Commission entitled, How to Identify and Resolve Radio-TV Interference Problems (#004-000-00345-4). Write to the U.S. Government
Printing Office, Washington, DC 20402.
DOC (Canada)
This digital apparatus does not exceed the Class A limits for
radio noise for digital apparatus set out in the Radio Interference
Regulations of the Canadian Department of Communications.
Normes de Sècuritè (Canada)
Le présent appariel numérique n’émet pas de bruits radioélectriques dépassant les limites applicables aux appareils numériques
de la Classe A prescrites dans le réglements sur le brouillage
radioélectrique édictés par le Ministére des Communications du
Canada.
v
Telecommunications
Network Statement
The ColorSpan VideoNet port on this device is not intended to
be connected to a public telecommunications network. Connection of this device to a public telecommunications network in a
European Community Member State will be in violation of
national law implementing Directive 91/263/EEC on the
approximation of laws of the Member States concerning telecommunication terminal equipment, including the mutual recognition of their conformity.
Der VideoNet port ist nicht dafür vorgesehen an ein öffentliches
Telefonnetz angeschlossen zu werden. Der Anschluß dieses
Gerätes an ein öffentliches Telefonnetz in einem Mitgliedstaat
der EU, verstößt gegen nationale Gesetze zur Ausführung der
Direktive 91/263/EEC, die sich mit der Annäherung von
Gesetzen von Mitgliedstaaten beschäftigt, betreffend Telekommuniktionsanlagen und die gegenseitige Anerkennung
ihrer Konformität.
vi
About This Manual
Read this manual to unpack, set up, and use the printer.
◆
Chapter 1 shows you how to unpack and assemble the
printer, and introduces you to its main features.
◆
Chapter 2 shows you how to use the control panel.
◆
Chapter 3 shows you how to install ink and media.
◆
Chapter 4 shows you how to calibrate the printer.
◆
Chapter 5 shows you how to maintain the printer.
◆
Appendix A shows you how to troubleshoot common
printing problems.
◆
Appendix B lists the printer’s technical specifications.
For further information, refer to the following ColorSpan
documentation:
◆
Quick Start Guide - START HERE to set up and install a brand
new ColorMark print server, and connect and configure
printers to it.
◆
Site Preparation Guide - explains how to prepare your site for
the printer’s arrival and installation.
◆
Watch Me First - a multimedia “how-to” guide on CD-ROM
(available on VHS cassette from MacDermid ColorSpan Technical Services).
◆
ColorSpan Print Server Documentation - the System Control
User Guide and Printing Tools User Guides shows you how to
print and RIP files through the ColorSpan print server. If the
printer is connected to a non-ColorSpan print server (RIP),
refer to the documentation that accompanies the server.
◆
Release Notes and Update Notes - late-breaking information,
update descriptions, and update instructions.
Further information about all ColorSpan products is also available over the Internet at the ColorSpan World Wide Web site at
http://www.colorspan.com.
vii
Conventions
This manual uses the following informational conventions:
Note
A special technique or information that may help
you perform a task or understand a process.
Hinweis
Ein Hinweis beschreibt eine spezielle technik zur
Lösung einer Aufgabe oder enthällt Informationen,
die Ihnen eine Prozedur näher erläutert.
Caution
Alerts you to something that has the potential to
cause damage to hardware, software, or data.
Vorsicht
Dieses Feld weist auf einen Umstand hin, der einen
Hardware-oder Software-Schaden oder Datenverlust
verursachen könnte.
WARNING Alerts you to something that has the potential to
cause physical harm to you or others around you.
WARNUNG Eine Warnung auf weist auf einen Umstand hin,
durch den Ihnen und anderen Personen ein physischer Schaden erwachsen könnte.
Other WARNING symbols used:
Electrical Hazard
Vorsicht steht unter Spannung
Lifting Hazard
Vorsicht beim Anheben
viii
TABLE OF CONTENTS
Revision Log.............................................................................................. iv
Regulatory Statements............................................................................... v
FCC-A ..................................................................................................... v
DOC (Canada)....................................................................................... v
Telecommunications Network Statement............................................. vi
About This Manual .................................................................................. vii
Conventions............................................................................................ viii
Table of Contents
1
Getting Started
2
Using the Control Panel
Operating Requirements ....................................................................... 1-2
Electrical............................................................................................. 1-2
Environmental.................................................................................... 1-2
Important Operating Notes ............................................................... 1-3
Safety Warnings ................................................................................. 1-4
Unpacking and Assembly ...................................................................... 1-5
Unpacking.......................................................................................... 1-5
Parts List ......................................................................................... 1-6
Stand Assembly.................................................................................. 1-7
Final Assembly ................................................................................... 1-8
Connecting to Power ....................................................................... 1-13
Connecting to the Print Server ........................................................ 1-14
Power-Up Sequence......................................................................... 1-15
What’s Next?.................................................................................... 1-15
Workflow Overview ............................................................................. 1-16
Parts Overview ..................................................................................... 1-17
Special Features ................................................................................... 1-21
Performance Features ...................................................................... 1-21
Ease-Of-Use Features ....................................................................... 1-21
Overview................................................................................................ 2-2
Ready Screen...................................................................................... 2-2
Front Page.......................................................................................... 2-2
Menu.................................................................................................. 2-2
User Assistance................................................................................... 2-3
Front Page.............................................................................................. 2-5
Navigation Keys ..................................................................................... 2-9
Menu.................................................................................................... 2-10
Calibrate Printer ............................................................................... 2-10
Configure Printer ............................................................................ 2-11
1
Printer Settings............................................................................. 2-11
Printer Options............................................................................. 2-14
Reset All Defaults ......................................................................... 2-15
Service Printer .................................................................................. 2-16
User Diagnostics .......................................................................... 2-16
Service Tests ................................................................................. 2-16
Calibrations .................................................................................. 2-17
Home Head.................................................................................. 2-17
Measure Media Width ................................................................. 2-17
Prime Pens.................................................................................... 2-18
Prime Bars .................................................................................... 2-18
Disable Media Sensor .................................................................. 2-18
Disable Latch Sensor .................................................................... 2-18
New Carriage ............................................................................... 2-18
Warnings & Actions ......................................................................... 2-18
Load Takeup..................................................................................... 2-18
Media Wizard................................................................................... 2-19
Menu Tree............................................................................................ 2-20
Front Page ........................................................................................ 2-20
Menu................................................................................................ 2-21
3
2
Installing Ink and Media
Variable Mode Printing .......................................................................... 3-2
Ink System Overview.............................................................................. 3-4
Spare Ink and Printheads ................................................................... 3-6
Selecting a Print Mode........................................................................... 3-7
AutoInk Maps..................................................................................... 3-9
Creating a Custom Color Map............................................................. 3-11
Switching Between Ink Sets ................................................................. 3-12
Installing Ink for the First Time in a New Printer................................. 3-14
Replacing Ink System Components ..................................................... 3-19
Replacing an Ink Reservoir in an Idle Printer................................... 3-19
Replacing an Ink Reservoir During Printing (“Hot Swapping”)...... 3-20
Replacing a Printhead ...................................................................... 3-21
Replacing An Ink Tube ..................................................................... 3-22
Loading Media ..................................................................................... 3-26
Loading 72-Inch Media ................................................................... 3-31
Takeup Options................................................................................ 3-32
Automatic Disable........................................................................ 3-32
Not Using the Takeup .................................................................. 3-32
Takeup Direction.......................................................................... 3-32
Linearization..................................................................................... 3-33
Dryer Options ...................................................................................... 3-34
Drying Delay .................................................................................... 3-34
Table of Contents
Drying Rate ...................................................................................... 3-34
Fans and Heater............................................................................... 3-34
Cutting and Unloading Media ............................................................ 3-35
Table of Contents
4
Calibrating the Printer
5
Maintaining the Printer
AutoSet................................................................................................... 4-2
Manual Calibrations .............................................................................. 4-3
Media Feed Calibration ..................................................................... 4-4
“On-the-Fly” Media Feed Adjustment........................................... 4-6
Manual Bidirectional Registration ..................................................... 4-7
Manual Head Registration ............................................................... 4-10
Manual Jet Mapping........................................................................ 4-13
Report Individual Bad Jets ........................................................... 4-15
Clear Individual Bad Jets ............................................................. 4-16
View Current Bad Jets .................................................................. 4-16
Clear All Bad Jets.......................................................................... 4-17
Jet Status Lines ................................................................................. 4-18
Zero Registration Data ..................................................................... 4-18
Auto Calibrations ................................................................................. 4-19
AutoTune ............................................................................................. 4-20
Quality Check Mode ........................................................................ 4-20
Calibration Summary ........................................................................... 4-21
Head Height Calibration...................................................................... 4-23
Auto Carriage Height....................................................................... 4-23
Manual Carriage Height .................................................................. 4-27
Adjust Head Height ......................................................................... 4-29
Linearization ........................................................................................ 4-31
Maintenance Schedule .......................................................................... 5-2
Cleaning Ink Jets .................................................................................... 5-3
Evaluating Printhead Performance After Cleaning ............................ 5-4
Cleaning Jet Outs................................................................................... 5-5
Cleaning the Service Station .................................................................. 5-8
Replacing the Wipers......................................................................... 5-9
Printing Prime Bars .............................................................................. 5-10
Manual Priming ................................................................................... 5-11
Cleaning the Top Cover....................................................................... 5-13
Purging the Printheads ........................................................................ 5-14
Purging Water.................................................................................. 5-15
Purging Air ....................................................................................... 5-15
Cleaning the Encoder .......................................................................... 5-17
Cleaning the Carriage Rail ................................................................... 5-18
3
A
Technical Specifications
B
Troubleshooting
Specifications ......................................................................................... A-2
Supported Ink and Media.................................................................. A-4
Supplies and Accessories ....................................................................... A-5
Troubleshooting Checklist ..................................................................... B-2
Diagnostics............................................................................................. B-4
Banding.................................................................................................. B-8
Stitch Banding.................................................................................... B-8
Edge Banding..................................................................................... B-8
Supply-Loop Banding ........................................................................ B-9
Texture Banding............................................................................... B-10
Swath Edge Banding........................................................................ B-10
Drying .................................................................................................. B-11
MacDermid ColorSpan Technical Services........................................... B-16
Help From Your Reseller .................................................................. B-16
Help From ColorSpan ...................................................................... B-16
If All Else Fails................................................................................... B-16
Index
4
Table of Contents
CHAPTER 1
Getting Started
This chapter shows you how to get started using your printer. It includes
these topics:
Getting Started
◆
Operating Requirements (page 1-2)
◆
Unpacking and Assembly (page 1-5)
◆
Workflow Overview (page 1-16)
◆
Parts Overview (page 1-17)
◆
Special Features (page 1-21)
1-1
Operating
Requirements
Choose a location for the printer before you unpack it. Keep the
following requirements in mind:
Electrical
Environmental
1-2
◆
See “Specifications” on page A-2 for detailed power requirements.
◆
Use the supplied power cord. Plug it directly into a grounded
electrical outlet. Do not lengthen the power cord with an
extension cord; the resulting voltage drop could damage the
printer.
◆
Make sure the line voltage does not vary more than 10
percent from the voltage marked on the back of the printer.
Install a voltage regulator or similar device if the power
source is not stable.
◆
Unplug the printer during power failures. Wait for the power
to return before plugging it back in.
◆
Connect the print server to a separate electrical circuit from
the printer.
◆
Make sure the room is well ventilated, with a temperature
and relative humidity within specifications (see “Specifications” on page A-2). Optimal printing and drying occurs
within these ranges. Printing slows automatically to aid drying in high humidity conditions.
◆
Store media and ink in an area with similar temperature and
humidity conditions as the printer.
◆
Locate the printer close enough to the print server (RIP) so
that they can be connected with the required cable.
◆
Locate the printer on a flat, level surface.
◆
Locate the printer where its normal operating noise will not
disturb quiet work areas.
Operating Requirements
◆
DO NOT install the printer near humidifiers, refrigerators,
fans, water faucets, heaters or similar equipment.
◆
DO NOT install the printer in areas where the temperature
changes abruptly, such as near air conditioners or in the path
of direct sunlight.
◆
DO NOT expose the printer to flames, dust or solvents.
Refer to Appendix A for detailed specifications.
Important Operating
Notes
Operating Requirements
◆
Wear cotton gloves (provided with each roll of ColorSpan
media) when loading media to prevent fingerprints that
could show after printing.
◆
Protect the media at all times from creases and tears, and
ensure that the media is cut cleanly. Do not rest or store a
media roll on end, or you could cause edge creases that
could strike the printheads during printing.
◆
Always use a lint-free cloth moistened with plain water to
clean the printhead.
◆
DO NOT touch the printhead’s ink jet nozzles (the metal
plate on the bottom of the printhead) with your fingers. Any
contaminants could clog the ink jet nozzles.
◆
DO NOT touch the electrodes on the back of the ink printhead. This could result in a faulty electrical connection,
which would cause jets to misfire.
◆
DO NOT clean the printhead surfaces with a dry cloth or
paper towel.
◆
DO NOT set heavy objects on the power cord or printer
cable; do not bend the cables or force them into contorted
positions.
◆
DO NOT place heavy objects anywhere on the printer.
1-3
Safety Warnings
WARNING WITH THE POWER SWITCH IN THE OFF POSITION, POWER
MAY STILL BE SUPPLIED TO THE PRINTER COMPONENTS.
To completely cut power from the printer, you must unplug
the power cords from the power outlets.
WARNUNG WENN DER NETZSCHALTER IN OFF POSITION STEHT,
WIRD DEN KOMPONENTEN TROTZDEM STROM
ZUGEFÜHRT. Um den Drucker komplett stromfrei zu
machen, müssen Sie den Netzstecker ziehen.
WARNING The printer is too heavy to be lifted safely by one person.
At least two persons are required to lift the printer.
WARNUNG Der Drucker ist zu schwer für eine Person. Mindestens 2
Personen sind erforderlich um den Drucker anzuheben.
WARNING THE PRINTER ELECTRONICS ASSEMBLY CONTAINS A LITHIUM BATTERY DEVICE. THERE IS A DANGER OF EXPLOSION
IF THE BATTERY IS INCORRECTLY REPLACED. The battery
must be replaced only by ColorSpan authorized personnel,
and must be replaced only with the same or equivalent
type. Dispose of this lithium battery device in accordance
with local, state (or province), and Federal (or country)
solid waste requirements.
WARNUNG DIE ELEKTRONIK DES DRUCKERS ENTHÄLT EINE LITHIUM
BATTERIE. ES BESTEHT EXPLOSIONSGEFAHR WENN DIESE
UNSACHGEMÄSS AUSGEWECHSELT WIRD. Die Batterie
darf nur durch einen ColorSpan authorisierten Technicker
ausgewechselt werden und muss mit dem gleichen oder
einem gleichwertigen Typ Batterie ersetzt werden. Bitte
entsorgen Sie die Lithium Batterie gemäss Ihren Landesoder Bundesgesetzen.
WARNING Moving parts. Keep fingers away from media path.
WARNUNG Bewegliche Teile, Verletzungsgefahr.
1-4
Operating Requirements
Unpacking and
Assembly
This procedure assumes that the printer is in its final location.
See the Site Preparation Guide for moving and unpacking hints.
WARNING The printer is too heavy to be lifted safely by one
person. At least two persons are required to lift the
printer.
WARNUNG Der Drucker ist zu schwer für eine Person. Mindestens 2 Personen sind erforderlich um den Drucker
anzuheben.
Note
Unpacking
If you will be installing a ColorSpan Print Server, set
it up now and power it on. This will allow the server
to perform its automatic one-time new system check
while you unpack and assemble the printer.
1. The printer is delivered to your site packed in one cardboard
box, attached to a plywood platform on two wooden pallets.
Examine the shipping packaging for shipping damage.
Report any damage or apparent rough handling immediately
to the shipper.
2. Remove the Unpacking and Assembly diagram, Watch Me
First CD-ROM, and other documents from the outside of the
box, and set them aside for reference.
You can use the Unpacking and Assembly diagram for reference during the unpacking and assembly process. The
Watch Me First CD-ROM contains useful “getting started”
information, including a demonstration of unpacking,
assembly, and setup.
3. Remove the bands that secure the box to the pallet and open
the top flaps of the box.
4. Carefully cut the corners of the outer box and remove it from
the pallet.
5. Remove the packing material from the printer.
6. Remove the stand crossbar and media spools, which are
packed on top of the printer (item ➌ as shown on the
Unpacking and Assembly diagram).
7. Remove the cardboard shipping end caps from each end of
the printer.
Unpacking and Assembly
1-5
8. Remove the ink tray boxes, stand legs, and accessory boxes,
which are packed together at the bottom of the pallet.
Do not remove the printer module from the pallet at this
time. The printer rests on two shipping supports. You will
use these supports and two assembly supports to help
assemble the printer.
Note
Replacement shipping packaging and instructions
are available from MacDermid ColorSpan Technical
Services (phone: 800-925-0563).
9. Refer to the following list to verify that you received all of the
parts and accessories.
Notify ColorSpan immediately if you are missing any of the
components listed in the following table.
Parts List
Main Box
Outside of Box:
◆ “Watch Me First” CD-ROM
◆ Unpacking & Assembly Diagram
◆ Declaration of Conformity
Inside of Box:
◆ (1) Printer Module
◆ (1) Stand crossbar
◆ (2) Media spools with collets
◆ (2) Stand legs
◆ (1) Ink tray box
◆ (1) Accessory box
Ink Tray Box
◆
(2) Ink trays
Accessory Box
◆
◆
◆
◆
◆
◆
◆
(2) Spare ink tubes
(2) Red-headed bolts with washers
(4) Silver Phillips head screws
(8) Black Phillips head screws
(1) Phillips screwdriver
(1) VideoNet or Ethernet cable
(1) Ink maintenance kit: manual priming
bulb, purge clip
(1) Fill system drain tube and drain bottle
(1 set) Color Map cards
(1 sheet) ink type/color labels
(1 sheet) ink position number labels
(1) Service station
(1) Power cord (U.S. or European)
Documentation, warranty, and software
license agreement
◆
◆
◆
◆
◆
◆
◆
1-6
Unpacking and Assembly
Stand Assembly
1. Locate the stand legs Œ and , and the crossbar Ž.
2. Using the Phillips head screwdriver and eight of the screws
provided, assemble the stand.
Start by positioning the two stand legs upright, at approximately the width of the crossbar. Align the holes on the
crossbar with the holes in the stand legs, and secure them
with the screws, but do not tighten them fully yet.
Fig. 1-1. Stand assembly
3. Bias the stand legs outward at the top, then tighten the
screws firmly.
With your foot braced against the outside of the left caster
support, gently tug the top of the stand leg toward you, then
tighten the screws. Repeat this process with the right stand
leg. This step is required to ensure proper clearance for the
media spools.
Unpacking and Assembly
1-7
Final Assembly
1. Remove the two red-headed bolts from the right-hand shipping support.
Fig. 1-2. Remove the red-headed bolts
2. Locate the assembly supports ➍.
The assembly supports are mirror images of each other; the
foam pad should be positioned toward the ends of the
printer.
3. Align the assembly supports  with the shipping supports
, at the rear of the pallet as shown.




Fig. 1-3. Assembly supports , shipping supports 
1-8
Unpacking and Assembly
4. Thread one of the red-headed bolts that you removed from
the shipping support  through the assembly support into
the pallet.
The pallet contains a threaded nut that will accept the bolt.
Tighten the bolt hand-tight.
5. Attach the other assembly support to the pallet with the
other red-headed bolt.
WARNING The printer is too heavy to be lifted safely by one
person. At least two persons are required to lift the
printer.
WARNUNG Der Drucker ist zu schwer für eine Person. Mindestens 2 Personen sind erforderlich um den Drucker
anzuheben.
6. With two to four persons, roll the printer onto its back, on the
assembly supports.
The printer is now resting entirely on the assembly supports. The right-hand shipping support is trapped with the
printer and will roll with it.
Fig. 1-4. Roll the printer onto its back
Caution
Unpacking and Assembly
Ensure that the blue power inlet on the bottom of
the electronics box clears the assembly support during this process.
1-9
7. Remove the right-hand shipping support from the printer,
and bolt it to the pallet as shown, using the two red-headed
bolts provided. Do not remove the bolts from the rear supports.
Note that the “tower” of the support is now at the front of
the pallet.
Fig. 1-5. Shipping supports reversed and bolted
8. Lift the left-hand shipping support from the pallet, reverse it,
and replace it into its guides on the pallet.
The “tower” of the support is now at the front of the pallet.
1-10
Unpacking and Assembly
9. Gently tip the assembled stand on its back, and set it down
on top of the shipping supports as shown in Fig. 1-6.
Fig. 1-6. Assemble the printer module and stand
10. Using the four silver Phillips head screws provided (two per
leg), attach the stand to printer module.
The silver screws are required to establish an electrical
ground connection between the printer and stand.
11. Press the caster locks down to prevent the printer from
rolling.
12. With the aid of one or more persons, carefully rotate the
assembled printer upright.
Be ready for the printer’s center of gravity to shift, so you
can tip the printer to its upright position in a controlled
manner.
13. Unlock the casters and roll the printer to its final location.
Then lock down the casters.
14. Locate the printer on a flat, level floor, with all four wheels of
the stand resting stationary on the floor. The printer must
remain stationary and level for proper ink flow and best print
quality.
15. Locate and connect the profiler docking station cable on the
left end of the printer, and connect it from the left-hand ink
tray to the port on the printer.
Unpacking and Assembly
1-11
Caution
Do not pinch the ribbon cable between the ink tray
support and the printer frame. If the ribbon cable is
damaged, it may need to be replaced.
16. Locate and connect the profiler docking station cable from
the right-hand ink tray to the port on the printer.
17. Using the screws installed in the back of the printer, attach
the ink trays ➌ and ➍.
The right and left trays are mirror images of each other. Position the trays so that the inks load from the front.
Loosen the screws, drop the trays into place onto the screws
through the cutouts in the tray supports, then tighten the
screws to secure the trays to the printer.
➍
➌
Fig. 1-7. Attach the ink trays,
connect docking station cable
18. Remove the shipping bands from the long black chain connected to the printhead carriage.
19. Remove the foam blocks that immobilize the carriage for
shipping.
1-12
Unpacking and Assembly
20. Install the service station by inserting it into the rectangular
cutout inside the right endcap (behind the control panel).
Position the service station so that the edge with the word
“FRONT” is closest to the front of the printer. Slide the service station fully to the left end of the cutout.
21. Join the connector on the twisted wires from the takeup
motor to the connector on the electronics assembly.
The connector on the electronics assembly is on the side of
the electronics enclosure, near the takeup spool bracket.
22. Level and stabilize the printer.
Leveling the printer and removing its weight from the stand
casters is required to ensure proper media tracking and
high-quality prints. Locate the printer on a flat, level floor.
Lower the leveling feet so they contact the floor, then continue lowering them until the printer’s weight is off the
casters. Next, use a bubble level to ensure that both legs are
level front-to-back by adjusting the leveling feet (raise the
lower end, and keep the printer’s weight off the casters).
Connecting to Power
See Appendix A, Technical Specifications, or refer to the Site
Preparation Guide, for detailed power requirements.
The print server may be connected to the same circuit as the
printer if the circuit’s amperage is sufficient for both devices.
Refer to the print server’s documentation for its amperage
requirement. Consult a qualified electrician if you have any
doubt as to how the circuits in your facility can accommodate
the printer and print server.
WARNING WITH THE POWER SWITCH IN THE OFF POSITION,
POWER MAY STILL BE SUPPLIED TO THE PRINTER
COMPONENTS. To cut power completely from the
printer, you must unplug the power cords from the
power outlets.
WARNUNG WENN DER NETZSCHALTER IN OFF POSITION
STEHT, WIRD DEN KOMPONENTEN TROTZDEM
STROM ZUGEFÜHRT. Um den Drucker komplett
stromfrei zu machen, müssen Sie den Netzstecker
ziehen.
Unpacking and Assembly
1-13
Connecting to the
Print Server
Connect the printer to the print server with the included
VideoNet (for ColorSpan print servers) or Ethernet cable (nonColorSpan RIPs). See Fig. 1-8.
Note
Do not connect the printer VideoNet cable to your
local area network. The VideoNet protocol is not
compatble with other network protocols.
Refer to the print server (RIP) documentation for further instructions on connecting the printer to the print server.
Fig. 1-8. Power and RIP connections
1-14
Unpacking and Assembly
Power-Up Sequence
Turn on the power switch to observe the typical power-up
sequence:
1. The control panel backlight illuminates. Move the contrast
lever (located to the right of the control panel screen) up and
down until the control panel graphics and messages are easily
visible.
2. The printer runs a series of self-tests, and reports any errors it
finds.
3. The camera searches for the location of the installed media’s
home and far edges. If media is installed, this data tells the
printer the width of the installed media. If no media is installed,
the printer will prompt you to load media when the next print
job is sent to the printer.
4. The control panel displays the status screen.
Fig. 1-9. Initial status screen after first power-up
What’s Next?
Unpacking and Assembly
◆
To familiarize yourself with the printer, refer to the remainder of this chapter.
◆
To proceed with installation, see Chapter 3, Installing Ink
and Media.
◆
For a complete description of using the control panel, see
Chapter 2, Using the Control Panel.
1-15
Workflow Overview
When the printer is connected to a ColorMark Pro print server,
here is how a typical print job progresses from the client workstation to the printer. If you are using a non-ColorSpan RIP, refer
to the documentation that accompanies it for details.
1. The operator sends a file to be printed from a client
workstation.
2. The print job is received by the print server.
Once it reaches the print server, the print job may be reprioritized, combined with other jobs, re-routed, or otherwise
manipulated. Refer to the print server online help or manual
for instructions.
3. The print server RIPs the job.
The raster image processing (RIP) process translates the
PostScript language data that comprises the print job into
the data required by the printer.
4. The server sends the image to the printer for printing.
1-16
Workflow Overview
Parts Overview
456
7
8
9
10
11
16
16
1
1
12
2
13
14
15
17
3
3
18
21
19
20
Fig. 1-1. Major parts of the printer
Parts Overview
1-17
Index Description
1
End cap (two places) — includes removable end covers
for maintenance access.
2
Stand — supports the printer.
3
Casters (four places) — enables easy location of the
printer, can be locked in place.
4
Encoder strip — allows precise positioning of the printhead carriage across the length of the platen.
5
Main carriage drive belt — moves the carriage across
the length of the platen.
Transport chain (not shown) — supports the ink supply tubes that carry ink from the ink reservoirs to the
printheads.
1-18
6
Top cover — protects the user from the rapid motion of
the printhead during printing. A safety interlock switch
stops printing and cancels the print if the cover is
raised.
7
Platen — supports the media under the printheads
during printing.
8
Printhead carriage — carries the printheads, digital
imaging sensor, and photodiode across the length of
the platen. (See also detail in Fig. 1-2. and Fig. 1-3. on
page 1-20.)
9
Media out sensor — detects whether media is loaded.
10
Service station (behind access door) — catches excess
ink from the printheads, wipes and caps the printheads
to prevent drying and clogging while not in use.
11
Prime access door — provides access to the carriage for
manually priming the printheads. A safety interlock
switch stops printing and cancels the print if the cover
is raised.
12
Control panel — displays messages and allows control
of certain printer operations. Includes a contrast adjustment lever and audio feedback.
13
Electronics module — contains the printer’s power
supply and control electronics. Includes a humidity
sensor to enable the printer to compensate for highhumidity conditions by slowing the speed of printing.
14
Pinch rollers (12 places) — grip the media during
loading and printing.
Parts Overview
Index Description
Parts Overview
15
Dryer — carries air blown from the dryer fans to the
printed output.
16
Ink reservoir tray (two places) — holds ink reservoir
boxes.
17
Takeup gearbox — powers the takeup spool to automatically take up printed output.
18
VideoNet port — connects printer to print server.
19
Standby power switch — places printer in standby
mode (to disconnect from power, disconnect power
cord).
20
Power inlet — connects the printer to electrical power.
21
Media advance switch — enables user to advance
media manually during loading.
22
Printhead carriage lock lever (two places) — locks
and unlocks the printhead assembly, for tilting it to the
upright position and returning it to the printing position.
23
Printhead cover (three places) — secures the printheads to the carriage.
24
Printhead cover latch (three places) — locks the printhead cover in place.
25
Printhead (replaceable, up to twelve places) —
delivers ink to the media.
26
Digital image sensor — detects the location of printed
pixels for precise alignment of the printheads, enables
the automatic replacement of poorly-printing ink jets
with substitute jets.
27
Photodiode — enables the creation of color transforms
without an external spectrophotometer (requires print
server support), and the linearization of existing transforms.
1-19
22
23
23
23
22
25
24
Fig. 1-2. Printhead carriage, printhead covers open
26
27
Fig. 1-3. Printhead carriage, tilted position for
cleaning and accessing ink tubes
1-20
Parts Overview
Special Features
Performance Features
Ease-Of-Use Features
Special Features
The printer has many advanced features to help you produce the
best printed output with the least effort.
◆
AutoSet Calibration — uses a high-resolution digital imaging sensor to align printheads automatically in the x-y
directions and bidirectionally for precise positioning of ink jet
pixels, also compensates for lost or misfiring jets by using
substitute jets without slowing printing speed.
◆
AutoTune — can run AutoSet at user-defined intervals, for
highest quality during unattended printing. Optionally, if
print quality falls below a user-defined level, printing stops
until the problem is corrected.
◆
“On-the-fly” media feed adjustment — the media feed
(advance) can be adjusted during printing by pressing the
up (increase) and down (decrease) arrows displayed on the
control panel.
◆
Onboard linearization — uses the onboard photodiode to
linearize output over the entire density range (with print
server or RIP support).
◆
Integrated heated dryer — dries output as it prints. Optionally, the dryer fans may be turned off to avoid streaking on
poly and film media.
◆
Humidity sensor — slows printing in high humidity conditions to ensure drying, and alerts the user when the ambient humidity is outside of optimal range.
◆
Temperature sensor — prevents overheating by halting
printing when the temperature exceeds specification.
◆
Modular ink delivery system — the ink system consists of
three components—ink reservoir, ink tube, printhead—each of
which can be replaced independently of the others as
needed.
◆
Tilt-up print-head carriage — printhead carriage tilts up for
easy access to the ink tubes, printheads, and image sensors.
◆
Manual priming system — recovers clogged ink jets without
removing the printhead from the printer.
◆
Manual air purging system — recovers printheads that are
disabled due to too much air being introduced.
◆
Integrated bidirectional takeup system — takes up printed
output onto a spool for extended unattended printing. Output may be wound image-side out or image-side in.
1-21
1-22
◆
Automatic head height setting — uses the onboard image
sensor to set the print head height and level the print head
carriage.
◆
Media width sensing — automatically detects the width and
position of the media loaded, for precise image placement.
◆
Simplified control panel interface — Front Page screen presents frequently-used functions, with recommended preset
configurations. A menu provides access to less-frequently
used functions and troubleshooting help.
◆
Media Wizard — whenever you specify any one of four key
settings (Media Feed Calibration, Head Height, Vacuum Fan
Level, Head Acceleration), the printer saves them for subsequent recall when reloading media. The Media Wizard
option on the menu provides a quick shortcut to these four
settings.
◆
User assistance — control panel features online help, interactive procedures, and diagnostics to assist the user “on-thefly,” reducing training and troubleshooting time.
Special Features
CHAPTER 2
Using the Control Panel
This chapter describes the functions of the control panel.
Using the Control Panel
◆
Overview (page 2-2)
◆
Front Page (page 2-5)
◆
Navigation Keys (page 2-9)
◆
Menu (page 2-10)
◆
Menu Tree (page 2-20)
2-1
Overview
The touch-screen control panel shows you the printer’s current
status, and enables you to interact with the printer when changing media and ink, respond to an error condition, or configure
options. There are three main control panel screens:
Ready Screen
◆
Ready (Status) Screen
◆
Front Page
◆
Menu
When you press the Online/Offline button from the Front Page
screen, the printer goes online and the Ready or Status screen
appears. The Ready screen displays the current status of the
printer and any currently printing job. It displays when the
printer is online (communicating with the print server) and
either ready to print or printing.
Fig. 2-1 Ready screen
2-2
Front Page
When you press the Online/Offline button from the Ready
Screen, the printer goes offline and the Front Page screen
appears. This screen is the top level of the printer’s menu system. It provides access to the most frequently-used offline functions. For details, see “Front Page” on page 2-5.
Menu
When you press the Menu key on the Front Page screen, the
Menu appears. The Menu provides access to advanced configuration options. For details, see “Menu” on page 2-10.
Overview
User Assistance
The control panel provides various forms of online user
assistance:
The ? button provides an explanation of the current function,
with some guidance for what to do next.
The ATTN (Attention) key blinks on the control panel when the
printer detects an error condition, potential error condition, or
when you make a change that suggests recalibration or other
action to ensure best print quality. There are three types of
ATTN messages:
◆
Actions — the printer has detected an error condition that
stopped printing or will prevent printing from starting. You
must correct the error before the printer will be ready to
print. When the printer senses that the error condition has
been addressed, the Action will be deleted the next time the
ATTN key is pressed.
◆
Warnings — the printer has detected a condition that, if left
unaddressed, could result in substandard prints or a condition that will require an action before printing can continue.
Any action on your part is optional, printing is not interrupted for a Warning message.
◆
Changes — the printer has detected a change to the inks,
media, or printer that could affect print quality. Pressing the
ATTN key displays a message that suggests the actions to
perform for optimal print quality, such as recalibration. You
can dismiss the message with or without actually performing the suggested action, although ignoring the messages
could result in substandard output quality. Printing is not
interrupted for a Change message.
When the printer issues one of these messages, the ATTN key
will blink, and an alert beep will sound. Press the ATTN key to
display a list of message titles, and select a title to display a
detailed cause-and-recovery screen.
If you choose to not correct a Warning or Change condition and
resume printing, the ATTN key will remain displayed, but will
not blink until the printer issues a new Warning, Action, or
Change message. The messages can be dismissed by correcting
the condition, or by pressing the applicable key on the detail
screen.
Overview
2-3
Tip
2-4
See page 2-13 for instructions for choosing an Expert
or Novice mode for displaying these messages
(Expert mode routes most messages to the Actions
& Warnings menu), and for disabling or enabling
the audible alarm. See the table beginning on page
B-5 for a list of errors and recovery procedures.
Overview
Front Page
The Front Page provides access to the most frequently-used
printing and maintenance functions. For advanced configuration options, press the Menu key (see “Menu” on page 2-10 for
instructions).
Fig. 2-2. Front Page
Front Page
◆
Printer Name — displays the name of the printer as defined
on the print server.
◆
Online/Offline — returns the printer to the Ready screen.
2-5
◆
Media & Ink — displays a listing of the media and ink currently installed in the printer. Press the p and C keys to
highlight “Media” or one of the inks, then press B (Proceed) to display information about the selection. From this
screen, you can press the m and q keys to scroll between
screens. Press B (Proceed) to return to the list, then z
(Menu Out) to display the Front Page screen.
Fig. 2-3. Media Info, Ink Info screens
2-6
Front Page
◆
Status — displays the status of all user-configurable options.
Press { (Page) to scroll between pages. To change an
option, go to the Printer Configuration section of the menu.
Page 4 contains the current Media Wizard settings (see
“Media Wizard” on page 2-19).
Fig. 2-4. Status page 1
Front Page
◆
Advance Media — press the p key to advance the media forward. When you press and hold the p key, the media moves
faster. You can also press the Media Advance switch on the
rear of the printer, below the left profiler docking station, to
advance the media. Press the C key to advance the media
back onto the supply spool. When you press and hold the C
key, the media moves faster.
◆
Menu — displays the complete printer menu for access to
advanced configuration options (see “Menu” on page 2-10
for instructions).
◆
AutoSet — performs a “one touch” calibration of the printer:
bidirectional and head-to-head alignment of printheads, and
AutoJet substitution mapping of deflected or missing jets.
See “AutoSet” on page 4-2 for instructions.
2-7
2-8
◆
Prime Bars — fires all jets by drawing a set of lines called
prime bars. This is a good way to inspect and prepare the
jets for printing after they have been idle for more than a few
hours. Choose Quick Prime Bars for most primes, or
Detailed Prime Bars when you want to locate individual
missing jets that AutoSet may have missed, so you can map
them manually under Calibrate Printer - Manual Calibrations - Manual Jet Mapping (see “Manual Jet Mapping” on
page 4-13 for instructions).
◆
Print Mode — interactively assists you in installing printheads in the correct positions, and setting the number of
print passes. See “Selecting a Print Mode” on page 3-7 for
instructions.
◆
Carriage — moves the carriage out of the service station so
you can load or clean the printheads and ink tubes, clean the
image sensors, and remove the service station.
◆
Media Wizard — provides access to the settings that the
printer are saves and associates with a particular media:
Media Feed (page 4-4), Head Height (page 4-23), and
Platen Vacuum Control (page 2-12). Page 4 of the Status
screen contains the current Media Wizard settings (see previous page).
◆
Unload — when unloading media, prints the calculated
amount of media remaining on the roll for reference (on the
lower right edge). When removing the partial roll from storage and re-loading on the printer, the user can report this
value to the printer during the Media Load operation. If
using the takeup, cut the media from the takeup spool
before pressing the Media Unload key (see “Cutting and
Unloading Media” on page 3-35).
◆
Load — measures the width of the media installed in the
printer, checks for proper media positioning on the platen
(for good vacuum contact), asks the user to enter the
amount remaining on the supply roll, and asks the user to
select a takeup option. See “Loading Media” on page 3-26
for instructions. You can also access this function from the
menu (see “Load Takeup” on page 2-18).
◆
AT TN (Attention) — blinks on the control panel when the
printer detects an error condition, potential error condition,
or when you make a change that requires recalibration or
other action to ensure best print quality. See “User Assistance” on page 2-3 for further details.
Front Page
Navigation Keys
The following table shows you how to move through the menu
system and perform printer control functions.
Key
Description
v
Display Menu — displays the printer menu.
p down the menu.
x
w top or bottom for the menu.
z
m
Menu Top/Bottom — moves the menu highlight to the
E
Menu Out, Menu In — moves to the next higher menu
in the hierarchy, or selects the highlighted option.
Back/Forward — moves between pages or screens, or
q selects printheads to calibrate.
B
Proceed — initiates the selected function.
{
Page — switches between pages of a multi-page screen.
r
Help — displays a summary description of the highlighted menu options.
|
~
Pause/Resume — pauses or resumes printing during a
calibration.
n
Cancel — cancels the current menu function or choice.
o
Continue (error screen) — proceeds to the next step in
a troubleshooting dialog.
s
Ignore (error screen) — specifies “ignore” in a troubleshooting dialog.
A
Retry (error screen) — specifies “retry” in a troubleshooting dialog.
}
Reboot Printer (error screen) — specifies “restart
printer” in a troubleshooting dialog.
t
Information (error screen) — displays further information about the error.
D
Navigation Keys
Menu Up/Down — moves the menu highlight up and
C
Yes/No (error screen) — indicates a Yes or No in a trouy bleshooting dialog.
2-9
Menu
The menu has five main sections:
◆
Calibrate Printer (see below)
◆
Configure Printer (page 2-11)
◆
Service Printer (page 2-16)
◆
Warnings & Actions (page 2-18), shown in Expert Messages
Mode only
◆
Load Takeup (page 2-18)
This section explains each of the functions on the printer menu.
See “Menu Tree” on page 2-20 for a listing of all menu options.
Calibrate Printer
2-10
For details on these options, see Chapter 4, Calibrating the
Printer.
◆
Manual Calibrations — allow you to calibrate the media
feed advance accuracy, and perform the various components of the automatic AutoSet calibration visually, without
the printer’s digital imaging sensor. Inaccurate judgments by
the operator during these tests could result in substandard
output. In most cases, use AutoSet instead. See “Manual Calibrations” on page 4-3 for instructions.
◆
Auto Calibrations — enables you to run a portion of the
AutoSet calibration, to save time. See “Auto Calibrations” on
page 4-19 for instructions.
◆
AutoTune — schedules AutoSet to run automatically after a
certain number of prints have printed. See “AutoTune” on
page 4-20 for instructions.
◆
Calibration Summary — prints summary information with
the AutoSet calibration test patterns, or transmits registration or jet data to a log file on the print server. “Calibration
Summary” on page 4-21 for details.
Menu
Configure Printer
Configure Printer enables you to set many options that control
how the printer operates.
Printer Settings
◆
Gutter Settings — determines the appearance of the top and
side gutters.
◆
Top Gutters — allows you to turn On or Off the gutter
pattern at the top edge of the print, which shows data
about the print such as date and time printed and print
mode, plus write-in blanks for other data.
Color set reported in the print job
Media name from the print server/RIP
Job name
Date and time printed
Ink type
Embedded software version
Print mode selected at control panel:
Heads per color, number of passes,
direction of printing, HQ mode,
ink color set
Printer
Fig. 2-5. Top gutter data
◆
◆
Menu
Side Gutters — sets the side gutter pattern to Narrow,
Medium, or Wide sizes, or turns them Off. Side gutter
patterns help keep the ink jets open by firing ink
through them in a pattern outside the printed image
area.
Takeup Direction — sets the direction of the takeup motor to
wind the media Printed Side In (default), or Printed Side
Out.
2-11
◆
Margin Settings
◆
◆
Space Between Prints — sets the blank space between
print jobs, between 0 and 10 inches (25 cm).
◆ Right and Left Margin — sets the amount of blank space
for the right and left margins, between 0 and 5 inches
(13 cm).
◆ Leading Margin — when enabled and a media out condition has been detected, the printer measures the media
width and finds the leading edge of the media before
printing. This makes it easier to print on cut sheets.
Drying Settings — sets parameters for the operation of the
dryer:
◆
◆
2-12
Drying Delay — select the printer’s preprogrammed
algorithm for slowing the print speed when the ambient
relative humidity is excessive, or specify a custom drying delay in seconds per print swath. A longer delay
allows the output to remain under the dryer longer,
which ensures adequate drying under higher ambient
relative humidity.
To increase the media advance speed, you can specify a
manual drying delay. If you specify a manual drying
delay interval that will be insufficient to dry the output,
the printer will display a warning message on the control panel. Be aware that if you override this warning
without increasing the drying delay, you should not use
the takeup system, and take care to remove output from
the printer before it reaches the floor, and store it flat
until it dries. Using the takeup to collect wet output, or
allowing wet output to pile on the floor, would likely
result in ruined prints.
◆ Drying Rate — sets the rate of media advance during
post-print drying. Select Standard for fastest throughput. Select Same as print speed to slow the advance if
additional drying time is needed.
Platen Vacuum Control — turns on the vacuum fans, then
allows you to raise or lower the speed of the vacuum fans.
Raise the speed if the media is rising off the platen, lower the
speed if the media is buckling or wrinkling.
Menu
◆
Service Station Settings — sets parameters for the operation
of the service station:
◆
◆
Service Station Algorithm — choose Optimized (default),
which wipes while moving the carriage; or Original.
◆ Service Station Interval — sets the printhead service station cycle: every 30 seconds, 60 seconds, or 90 seconds. The service station cycle helps keep the ink jets
open by expelling ink and wiping the jets. A shorter
period can keep jets cleaner, a longer period increases
printing throughput with less frequent service station
“visits.”
◆ EnduraChrome Spits, PermaChrome Spits — allows you
to set the number of spits per service station visit for
each ink type. A lower setting saves ink usage. Increase
from the default setting only if jets are clogging (in this
case, service station wipers may be worn and need to be
replaced).
Expert/Novice Messages — Novice mode presents Warnings & Changes (alerts that do not prohibit printing) and
Actions (conditions that require user intervention before
printing can proceed). Expert mode presents Actions only,
presents fewer “press Proceed” prompts after an Action has
been addressed, and does not require you to press Proceed
after manually winding back a service loop. The default is
Novice mode.
When in Expert mode, active Warnings, Changes, and
Actions can be displayed by selecting Warnings & Actions
from the menu, since Warnings will not cause the ATTN icon
will appear in Expert mode. See “User Assistance” on page 23 for further information about Actions and Warnings. See
“Warnings & Actions” on page 2-18 for further information
about this menu option.
Menu
◆
Head Height — sets the height of the printhead to Normal
(0.050 inches/1.27 mm) or Custom. Use Normal unless the
media is curling or the printhead carriage is striking the
media. Lower settings reduce ink overspray, but increase the
chances of the printhead striking the media. When the head
height is 0.070 inches (1.78 mm) or higher, do not run
AutoSet, run the manual calibrations instead.
◆
Units — sets English or Metric units of measure for data displayed by the control panel.
◆
Audible Alarm — when On and one or more Actions are
pending, sounds a beep until the AT TN key is pressed.
2-13
Printer Options
2-14
◆
Dryer — turns the dryer fans On or Off. Disable the dryer
fan to avoid streaking output on poly media and films.
◆
Print White Space — when Print White Space is selected,
the printhead carriage always travels the width of the media,
even when there is a white (blank) space in the image.
When Do Not Print White Space is selected, the printhead
remains in its home position and the media advances past
white spaces in the image. This increases throughput on
print jobs that have large areas of white space.
◆
Quality Check — determines how AutoTune errors are handled (see “AutoTune” on page 4-20 for information about
AutoTune). When enabled, the printer determines the number of misfiring or not firing ink jets that are not being
replaced by other jets. If this number exceeds a maximum
value, an error occurs. This can give the operator a chance to
print anyway, or cancel printing so the problem can be
resolved.
◆
Attended Mode — user must press B (Proceed) to
acknowledge the error and print the job (if one is pending), or y (Cancel) to cancel printing.
◆
Unattended Mode — no user acknowledgment of errors
is required. When a quality check fails, print jobs are sent
to the ColorSpan print server’s Attention queue with a
disposition of “Uncalibrated Printer” (this feature may
not be supported on non-ColorSpan print servers).
◆
OFF — no quality check is performed, all jobs will print.
◆
Print Position — positions the print in the horizontal (x-axis)
direction, either in the center or flush right.
◆
Create Custom ColorMaps — enables you to define custom
ink sets (color maps), using any combination of ink colors, in
any order. See “Creating a Custom Color Map” on page 3-11
for instructions.
Menu
◆
FineLine Mode — allows you to tune the printheads for
improved fine line quality, and eliminate the “ghost” image
on backlit media, caused by ink transfer during takeup.
Select FineLine Mode Off (the default setting) for most
printing with large areas of high ink coverage. Select FineLine Mode On to reduce the jagged appearance of fine lines
and eliminate “ghosting.”
FineLine Mode is effective during the earlier portion of the
printhead’s service life. When excessive jet-outs or banding
occurs, select FineLine Mode Off, and operate the printhead
in this mode for the remainder of its service life.
Reset All Defaults
Menu
◆
Restore All Defaults — restores all Printer Configuration settings to their factory default values, and zeroes all registration data. After running this option, all calibration values
must be reestablished by running AutoSet.
◆
Zero Platen Width — sets the platen width to zero, which
forces the printer to measure the platen on the next power
up.
◆
Measure Platen — measures the platen width.
2-15
Service Printer
User Diagnostics
User Diagnostics presents an interactive troubleshooting program to diagnose problems before calling MacDermid
ColorSpan Technical Services. It walks you through a series of
tests and checks for certain printer functions. The printer asks
you to make observations or run simple tests to help it diagnose
problems and suggest corrective actions. It has the following
sections:
◆
VideoNet Status
◆
Head Statistics
◆
Carriage Motion
◆
VideoNet Connection
◆
Calibration
◆
Error History
◆
Actions and Warnings List — table of all actions and warnings with cause and recovery. This is an abbreviated version
of the table “Actions and Warnings” on page B-5.
◆
Log Error History
Service Tests
These tests are for factory, service, and technical support use.
2-16
◆
Profiler Test — identifies and verifies profilers in each position. The printer will report the profiler number, color, and
ink percentage remaining. Particularly useful when the
printer is connected to a non-ColorSpan RIP that cannot display profiler status.
◆
Print Test — the user selects a print width, one or more printheads to test, and (if multiple heads are selected) whether to
print multiple heads side-by-side or on top of each other,
then the printer begins firing the printhead(s) continuously
until canceled by the user. The test can help to identify intermittently failing printheads.
◆
Color Sensor Tests — Blackpoint and Whitepoint tests the
ability of the photodiode to get black point and white point
readings. Print and Read Patches prints and reads patches
from across the color spectrum and compares the readings
with expected values. Visually Inspect LEDs switches on and
off the LEDs, allowing you to compare their appearance with
the expected colors listed on the control panel.
Menu
◆
Horizontal Dot Accuracy — for factory/service use only.
◆
Vertical Dot Accuracy — for factory/service use only.
◆
Print Image on Image Sensor — the printer prints a small set
of lines which are scanned by the digital image sensor. Then
the printer prints an enlargement of the image as the sensor
captured it.
◆
Spit and Wipe Jets — tests the functionality of the service
station by firing ink (spit) and drawing the printheads over
the service station wipers (wipe).
◆
Takeup Test — tests the functionality of the takeup system.
◆
Vacuum Fan Test — runs the platen vacuum fans to test for
correct operation.
◆
Dryer Test — runs the dryer heater assembly to test for correct operation.
◆
Isolation Print Test — for factory/service use only.
◆
Control Panel Test — tests the functionality of the control
panel display.
◆
Pod Test — for factory/service use only.
Calibrations
These calibrations are performed at the factory. If any of them
are detected as out-of-specification, a message is displayed on
the control panel, recommending that you perform the applicable calibration:
◆
Head Height — provides a head height reset, automatic and
manual carriage height calibrations, and head height adjustment. See “Head Height Calibration” on page 4-23 for
instructions.
◆
Media Sensor — locates the platen to establish the “media
out” head height
Home Head
Recalibrates the home position of the printhead carriage. If the
printhead carriage will not return to the service station between
prints, select this option. Cycling the power off and on will also
run the Home Head function.
Measure Media Width
Measures the width of the media.
Menu
2-17
Prime Pens
Moves the carriage out of the service station home position so
that it can be accessed behind the access door for manual priming (for instructions, see “Manual Priming” on page 5-11).
Prime Bars
Prints a wide-swath version of the prime bars.
Disable Media Sensor
If the media sensor is malfunctioning, disable it to continue
printing. Note that with the media sensor disabled, the printer
will not be able to detect when there is no media in the printer.
Disable Latch Sensor
If the carriage latch sensor is defective, this function allows you
to disable the sensor until a replacement can be installed. Do
this only at the direction of MacDermid ColorSpan Technical
Services.
New Carriage
Select this option when installing a new carriage, to set the head
height to “uncalibrated.” After doing so, printing is not allowed
until the head height is calibrated (see Chapter 4, Calibrating the
Printer, for instructions).
Warnings & Actions
When in Expert mode, active Warnings, Changes, and Actions
can be displayed by selecting Warnings & Actions from the
menu, since Warnings will not cause the ATTN icon will appear
in Expert mode. This option does not appear in Novice mode.
See “User Assistance” on page 2-3 for further information about
Actions and Warnings, and the table beginning on page B-5 for a
list of recovery procedures. See page 2-13 for a description of the
Expert/Novice Messages mode.
Load Takeup
This option helps you to load media: it measures the width of
the media, checks for proper media positioning on the platen
(for good vacuum contact), asks the user to enter the amount
remaining on the supply roll, and asks the user to select a takeup
option. See “Loading Media” on page 3-26 for instructions.
You can also access this function from the Front Page screen,
under Load (see page 2-8).
2-18
Menu
Media Wizard
Menu
This option provides access to the four settings that the printer
saves and associates with a particular media: Media Feed (page
4-4), Head Height (page 4-23), Platen Vacuum Control (page 212), and 1-Pass Coverage. Page 4 of the Status screen contains
the current Media Wizard settings (see page 2-7). The settings
are saved automatically whenever they are changed, and can be
recalled when the media is subsequently reloaded.
2-19
Menu Tree
Front Page
Online/Offline
Media & Ink
Status
Printer
Status
Show
Menu
Advance
Media
Print
Prime Bars
Select
Print Mode
Run
AutoSet
Attention
Access
Carriage
2-20
Media Wizard
Unload
Media
Load
Media
Menu Tree
Menu
This menu tree reflects version 1.22 of the embedded printer software.
Refer to the Release Notes for more recent versions.
Calibrate Printer
Manual Calibrations
Media Feed
Manual Bidi Registration
Manual Head Registration
Manual Jet Mapping
Jet Status Lines
Default Registration Data
Auto Calibrations
Auto Bidi & H2H Calibration
AutoBidi Calibration
AutoH2H Calibration
AutoJet Calibration
AutoTune
Calibration Summary
AutoSet Summary
Log Head Registration Data
Log Jet Data
Configure Printer
Printer Settings
Gutter Settings
Top Gutters
Side Gutters
Takeup Direction
Margin Settings
Space Between Prints
Right and Left Margin
Leading Margin
Drying Settings
Drying Delay
Drying Rate
Platen Vacuum Control
Service Station Settings
Service Station Algorithm
Service Station Interval
EnduraChrome Spits
PermaChrome Spits
Expert/Novice Messages
Head Height
Units
Audible Alarm
Printer Options
Dryer
Print White Space
Quality Check
Print Position
Create Custom ColorMaps
FineLine Mode
Menu Tree
Reset All Defaults
Restore All Defaults
Zero Platen Width
Measure Platen
Service Printer
User Diagnostics
VideoNet Status
Head Statistics
Carriage Motion
VideoNet Connection
Calibration
Error History
Warnings and Actions List
Log Error History
Service Tests
Profiler Test
Print Test
Color Sensor Tests
Horizontal Dot Accuracy
Vertical Dot Accuracy
Print Image on Image Sensor
Spit and Wipe Jets
Takeup Test
Vacuum Fan Test
Dryer Test
Isolation Print Test
Control Panel Test
Pod Test
Calibrations
Head Height Reset
Auto Carriage Height
Manual Carriage Height
Adjust Head Height
Home Head
Measure Media Width
Prime Pens
Prime Bars
Disable Media Sensor
Disable Latch Sensor
New Carriage
Warnings & Actions (Expert mode
only)
Load Takeup
2-21
2-22
Menu Tree
CHAPTER 3
Installing Ink and Media
This chapter describes:
Installing Ink and Media
◆
Variable Mode Printing (page 3-2)
◆
Ink System Overview (page 3-4)
◆
Selecting a Print Mode (page 3-7)
◆
Installing Ink for the First Time in a New Printer (page 3-14)
◆
Replacing Ink System Components (page 3-19)
◆
Loading Media (page 3-26)
◆
Cutting and Unloading Media (page 3-35)
3-1
Variable Mode
Printing
The printer uses these techniques to vary the quality of a print
and speed of printing:
◆
Color Set — ink sets may contain one each of a different
color, two each of a different color, varying densities of certain colors, or combinations. Using two sets of colors speeds
printing, while using multidensity inks creates smoother
transitions between light tones, and increases the perceived
resolution of the print.
◆
Jet Replacement — jets on the printhead that are misfiring or
not firing at all can be replaced with alternate jets. Ideally,
every pixel called for in a print is printed. In reality, some
pixels are not printed because the ink jets tend to become
partially or completely clogged with ink, which reduces print
quality. AutoJet mapping substitutes an otherwise unused jet
for a missing or deflected jet.
◆
Passes — number of times the printhead passes over a given
area of the image. A greater number of passes makes a
greater number of substitute jets available, but slows printing speed.
Print quality (apparent resolution and smooth gradients) is
improved by:
3-2
◆
Increasing the number of different ink colors (and/or
densities); see “Selecting a Print Mode” on page 3-7
◆
Increasing the number of passes (see “Selecting a Print
Mode” on page 3-7)
Variable Mode Printing
Print speed is increased by:
Variable Mode Printing
◆
Reducing the number of passes (see “Selecting a Print
Mode” on page 3-7)
◆
Reducing the number of different colors or using smaller ink
sets (four or six colors instead of eight or more)
◆
Printing with two heads per color (see “Selecting a Print
Mode” on page 3-7)
◆
Printing in low relative humidity to avoid drying delays
◆
Selecting “Do not print white space” under Configure
Printer - Printer Options - Print White Space (see “Printer
Options” on page 2-14)
◆
Selecting “Optimized” under Configure Printer - Printer
Settings - Service Station Settings - Service Station Algorithm
◆
Using MediaSaver (ColorSpan Print Server feature) to group
jobs together, eliminating the end-of-job drying delay
between jobs
◆
Using MediaSaver or N-UP (ColorSpan Print Server features)
to print as wide as possible, thereby minimizing the number
of times the printhead has to change directions during
printing
3-3
Ink System Overview
The printer’s ink system consists of three main components:
◆
Ink reservoir — a plastic box containing the ink supply and
an electronic profiler, which specifies the ink type, color, and
amount remaining. The profiler plugs into a connector on
the ink tray, allowing it to communicate with the printer and
print server. The reservoir is self-contained and seals automatically for easy handing.
◆
Ink tube — carries the ink from the reservoir to the printhead, self-sealing on both ends for ease of handling.
◆
Printhead — delivers the ink to the media.
Each of these components can be replaced independently of the
others. This enables you to consume the ink from two or more
reservoirs before replacing the printhead when an excessive
number of clogged jets cannot be recovered with priming or
cleaning. The ink tubes need not be replaced unless you switch
ink types (for example, from a dye ink to a pigmented ink, or to
a different set of colors), or if a tube becomes damaged.
Fig. 3-1. Ink system components
3-4
Ink System Overview
The ink system also includes a labeling system to help keep the
components of each ink color together:
◆
Color Map Cards — lists all of the supported ink sets, fits in
plastic sleeve inside the printer’s top cover for easy reference
during installation and printing.
Fig. 3-2. Color Map card
Tip
If you cannot locate the color map card for a particular ink set, use the color map display on the control
panel. To access, press the Print Mode key on the
Front Page (for details, see “Selecting a Print Mode”
on page 3-7).
◆
Ink Type Label — used to identify the ink type used in each
ink tube.
◆
Ink Tube Number Label — used to label each end of each ink
tube (ink reservoir end and printhead end) from 1 to 12; corresponds to the factory-labeled ink tray positions 1 to 12.
Fig. 3-3. Ink type and ink number labels
Ink System Overview
3-5
Spare Ink and Printheads
For maximum productivity and minimum down time,
ColorSpan recommends stocking extra ink reservoirs and printheads. When the ink supply runs low, or a printhead needs to be
replaced, having spares will ensure that printing can resume as
quickly as possible.
Since ink and printhead usage will vary depending on the
amount and types of printing you do, experience will help you
determine how to stock an efficient spare inventory. For example, in a “2x6” configuration (two six-color sets of ink),
ColorSpan recommends stocking two six-color sets of ink reservoirs, plus six printheads (one for each color). Both ink reservoirs in a pair tend to run out of ink at the same time, so two
spares per color would allow you to continue printing with a
minimum of delay. The printheads tend to need replacement
one at a time, so one spare per color would be sufficient most of
the time.
Tip
To clean a printhead with jet-outs, see “Cleaning Ink
Jets” on page 5-3.
Printhead Handling Tips
3-6
◆
DO hold the printhead by the plastic body only.
◆
DO clean the printheads with a clean lint-free cloth moistened
with plain water.
◆
DO NOT touch the ink jet nozzles on the bottom of the printhead.
◆
DO NOT touch the electrodes on the back of the printhead. The
printhead is fired by an electrical signal. The electrodes that carry
this signal are easily contaminated.
◆
DO NOT set the printhead down anywhere before you install it.
◆
DO NOT wipe the printhead with any fiber-cellulose material,
such as a paper tissue.
◆
NEVER APPLY ISOPROPYL ALCOHOL ON THE PRINTHEAD OR
SERVICE STATION. USE PLAIN WATER. Alcohol reacts with pigmented inks, rendering the printhead unusable. To clean ink clogs,
see “Cleaning Ink Jets” on page 5-3.
Ink System Overview
Selecting a Print Mode
Before installing ink, report to the printer how you will use the
ink you will install (the “print mode”). This is necessary because
although the printer can detect which inks are installed, a given
ink set may be usable in several different modes.
For example, consider an installation of two six-color (C2M2YK)
sets of ink. By changing the color map selected at the control
panel, and without moving or removing any of the ink reservoirs or printheads, these twelve inks may be used as:
◆
2 six-color ink sets
◆
1 six-color ink set
◆
2 four-color ink sets
◆
1 four-color ink set
See “Switching Between Ink Sets” on page 3-12 for further
details.
To configure the print mode:
1. From the Front Page screen on the control panel, press the
Print Mode key.
The control panel displays the Current Selection screen. This
shows the current settings for the options you are about to
specify.
2. Press the B (Proceed) key.
The control panel displays the Print Direction menu.
3. Press the C and p keys to select the number of printheads
per color you plan to use, then press the D key.
The Select Ink Type menu appears. Select User Defined to
select one of four available custom color maps. For more
information about custom color maps, see “Creating a Custom Color Map” on page 3-11.
Selecting a Print Mode
3-7
4. Press the C and p keys to select the ink type, then press the
D key.
The control panel displays the Select Color Map screen. At
the top of this screen are the color sets that are valid for the
number of heads per color you selected. At the bottom of
the screen is a schematic diagram showing the placement of
the printheads in the printhead carriage.
Fig. 3-4. Select Color Map screen
Printhead Positions
1
5
2
9
6
3
10
11
7
4
8
12
Ink Colors
C
mC
lC
M
mM
lM
Y
K
3-8
Cyan
Medium Cyan
Light Cyan
Magenta
Medium Magenta
Light Magenta
Yellow
Black
lK
mlK
mK
B
O
R
G
xxx
LIght Black
Medium Light Black
Medium Black
Blue
Orange
Red
Green
Ignored/Not used
Selecting a Print Mode
Ink Type (Suffix)
E
P
AutoInk Maps
Endura•Chrome
Perma•Chrome
There are three AutoInk maps, which allow you to load and print
with one Endura•Chrome dye ink set, and one Perma•Chrome
pigment ink set, as follows:
◆
1x6E-1x6P — one six-color Endura•Chrome set and one
six-color Perma•Chrome set
◆
1x6P-1x6E — one six-color Perma•Chrome set and one
six-color Endura•Chrome set. This configuration eliminates
rough edge effects in black lines when printing on
Perma•Chrome FineArt Paper.
◆
1x8E-1x4P — one eight-color Endura•Chrome set and one
four-color Perma•Chrome set.
5. Press the C and p keys to select the color map you will use.
The color map diagram changes with your selection.
6. Press D to continue.
The control panel displays the Select Passes menu.
7. Press the C and p keys to select the number of print passes
you want to use.
A higher number of passes produces the best print quality,
but a lower number of passes will increase print speed. The
default is 8 passes.
8. Press D to continue.
The control panel displays this message:
USE MEDIA WIZARD VALUES?
followed by the current settings for platen vacuum, head
height, and 1-pass coverage.
9. Press n to use the setting values you entered, or B to ignore
the new values and use the currently-saved values.
The Front Page screen appears. The print mode is now
selected. If you changed the number of passes by more than
one pass, you should run a Media Feed Calibration (see
“Media Feed Calibration” on page 4-4) and Head-to-Head
Selecting a Print Mode
3-9
registration (“Auto Calibrations” on page 4-19) before printing.
10. Install the Color Map card that corresponds to the mode you
selected into the plastic sleeve on the printer’s top cover.
Refer to the Color Map card to help you load inks into the
correct locations. See the figure on page 3-5 for an illustration of a Color Map card.
3-10
Selecting a Print Mode
Creating a Custom
Color Map
You can create a custom ink set that uses colors of your choosing, in the positions where you want to place them.
1. From the Front Page screen, press the Menu key to enter the
menu system.
2. Press the pkey to highlight Configure Printer.
3. Press the E (Menu In) key to display the menu.
4. Press the p key repeatedly until Printer Options is highlighted.
5. Press the E (Menu In) key to display the menu.
6. Press the p key repeatedly until Create Custom Colormaps is
highlighted.
7. Press the E (Menu In) key.
The printer prompts you to insert the ink reservoirs.
8. Load the ink modules into the ink trays in the order you
intend to use them.
9. Press B (Proceed) to continue.
The choices for heads per color appear.
10. Select the number of heads per color (press p or C if necessary), then press B to continue.
11. Select the ink type, then press B to continue.
12. Press p or C to select one of the User Defined color maps
from the list, then press B to continue.
The printer displays a summary of your selections, including
a schematic diagram of the new color map.
13. Press B to confirm your settings, or n to cancel.
If you pressed Proceed, your new color map is saved.
14. Press B to continue.
The Printer Options menu appears. The new ink set (color
map) you defined is now available under the Print Mode
button on the Front Page. To replace this user-defined color
map, repeat this procedure and select the map you want to
replace in step 12.
Creating a Custom Color Map
3-11
Switching Between Ink
Sets
The inks are located in specific numbered locations on the
printer for optimal print and color quality. The software ignores
ink positions that are not needed for a print mode, so any ink
(or no ink) can be present in these positions. This provides flexibility while minimizing the need to swap or reposition inks. For
example, by loading a 2x6 C2M2YK ink set, you can switch
between 2x6, 1x6, 2x4, and 1x4 print modes at the control
panel without moving or changing any inks (see below).
1x6
2x6
2x4
1x4
C = Cyan, mC = Medium Cyan
M = Magenta, mM = Medium Magenta
Y = Yellow
K = Black
Fig. 3-5. Possible modes with a 2x6 ink set
3-12
Switching Between Ink Sets
Switching between eight-color and six-color modes, however,
does require switching ink(s):
1x6
1x8
2x6
C = Cyan, mC = Medium Cyan, lC = Light Cyan
M = Magenta, mM = Medium Magenta, lM = Light Magenta
Y = Yellow
K = Black
CX = Change Ink
Fig. 3-6. Possible modes with a 1x8 ink set
Caution
When changing ink colors, if you change the printhead and reservoir without changing the existing ink
tube, ink from the reservoir will mix with the different ink in the ink tube, producing a third color. When
you change ink colors, you must replace the existing
printhead, tube, and reservoir with the printhead,
tube, and reservoir containing the new ink color.
The printer will display an error if you install a printhead and/or reservoir in the wrong position for the
selected ink set, but it cannot detect whether the ink
tube does not match the other components.
Since inks of different dilutions are very difficult to
visually discern in the ink tubes, be sure to label all
components and replace them one color at a time, as
described in “Replacing Ink System Components” on
page 3-19.
Switching Between Ink Sets
3-13
Installing Ink for the
First Time in a New
Printer
When you receive a new printer, numbered empty ink tubes are
preinstalled at the factory. This prepares the printer to accept ink
reservoirs and printheads with any ink type or color set. It also
avoids introducing air into the ink, which would occur gradually
if ink tubes filled with ink were installed and stored unpressurized (without an ink reservoir connected).
During the ink installation process, you will displace the air
inside the ink tube with ink before you connect the tube to the
printhead.
Caution
Always fill an empty ink tube with ink before connecting it to a printhead. Connecting an empty ink
tube to a printhead will result in enough air to be
introduced to cause the printhead to fail. This condition may be recoverable by purging the cartridge of
air (see “Purging the Printheads” on page 5-14 for
instructions), and then priming them (see “Manual
Priming” on page 5-11).
1. On the printer’s Ready screen, press the Online/Offline key.
The Front Page screen appears.
2. On the control panel Front Page screen, press the Carriage
key.
The printhead carriage moves to the center area of the platen
so you can load the printheads.
3. Open the printer’s top cover.
4. If desired, label the ink tubes at the reservoir end.
Referring to the Color Map card, affix the labels showing the
ink color and ink type onto the ink tubes at the reservoir
end. This will identify the ink used in each tube, and help
3-14
Installing Ink for the First Time in a New Printer
reconnect any tubes that are removed and stored to the correct ink reservoir and printhead.
5. If not pre-assembled, insert the drain tube into the connection on top of the drain bottle.
Fig. 3-7. Assembling the drain tube to the top
of the drain bottle.
6. Place the drain bottle on the floor and tape the drain tube to
the dryer tube, providing a descent from carriage-level to the
drain bottle.
Fig. 3-8. Placing the drain bottle
Installing Ink for the First Time in a New Printer
3-15
7. Referring to the Color Map card, place an ink reservoir into its
numbered position (1 through 12) in the ink tray.
Be sure to insert the profiler into its port in the ink tray.
Work with the ink reservoir, tube, and printhead that correspond to one position at a time. This will help prevent crossconnecting components.
8. Referring to the Color Map card, affix the labels showing the
ink color and ink type onto the connectors of the ink supply
tube (see Fig. 3-3 on page 3-5).
9. Open one of the carriage covers to expose the printhead
slots.
Release the cover by pressing its latch at the front of the
carriage.
10. Insert the needle end of the drain tube into the nozzle end of
the supply tube that is located in the printhead slot in the
carriage assembly (see Fig. 3-9).
This will allow air to escape from the supply tube.
Fig. 3-9. Connecting the drain bottle tube to the supply tube
11. Connect the ink supply tube into its corresponding fitting on
the ink reservoir.
The ink will begin to flow from the reservoir toward the ink
bottle. The ink will displace the air in the tube, filling it
with ink. To ensure that the drain tube needle does not slip
out of the ink tube, hold the drain tube needle in place during the fill process.
3-16
Installing Ink for the First Time in a New Printer
The ink should flow for a few inches into the drain tube,
then stop.
◆
If the ink continues to flow, this may indicate that the
seal between the printhead and the supply tube is faulty.
Replace the supply tube (see “Replacing An Ink Tube”
on page 3-22for instructions).
◆
If ink leaks out of the seal between the supply tube and
the printhead, replace the supply tube.
◆
If ink does not flow out of the ink module into the supply tube, the seal between the ink module and supply
tube may be faulty. Replace the supply tube.
12. As soon as you see ink flowing into the drain tube, pinch the
drain tube and remove it from the nozzle end of the ink tube.
By pinching the drain tube, a vacuum is formed between the
pinched tube and the end of the needle, keeping any residual ink from draining from the needle as it is removed.
Fig. 3-10. Removing the drain tube
13. Wipe clean the needle end of the drain tube, and set it aside,
keeping the ink inside from spilling out.
14. Remove the packaging from a printhead that contains the
same ink as the ink reservoir.
Remove the tape covering the electronic contacts, and
remove the plug from the ink inlet. Do not touch any of the
metallic electronic contacts.
Installing Ink for the First Time in a New Printer
3-17
15. Install the printhead into the carriage.
Install the printhead into the correct position. You can use
the built-in handle to help position the printhead.
16. Repeat steps 7 through 15 for each ink tube you want to fill.
17. Close and latch the carriage cover(s).
18. Close the printer’s top cover.
On the control panel Front Page screen, press the B (Proceed) key to park the printhead carriage into the service station.
See “Loading Media” on page 3-26 for media loading
instructions.
After installing one or more printheads, always run AutoSet. See
“AutoSet” on page 4-2 for instructions.
3-18
Installing Ink for the First Time in a New Printer
Replacing Ink System
Components
Replacing an Ink Reservoir
in an Idle Printer
This section shows you how to replace the individual components in the ink system:
◆
Replacing an ink reservoir in an idle printer (below)
◆
Replacing (“hot swapping”) an ink reservoir during printing
(page 3-20)
◆
Replacing a printhead (page 3-21)
◆
Replacing an ink tube (page 3-22)
Replace an ink reservoir when there is insufficient ink to print,
or when you want to use a different color or type of ink. If you
replace an ink reservoir with the same color and type of ink,
there is no need to replace the printhead and ink tube.
Caution
When switching to a new ink color or ink type,
replace the ink reservoir, printhead, and ink tube as a
matched set. Failure to do so will contaminate the
ink system and compromise performance or output
quality.
When installing ink tubes, avoid placing excessive tension on
the tube end connected to the printhead. Excessive tension may
cause kinking and blockage of the ink flow, and could cause the
tube to separate from its connector, resulting in an unrestricted
flow of ink from the tube.
1. Remove the ink reservoir from the ink tray. Do not disconnect
the ink tube at this time.
This disconnects the profiler, which is built into the ink reservoir, from its port on the back of the tray. The printer
detects that the profiler has been disconnected, but will not
report an error condition unless you try printing.
2. Install the new ink reservoir into place in the ink tray. Carefully connect the profiler into its port at the back of the tray.
If you install ink of a different color or type than was originally installed, the printer will report this as an error message on the printer control panel.
3. Disconnect the ink tube from the old ink reservoir, and connect it to the new ink reservoir.
Replacing Ink System Components
3-19
Replacing an Ink Reservoir
During Printing (“Hot
Swapping”)
You can replace an ink reservoir during printing (“hot swap”)
only with an ink reservoir of the same color and ink type.
Caution
When switching to a different ink color or ink type,
wait for printing to finish, then replace the ink reservoir, printhead, and ink tube as a matched set. Failure to do so will contaminate the ink system and
compromise performance or output quality.
1. Place the new ink reservoir near the reservoir to be replaced.
2. Remove the ink reservoir from the ink tray. Do not disconnect
the ink tube at this time.
This disconnects the profiler, which is built into the ink reservoir, from its port on the back of the tray. The printer
detects that the profiler has been disconnected, but will not
report an error condition unless you fail to connect the new
ink reservoir to the profiler docking station within ten
seconds.
3. Install the new ink reservoir into place in the ink tray. Carefully connect the profiler into its port at the back of the tray.
Do this promptly. Since the printer keeps track of ink used,
the longer it takes for you to replace the ink reservoir, the
less accurate this “count” will be. If you install ink of a different color or type than was originally installed, the printer
will report this as an error message on the printer control
panel, and printing will stop.
4. Disconnect the ink tube from the old ink reservoir, and connect it to the new ink reservoir.
Connect the new ink reservoir within five seconds, or the
printhead may deprime, which will damage printed output.
3-20
Replacing Ink System Components
Replacing a Printhead
Replace a printhead when the printer:
◆
When the printer can no longer compensate for missing or
deflected jets by increasing the number of print passes, and
you cannot recover these jets (see “Cleaning Ink Jets” on
page 5-3 for instructions).
◆
When the number of passes required increases print times to
unacceptable levels.
◆
When switching ink color or type.
To replace a printhead:
1. Wait for the printer to stop printing.
2. From the ready screen, press the Online/Offline button.
The Front Page screen appears.
3. Press the Carriage button.
The printhead carriage moves out of the service station.
4. Open the top cover.
5. Open the carriage cover of the printhead that you want to
replace.
Press the cover’s latch at the front of the carriage.
6. Remove the printhead from the carriage by lifting the printhead straight up.
Use the printhead handle to help you lift it up.
7. Install the new printhead into the carriage.
Remove the tape covering the electronic contacts, and
remove the plug from the ink inlet.
8. Close and latch the carriage cover.
9. Close the top cover.
10. On the control panel, press the B (Proceed) key to park the
printhead carriage into the service station.
11. Run an AutoSet calibration.
Replacing Ink System Components
3-21
Replacing An Ink Tube
To ink trays
From printheads
Fig. 3-11. Ink tube routing
Replace an ink tube when switching ink colors or types, or if the
ink tube leaks. You need not replace an ink tube when you
change an ink reservoir and/or printhead without changing ink
color or type, if the tube is functioning normally.
Each of the ink tubes is routed to a specific ink tray position, to
enable the replacement of individual tubes without crossing or
tangling with other tubes.
3-22
Caution
Always remove and replace ink tubes one at a time,
to ensure correct routing of the tube. Although the
printer can detect the proper placement of the ink
reservoirs and printheads, it cannot detect whether
the ink tubes are routed correctly. Incorrectly routed
ink tubes would likely mix inks in the printhead, and
cause printing problems.
Tip
Wear protective gloves during this procedure to protect your hands from ink stains.
Replacing Ink System Components
1. Wait for the printer to stop printing.
2. From the ready screen, press the Online/Offline button.
The Front Page screen appears.
3. Press the Carriage button.
The printhead carriage moves out of the service station.
4. Open the printer top cover.
5. Disconnect the ink tube from the ink reservoir.
The tube automatically seals when you disconnect it. This
prevents ink from spilling out.
6. Depress the lock levers to unlock the penholder assembly,
and swing the carriage up to expose the printheads.
7. Disconnect the ink tube from the printhead.
8. Carefully remove the ink tube from its clips, beginning at the
ink tray end.
Unless the tube is damaged, you can store the tube (with ink
sealed inside) for future use. Be sure that it is labeled with
position number and ink type. At the end of the track, open
the stabilizer clip, and remove its top cover and pad. Save
them for reinstallation.
9. Remove the corresponding printhead, handling with care. Set
it in a safe location where it will not be bumped or dropped.
10. Clip the new ink tube into the bottom of the penholder and
begin installing the tube into its guides.
Beginning at the penholder end ensures that the slack portion of the tube ends up at the ink tray end.
11. At the end of the track, route the tube through the stabilizer
clip (see Fig. 3-12. on page 3-24).
Push the tube into the clip (some stretching and wiggling of
the tube may be necessary), replace the stabilizer clip pad Œ
on top of the tubes, then replace its top cover  and snap it
shut to hold the tubes securely. Leave some slack in the Sshaped curve between the chain and the rear of the printer.
Caution
Replacing Ink System Components
Ensure that the ink tubes will not be pinched or severed when the stabilizer clip is closed.
3-23

Œ
Ink tray
Tube guides inside the tube chain
(shown empty with cable)
Tube guides along rear of printer
Fig. 3-12. Location of tube guides and routing
3-24
Replacing Ink System Components
12. Fill the empty ink tube by following steps 10 through 12
beginning on page 3-16.
Caution
Always fill an empty ink tube with ink before connecting it to a printhead. Attempting to print with an
empty ink tube connected to a printhead will result
in enough air to be introduced to cause the printhead to fail. This condition may be recoverable by
purging the cartridge of air (see “Purging the Printheads” on page 5-14 for instructions).
13. Label the new ink tube with the ink color on the connector to
the ink reservoir, and with the tube number (1 through 12)
on the connector at both ends.
Proper labeling will help ensure that the tubes are always
connected to the right ink reservoirs and printheads. This
will help reduce the possibility of reconnecting tubes to the
wrong printheads.
14. Wipe clean the needle end of the drain tube, and set it aside,
keeping the ink inside from spilling out.
15. Reinstall the printhead into the carriage.
Install the printhead into the correct position. You can use
the built-in handle to help position the printhead.
16. Connect the new ink tube to the printhead.
17. Swing the printhead assembly down into the printing position, and push the printhead assembly down into position
until it engages the lock levers with a click.
18. Close the printer top cover.
19. On the control panel Front Page screen, press the B (Proceed)
key to park the printhead carriage into the service station.
20. Run an AutoSet calibration (see “AutoSet” on page 4-2 for
instructions).
Replacing Ink System Components
3-25
Loading Media
Wear cotton gloves during this procedure, or handle the media
only by its very outside edges. This will prevent skin oils from
being deposited on the media, which could render output quality unacceptable.
Tip
For best results, use genuine ColorSpan media. All
ColorSpan media is provided on two-inch cores in
lengths to ensure accurate media advance.
Caution
Do not store or rest a media roll on either end before
loading it onto a spool. This could result in an indentation on the edge of the media, which can be struck
by the printhead carriage during printing.
Far side
Home side (toward control panel)
Fig. 3-13. Installing media roll and collets onto the spool
1. Ensure that the fixed collet (with the metal pin) is in the
proper location on the supply spool.
The collet is designed to accommodate 2-inch and 3-inch
cores.
◆
If you are loading media with a 2-inch core, set the collet into the outside (closest to the home side) hole of the
spool. This is how the collet is installed at the factory.
◆
If you are loading media with a 3-inch core, set the collet into the inside hole (closest to the far side) of the
spool. Tighten the pin with a 5/16-inch hex wrench.
2. Load the media roll onto the spool.
3. Load and secure the other collet against the end of the media
roll.
The far-side collet does not have a metal pin. Push the collet
into the core, and friction will hold it in place.
3-26
Loading Media
4. From the rear of the printer, load the media and spool into
the printer’s supply spool holder.
Press the home side of the supply spool into the home side
holder (on the left from the rear of the printer), then swing
the far side of the supply spool into the far side holder (on
the right).
5. With your right hand, feed the leading edge of the media
into the printer’s pinch rollers and hold it in place until the
following step.
If loading 72 inch media, see “Loading 72-Inch Media” on
page 3-31.
Note
The printer automatically locates the right and left
edges of the media, so it is not necessary to align
the media edges to a reference mark on the platen.
6. With one hand, press the Media Advance button to advance
media a few inches (several centimeters).
The Media Advance button is located to the left of the
installed supply spool, on the rear of the printer next to the
ink module tray and electronics enclosure.
7. While holding the left collet stationary, press the Media
Advance button a few seconds, until the media web is tight
with no wrinkles.
Ensure that the right and left edges of the media web are
perpendicular to the sides of the printer, that the tension
appears uniform across the media web, and that the media is
not unrolling unevenly (“telescoping”) from the supply
spool.
Note
Loading Media
These checks ensure that the tension is uniform
across the width of the media. This is critical to
trouble-free printing.
3-27
8. On the Front Page screen of the control panel, press the Load
Media key.
The control panel prompts you to press the B key to load
media, or n to cancel.
9. Press the B key to proceed.
The control panel prompts you to advance the media.
10. Press the p key to advance the media past the front edge of
the platen.
11. Press the B key to proceed.
12. Select a media thickness from the list.
You can select a ColorSpan media from the list, or select
Custom (at the end of the list) to specify a custom thickness.
If Media Wizard values are present for the media you
selected, the control panel displays this message:
USE MEDIA WIZARD VALUES?
followed by the current settings for platen vacuum, head
height, and 1-pass coverage.
13. Press n to use the setting values you entered, or B to ignore
The control panel displays a numeric keypad.
Fig. 3-14. Numeric entry screen
14. Enter the length of the media roll (if it is a new roll) or the
length remaining (if it is a partially used roll), and press the
Enter key to continue.
3-28
Loading Media
To skip this step, press Esc or Enter without entering a value.
The printer will not track the amount of media remaining
on the roll, and it will be unable to display a warning when
the amount of media runs low. The media length will display as “undefined,” and the Unload Media process will be
unable to print the amount of media remaining on the supply spool.
15. The control panel asks whether you want to use the takeup
system.
See “Takeup Options” on page 3-32 for details on using the
takeup system.
◆
If you will be printing without using the takeup system,
or if you will be performing a Media Feed Calibration,
press the n key to skip loading the takeup. See “Media
Feed Calibration” on page 4-4 for instructions.
◆
To use the takeup system, press the B key.
16. Press and hold the p key until the end of the media reaches
past the takeup spool.
17. Grasping the middle of the media web, pull straight back and
tape the middle of the web to the takeup core.
Note
Be sure that the direction you wrap the media
around the takeup spool is consistent with the direction specified in the Takeup Direction option of the
menu (see “Takeup Options” on page 3-32 for
details). The default direction is Printed Side Out.
18. Press the B key to continue.
The control panel displays an informational message suggesting that you perform a Media Feed calibration.
19. Press the B key to perform a Media Feed calibration, or n to
skip the calibration.
See “Media Feed Calibration” on page 4-4 for instructions.
You are now ready to begin printing. The printer will verify
that the media is wide enough for each print job it receives.
Loading Media
3-29
Tip
3-30
The media should be consistently tensioned across its
width when attached to the takeup spool. Ensure
that the web is straight and smooth from side to side.
Loading Media
Loading 72-Inch Media
The width of the 72-inch media makes it impossible for most
persons to load it by grasping its left and right edges at the same
time. Follow this procedure to more easily load 72-inch wide
media.
Wear cotton gloves during this procedure, or handle the media
only by its very outside edges. This will prevent skin oils from
being deposited on the media, which could render output quality unacceptable.
1. With one hand, grasp the media at the center of its leading
edge, and pull it forward into the center grip rollers.
2. While continuing to hold the center of the leading edge of
the media in place, grasp the left edge of the media with
your left hand.
3. Pull the left edge of the media into the leftmost grip rollers.
4. Hold the media in place with your left hand.
5. Grasp the right edge of the media with your right hand, and
pull it into the rightmost grip rollers.
6. With both hands, feed the media web evenly into all grip
rollers.
7. With your right hand, hold the media spool at the collet to
prevent the spool from moving.
8. With your left hand, press the media advance button for 2-3
seconds. The grip rollers will spin beneath the stationary
media, thus equalizing the tension on the roll.
9. Press the Media Advance button to finish loading the media.
10. Verify that the media web is even and unwrinkled across its
width.
11. When loading the media onto the takeup spool, ensure that
the media is tightly wound onto the spool across its width.
Uneven or excessive tension may cause the spool to pull out
of the left spool holder.
Loading Media
3-31
Takeup Options
Automatic Disable
The takeup is automatically turned on (enabled) when you load
the takeup. The takeup is turned off (disabled):
◆
When you press the Load key or Unload key on the Front
Page
◆
When you select the Load Takeup or Restore All Defaults
option from the menu
◆
If you skip loading the takeup during the Load process
◆
If the takeup was loaded and the printer detects that the
takeup is no longer loaded (for example, if the media is cut
from the takeup spool and not reloaded, or if the supply
spool runs out of media)
◆
If the printer detects that the takeup spool is full (by estimating the diameter of the media on the takeup spool); this
condition also generates an Action message that requires the
full spool to be removed, followed by a Load or Load
Takeup operation
Not Using the Takeup
When printing one print at a time, you may choose to not use
the takeup system at all. In this case, advance the media, cut the
finished print from the roll, then back up the media for the next
print. (To advance and back up the media using the control
panel, see “Front Page” on page 2-5).
Caution
If you do not use the takeup system, the software
assumes that you are cutting individual prints as
they are printed. If you send a large number of jobs
to the printer without the takeup system loaded,
and allow printing to continue unattended, the
prints will pile onto the floor.
Takeup Direction
You can also configure the takeup system so it winds the image
facing to the inside or outside of the spool. This is useful for
compatibility with a laminator or other finishing equipment.
See Takeup Control under “Printer Settings” on page 2-11 for
instructions.
3-32
Loading Media
Linearization
When changing media types, you should perform a color calibration or linearization (if supported by the RIP). This compensates for the differences between medias that affect color
accuracy.
For further information, see “Linearization” on page 4-31.
When replenishing the media supply with the same type of
media, relinearization is unnecessary unless print color quality
has changed noticeably.
Loading Media
3-33
Dryer Options
Drying Delay
As the printed output advances past the dryer outlets, the dryer
blows air over the output to dry it. The print will continue to
advance until the trailing edge of the print has passed under the
dryer. The print remains stationary for twenty seconds, then will
reverse or advance according to the print mode. To cancel the
twenty-second delay, press the n (Cancel) key.
The printer’s relative humidity sensor enables the printer to
adjust the media advance speed to ensure adequate drying.
Higher relative humidity will result in slower printing. You can
adjust the amount of delay from the control panel; for instructions, see page 2-12.
Relative
Humidity
Drying Rate
Fans and Heater
0–29%
Low humidity warning displayed, jets may drop out
and media may lift from the platen
30–59%
Optimal, no warning or drying delay
60–79%
High humidity warning displayed, media advance is
delayed automatically as humidity increases
> 80%
Action displayed, printing stops. User must specify a
manual drying delay to proceed with printing (see
Drying Delay on page 2-12)
There are two rates of media advance during post-print drying.
Select Standard for the fastest throughput. Select Same as print
speed to slow the advance if additional drying time is needed.
See Drying Rate on page 2-12.
To turn off the dryer fans, select Configure Printer - Printer
Options - Dryer from the menu.
Caution
3-34
Printer Action
Output on polyester films can be streaked by the
dryer air flow. To avoid this, turn off the dryer fans
from the control panel.
Dryer Options
Cutting and
Unloading Media
1. Press the p key on the Front Page screen to advance the
printed portion of the media past the cutter anvil (on the
front edge of the platen).
2. From the front of the printer, place a utility knife blade in the
cutter channel and draw the cutter across the media.
Support the trailing edge of the media as you cut it from the
supply spool.
3. On the Front Page screen of the control panel, press the
Unload Media key.
4. The control panel prompts you to press B to unload media,
or n to cancel.
5. Press B to continue.
The control panel asks if you want to print the calculated
length of media remaining on the supply spool onto the
media for reference. When reloading the media later, the
control panel will prompt you to enter this value so it can
continue to track the amount of media remaining.
6. Press B to print the length remaining, or n to skip printing.
7. As desired, take the single print or takeup spool with printed
output to your finishing area, and re-load the takeup system.
To re-load the takeup, from the menu, select Load Takeup
(located at the end of the menu).
Cutting and Unloading Media
3-35
3-36
Cutting and Unloading Media
CHAPTER 4
Calibrating the Printer
This chapter explains how to calibrate the printer for the best possible
output:
Calibrating the Printer
◆
AutoSet (page 4-2)
◆
Manual Calibrations (page 4-3) — Media Feed, Manual BiDi Registration, Manual Head Registration, Manual Jet Mapping, Jet Status
Lines, Default Registration Data
◆
Auto Calibrations (page 4-19) — AutoBiDi Calibration, AutoH2H
(Head-to-Head) Calibration, AutoBiDi & H2H Calibration, AutoJet
Calibration
◆
AutoTune (page 4-20)
◆
Calibration Summary (page 4-21)
◆
Head Height Calibration (page 4-23)
◆
Linearization (page 4-31)
4-1
AutoSet
AutoSet is an advanced printer calibration feature that uses an
onboard digital imaging sensor and sophisticated software to
detect and compensate for variations in ink jet printing. It can
be initiated by the user or run automatically at specified intervals (AutoTune). AutoSet is designed to be a “one-button” calibration, the only calibration you need to run in most cases for
superior quality output.
When you press the AutoSet key on the Front Page control panel
screen, these functions are performed automatically:
4-2
◆
Bidirectional Registration — ensures that every working jet
fires a pixel at precisely the same location, regardless of the
carriage’s direction of travel.
◆
Head-to-Head Registration — ensures that the printheads
are in alignment relative to each other.
◆
AutoJet substitution mapping — detects and disables individual ink jets that are misfiring or not firing at all. During
subsequent printing, the printer compensates for these jets
by using other jets in their place, ensuring maximum print
quality without reducing print speed.
Note
Clean printheads produce the best printed output
and accurate calibration patterns.
Note
AutoSet does not work with transparent media. In
this case, you should run AutoSet on a white media
that is similar in thickness to the clear media, then
switch to the transparent media; or manually run
the calibrations under the Calibrate Printer menu
using the transparent media.
Tip
If the printhead carriage head height is set to 0.070
inches (1.78 mm) or higher, do not run AutoSet. For
best accuracy, run the manual calibrations instead.
For instructions on running the manual calibrations,
see “Manual Calibrations” on page 4-5.
AutoSet
Manual Calibrations
When you run the calibrations from this menu, you evaluate the
calibration test patterns visually and enter the calibration values
via the control panel. In most cases, AutoSet is more accurate
and should be used instead (see “AutoSet” on page 4-2).
Note
Manually performing the component calibrations of
AutoSet is time-consuming and can be error-prone,
but is necessary when the head height is 0.070
inches (1.78 mm) or greater, or when calibrating
transparent media. (There is no automatic media
feed calibration, so you must always perform it
manually.)
If you decide to manually calibrate the printer, first clean the
printhead jets as described in “Cleaning Ink Jets” on page 5-3.
The Manual Calibration menu consists of these options:
◆
Media Feed (page 4-4) — enables you to calibrate the
printer’s media advance accuracy by printing and visually
inspecting your choice of test patterns.
◆
Manual BiDi Registration (page 4-7) — prints bidirectional
registration patterns and allows you to report which pattern
is the most precise.
◆
Manual Head Registration (page 4-10) — precisely aligns
the printheads relative to each other, for accurate colors and
precise registration of images.
◆
Manual Jet Mapping (page 4-13) — enables you to detect
and report nonfiring or misfiring ink jet nozzles, which
enables the printer to “fill in” for them.
◆
Jet Status Lines — prints a quick test pattern that shows
which jets are out.
◆
Default Registration Data — sets all registration data to
zero.
After calibration and jet mapping, perform a linearization, or
color calibration (as supported by your print server or RIP). For
further information, see “Linearization” on page 4-31.
Manual Calibrations
4-3
Media Feed Calibration
This calibration allows you to calibrate the accuracy of the
media feed process. You perform this calibration when loading
media, if print quality is poor, or if prints requiring very accurate length (for example, output that will be tiled) are found to
be the wrong length. The Media Wizard stores this value by
media type.
◆
Before performing a Media Feed calibration, print the Prime
Bars and clean the ink jets to get the maximum number of
jets working.
◆
After performing a Media Feed calibration, run AutoSet.
1. If you will be performing this calibration with a new roll of
media, advance the media to the floor, back it up to the
platen, and remove the supply loop (see page 2-14).
This will remove the advance error that would be introduced
by the tighter winding at the beginning of a new roll of
media.
2. Press the v (Menu) key from the Front Page screen on the
control panel to display the menus.
3. Press the E (Menu In) key display the Calibrate Printer menu.
4. Press the p key to highlight Manual Calibration.
5. Press the E (Menu In) key.
6. Press the E (Menu In) key to select the Media Feed option.
The following prompt appears:
Press Proceed to print pattern
Press Cancel to adjust without printing
7. Press the Proceed key to print a test pattern, or Cancel to skip
printing.
If you press Cancel, to go step 12.
When you press Proceed, you can choose between the following calibrations:
4-4
◆
34-Inch (900 mm) Calibration — prints two reference
marks along the direction of media feed; measure the
distance between the marks to determine advance
accuracy.
◆
12-Inch (305 mm) Calibration — same as previous calibration, uses less media but may be less accurate.
Manual Calibrations
8. Select one of the options and press the E (Menu In) key to
continue.
The printer asks whether you want to print the media feed
calibration.
9. Press the B key to continue.
The printer asks whether you want to print the media feed
calibration.
10. Press the B key to continue.
The printer prints the calibration marks, and prompts you to
adjust the advance.
Measure from here...
...to here.
Fig. 4-15. Media Feed Calibration pattern
11. With a metal yardstick, measure the distance between the
hairline marks (the thicker marks are to ensure working jets).
A measuring stick with 1/64 inch markings works best. For
maximum accuracy, begin measuring at the 1-inch mark,
and subtract 1 inch from the result.
12. Adjust the media feed advance using the control panel.
You can increase the advance by pressing the C key, or
decrease it by pressing the p key.
13. Press B (Proceed) to save the advance value you entered.
14. Press B (Proceed) to return to the menu.
Manual Calibrations
4-5
“On-the-Fly” Media Feed Adjustment
The media feed (advance) can be adjusted by 1/4 pixel increments during printing by pressing the up (increase) and down
(decrease) arrows displayed on the control panel.
When you see dark bands or blank spaces between print swaths,
this indicates that the media advance is too short (dark bands) or
too long (blank lines). Depending on the individual print job, it
still may be useable after using the media feed adjustment while
it is still printing. This enables you to avoid cancelling the job,
running a media feed calibration, and restarting the job.
Increase media advance
Decrease media advance
Fig. 4-16. On-the-fly media advance adjustment
4-6
Manual Calibrations
Manual Bidirectional
Registration
Bidirectional registration is a method to align each of the printheads so that dot placement is accurate in both directions along
the X axis (along the direction of print head travel).
The bidirectional registration pattern consists of a series of vertical lines. Half the pixels in this pattern are printed in one direction, half of them in the other direction. When the pixels are
accurately aligned, the pattern is clear. When the dots are not
aligned, the pattern appears fuzzy and ill-defined.
Tip
AutoSet incorporates an automatic version of this
calibration. Try AutoSet first before running this
manual calibration (see “AutoSet” on page 4-2 for
details).
There are three bidi patterns from which to choose:
◆
Fine — allows 0.25 pixel adjustments
◆
Medium — allows 0.5 pixel adjustments
◆
Coarse — allows 1 pixel adjustments
For the most precise image reproduction, perform these calibrations one after the other, starting with Coarse, then Medium,
then Fine.
1. Press the v (Menu) key from the Front Page screen on the
control panel to display the menus.
2. Press the E (Menu In) key display the Calibrate Printer
menu.
3. Press the p key to highlight Manual Calibrations.
4. Press the E (Menu In) key.
5. Press the p key to highlight Manual BiDi Registration.
6. Press the E (Menu In) key to select the option.
7. Press B (Proceed).
The control panel displays this prompt:
Print a manual bidi registration page?
8. Press B (Proceed).
9. Press the p key repeatedly to highlight the Fine, Medium, or
Coarse option.
Manual Calibrations
4-7
10. Press B (Proceed).
The printer prints the calibration pattern you selected.
11. When the calibration page has printed, the control panel displays this prompt:
Bidi registration
Head 1: 0
12. Examine the BiDi Registration pattern for the current head,
and determine which pattern is the closest to perfectly
aligned.
Use a printer’s loupe to select the pattern, since the lines in
the patterns may be difficult to discern.
+6
+4
+2
0
-2
Fig. 4-17. BiDi Registration pattern.
13. Press the C or p control panel keys repeatedly until the
number next to the pattern that is closest to aligned perfectly
is displayed.
For example, if pattern +2.0 is the closest aligned, press the
C key to change the display to:
HEAD-1
+2.0
If a printhead is extremely out of alignment, there may be
no pattern in alignment. Since the black vertical bars are
nominally five pixels apart, you can add +5 or -5 to a pattern
number to shift the colored bars right or left by one black
bar. Alternatively, you can perform the BiDi Registration
repeatedly, which will move the head in smaller increments,
until the head is aligned.
14. Press B (Proceed).
The control panel message increments the head number by
one.
4-8
Manual Calibrations
15. Repeat steps 12 through 14 for each of the twelve heads.
When you have entered registration values for all heads, the
control panel displays this message:
Registration Successful
Manual Calibrations
4-9
Manual Head Registration
The printer creates images by firing dots of ink onto a sheet of
media. Precise positioning of each dot is essential for optimal
print quality. This is possible only if you register all printheads
in the printhead assembly to each other in both the X (along the
length of the platen) and Y (along the length of the media) directions.
This is a two-part process:
◆
Print a registration pattern.
◆
Enter the X and Y registration data for each head.
Tip
AutoSet incorporates an automatic version of this
calibration. Try AutoSet first before running this
manual calibration (see “AutoSet” on page 4-2 for
details).
1. Press the v (Menu) key from the Front Page screen on the
control panel to display the menus.
2. Press the E (Menu In) key display the Calibrate Printer
menu.
3. Press the p key to highlight Manual Calibration.
4. Press the E (Menu In) key.
5. Press the p key to highlight Manual Head Registration.
6. Press the E (Menu In) key to select the option.
The control panel asks whether you want to print a manual
head-to-head calibration page.
7. Press the B key.
The control panel displays a menu to allow you to select a
Fine, Medium, or Coarse registration pattern.
8. Press the p and C keys to select a pattern, then press the B
key.
If you have a calibration pattern from a recent print, you
can use it to calibrate the heads. Press n (Cancel) and go to
step .
4-10
Manual Calibrations
If you need to print a new calibration pattern, press B (Proceed). The printer prints a calibration page.
X-direction patterns
Y-direction patterns
Fig. 4-18. Head-to-Head Registration patterns
When the calibration page has printed, the control panel
displays this prompt:
Take readings from left side of pattern.
9. Press the B key.
The control panel displays this message:
X Direction Registration
Head 2: +0
10. Examine the X direction pattern (in the left-hand group of
patterns) for the current head, and determine which pattern
of colored and black lines are the closest to perfectly aligned.
Use a printer’s loupe to select the pattern, since the lines in
the patterns may be difficult to discern otherwise.
+0
+1
+2
Fig. 4-19. Sample head calibration patterns.
In this example, pattern “+1” is aligned the closest,
so “+1” would be entered.
11. Press the C or p control panel keys repeatedly until the
number next to the pattern that is closest to aligned perfectly
is displayed.
Manual Calibrations
4-11
For example, if pattern +2 is the closest aligned, press the C
key to change the display to:
X REG
HEAD-1
+2
If a printhead is extremely out of alignment, there may be
no pattern in alignment. Since the black vertical bars are
five pixels apart, you can add +5 or -5 to a pattern number
to shift the colored bars right or left by one black bar. Alternatively, you can repeatedly perform an X calibration, which
will move the head in smaller increments, until the head is
aligned.
12. Press B (Proceed).
The control panel message increments the head number by
one.
13. Repeat steps 10 through 12 for each of the heads.
When you have entered registration values for all the heads,
the control panel displays this message:
Take readings from right side of pattern.
14. Press the B key.
Y Direction Registration
Head 2: 0
X registration is complete. You are now ready to begin Y registration.
15. Examine the Y registration pattern (in the right-hand group
of patterns) for the current head, and determine which pattern of colored and black lines are the closest to perfectly
aligned.
16. Press the C or p control panel keys repeatedly until the
number next to the pattern that is closest to aligned perfectly
is displayed.
17. Press B (Proceed).
The control panel message increments the head number by
one.
18. Repeat steps 15 through 17 for each of the Y patterns.
When you have entered registration values for all of the patterns, the control panel displays this message:
Registration successful.
4-12
Manual Calibrations
Manual Jet Mapping
Each of the printheads used by the printer has 512 ink jet nozzles
(jets). If any one of these jets is clogged or has a bad electrical
connection, print quality may be affected. A certain number of
non-firing jets is within the performance specifications of most
printers that use this technology.
Using a patent-pending technique, the printer “fills in” the pixels that were not printed by the non-firing jets, without reducing
print speed. The end result is that every print is made with no
missing pixels.
The printer automatically maps out missing jets that are not firing for electrical reasons. Jets that are missing or misfiring for
other reasons are usually detected during the AutoSet or AutoJet
calibrations. You may also map jets manually using the following procedure.
Tip
AutoSet incorporates an automatic version of this
calibration. Try AutoSet first before running this
manual calibration (see “AutoSet” on page 4-2 for
details).
Tip
For best results, before performing this procedure,
clean the printhead jets as described in “Cleaning
Ink Jets” on page 5-3. Autodetected missing jets
sometimes can be recovered by carefully wiping the
electrical contacts on the printhead and their corresponding contacts on the printhead carriage with a
lint-free wipe moistened with plain water.
1. Press the v (Menu) key from the Front Page screen on the
control panel to display the menus.
2. Press the E (Menu In) key display the Calibrate Printer
menu.
3. Press the p key to highlight Manual Calibration.
4. Press the E (Menu In) key.
5. Press the p key to highlight Manual Jet Mapping.
6. Press the E (Menu In) key to select the option.
The control panel displays this message:
Print Jet Map
Page 1 of 2 now?
Manual Calibrations
4-13
If you have a calibration pattern from a recent print, you
can use it to calibrate the heads. Press n (Cancel) and go to
the next step. Otherwise, press B.
The printer prints a jet map test pattern for printheads 1-6.
➋
➌
➋
➌
➊
Fig. 4-20. Sample jet mapping pattern
➊ Head number
➋ Test pattern and codes
➌ Jet number
◆
If a line segment is missing or broken, the jet listed in
the same column is out. In Fig. 4-20, jets 263 and 265
are out.
◆
If a line segment is marked with a code letter, it has
already been detected by the software, so no further
action by you is required. This data, however, may be
requested by MacDermid ColorSpan Technical Services
(phone: 800-925-0563) to help diagnose printing
problems.
Note
If this test auto-detects (marks with an E) that more
than twelve jets are missing on any one printhead,
the printhead may be improperly seated. Try reseating the printhead, and print another Jet Coverage
pattern.
7. When the calibration pattern has printed, the control panel
displays a menu with the following options:
4-14
◆
Report individual bad jets — enables you to report a
bad jet.
◆
Clear individual bad jets — enables you to clear (mark
as good) a jet.
◆
View current bad jets — lists the bad jets on a given
printhead.
Manual Calibrations
◆
Clear all bad jets — clears (marks as good) all jets currently marked as unusable.
Select an option and follow the corresponding procedure
below.
Report Individual Bad Jets
When you select Report Individual Bad Jets, the control
panel displays the following prompt:
Head 1:
Press Proceed to report a bad jet.
8. Press C and p to select a head number, then press B
(Proceed).
The control panel displays a numeric keyboard that you can
use to enter the number of the bad jet.
Fig. 4-21. Numeric entry screen
9. Enter the jet number, then press the Enter key.
10. When you are finished entering jet numbers, press the Esc
key.
The control panel displays the head selection message again.
11. Press C and p to select the next head number, then press B
(Proceed).
12. Repeat steps 9 through 11 for each head containing bad jets
you want to report.
Manual Calibrations
4-15
13. When you are finished reporting bad jets, press n.
The control panel displays the previous menu.
Clear Individual Bad Jets
When you select Clear Individual Bad Jets, the control panel
displays the following prompt:
Head 1:
Press Proceed to clear a bad jet.
14. Press C and p to select a head number, then press B
(Proceed).
The control panel displays a numeric keyboard that you can
use to enter the number of the bad jet.
15. Enter the jet number, then press the Enter key.
16. When you are finished entering jet numbers, press the Esc
key.
The control panel displays the head selection message again.
17. Press C and p to select the next head number, then press B
(Proceed).
18. Repeat steps 15 through 17 for each head containing bad jets
you want to clear.
19. When you are finished clearing bad jets, press n.
The control panel displays the previous menu.
View Current Bad Jets
When you select View Current Bad Jets, the control panel
displays the following prompt:
Head 1:
Press Proceed to view bad jets.
20. Press C and p to select a head number, then press B
(Proceed).
The control panel displays a message that lists the bad jets by
number.
21. Press B to return to the head selection screen.
22. Repeat steps 20 and 21 for each head you want to check for
bad jets.
23. When you are finished clearing bad jets, press n.
4-16
Manual Calibrations
The control panel displays the previous menu.
Clear All Bad Jets
When you select Clear All Bad Jets, the control panel displays the following prompt:
Are you sure you want to clear
ALL reported bad jets?
◆
Press n to cancel this function, or
◆
Press B (Proceed). The control panel displays this
message:
All reported bad jets have been cleared.
24. Press B.
The following prompt appears:
Print Jet Map
Page 2 of 2 now?
25. Press B.
26. Repeat steps 7 through 24.
When you have finished mapping jets, the following summary appears on the control panel:
x jets currently reported bad.
x new bad jets reported.
x previous bad jets cleared.
where x is the number of jets.
Manual Calibrations
4-17
Jet Status Lines
This option prints a test pattern that shows which jets are working, and which jets are out.
Zero Registration Data
This option resets all registration data. Since there is no registration data after running this option, all calibration values must
be reestablished by running the calibrations.
4-18
Manual Calibrations
Auto Calibrations
AutoSet is a convenient “one button” action to run three different calibrations automatically. You can also run each one individually, from the Auto Calibrations menu.
To evaluate the calibration test patterns visually and enter the
calibration values via the control panel, run the Manual Calibrations. For instructions, see “Manual Calibrations” on page 4-3.
1. On the Front Page screen, press the v (Menu) key to enter
the menu system.
2. Press the E (Menu In) key display the Calibrate Printer
menu.
3. Highlight Auto Calibrations and press the E (Menu In) key.
4. Select one of the Auto Calibrations.
Auto Calibrations
◆
AutoBiDi Calibration
◆
AutoH2H (Head-to-Head) Calibration
◆
AutoBiDi & H2H Calibration
◆
AutoJet Calibration
4-19
AutoTune
AutoTune runs AutoSet automatically at intervals you specify.
When you use the AutoTune scheduler to run AutoSet, AutoSet
always performs its three calibrations without prompting the
user or canceling due to too many bad jets. You can use the
Quality Check Mode feature to handle AutoSet errors, with or
without user intervention.
To run AutoSet at specified intervals (AutoTune):
1. On the Front Page screen, press the v (Menu) key to enter
the menu system.
2. Press the E (Menu In) key display the Calibrate Printer
menu.
3. Press the p key to highlight AutoTune.
4. Press the E (Menu In) key.
The control panel prompts you to specify an AutoTune
interval.
5. Press B (Proceed).
The control panel displays this message:
Run AutoSet every 0 prints.
6. Press the C key repeatedly to increment the AutoTune interval to the number of prints you desire.
7. Press B (Proceed).
8. Press the z (Menu Out) key repeatedly until the Front Page
screen is displayed. Press the Online/Offline button to return
the printer to the Ready state.
Quality Check Mode
4-20
When you run AutoSet manually, the software notifies you if
there are any jet or alignment problems so that they can be
addressed. When AutoTune runs AutoSet at scheduled intervals,
you can use the Quality Check Mode feature to handle AutoSet
errors. For instructions on setting the Quality Check Mode, see
page 2-14.
AutoTune
Calibration Summary
These options allow you to print a summary of the AutoSet calibration, or transmit calibration data to a log file on the print
server.
◆
AutoSet Summary — when enabled, a table of the results of
the AutoSet calibration is printed after the AutoSet test
patterns. If you enable the AutoSet Summary, you can show
or hide the detailed calibration data.
◆
Log Head Registration Data — sends head registration data
to a log file on the print server.
◆
Log Jet Data — sends jet data to a log file on the print server.
Fig. 4-22. AutoSet Summary (Show Details Version)
Description
Show Details Version
Hide Details Version
Calibration Results — Reports whether the printer was
calibrated successfully.
Shown
Shown
Header — Date and time of the AutoSet calibration,
printer software version, printer model, estimated head
height
Shown
Shown
Ink Sample — Sample color block, for identification only
(not a print quality test).
Shown
Shown
Head — Printhead position number.
Shown
Shown
Profiler/Pen Present — The ink type (EC-Endura•Chrome Shown
or PC-Perma•Chrome) and color reported by the profiler.
Shown
Cartridge Needs Cleaning — No: passed all calibrations, Shown
or Yes: failed one or more calibrations.
Shown
Total Bad Jets — The number of missing and deflected
Shown
jets on the printhead. Use this number and the Jets Disqualified, Jets Out, and Jets Unfixed numbers to evaluate
cartridge performance.
Hidden if no bad jets present,
Shown if bad jets present
Calibration Summary
4-21
Description
Show Details Version
Hide Details Version
Sabre Angle — Troubleshooting data for MacDermid Col- Shown
orSpan Technical Services.
Hidden
Head-to-Head Registration — OK indicates that the
Shown
printhead was successfully registered relative to the other
printheads; if not, the amount of error in pixels is shown.
Hidden if no errors found,
Shown if offset errors present
Bidirectional Registration — OK indicates the printhead
was successfully registered in both X (horizontal) directions; if not, the amount of error in pixels is shown.
Hidden if no errors found,
Shown if bidi errors present
Shown
AutoJet Registration — OK indicates that AutoJet was
Shown
successful; otherwise, a reference number appears and a
corresponding error message is printed under the header.
Hidden if no errors found,
Shown if errors present.
Jets Disqualified by AutoJet — Number of jets that Auto- Shown
Jet determined must be substituted by other working
jets.
Hidden if no errors found,
Shown if errors present.
Jets Out for X Offset — Number of jets that are out of
registration in the X (horizontal) direction.
Shown
Hidden if no errors found,
Shown if errors present.
Jets Out for Y Offset — Number of jets that are out of
registration in the Y (vertical) direction.
Shown
Hidden if no errors found,
Shown if errors present.
Jets Unfixed — Shows the print mode and the number of Shown
unfixed jets on each printhead. This number should be
zero for all printheads; more substitute jets are available
with a higher number of print passes.
4-22
Shown
Calibration Summary
Head Height
Calibration
The printer offers an automatic head height calibration, in addition to two manual options.
◆
Auto Carriage Height uses the onboard image sensor to precisely set the height of the printheads above the media and
level the carriage. This method can be used if at least one
pair of ink reservoirs and printheads are installed in certain
positions, so that the carriage can be automatically leveled.
Due to the use of the image sensor, this method does not
work with film or canvas media.
◆
Manual Carriage Height uses sheets of paper as “shims” to
set the head height and level the carriage.
◆
Adjust Head Height can be used to raise or lower the left or
right side of the carriage without performing a full calibration, using paper shims as with Manual Carriage Height.
◆
Head Height Reset resets the head height to its position
after the previous Auto Carriage Height or Manual Carriage Height operation.
These options are designed to be used as follows:
Ink Configuration
If Image Sensor is OK...
If the Image Sensor is
disabled...
Ink reservoirs and printheads Auto Carriage Height
installed in at least one of the
following positions: 1 and 9,
2 and 10, 3 and 11, or 4 and
12.
Manual Carriage Height
Ink installed in all other con- Manual Carriage Height
figurations
Manual Carriage Height
The procedures for using Auto Carriage Height, Manual Carriage Height, and Head Height Adjust appear in the following
sections.
Auto Carriage Height
This procedure calibrates the head height relative to the platen,
then uses the on-board image sensor to precisely set the head
height and level the carriage.
1. Verify that the appropriate Head Height setting is selected.
The options under Configure Printer - Printer Settings Head Height determine whether the head height will be set
to the Normal (0.050 inches/1.27 mm) or Custom height rel-
Head Height Calibration
4-23
ative to the media. Use Normal unless you need to raise the
head height to avoid printhead strikes against the media.
2. On the menu, select Service Printer.
The Service Printer menu appears.
3. On the Service Printer menu, select Calibrations.
The Calibrations menu appears.
4. On the Calibrations menu, select Head Height.
The Head Height menu appears.
5. Select Auto Carriage Height.
The control panel displays this message:
This procedure will reset head height information. Press
Proceed to continue, or cancel to leave the head height
information as is.
If you press n (Cancel) at this screen, you will simply exit
this process and the current calibration settings will be
retained.
If you press n (Cancel) later during this process, all head
height calibration data will be lost, and you will have to run
Auto Carriage Height or Manual Carriage Height before
printing.
6. Press B to continue.
A message appears warning you to unload media. The first
part of the calibration sets the head height relative to the
platen without media present.
If media is installed, cut the media from the takeup, then
back up the media using the C key on the control panel.
WARNING
Keep the printer cover closed during this procedure.
The carriage moves out of the service station to the
access position quickly, without further warning.
Operator injury or damage to the carriage could
occur if the carriage movement is blocked.
7. Press B to continue.
The control panel displays a series of messages as the carriage is raised and is moved to the carriage access position
on the platen.
4-24
Head Height Calibration
Next, the control panel displays a message asking you to
place one sheet of copier paper under the right side of the
carriage, and another sheet of copier paper under the left
side of the carriage. Use standard 20 lb. copier paper. One
letter-size sheet cut in half to make two 8-1/2 x 5-1/2 inch
sheets works well for this purpose.
8. Place sheets of copier paper under the carriage as specified
by the control panel, and press B to continue.
The control panel displays the C and p (Up/Down) keys
and this message:
Use the arrow keys to carefully move the entire carriage
up/down until one side or the other is LIGHTLY resting
on the paper. Press Proceed when ready.
Note
The purpose of this measurement is to give the software a rough estimate of the head height relative to
the platen, to allow the software to use the image
sensor to set the head height precisely. In contrast,
the Manual Carriage Height and Adjust Head
Height procedures use the copier paper “shims”
rather than the image sensor to set the head height.
9. Press the p key to move the carriage down, and move the
right and left sheets of paper repeatedly, until you feel resistance from the carriage touching the paper on either side of
the carriage.
If the carriage is so low that you cannot move the paper at
all, press the C key to raise the carriage until you can move
the paper, yet still feel some resistance. Raise and lower the
carriage as necessary before you proceed.
10. Press the B key.
The control panel prompts you to load media for the second
portion of the calibration, which will set the head height relative to the selected media.
11. Load the media for setting the head height.
12. Press the B key.
The control panel displays the C and p (Media Advance)
keys and prompts you to load media, then press B (Proceed)
to continue.
13. After loading the media, press the B key.
Head Height Calibration
4-25
The control panel displays a list of standard ColorSpan
media types.
14. Select a media type from the menu, and press the B key.
If your media type is not displayed, select a media that most
closely matches the thickness (caliper) of the media you are
using.
15. Press the B key.
The printer measures the width of the media. Then the control panel displays an alphanumeric keyboard, and prompts
you to enter the length of media remaining on the supply
spool. The printer uses this value to calculate the amount of
media remaining as printing proceeds.
16. Enter the length of media remaining and press the Enter key,
or press the Enter key without entering a length if it is
unknown.
The control panel prompts you to load the takeup.
17. Press the B key to use the takeup; otherwise, press n (Cancel) and go to step 21.
A menu appears allowing you to specify the Printed Side
Out or Printed Side In option for the takeup.
18. Select a takeup direction, then press the D key to save your
choice.
19. Press the z (Out) key to exit the menu.
The control panel displays this message:
Takeup is now off. Press Proceed when takeup is ready
to load, up/down to advance media.
20. Load the takeup and press B, or press n (Cancel) if you do
not want to use the takeup.
The control panel notifies you that next the printer will
print a set of prime bars so you can check the performance
of the printheads. If too many jets are out or misfiring, the
accuracy of the automatic head height process will be compromised.
21. To print the prime bars press B, or press n (Cancel) to skip
printing the prime bars.
If you skip the prime bars, go to step 24. Otherwise, the control panel prompts you to adjust the width of the prime
bars.
4-26
Head Height Calibration
22. Adjust the width of the prime bars, and press B.
The printer prints the prime bars, and prompts you to evaluate the pattern.
23. Evaluate the prime bars.
◆
If the prime bars look good, press B.
◆
If the prime bars reveal an excessive number of jet-outs,
press n (Cancel) to exit the Auto Carriage Height process and clean the printheads. Then run Auto Carriage
Height again.
If you press B, the printer begins the automatic head height
procedure. When it finishes, the control panel displays this
message:
The head height is calibrated.
24. Press B to park the carriage and return to the Calibrations
menu.
Manual Carriage Height
This procedure calibrates the head height relative to the platen,
and levels the carriage, using paper shims and your input. Once
calibrated, the printer raises the carriage to the appropriate
height relative to the media.
1. Verify that the appropriate Head Height setting is selected.
The options under Configure Printer - Printer Settings Head Height determine whether the head height will be set
to the Normal (0.050 inches/1.27 mm) or Custom height relative to the media. Use Normal unless you need to raise the
head height to avoid printhead strikes against the media.
2. On the menu, select Service Printer.
The Service Printer menu appears.
3. On the Service Printer menu, select Calibrations.
The Calibrations menu appears.
4. On the Calibrations menu, select Head Height.
The head height menu appears.
5. Select Manual Carriage Height.
A message appears that describes this function.
6. Press B to continue.
Head Height Calibration
4-27
A message appears warning you to unload media. The first
part of the calibration sets the head height relative to the
platen without media present.
If media is installed, remove or cut the media from the
takeup, then back up the media using the C key on the control panel.
WARNING
Keep the printer cover closed during this procedure.
The platen moves out of the service station to the
access position quickly, without further warning.
Operator injury or damage to the carriage could
occur if the carriage movement is blocked.
7. Press B to continue.
The control panel displays a series of messages as the carriage is raised and moved to the carriage access position on
the platen.
The control panel displays a message asking you to place
one sheet of copier paper under the right side of the carriage, and another sheet of copier paper under the left side
of the carriage. Use standard 20 lb. copier paper. One lettersize sheet cut in half to make two 8-1/2 x 5-1/2 inch sheets
works well for this purpose.
8. Place sheets of copier paper under the carriage as specified
by the control panel, and press B to continue.
The control panel displays the C and p (Up/Down) keys
and this message:
Use the arrow keys to carefully move the entire carriage
up/down until one side or the other is LIGHTLY resting
on the paper. Press Proceed when ready to level the
carriage.
9. Press the p key to move the carriage down, and move the
right and left sheets of paper repeatedly, until you feel resistance from the carriage touching the paper on either side of
the carriage.
If the carriage is so low that you cannot move the paper at
all, press the C and p keys to raise or lower the carriage
until you can move the paper, yet still feel some resistance.
10. Press the B key.
The control panel displays two sets of C and p keys, one
for the right and one for the left side of the carriage.
4-28
Head Height Calibration
11. Level the carriage by using the right and left sets of C and p
keys with the sheets of copier paper, as you did in step 9.
12. When the carriage is level, press the B key.
The control panel displays this message:
The head height is calibrated.
13. Press B to park the carriage and return to the Calibrations
menu.
Adjust Head Height
This procedure allows you to use paper shims to make small
adjustments to the right or left side carriage height, without
going through the full Auto or Manual Carriage Height calibration.
1. Verify that the appropriate Head Height setting is selected.
The options under Configure Printer - Printer Settings Head Height determine whether the head height will be set
to the Normal (0.050 inches/1.27 mm) or Custom height relative to the media. Use Normal unless you need to raise the
head height to avoid printhead strikes against the media.
2. On the menu, select Service Printer.
The Service Printer menu appears.
3. On the Service Printer menu, select Calibrations.
The Calibrations menu appears.
4. On the Calibrations menu, select Head Height.
The head height menu appears.
5. Select Adjust Head Height.
A message appears that describes this function.
WARNING
Keep the printer cover closed during this procedure.
The platen moves out of the service station to the
access position quickly, without further warning.
Operator injury or damage to the carriage could
occur if the carriage movement is blocked.
6. Press B to continue.
The carriage moves to the access position on the platen.
The control panel displays two sets of C and p keys, one
for the right and one for the left side of the carriage.
Head Height Calibration
4-29
7. For one side of the carriage, press the p key to move the carriage down, and move the sheet of paper repeatedly, until
you feel resistance from the carriage touching the paper on
either side of the carriage.
If the carriage is so low that you cannot move the paper at
all, press the C and p keys to raise or lower the carriage
until you can move the paper, yet still feel some resistance.
8. Repeat step 7 for the other side of the carriage.
9. When the carriage is level, press the B key.
The control panel displays this message:
The head height is calibrated.
10. Press B to park the carriage and return to the Calibrations
menu.
4-30
Head Height Calibration
Linearization
As the density of an image varies from highlights to shadows, or
from lighter tints to darker tints, the printer should accurately
reproduce these areas in a predictable, or linear, fashion. The
process of linearization (or color calibration) involves printing
and reading color test patches, and calibrating the printer to
ensure that the expected and printed densities will match. This
in turn will ensure optimal color matching.
You should perform a linearization when:
◆
You notice a shift (change) in color output
◆
Changing ink types or sets
◆
Changing media types
◆
Changing print mode (only if the most precise color matching is required)
Linearization is a feature of the print server or RIP connected to
the printer. Refer to the documentation that accompanies the
print server for further information.
Tip
Linearization
For best results, be sure that the linearization
patches are dry before taking readings. Use the
printer’s dryer with heat to ensure complete drying.
4-31
4-32
Linearization
CHAPTER 5
Maintaining the Printer
This chapter describes how to maintain the printer:
Maintaining the Printer
◆
Maintenance Schedule (page 5-2)
◆
Cleaning Ink Jets (page 5-3)
◆
Cleaning Jet Outs (page 5-5)
◆
Cleaning the Service Station (page 5-8)
◆
Printing Prime Bars (page 5-10)
◆
Manual Priming (page 5-11)
◆
Cleaning the Top Cover (page 5-13)
◆
Purging the Printheads (page 5-14)
◆
Cleaning the Encoder (page 5-17)
◆
Cleaning the Carriage Rail (page 5-18)
5-1
Maintenance Schedule
The following types of maintenance are recommended:
◆
Daily and “as needed” maintenance
◆
Printing interval warning — the printer maintains a periodic
maintenance clock that tracks the total amount of time the
printer has spent printing. After the periodic maintenance
interval has been reached, the AT TN key will appear on the
control panel, and the user will be advised to perform the
periodic maintenance items described in this chapter. When
you dismiss the warning message, the maintenance clock is
reset. The printer does not verify that the periodic maintenance is actually performed.
See the following table and the remainder of this chapter for
details and instructions.
Item
Action
Interval: Daily
Printhead jets
Clean (see page 5-3)
Service station
Clean (see page 5-8)
Ink tubes
Inspect for kinks, potential snags or tangles
Pinch rollers
Inspect for ink, dust buildup
Carriage rail
Inspect for ink, dust buildup
Interval: As needed
Print prime bars
See page 5-10
Manual priming
See page 5-11
Top cover cleaning
See page 5-13
Purge air and/or water See page 5-14
Interval: When printing interval warning appears
Encoder strip
5-2
Clean (see page 5-17)
Carriage rail
Clean (see page 5-18)
Service station
Clean (see page 5-8)
Spools and collets
Inspect for slippage, reposition and tighten collet screws if necessary
Maintenance Schedule
Cleaning Ink Jets
Maintenance interval: daily.
Before running AutoSet, which compensates for missing and
misfiring ink jets, you should clean the jets as described in the
following paragraphs to help keep them clear of accumulated
ink.
The effectiveness of the high-resolution printing process used
by the printer can be impaired by printheads that are improperly maintained. Partially clogged nozzles may cause the jets to
misfire intermittently, or deflect ink slightly in the wrong direction.
Cleaning the ink jets daily should be sufficient in most cases.
Cleaning will likely be required more often if the printer sits idle
for extended periods.
1. From the Front Page screen of the control panel, press the
Carriage key.
The carriage moves out from the service station and stops.
2. Open the printer’s top cover.
3. Depress the lock levers to unlock the printhead assembly, and
swing up the carriage to expose the ink jets.
4. Gently wick the ink jet nozzles with a nonfibrous, lint-free
swab moistened with water. DO NOT USE ALCOHOL, use
plain water.
If you find excessive buildup on the bottom of the printhead, clean off the excess using a moistened pad, and then
wipe the bottom of the printhead with the swab.
Caution
Do not to touch the contacts or orifice plate (jet nozzles) with your bare fingers. Also, take care not to
use excessive force when wiping the printheads with
the swabs or pads.
5. Close the printer’s top cover.
6. Swing the printhead assembly down into the printing position, and push the printhead assembly down into position
until it engages the lock levers with a click.
Cleaning Ink Jets
5-3
7. Clean the service station as described in “Cleaning the Service Station” on page 5-8.
8. On the control panel Front Page screen, press the B (Proceed)
key to park the printhead carriage into the service station.
Evaluating Printhead
Performance After
Cleaning
The Jet Status Lines test provides a quick method of determining
the effectiveness of (or the need for) cleaning. This test prints a
pattern of lines, each segment of which corresponds a single jet.
If there are any missing segments in the lines, then a cleaning is
recommended. If, however, the lines appear solid and consistent,
then cleaning is most likely not required at this time.
The Jet Status Lines function is on the Calibrate Printer Manual Calibrations menu.
5-4
Cleaning Ink Jets
Cleaning Jet Outs
Follow these instructions to recover clogged printheads when
other cleaning methods or priming are ineffective. Daily (or
after each roll of media, whichever occurs first) cleaning of the
printer service station, and wiping the printheads with a lint-free
cloth moistened with water, will reduce the need to use the
ultrasonic cleaner, extend the life of the printheads, and reduce
the cost of printing.
A printhead may be ultrasonically cleaned as needed to recover
clogged jets. Cleaning a printhead more than twice during its
service life may cause automatic ink counting to under-report
ink usage. Discard the printhead when ultrasonic cleaning fails
to recover enough jets for AutoJet jet replacement to replace all
missing jets, or when enough jets are intermittently working or
deflected to affect print quality.
Recommended equipment: Bransonic Tabletop Cleaner Mechanical
Timer & Heat Unit, (110V Model B1510R, 230V Model B1510E)
Branson Ultrasonics Corp.
Web site: http://www.bransonultrasonics.com
E-mail: [email protected]; telephone: 1-800-732-9262
Tip
Print an image before cleaning the printheads, and
print the same image after cleaning. This enables you
to evaluate the effectiveness of the cleaning. If there
is a noticeable color shift between the “before” and
“after” prints, additional purging of air or water may
be necessary.
1. Read and follow all manufacturer’s safety precautions and
operating instructions for the ultrasonic cleaner.
2. Fill the ultrasonic cleaner tank with distilled water (if available) or clean tap water, up to the fill line as shown on the
tank and in the manufacturer’s instructions.
3. Switch on the ultrasonic cleaner’s heater.
4. Set the timer for 30 minutes.
Cleaning Jet Outs
5-5
5. Immerse the bottom of the printhead only to the bottom of
the label on the printhead (as shown in the diagram). Suspend the printhead from in this position by its blue handle
until cleaning is complete. An improvised stand (for example,
fashioned out of a coat hanger) works well for this purpose. If
necessary, you may clean multiple printheads at once.
Fig. 5-1. Immersing the printhead for cleaning
6. After 30 minutes of cleaning, purge the printhead of air and
water. Insert the printhead as shown into the purge clip Œ.
Ž

Œ

Fig. 5-2. Printhead and purge clip
7. Hold the printhead so its jet orifice plate  points up.
8. Connect the ink tube from the corresponding ink module into
the ink inlet Ž on the printhead.
9. Gently press and hold the purge bulb  for a few seconds,
allowing the air to escape as bubbles or foam. Be sure that
the hole on the end of the purge bulb is covered by your finger as you press.
5-6
Cleaning Jet Outs
10. Blot the ink with a paper towel, but do not wipe (wiping
could clog the ink jets). Keep the ink from dripping onto the
printhead’s electrical contacts.
11. Release the bulb and wait five seconds, to allow the printhead to fill with ink.
12. Gently press and hold the purge bulb down again, this time
tilting the printhead from side to side, and front to back, to
allow the release of trapped pockets of air.
13. Repeat steps 11 and 12 until ink is expelled without foaming.
The color of the ink return to normal during this process.
14. Disconnect the ink tube from the printhead.
15. Reconnect the ink tube to its clips and connector on the printhead carriage. Match the number label on each ink tube to
the number molded into the plastic holder assembly. The
positions are numbered 1-12, from left to right.
16. Swing the printhead assembly down into the printing position, and push the printhead assembly down into position
until it engages the lock levers with a click.
17. Replace the printhead into its position in the carriage.
18. Repeat steps 5 through 17 for each printhead you want to
purge.
19. Snap the carriage cover closed.
20. Close the printer’s top cover.
21. From the control panel Front Page screen, press the Carriage
key. The printhead carriage returns to the home position.
22. To verify a successful purge, run the following test prints:
◆
Quick Prime Bars (twice) — compare the output with
the output printed before priming. If it is noticeably discolored, run the Print Test.
◆
Print Test (60 seconds) — this should flush the remaining water and/or air from the printhead(s).
◆
AutoSet
23. Resume printing.
Cleaning Jet Outs
5-7
Cleaning the
Service Station
Maintenance interval: daily, and when switching between dye
and pigment inks.
Cleaning the service station helps to prevent dried ink from
clogging the ink jets. Keep a replacement set of wipers on hand
to replace damaged or worn wipers. A set of and twelve spare
wipers is included with the printer.
Boots
Wipers
Fig. 5-3. Service station parts
1. From the Front Page screen on the control panel, press the
Carriage key.
This moves the printhead carriage to the center of the platen.
2. Open the service station access door.
3. Reach inside the right endcap (behind the control panel) and
lift the service station out of the printer.
Hold the service station level to avoid spilling any ink that
may be present.
4. Hold the service station with the wipers under running water.
Rinse as much ink as possible from the wipers.
5. Blot any remaining water from the service station with a
clean, lint-free cloth.
To avoid contaminating the ink, be sure to dry all water
from the boots and boot holders.
6. Replace the service station into the printer.
7. Close the service station access door.
8. On the Front Page screen, press the Carriage key.
The printhead carriage returns to the service station.
5-8
Cleaning the Service Station
Replacing the Wipers
When you notice that one or more wipers are worn or damaged, replace them. This may be indicated visually or by
ineffective wiping of the orifice plate, which would result in
a greater number of clogged jets. A replacement set of wipers
is included with the printer.
Early service station units had replaceable boots, but the
boots on recent units are glued in for reliability, and are not
replaceable. In the latter case, if the boots become damaged
and no longer cap the printheads effectively (indicated by
clogged jets after extended idle periods), replace the service
station.
The 0900833 Productivity Kit contains commonly-used
spare parts and accessories (including wipers and a service
station) in a convenient kit. Contact your ColorSpan reseller
or ColorSpan Technical Services for details.
Cleaning the Service Station
5-9
Printing Prime Bars
Maintenance interval: as needed.
To keep the printhead jets firing properly, you can print solid
blocks of ink from each printhead. By inspecting these prime
bars for blank bands, you can also do a quick check for nonfiring and deflected jets. Based on this quick test, you may want to
proceed to more detailed jet tests (see Chapter 4, Calibrating the
Printer, for instructions).
1. From the control panel Front Page screen, press the Prime
Bars key.
2. Choose Quick Prime Bars or Detailed Prime Bars.
Choose Quick Prime Bars for most primes, or Detailed Prime
Bars when you want to locate individual missing jets that
AutoSet may have missed, so you can map them manually
under Calibrate Printer - Manual Calibrations - Manual Jet
Mapping (see “Manual Jet Mapping” on page 4-16 for
instructions).
The control panel displays a prompt asking you to enter the
total width of the prime bar pattern you wish to print.
3. Enter a width for the prime bar pattern by pressing the p
and C keys.
4. Press the B (Proceed) key to continue.
The printer prints the prime bar pattern.
5-10
Printing Prime Bars
Manual Priming
Maintenance interval: as needed.
If you discover that an excessive number of jets are out on a
printhead (after cleaning or printing the prime bars or other
test), you can attempt to recover jets by performing a manual
prime.
This procedure requires a special priming bulb, included with
the printer. Each prime will expel approximately 1 ml of ink. To
keep ink counting as accurate as possible. you will report the
number of primes to the printer via the control panel.
Fig. 5-4. Manual prime bulb
1. From the control panel Front Page screen, press the Menu
key.
2. From the Menu, select Service Printer.
3. From the Service Printer menu, select Prime Pens.
This moves the carriage out of the home position, in back of
the service station access door.
4. Open the service station access door.
Manual Priming
5-11
5. Insert the priming bulb into one of the priming access holes
in the top cover of the carriage.
Fig. 5-5. Inserting the priming bulb
6. Depress and release the priming bulb to prime the printhead.
7. On the control panel, report how many primes you performed.
8. Repeat steps 5 and 6 for any other printheads needing manual priming.
9. Close the service station access door.
10. Press the B key to return the carriage to the home position.
5-12
Manual Priming
Cleaning the Top
Cover
Maintenance interval: as needed.
The printer’s top cover is designed to protect you from the carriage when it is moving (it moves very fast during printing) and
reduce noise, while providing an unobstructed view of the print
area.
Careful cleaning when needed, according to the following
guidelines, will preserve the cover’s appearance:
Cleaning the Top Cover
◆
Do not use cleaners that contain ammonia (such as glass
cleaner) or alcohol.
◆
Do not use paper towels or abrasive cloths or pads.
◆
Use only 100% cotton cloths and mild detergents (such as
dishwashing liquid) and water, or cleaners and polishes
developed for plastics (such as NOVUS Plastic Polishes, see
your ColorSpan reseller for details). Blot dry; wiping could
scratch the surface and create an electrostatic charge.
5-13
Purging the
Printheads
Maintenance Interval: as needed.
During normal printing, a small amount of air is introduced
into the printheads. An excessive amount of air in a printhead
may cause individual jets to stop working. The printheads may
need to be purged of this air at least once during their lifetime.
Since removing, purging, replacing, and recalibrating a printhead is a time-consuming process, purge all printheads currently
installed in the carriage in a single session.
Besides preventive maintenance, you should purge a printhead
of water introduced during the ultrasonic cleaning process. The
following procedure covers purging air and purging water.
To perform this process, you will need the purge clip, included
with the printer, and paper toweling to blot the ink that will
come out of the printhead during purging. You may also want to
wear gloves to avoid staining them with ink.
1. If you are purging a single printhead after ultrasonic cleaning, go to step 13.
2. From the control panel Front Page screen, press the Carriage
key.
The printhead carriage moves to the access position.
3. Open the printer’s top cover.
4. Open the carriage cover.
5. Remove the printhead from the carriage.
6. Depress the lock levers to unlock the printhead assembly, and
swing it up to expose the bottom of the carriage.
7. Disconnect the ink tube from its attachment clips on the
carriage.
5-14
Purging the Printheads
Purging Water
8. If you just want to purge air from the printhead (if an ultasonic cleaning was not performed), go to step 13.
9. Insert the printhead into the purge clip.
Hold the printhead so its jet orifice plate points up.
Fig. 5-6. Printhead installed in the purge clip
10. Connect the ink tube from the corresponding ink module into
the ink inlet on the printhead.
11. Hold the printhead over a bucket or other receptacle with the
jet nozzles facing down.
12. Depress the bulb on the purge clip five to seven times, or
until the color of the ink looks undiluted.
Purging Air
13. Insert the printhead as shown into the purge clip.
Hold the printhead so its jet orifice plate points up.
Fig. 5-7. Printhead installed in the purge clip
14. Connect the ink tube from the corresponding ink module into
the ink inlet on the printhead.
Purging the Printheads
5-15
15. Gently press and hold the purge bulb down for a few seconds, allowing the air to escape as bubbles or foam.
Be sure that the hole on the end of the purge bulb is sealed
with your finger as you press. Blot the ink with a paper
towel, but do not wipe (wiping could clog the ink jets). Keep
the ink from dripping onto the printhead’s electrical contacts.
16. Release the bulb and wait five seconds, to allow the printhead to fill with ink.
17. Gently press and hold the purge bulb down again, this time
tilting the printhead from side to side, and front to back, to
allow the release of trapped pockets of air.
18. Repeat steps 16 and 17 until ink is expelled without foaming.
19. Disconnect the ink tube from the printhead.
20. Reconnect the ink tube its clips and connector on the printhead carriage.
Match the number label on each ink tube to the number
molded into the plastic holder assembly. The positions are
numbered 1-12, from left to right.
21. Swing the printhead assembly down into the printing position, and push the printhead assembly down into position
until it engages the lock levers with a click.
22. Replace the printhead into its position in the carriage.
23. Snap the carriage cover closed.
24. Repeat steps 5 through 23 for each printhead you want to
purge.
25. Close the printer’s top cover.
26. From the control panel Front Page screen, press the Carriage
key.
The printhead carriage returns to the home position.
27. To verify a successful purge, run the following test prints:
5-16
◆
Quick Prime Bars (twice) — compare the output with
the output printed before priming. If it is noticably
lighter, run the Print Test.
◆
Print Test (60 seconds) — this should flush the remaining water and/or air from the printhead(s).
◆
AutoSet
Purging the Printheads
Cleaning the Encoder
Maintenance interval: at Maintenance Clock Alarm.
The encoder strip allows the printer to precisely locate the printhead carriage across the width of the platen. If the encoder
becomes dirty with paper dust or ink, the printer cannot print
accurately, and print quality will suffer.
The encoder strip Πis a clear plastic strip, imprinted with a precision encoding pattern, and mounted horizontally along the
rail . To clean the encoder strip, use a can of compressed air,
sold at camera or graphic supply stores, to blow dust and other
particles from it.
Œ

Fig. 5-8. Encoder and rail
Cleaning the Encoder
5-17
Cleaning the
Carriage Rail
Maintenance interval: at Maintenance Clock Alarm.
The carriage rail carries the printhead carriage across the width
of the platen. If dust or other particles accumulate on the rail,
the material could accumulate on the carriage wheels (bearings)
and cause banding in printed output or noisy carriage motion.
To clean the rail, wipe it with a water-moistened cloth or paper
towel. Be sure to remove any excess water from the rail before
resuming printing.
5-18
Cleaning the Carriage Rail
APPENDIX A
Technical Specifications
This chapter lists the printer’s specifications and information about
ordering supplies.
Technical Specifications
A-1
Specifications
A-2
General
Dimensions
(Assembled)
72-inch model:
Length: 132 inches (335.3 cm)
Depth: 31 inches (78.7 cm)
Height: 58.5 (148.6 cm)
60-inch model:
Length: 122 inches (309.8 cm)
Depth: 31 inches (78.7 cm)
Height: 58.5 (148.6 cm)
Weights
(Assembled)
72-inch model: 380 lbs. (173 kg.)
60-inch model: 355 lbs. (161 kg.)
Temperature
Storage: 0–120° F (-17–49° C)
Operating: 60–90° F (16–32° C)
Relative
Humidity
Storage: 10–80%, non-condensing
Operating: 10–80%, non-condensing,
30–60% optimum
Built-in humidity sensing automatically adjusts
printing speed to ensure adequate drying for
the combination of media and ink selected
Approvals
Safety: UL, c-UL, CE
Emissions: FCC-A, CE, VCCI-1
Immunity: CE
Specifications
Electrical Power
Power used: 200-240VAC, 30 Amps, 50/60 Hz,
single phase
Required electrical circuit:
220 VAC, 50 Amps, single phase, with NEMA
L6-50R wall receptacle (North America and
Japan), OR
220 VAC, 32 Amps, single phase, with IEC 60309
wall receptacle (Europe)
NEMA L6-50R
wall receptacle
(North America/Japan)
IEC 60309
wall receptacle
(Europe)
Required power cord:
Power cord for North American (UL/CSA
approved) or European (Harmonized) use is
supplied with the product.
If your building receives power from a standard
three-phase supply, note that the printer will
use only one of the three phases. This means
that your building’s three-phase power transformer may have an unbalanced load. Check
with your electrician to verify that your building
has sufficient capacity for this unbalanced load.
Performance
Specifications
Humidity
Compensation
Slows printing in high-humidity environments
(within specifications) to ensure complete drying.
Maximum Print
Width
72 inches (182.0 cm), 71.5 inches (181.6 cm)
image width
60 inches (181.6 cm), 59.5 inches (151.1 cm)
image width
Maximum Media
Thickness
0.125 inches (3.18 mm)
A-3
Sample Print Speeds
Application
Ink Configuration
Print Mode Print Speed
Economy
600 dpi
2 x CMYK
Draft
High Speed
Production
High Quality
600 ft2/hr. (55.7 m2/hr.)
400 ft2/hr. (37.2 m2/hr.)
200 ft2/hr. (18.6 m2/hr.)
150 ft2/hr. (13.9 m2/hr.)
HiRes
1200 dpi apparent image
resolution
2 x C2M2YK
Draft
High Speed
Production
High Quality
600 ft2/hr. (55.7 m2/hr.)
400 ft2/hr. (37.2 m2/hr.)
200 ft2/hr. (18.6 m2/hr.)
150 ft2/hr. (13.9 m2/hr.)
Ultimate Quality Color or Black & 1 x C3M3YK plus K3 or
White
1 x K4
1800 dpi apparent image
resolution
Draft
High Speed
Production
High Quality
300 ft2/hr. (27.9 m2/hr.)
200 ft2/hr. (18.6 m2/hr.)
100 ft2/hr. (9.3 m2/hr.)
75 ft2/hr. (7.0 m2/hr.)
Extended Gamut
1800 dpi apparent image
resolution
1 x C3M3YKOGRB
Draft
High Speed
Production
High Quality
300 ft2/hr. (27.9 m2/hr.)
200 ft2/hr. (18.6 m2/hr.)
100 ft2/hr. (9.3 m2/hr.)
75 ft2/hr. (7.0 m2/hr.)
HiRes AutoInk
Dye/Pigment
1200 dpi apparent image
resolution
1 x C2M2YK Endura•Chrome Dye Draft
plus 1 x C2M2YK Perma•Chrome High Speed
Pigment
Production
High Quality
300 ft2/hr. (27.9 m2/hr.)
200 ft2/hr. (18.6 m2/hr.)
100 ft2/hr. (9.3 m2/hr.)
75 ft2/hr. (7.0 m2/hr.)
Supported Ink and Media
A-4
Consult MacDermid ColorSpan or your MacDermid ColorSpan
representative for an updated listing of supported ink and
media.
Specifications
Supplies and
Accessories
Supplies and accessories are available from MacDermid
ColorSpan by calling:
MacDermid ColorSpan Supplies Sales
Supplies and Accessories
◆
USA and Canada: (800) 723-3002 or (952) 943-3636
◆
Europe: (+31) 23.5622000
◆
Asia: (952) 943-3300
◆
Latin America: (800) 664-7242 or (952) 943-3600
A-5
A-6
Supplies and Accessories
APPENDIX B
Troubleshooting
This appendix explains how to prevent and diagnose printing problems
and provides information about getting help from ColorSpan.
For other software-specific troubleshooting procedures, refer to your
application software documentation or the other ColorSpan documentation listed on page vi of this manual.
If your printer is connected to a non-ColorSpan RIP or print server, refer
to the accompanying third-party documentation.
Troubleshooting
B-1
Troubleshooting
Checklist
Before you troubleshoot your printer, make sure that it is properly installed as described in Chapter 1, Getting Started.
Follow the steps in this checklist to isolate and resolve printing
problems.
1. Does the printer’s power come ON?
YES: Go to question 2.
NO: The following could be the problem:
◆
The power cable may not be plugged into an electrical
outlet.
◆
If the printer is plugged into a surge protector, the surge
protector may not be connected to power, or it may be
switched off.
2. Did the start-up sequence of the control panel end by displaying a Ready (status) screen similar to the one shown in
Fig. 2-1 on page 2-2?
YES: Go to question 3.
NO: The following could be the problem:
◆
There may be a hardware problem with the printer’s
internal components. Follow the diagnostic routine on
the control panel to determine the problem. Call MacDermid ColorSpan Technical Services as directed by the
control panel.
3. Can you send a file from the print server to the printer?
YES: Go to question 4.
NO: The following could be the problem:
◆
The cable may not be securely connected between the
print server and the printer. Refer to the server’s documentation for more information.
◆
The cable may be connected to the wrong port on the
print server. Refer to the server’s documentation for
more information.
4. Can you send (print or download) a document from a client
computer to the server?
YES: Go to question 5.
NO: The following could be the problem:
◆
B-2
The connection from the client to the local area network
may not be configured correctly. See your system administrator for assistance.
Troubleshooting Checklist
◆
The cable between your computer or network and the
print server may not be securely connected at both ends.
Refer to the print server manual for more information.
◆
Your computer may not be working properly. Run an
application that you know works correctly and print to
be sure.
◆
The computer’s port may not be working properly. Print
to another output device that you know works correctly
(and is not connected to the print server) to check this.
◆
There may be another error condition reported by the
print server.
5. Is the print quality good?
YES: Then the problem is not covered in this checklist.
Contact MacDermid ColorSpan Technical Services.
NO: The following could be the problem:
Troubleshooting Checklist
◆
The printer may need to be calibrated. See Chapter 4,
Calibrating the Printer, for instructions.
◆
One or more ink jets may be clogged or not firing. See
“Cleaning Ink Jets” on page 5-3 for instructions.
◆
If the print head is striking the media, check how the
media is tracking from the supply spool to the takeup
spool. The sides of the media should be parallel to the
sides of the printer, with no wrinkling or buckling. If necessary, reload the media. See “Loading Media” on page
3-26 for instructions.
◆
Verify that the print head carriage is at the proper
height. See “Printer Settings” on page 2-11 for instructions.
B-3
Diagnostics
The printer includes a series of self-diagnostic tests designed to
help MacDermid ColorSpan Technical Services solve printer
hardware problems. If one of the tests encounters an error, and
error message appears, which includes:
◆
Error code - always write down this code for future reference
by MacDermid ColorSpan Technical Services.
◆
Brief description of the error
◆
A series of buttons that allow you to respond to the error. In
some cases, you can ignore the error or enter a further diagnostic routine. In other cases, you must restart the printer.
During the course of operating the printer, another class of error
messages may appear on the control panel. The ATTN (Attention) key blinks on the Ready or Front Page screen when the
printer detects an error condition, or potential error condition.
When you press this button, the panel displays one or more
messages of the following types:
◆
Warnings — the printer has detected a condition that, if left
unaddressed, could result in substandard prints or a condition that will require an action before printing can continue.
Any action on your part is optional.
◆
Actions — the printer has detected an error condition that
stopped printing or will prevent printing from starting. You
must correct the error before the printer will be ready to
print.
◆
Changes — the printer has detected a change to the inks,
media, or printer that could affect print quality. Pressing the
AT TN key displays a message that suggests the actions to
perform for optimal print quality, such as recalibration. You
can dismiss the message with or without actually performing the suggested action, although ignoring the messages
could result in substandard output quality. Printing is not
interrupted for a Change message.
The following table describes the Actions and Warnings in
detail. The cross-referenced page numbers refer to this manual.
B-4
Diagnostics
Table B-1. Actions and Warnings
Code, Message
(CA) Carriage
A-CA-1 - Carriage Rotation Sensor
(IS) Ink Sensing
A-IS-1through A-IS-12 Module Out of Ink, Slot # n
Cause
What to Do
Carriage is not locked into printing
position.
Rotate the carriage down into the
locked position.
Ink reservoir n is out of ink.
Replace ink reservoir.
A-IS-13 through A-IS-24 Color/type in printhead and module Ensure that color & type match in
Printhead/Module Mismatch, Slot #n n do not match.
printhead & module.
A-IS-25 through A-IS-36 Missing Module/Printhead, Slot #n
Either module or printhead n is not
detected.
A-IS-37 - No Print Mode Selected
Print mode incomplete or not speci- Press Print Mode key on control panel
fied.
(page 3-7).
W-IS-1 through W-IS-12 Low Ink, Slot #n
Ink reservoir n has about 50 ml of ink Replace the ink reservoir soon.
remaining.
(MC) Maintenance Clock
W-MC-1 - Preventive Maint. Clock
Alarm
Encoder strip and service station
need cleaning.
Clean encoder strip and service
station.
(MD) Media Drive
A-MD-1 - Media Advance Stalled
The media drive motor has stalled.
Check supply spool for binding,
motor for failure.
W-MD-1 - Index Sensor Not Detect- Media drive cannot detect index
ing Index
pulse.
Ensure that module and printhead
are installed.
Clean or replace media drive sensor.
W-MD-2 - Media Advance Turnaround Time Exceed
Media is taking too long to advance. Check supply spool for binding.
W-MD-3 - Media Advance Data
Warning
Media advance needs calibration.
W-MD-4 Media Advance/Drive Too Media advance motor is too slow.
Slow
(MS) Media Sensing
A-MS-1 - Media Too Thick at Load
The media you loaded is too thick.
Run Media Advance Calibration (service menu).
Determine the cause of the drag on
the media advance servo motor. Listen for unusual noises coming from
the grit roll shaft which might indicate sticking or binding. Advance the
media with a supply loop in the
media supply to eliminate media supply spool tension problems.
Reload with a media less than 0.125
inches thick.
A-MS-2 - Media Thickness Increased The media being printed is too thick. Reload with a media less than 0.125
inches thick.
Diagnostics
B-5
Table B-1. Actions and Warnings
Code, Message
Cause
What to Do
A-MS-3 - Media Too Far Left/Right
Media is loaded too far to the left or Reload the media; align right edge to
right.
reference mark.
A-MS-4 - Media Out
There is no media loaded.
A-MS-5 - Media Too Narrow
Media is not wide enough for print- Load media that is at least 24 inches
ing.
wide.
A-MS-6 - Media Too Wide
Media is too wide for printing.
W-MS-1 - Media Low
Less than 10 feet (3 meters) of media Load media or adjust Media Remainremains.
ing value at panel (page 3-26).
W-MS-2 - Non-Standard Media
Width
Media loaded may cause head strike. Continue printing or replace media.
W-MS-3 - Media End Not Detected
During Unload
The Unload function cannot find end Cut media prior to Unload, or do not
of media.
use Unload.
(PC) Printing Calibrations
A-PC-1 - Too Many Jets Mapped Out Too many missing jets could be
replaced.
Load media.
Use narrower media (page A-3).
Prime/clean printheads (page 5-13),
or increase number of passes (page
3-7).
W-PC-1 - Printhead Removed Recalibrate
A printhead was repositioned.
Run AutoSet (page 2-7).
W-PC-2 - Media Replaced Recalibrate
Media caliper may need to be remea- Run AutoSet if media type was
sured.
changed (page 2-7).
W-PC-3 - Head Height Changed Recalibrate
Change in head height has invalidated calibration.
Run AutoSet (page 2-7).
W-PC-4 - AutoJet - Jets Not Mapped Not all missing jets could be
Out
replaced.
Prime/clean printheads (page 5-3), or
increase number of passes (page 3-7).
(PD) Primer Door
A-PD-1 - Door Opened, Prime Not
Selected
The primer door is open.
Close the primer door.
(PG) Purge
W-PG-1 - Pens Require Purge
The printheads should be purged.
Purge all printheads (page 5-14).
(SC) System Calibrations
W-SC-1 - Media Adv. Run Out Not
Calibrated
Calibration was reset or not performed.
Calibrate media advance (page 4-4).
W-SC-3 - Media Thickness Sensor Not Calibration was reset or not perCalibrated
formed.
Calibrate media sensor (page 2-17).
W-SC-4 - Head Height Not Calibrated Calibration was reset or not performed.
Calibrate head height (page 2-17).
W-SC-5 - Printer Length Not Known
Calibrate printer length by restarting
printer.
B-6
Calibration was reset or not performed.
Diagnostics
Table B-1. Actions and Warnings
Code, Message
Cause
What to Do
Defective electronics assembly.
Call service provider for replacement
electronics.
(SM) System
A-SM-1 - Printer Not Imprinted
A-SM-2 - Release S/W Found Debug Defective software.
S/W
Call service provider for updated
software.
(SS) Service Station
W-SS-1 Service Station Tray Not
Present
The service station is not installed, or Install service station properly, or deit is installed too far to the right.
feat service station sensor (page 1-13).
(TC) Top Cover
A-TC-1 - Cover Open
The top cover is open.
Close the top cover.
(TU) Take Up
A-TU-1 - Takeup Full
The media takeup spool is full.
Unload the takeup spool and reload
media (page 3-26).
A-TU-2 - Takeup Stall
The takeup motor has stalled.
Check for mechanical interference or
binding, overloaded spool, out of
balance spool, or failure in electronics
or motor.
A-TU-3 - The Takeup Has Been Pulled The takeup was pulled out of position
Out of Position
by more than two inches, probably
due to the operator pulling media off
the takeup spool, or the roll on the
takeup has become unbalanced.
Press the Reset button displayed on
the control panel. The printer now
considers the takeup to be unloaded.
To reload, press Load on the Front
Page screen.
W-TU-1 - Takeup Nearly Full
The media takeup spool is almost full. Unload the takeup spool and reload
media (page 3-26).
W-TU-2 - Takeup Connected Slipping
The media takeup core is slipping.
Reload the media (page 3-26).
The printer cannot detect a print
server.
Connect cable, turn on server, add
printer to server.
(VN) VideoNet
W-VN-1 - VideoNet not Connected
Diagnostics
B-7
Banding
This is an explanation of the varieties of banding that may occur
in output. The names applied to the banding here are also an
attempt to generate a common language for describing and discussing types of banding.
Stitch Banding
“Stitch banding” results from inaccurate media advance and/or
inaccurate head-to-head Y-axis registration. It can be described
as regularly appearing bands, equally spaced according to the
width of the print swath. Bands will be darker than the surrounding area if there is too little advance, or lighter than the
surrounding area if there is too much advance.
To eliminate or reduce stitch banding:
1. Run an automatic or manual head-to-head calibration to correct any Y-offsets, especially if printing in 2x6 or 2x4 print
modes.
2. Run a Media Advance Calibration to correct the media
advance rate.
3. Re-run an automatic or manual head-to-head calibration to
compensate for any Y-offset changes created by adjusting the
media advance. Do this for both 1x and 2x print modes.
4. Run a test print to verify that banding has been eliminated.
Repeat steps 2 and 3 if banding persists.
Edge Banding
Edge banding (or “spears”) results from either the service station
configured for “Spit Only 30 seconds,” broken mechanical parts
in the service station or carriage, or a missing service station.
Without regular wiping, ink builds up on the printhead orifice
plates during printing. As the liquid component of the ink evaporates, solids are left behind. New ink is jetted through the dried
particles, which are picked up and deposited on the media, creating a dark band. If the build-up on the printhead is sufficiently
heavy it will inhibit jetting and lead to light bands.
Prints will generally look good at the beginning, but will deteriorate as their printed length increases. Bands will be equally
spaced down the length of the print. Banding will be most
apparent at the outside left and right edges of the print and will
taper off and possibly disappear altogether toward the center.
B-8
Banding
To reduce or eliminate edge banding:
1. Clean the printheads.
2. Confirm that the service station is installed.
3. Confirm that the service station algorithm under Menu Configure Printer - Printer Settings - Service Station Settings - Service Station Interval is set to 30 Seconds.
4. Examine the boots and wipers on the service station. If they
appear worn, replace them or the entire service station. Contact your Authorized Service Provider or ColorSpan Technical
Services for service.
Supply-Loop Banding
Supply-loop banding results from calibrating the printer with no
supply loop present, but printing actual jobs with a supply loop.
The tension on the media supply and the force necessary to pull
media from the supply are factors in the media advance calibration. If calibration has been adjusted to compensate for a certain
level of resistance from the supply, but printing takes place with
a different resistance, then the output will show bands. The
bands will be stitch bands, but they will disappear as soon as the
supply loop has been taken up. A common description of the
problem would be “The print looks fine except for the first 6
inches or so.”
It is also possible to have calibrated the advance with a supply
loop; in this case, if the job begins with the loop also, then the
job will be band-free initially but will start banding as soon as
the loop is taken up. This situation is less likely to occur. If the
calibration was performed with a loop, but printing begins with
no loop, then the appearance will be stitch banding throughout
the print.
To eliminate or reduce supply-loop banding:
1. Confirm that the printer was properly calibrated. Verify that
the media advance calibration is performed with no supply
loop, and that the calibration is accurate.
2. Ensure that there is no supply loop present at the start of the
print job.
3. Reprint the same job with no supply loop present and confirm that the banding is eliminated.
4. Recommended: set Configure Printer - Printer Options Supply Loop to Prevent Supply Loop. This will prevent
media from reversing and creating a loop in the first place.
Banding
B-9
Texture Banding
Texture banding results from either unexpected changes in head
height during printing, or failure to recalibrate after an intentional head height change. An accurately calibrated engine will
produce random, equally distributed concentrations of dots,
regardless of the intensity of coverage. A change to the head
height without corresponding recalibration of bidirectional
accuracy results in overall graininess and banding patterns.
To eliminate or reduce texture banding:
1. Reset the head height through Menu - Service Printer - Calibrations - Head Height. This returns the head to a known
height in the event that it has moved unexpectedly.
2. Confirm the desired head height setting through Menu Configure Printer - Printer Settings- Head Height.
3. Run AutoBidi and Auto Head-to-Head Calibration, or run
AutoSet.
Swath Edge Banding
Swath edge banding occurs at the edges of print swaths, which
are the strips of printed output created as the carriage moves
across the page.
To eliminate or reduce swath edge banding:
1. Print in HQ mode. See “Selecting a Print Mode” on page 3-7.
2. If you are printing with two printheads per color, determine
which color is causing the banding, and switch the printhead
positions in the carriage.
Call MacDermid ColorSpan Technical Services at one of the
numbers listed at the front of this manual.
B-10
Banding
Drying
The printer is equipped with a heated forced-air drying system
to help the printed output to dry. The effectiveness of this system depends on numerous variables, including:
◆
Media type — glossier media and films take longer to dry.
Satin and micropore media dry faster.
◆
Ambient relative humidity — the higher the relative humidity, the longer it takes to dry printed output. Lower relative
humidity enables faster drying.
◆
Number of print passes — faster throughput from fewer
print passes results in printed output spending less time
under the dryer and less effective drying. Slower throughput from more print passes results in more time under the
dryer and more effective drying.
By understanding the relationships among these variables, you
can adjust the workflow to meet production requirements. This
is particularly important when using the takeup system. If the
output is not completely dry by the time it reaches the takeup
spool, ink could transfer to the back of the media, possibly damaging the print.
Fig. B-1. Operating curves for various media types
Drying
B-11
The following table shows the maximum relative humidity that
will still allow printed output to dry sufficiently to be spooled
onto the takeup without damage, for selected media types and
print passes.
Table B-2. Test Results: Maximum Relative Humidity
That Allows Output to Dry Prior to Takeup*
Media
Print
Maximum
Passes Relative Humidity
Endura•Chrome Plus White Film
8
35%
12
45%
4
25%
8
50%
Endura•Chrome Plus Backlit Film
Satin Photobase PXS
4
50%
8
60%
Glossy Photobase PXG
4
45%
FineArt UltraWhite Satin Canvas
4
50%
UltraDry Satin Micropore Paper
2
50%
* Test conditions:
Ink set used: 2x6 C2M2YK
Media width: 34 inches
Test image file: Heavy coverage, full-width continuous-tone color
image with large areas of Rich Black
Tip
To increase drying effectiveness, reduce the relative humidity, increase the number of print passes,
or select a faster-drying media.
Other factors that influence drying performance include:
◆
B-12
Print width — wider images take longer to print and spend
more time under the dryer. Narrower images take less time
to print and spend less time under the dryer. When an image
does not occupy the entire width of the media, you can slow
throughput for more drying by enabling Print White Space
(see menu at Configure Printer - Printer Options - Print
White Space). With the ColorSpan print servers, you can
print copies of narrower jobs across the media (N-UP) or
group jobs with MediaSaver. This also reduces media waste.
Drying
◆
Coverage — heavier ink coverage yields more saturated colors, but takes longer dry. Ink coverage is determined by the
image itself (continuous-tone photograph vs. text or line
art), and the color profile used (some ColorMark profiles
have a High Quality version with more ink coverage and an
Economy version with less ink coverage). You can use the
ColorMark+ software or third-party color management software to create color profiles with lower maximum ink levels.
For 1-pass printing, you can specify Full or Reduced coverage (see menu at Configure Printer - Printer Settings - 1Pass Coverage).
Note
There is no jet replacement in 1-pass mode. If print
quality is unacceptable in 1-pass mode, reprint the
job in 2-pass or greater mode.
ColorSpan print server software includes a Lighter Prints Darker Prints control that allows you to adjust the maximum ink coverage (see the Printer Configuration dialog
box in the System Control interface).
Drying
◆
Linearization — accurate linearization or color calibration
ensures accurate ink coverage across all areas of the image,
avoiding unnecessarily high coverage that would increase
drying time. Linearization is a feature of the ColorSpan print
server and third-party RIPs.
◆
1x or 2x ink sets — single ink sets (one of each color) print
slower, and spend more time under the dryer than double
ink sets (two of each color). You can switch between 1x and
2x modes from the printer control panel (see menu at Front
Page - Print Mode). After doing so you should also perform
a new Media Feed calibration and AutoSet, unless you select
saved values from the Media Wizard.
◆
Rich Black or Pure Black — Rich Black is created by mixing
the various colors of ink, and takes more time to dry than
Pure Black, which uses black ink only. The type of black can
be controlled by the application creating the image, and by
the ColorSpan print server (see the Port Configuration or
Document Details dialog box).
◆
Auto or manual drying delay — the printer automatically
slows the print speed when the ambient relative humidity
rises above certain points. If you override this setting and
specify less of a delay to speed throughput, there will be less
B-13
drying. You can specify a Drying Rate of Same as print
speed to provide more drying time (see menu at Configure
Printer - Printer Settings - Drying Settings).
B-14
◆
Dryer fans — the dryer fans can be turned off to avoid
streaking the ink on some films, but this results in less effective drying. If output is not drying, check to see whether the
fans are turned on (see menu at Configure Printer - Printer
Options - Dryer).
◆
Ambient temperature — the lower the ambient temperature
at any given relative humidity, the more effective the dryer
will be. This is because a greater difference between the
temperatures of the media entering the dryer and leaving
the dryer enables more drying.
Drying
Index
Index-1
A
Actions and warnings 16
Advance Media 7
ATTN (Attention) 8
Audible alarm 13
Auto Calibrations 10
AutoJet calibration 2
AutoSet calibration 21, 7, 2
quality check mode 20
AutoSet summary 21
AutoTune scheduling 21, 10, 3
quality check mode 20
B
Bidirectional registration 2, 7
C
Calibrating the printer 1
Calibration 10, 17, 1
AutoJet 2
AutoSet 21, 2
AutoTune Scheduling 21
bidirectional 2, 7
color 31
head-to-head 2, 10
manual jet mapping 13
quality check mode 20
Calibration summary 10, 21
Carriage 18
Carriage access function 8
Carriage rail
cleaning 18
Cleaning
carriage rail 18
encoder strip 17
jet-outs 5
Index-2
printheads 13
service station 8
Color calibration 31
Color map 5, 8
cards 5
creating custom 11
Color set
defined 2
Control panel
actions 3
actions and warnings 16
ATTN key 3
audible alarm 13
Auto Calibration 10
AutoTune 10
calibration summary 10, 21
changes 3, 4
dryer 14
drying delay 12
error history 16
Front Page screen 2, 5
gutters 11
head height 13
home head 17
jet status lines 18
log error history 16
log head registration data 21
log jet data 21
manual calibration 10
margins 12
measure platen 15
menu 2
navigation keys 9
print mode 7
print position 14
print settings 11
print white space 14
printer configuration 11
printer options 14
quality check mode 14
Ready screen 2
reset all defaults 15
restore all defaults 15
service printer 16
service station 13
service tests 16
space between prints 11
takeup direction 11
units 13
user assistance 3
user diagnostics 16
vacuum control 12
warnings 3
zero platen width 15
zero registration data 18
Cutting media 35
D
Diagnostics 4
Dryer 21, 14, 34
Drying delay 12
Drying tips 11
E
Electrical requirements 2
Encoder strip
cleaning 17
Environmental requirements 2
Error history 16
F
H
Head height 13
Head-to-head registration 2, 10
Home head 17
Hot swapping 20
Humidity sensor 21
I
Ink
color map 5
color set defined 2
hot swapping 20
ink tube number label 5
ink type label 5
installation 14
replacing 19, 20
spares 6
Ink dryer 34
Ink module 4
replacing 19, 20
Ink tube 4
replacing 22
Ink tube number label 5
Ink type label 5
Installation
ink 14
media 26
printer 5
FCC statement v
Front Page screen 2, 5
J
G
Jet replacement 2
Jet status lines 18, 4
Jet-outs, cleaning 5
Gutters 11
Index-3
L
Linearization 21, 31
Loading media 8, 26
Log error history 16
Log head registration data 21
Log jet data 21
M
Manual calibration 10
Manual jet mapping 13
Margins 12
Measure platen 15
Media
cutting 35
loading 8, 26
unloading 8, 35
Media dryer 34
Media Feed calibration 4
Media sensor 18
disable 18
Media spool 26
Media width 22
Media Wizard 22, 8, 19
Menu 2
Menu tree 20
Modular ink delivery system 21
O
Ordering supplies 5
P
Parts list 6
Index-4
Parts overview 17
Passes 2
defined 2
Periodic maintenance 2
Prime access door 18
Prime bars 8, 10
Priming 21, 10
manual 11
Print mode 2, 7
Print passes
defined 2
Print position 14
Print settings 11
Print white space 14
Printer configuration 11
Printer options 14
Printheads 4
cleaning 13
replacing 21
Printing
jet replacement 2
passes 2
Purging 21, 14
Q
Quality check mode 14, 20
R
Ready screen 2
Regulatory statements v
Related manuals vii
Relative humidity sensor 21
Reset All Defaults 15
Restore all defaults 15
S
W
Safety warnings 4, 5, 9, 13
Service printer 16
Service station 13
cleaning 8
Service tests 16
Space between prints 11
Spare ink 6
Specifications 1
Supplies and accessories 5
Supply loop 9
Warnings 4, 5, 9, 13
Workflow overview 16
Z
Zero platen width 15
Zero registration data 18
T
Takeup direction 11
Takeup system 21
options 32
Technical Support 11
Top cover 18
Troubleshooting 1
U
Ultrasonic cleaning printheads 5
Units 13
Unloading media 8, 35
Unpacking and assembly 5
User diagnostics 16
V
Vacuum control 12
Variable Mode Printing 2
Index-5
Index-6

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