Gerber Solara ion Owner's manual

4/29/10 Rev G

Gerber Solara ion

V ™

UV Ink Jet Printer

Owner’s Guide

4/29/10 Rev G

Solara ion

V

Print Modes

User Selectable Print Modes Print

Throughput

(4' x 8' sheet)

Approximate

Print Time

(4' x 8' sheet)

Print

Throughput

(4' x 8' sheet)

Approximate

Print Time

(4' x 8' sheet)

360 x 360 720 x 720

Performance (2 Pass, Bidirectional) 181 ft

2

/ hr 11 min - -

Performance (2 Pass, Unidirectional) 125 ft

2

/ hr 15 min 36 ft

2

/ hr 53 min

Production (4 Pass, Bidirectional) 107 ft

2

/ hr 18 min - -

Production (4 Pass, Unidirectional) 70 ft

2

/ hr 27 min 18 ft

2

/hr 107 min

High Quality (8 Pass, Bidirectional) 55 ft

2

/ hr 35 min - -

Ultra-High Quality (8 Pass, Unidirectional) 33 ft

2

/ hr 58 min 9.5 ft

2

/ hr 202 min

 Warranty

Please see Product Specifications for required operating environment and consult your

Owner’s Guide for required preventative maintenance procedures.

 Additional Documentation

Further documents, and updates to current documentation, will be available with each

new firmware release. For the most up-to-date literature, contact your Gerber Service

representative or check the eService Document Library which can be accessed from the

Support section of the Gerber web site: www.gspinc.com.

4/29/10 Rev G

Copyright Notice

This document may not be reproduced by any means, in whole or in part, without written

permission of the copyright owner.

This document is furnished to support the Gerber Solara ion

V

Ink Jet Printer. In consideration

of the furnishing of the information contained in this document, the party to whom it is given

assumes its custody and control and agrees to the following:

The information herein contained is given in confidence, and any part thereof shall not be

copied or reproduced without written consent of Gerber Scientific International, Inc.

This document or the contents herein under no circumstances shall be used in the manufacture

or reproduction of the article shown and the delivery of this document shall not constitute any

right or license to do so.

Information in this document is subject to change without notice.

Printed in USA

Gerber Solara ion, GerberCAT, Cold Fire Cure Technology, FastFacts, ImageRIP, OMEGA, Support First,

and Matched Technology System are trademarks and GSP is a registered trademark of Gerber Scientific

Products. Onyx and PosterShop are registered trademarks and ProductionHouse is a trademark of Onyx

Graphics. X-ACTO is a registered trademark of Hunt Corporation. Anticon is a registered trademark of

Milliken & Company. Firefox is a registered trademark of Mozilla. Microsoft, Internet Explorer,

Windows, and Windows XP are registered trademarks of Microsoft in the USA and other countries.

Wasatch SoftRIP is a registered trademark of Wasatch Computer Technology. SignLab is a trademark of

CADlink Technology Corporation. Flexi and PhotoPrint are trademarks of SA International, Inc.

4/29/10 Rev G

FCC Compliance

Warning: Changes or modifications to this unit not expressly approved by the party responsible

for compliance could void the user’s authority to operate the equipment.

Note: 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 their own expense.

This Class A digital apparatus complies with Canadian ICES-003.

Cet appareil numérique de la classe A est conforme à la norme NMB-003 du Canada.

4/29/10 Rev G

Contents

Quick Print Checklist................................................................................................................ 10

Chapter 1: Introduction........................................................................................................... 11

In this manual.........................................................................................................................................12

Conventions used in this booklet ........................................................................................................12

Safety information .................................................................................................................................13

Electrical...............................................................................................................................................13

Ink handling and disposal.................................................................................................................13

Printer ventilation...............................................................................................................................14

Personal precautions ..........................................................................................................................14

UV lamp precautions .........................................................................................................................14

Technical support ..................................................................................................................................14

Additional sources of information ...................................................................................................14

Chapter 2: Product Overview ................................................................................................. 15

General requirements............................................................................................................................15

Size and weight...................................................................................................................................15

Ambient conditions ............................................................................................................................16

Power requirements ...........................................................................................................................16

Printer orientation...............................................................................................................................17

Locating the serial number................................................................................................................17

Computer and software requirements.............................................................................................18

UV bulb technology...............................................................................................................................18

UV ink technology.................................................................................................................................19

Storing inks and materials....................................................................................................................19

UV ink storage.....................................................................................................................................19

Material storage ..................................................................................................................................20

Gerber Solara ion control panel ...........................................................................................................20

Main control panel..............................................................................................................................21

Auxiliary keypad ................................................................................................................................21

Control Panel keys..............................................................................................................................22

Power-up functions ............................................................................................................................24

Exploring the printer's menu system ..................................................................................................24

Status..........................................................................................................................................25

Setup..........................................................................................................................................25

Calibration ................................................................................................................................25

Maintenance..............................................................................................................................26

The Gerber Solara ion web pages ........................................................................................................27

Starting and stopping the printer ........................................................................................................27

Firmware startup and internal diagnostics.....................................................................................28

Automatic ink level check .................................................................................................................28

Automatic printhead cleaning check ...............................................................................................28

Sleep/Idle mode .................................................................................................................................28

Emergency Stop ..................................................................................................................................29

4/29/10 Rev G

Chapter 3: Setting up the Gerber Solara ion...................................................................... 31

Networking your Gerber Solara ion printer ......................................................................................31

Setting fixed (static) network addresses ..........................................................................................31

Setting the IP Address and Subnet Mask of your computer.........................................................33

Checking network connections............................................................................................................37

Viewing the current network settings.................................................................................................37

Chapter 4: Loading Inks and Materials ............................................................................... 39

Loading the inks.....................................................................................................................................39

Checking the ink level........................................................................................................................40

Replacing ink pouches when ink remains in the reservoir...........................................................40

Replacing an ink pouch when the reservoir is empty ...................................................................42

Loading the material .............................................................................................................................42

Printer/graphic orientation...............................................................................................................44

Choosing a material type...................................................................................................................45

Normalizing material.........................................................................................................................46

Cleaning material................................................................................................................................46

Using material hold-down devices for roll material......................................................................48

Loading roll material in the Roll-to-Roll configuration....................................................................49

Using the material roller....................................................................................................................50

Loading roll material into the printer ..............................................................................................51

Using the winding unit ......................................................................................................................52

Removing material from the winding unit and printer ................................................................54

Loading rigid material ..........................................................................................................................55

Uniform Print Gap & Elimination of Gap Between Prints............................................................56

Understanding printing margins.........................................................................................................59

Chapter 5: Printing Jobs on the Gerber Solara ion........................................................... 61

Using RIP software and profiles..........................................................................................................61

Print mode options ................................................................................................................................61

Printer operations ..................................................................................................................................62

UV lamp automatic shut-off or Continuous mode ........................................................................62

Lamp Delay mode ..............................................................................................................................62

Lamp Spec mode.................................................................................................................................63

Large Field mode ................................................................................................................................64

Step Blending mode ...........................................................................................................................64

X Gantry Adjustment .........................................................................................................................65

UV lamp warm-up..............................................................................................................................66

Sleep/Idle mode .................................................................................................................................66

Automatic spitting to clear the nozzles ...........................................................................................66

Cleaning the printheads.....................................................................................................................67

Pausing a job due to data starvation................................................................................................67

Choosing a print mode for Roll-to-Roll printing...............................................................................67

Single mode .........................................................................................................................................67

Continuous mode ...............................................................................................................................67

Viewing job information at the printer...............................................................................................68

Printing a single Roll-to-Roll or Flat Bed job......................................................................................69

Media feed adjustment on a Roll-to-Roll job ..................................................................................71

Printing a full bleed Flat Bed job .........................................................................................................72

Printing double-sided, full-bleed......................................................................................................73

Printing multiple Roll-to-Roll jobs in Continuous mode .................................................................75

Canceling a job .......................................................................................................................................77

4/29/10 Rev G

Chapter 6: Routine Printer Maintenance ............................................................................ 78

Required routine maintenance supplies.............................................................................................78

Gerber Solara ion

V

Regular Preventive Maintenance........................................................................79

Daily maintenance.................................................................................................................................82

Tips for Clean Heads procedure.......................................................................................................82

1) What is the purpose of the Clean Heads procedure? ................................................................82

2) How hard do I press the Anticon-covered swab against the surface of the printhead nozzle plate?

...............................................................................................................................................................82

3) How can I be sure my clean was effective?.................................................................................82

4) Why do I lose nozzles? ..................................................................................................................82

Clean Heads Procedure......................................................................................................................84

End of Day Clean................................................................................................................................86

Cleaning the sliding UV shield and side plates..............................................................................88

Cleaning individual color printheads..............................................................................................91

Emptying and cleaning the waste ink tray......................................................................................93

40 Hour Maintenance ............................................................................................................................95

Periodic Maintenance Process to correct angled nozzles on the Gerber Solara ion......................95

Materials needed.................................................................................................................................95

Process overview ................................................................................................................................95

Cleaning the flat bed ..........................................................................................................................97

Cleaning the roll-to-roll platen..........................................................................................................97

Cleaning the head access door..........................................................................................................97

Cleaning the ink drawers...................................................................................................................98

Cleaning the Maintenance Shelf Mat ...............................................................................................98

Cleaning the outside of the Gerber Solara ion................................................................................98

Monthly maintenance ...........................................................................................................................99

Six month maintenance.......................................................................................................................100

Cleaning the table rails.....................................................................................................................100

Cleaning the Roll-to-Roll grit wheels.............................................................................................100

Cleaning the Roll-to-Roll rubber drive wheels.............................................................................101

Yearly maintenance .............................................................................................................................101

Replacing the light shields (flaps) ..................................................................................................101

Purging ink lines to remove air..........................................................................................................102

Clearing the ink lines...........................................................................................................................106

Filling the ink lines ..............................................................................................................................109

Preparing a printer that will not be used for up to two weeks......................................................113

Steps for preparing the Solara ion for two weeks of idle time ...................................................113

Steps for restarting the Solara ion after two weeks of idle time.................................................113

Shutting down the printer for more than two weeks .....................................................................114

Steps for shutting down the Solara ion..........................................................................................114

Steps for restarting the Solara ion...................................................................................................114

Steps for shutting down your Solara ion.......................................................................................114

Steps for restarting your Solara ion................................................................................................123

Chapter 7: Gerber Solara ion Web Pages.......................................................................... 124

Accessing the Gerber Solara ion web pages.....................................................................................124

Home page............................................................................................................................................125

System Status page ..............................................................................................................................125

System Status page ..............................................................................................................................126

System Settings page...........................................................................................................................127

Changing the printer name .............................................................................................................127

Changing the System Log Level .....................................................................................................127

4/29/10 Rev G

Choosing the numeric units ............................................................................................................128

Choosing the language.....................................................................................................................128

Setting the Lamp Delay mode.........................................................................................................128

Setting the Lamp Spec Mode...........................................................................................................128

Setting Large Field mode.................................................................................................................128

Setting Step Blending mode ............................................................................................................128

Network Settings .................................................................................................................................129

Using Static Settings .........................................................................................................................129

Other settings ....................................................................................................................................130

Job Status page .....................................................................................................................................130

Diagnostics page ..................................................................................................................................131

Restoring Factory Default Settings.................................................................................................132

Version Information .........................................................................................................................133

View System Log ..............................................................................................................................134

View Satellite Log.............................................................................................................................135

Sensors................................................................................................................................................136

Configuration Info page...................................................................................................................138

USB Test page....................................................................................................................................138

Statistics..............................................................................................................................................140

Error History page............................................................................................................................141

Calibration web page ..........................................................................................................................142

X Gantry Adjustment .......................................................................................................................143

Y Carriage Steps/Inch—Y Encoder Calibration...........................................................................144

Calibrating the location of a printed image (Print Pos Offset Front and Side) ........................146

Calibrating the printhead park position........................................................................................147

Calibrating Image Quality...............................................................................................................149

Update page..........................................................................................................................................156

Loading firmware upgrades............................................................................................................156

Starting the printer in Bootloader mode........................................................................................160

Downloading new color profiles ....................................................................................................161

Contacts web page...............................................................................................................................161

Chapter 8: Troubleshooting.................................................................................................. 163

RIP software issues..............................................................................................................................163

Determining the category of problems .............................................................................................163

Printer issues ........................................................................................................................................164

Printer will not turn on ....................................................................................................................164

Printer is stuck on “Gerber” screen at power-up .........................................................................164

Printer is stuck on “Check the Shelf” screen.................................................................................164

Printer is stuck on “Warming” screen ...........................................................................................164

Job will not print ...............................................................................................................................164

Winder does not roll up the material.............................................................................................165

Material jams when printing...........................................................................................................165

Quality of printed output ...................................................................................................................167

Missing nozzles.................................................................................................................................167

Banding in the flat bed prints..........................................................................................................167

Banding in roll-to-roll prints ...........................................................................................................167

Missing or angled nozzles ...............................................................................................................168

The print is blurred...........................................................................................................................169

Smearing or fading in the print.......................................................................................................169

Objects are printing in the wrong place.........................................................................................170

Color balance is different between software and print ...............................................................170

Overlap on a roll-to-roll job.............................................................................................................170

4/29/10 Rev G

Small text quality is poor.................................................................................................................170

Ink not curing....................................................................................................................................171

The ink forms small puddles on the print.....................................................................................171

Ink mist at front left corner of material..........................................................................................171

Image easily scratches off the material ..........................................................................................171

Entire print smudges when touched..............................................................................................171

First few inches (50-100cm) of the job is not curing .....................................................................172

One side of the print is not curing well .........................................................................................172

Job data errors ......................................................................................................................................173

Data errors and interruptions during printing.............................................................................173

Incorrect data is printing .................................................................................................................173

Objects are printing in the wrong place.........................................................................................173

Prints are not the correct size ..........................................................................................................174

Left edge of job is inconsistently located.......................................................................................174

Printer does not always start in same location .............................................................................174

The printer pauses between passes................................................................................................174

Messages ...............................................................................................................................................174

Error Messages.....................................................................................................................................178

Running the control panel screen test...............................................................................................180

Printer Menu Tree – Rev G Version .................................................................................... 182

Index .......................................................................................................................................... 184

4/29/10 Rev G

Quick Print Checklist

After you have setup your Gerber Solara ion for the first time, use this checklist

to help guide you through the steps required for getting the machine ready for printing.

Refer to the page numbers provided next to each step for more information.

1 Check the Ink Level by pressing the Ink Level button on the control

panel.

(Replace ink pouches if necessary)

2 Clean the heads. (Repeat every 4 hours of printing and after 2 hours of idle

time, and at start and end of each day.)

3 Prep the material.

(Normalize and clean for best results)

4 Select material type if equipped with the Roll-to-Roll option. (Roll-to-

Roll (Single or Continuous) or Flat)

5 Load the material.

(Roll-to-Roll or Flat)

6 Adjust the UV shield for flat material or adjust the material hold-

downs for roll-to-roll material.

Using your selected RIP software

7 Open, adjust, and arrange your image(s).

8 Select the appropriate material profile and page size.

9 Select the print quality.

(2 pass, 4 pass, or 8 pass)

10 Send the job to the printer.

11 View job information to confirm that the correct material is loaded.

12 Press Run Job to begin printing your job.

13 UV Lamp warm-up.

(If lamps are not to proper temperature.)

14 Job will begin printing.

p. 40

p. 84

p. 46

p. 45

p. 42

p. 49 or 55

p. 61

p. 69

p. 68

p. 69

p. 18

p. 69

11

4/29/10 Rev G

Chapter 1:

Introduction

Thank you for purchasing the Gerber Solara ion

V

™, an outdoor-durable, UV-cured ink jet

printer. The Gerber Solara ion’s versatile printing methods allow shops to meet diverse

customer needs. The printer has a generous flatbed which accommodates large jobs with ease. It

can print on rigid materials such as foam board, corrugated plastic, polycarbonate, expanded

PVC, aluminum, or MDO, as well as flexible materials such as banner, vinyl, and backlit. In

addition, you have the option of printing full-bleed.

If you have chosen to add a roll-to-roll option, the printer can accommodate flexible materials

such as banner, vinyl, and backlit. In addition the roll-to-roll option expands the length of the

flatbed to 120" (3m/304.8cm).

The Gerber Solara ion

produces all kinds of durable, outdoor or indoor graphics on a wide

variety of materials which meet the following standards:

 Maximum rigid or roll material width is 64" (1.6m/162.6cm).

 Maximum rigid material thickness is 1" (25.4mm).

 Maximum rigid material length for the roll-to-roll configuration is 120" (3m/304.8cm).

 Maximum rigid material length for the flatbed-only configuration is 100"

(2.5m/254cm).

 Maximum rolled material thickness is 0.030" (0.76mm).

 Minimum rolled material width is 24" (61cm).

 Minimum sheet size is 12" x 12" (30.5cm x 30.5cm).

The Gerber Solara ion printheads use multiple-drop technology to provide vivid colors and an

expanded color gamut. The printer has several print modes to maximize throughput or quality.

The printing rate varies based on the selected print mode and the chosen material profile (as

determined by the RIP software).

Gerber’s exclusive GerberCAT™ ultraviolet ink set includes four colors - Cyan, Magenta,

Yellow, and Black, which achieve an outstanding color gamut and brilliant hues. The cationic

inks are cured using Gerber's proprietary Cold Fire Cure™ technology. This low energy, low

temperature cure creates a mechanical bond between the ink and the substrate, providing better

abrasion resistance and eliminating adhesion loss which can occur with vinyl graphics. The

low-temperature cure also greatly expands the range of materials that can be printed by the

Gerber Solara ion. Heat sensitive plastic, vinyl, fabric, and paper-based materials can be printed

using Gerber's Cold Fire Cure and GerberCAT inks without concern over ink adhesion or

material damage.

The Gerber Solara ion inkjet printer is part of Gerber’s Matched Technology System™ which

provides users with a complete, integrated solution from start-to-finish.

CHAPTER 1

12

Introduction

4/29/10 Rev G

In this manual

The following chapters introduce you to the Gerber Solara ion, describe the printing process,

and show you how to maintain your printer for maximum quality output.

Chapter 1: Introduction provides details on how to use this manual and important customer

service and safety information.

Chapter 2: Product Overview provides details of the general product features and requirements

and describes the control panel and menu structure as well as the startup sequence.

Chapter 3: Setting up the Gerber Solara ion directs you in setting up the Gerber Solara ion to

run on a network and other user-controlled options.

Chapter 4: Loading Inks and Materials directs you in loading the Gerber Solara ion ink and

installing materials.

Chapter 5: Printing Jobs on the Gerber Solara ion describes how to print on either flexible or

rigid material with RIP software.

Chapter 6: Routine Printer Maintenance details cleaning and purging of printheads as well as

the daily, weekly and monthly maintenance routines.

Chapter 7: Gerber Solara ion Web Pages describes the onboard web interface program that can

be used to check on the printer's current status and ink status, to view or change system and

network settings, view message logs, assist in diagnostics, and to install new firmware.

Chapter 8: Troubleshooting highlights potential printing problems and provides possible

solutions. The Messages section list common messages that may display on your control panel

screen and their meaning.

Menu Tree provides a visual layout of the Gerber Solara ion printer's menu.

Preventive Maintenance chart is a handy reference for the routine preventive maintenance tasks

and scheduled service procedures.

Conventions used in this booklet

The following conventions are used in this booklet:

WARNING: A warning statement contains information which, if not followed,

could result in electrical shock hazard.

CAUTION: A caution statement contains information which, if not followed, could

result in personal injury or equipment damage.

NOTE: A note contains important information that affects the successful completion of a task.

TIP: A tip contains a suggestion to make your task easier or to remind you of something that

may appear elsewhere in the booklet.

CHAPTER 1

13

Introduction

4/29/10 Rev G

Safety information

Electrical

WARNING: Observe these safety precautions to avoid possible electrical shock

hazard when using the Gerber Solara ion.

 Use the correct power cord; do not use a damaged power cord.

 Use an outlet with a ground terminal or electric shock can occur.

 Turn printer off and unplug it from the power source before servicing.

 Unplug any communications cables before servicing.

 Never open covers affixed by screws unless directed by Gerber service personnel.

Doing so may result in electric shock or damage to the printer.

 Remove any electrostatic charge from your clothing or body by touching a metal part

of the printer before servicing. Electronic components (such as memory) may

malfunction if exposed to electrostatic charge.

 Industrial rubber mats are required under and around the printer if it is installed on

carpeting.

Ink handling and disposal

CAUTION: Observe these general safety precautions when operating the Gerber

Solara ion

Ink Jet Printer.

CAUTION: Use impervious gloves to protect your hands. Nitrile gloves of no less

than 8 mils have proven impervious for one hour of exposure. Gloves should be

disposed of after one hour of exposure time. Wear goggles to protect your eyes.

Dispose of used swabs, wipes, and gloves according to local laws and regulations.

 Do not use inks other than GerberCAT inks. Using other inks will void the warranty

and will damage the printer.

 Consult the Gerber CAT ink MSDS for proper handling, disposal, and safety

recommendations. Also consult local laws and regulations.

 Do not open ink pouches. Ink could get on your skin or in your eyes.

 When handling ink pouches and waste ink, be careful that the ink does not get on your

skin by wearing impervious nitrile gloves. If it does, wash your skin with mild soap

and water for 15 minutes. Seek medical attention if symptoms occur.

 If your clothing comes in contact with uncured ink, remove any contaminated clothing

and wash them separately with soap and water.

 If ink gets in your eyes, immediately rinse your eyes with copious amounts of water

for at least 15 minutes and seek medical attention immediately.

 Dispose empty ink pouches, waste ink, wipes, used swabs and gloves according to

local laws and regulations.

CHAPTER 1

14

Introduction

4/29/10 Rev G

Printer ventilation

CAUTION: Observe these general safety precautions when operating the Gerber

Solara ion

Ink Jet Printer.

 Do not obstruct printer exhaust fans.

Personal precautions

CAUTION: Observe these general safety precautions when operating the Gerber

Solara ion

Ink Jet Printer.

 There are two emergency stop switches located on either end of the gantry. Press

either switch to immediately shut down the UV lamps and abort printing.

 Be careful when reaching into the printer to open the maintenance shelf, or swab the

printhead. The UV lamp assemblies and interior surfaces of the printer may be hot.

 Be careful not to pinch fingers in drawers, pinch wheels, and material feed system.

 Use caution when lifting heavy rolls or pieces of material.

UV lamp precautions

UV WARNING

Exposure to UV light can be dangerous to eyes and skin and should be avoided.

Never operate the Gerber Solara ion with any of the covers removed.

Never operate the printer with the rubber light shields (flaps) missing or damaged.

Contact Gerber if any of the rubber light shields (flaps) need to be replaced.

Technical support

If you have questions regarding using, maintaining, or troubleshooting the Gerber Solara ion

please contact your Gerber distributor or Gerber Service.



phone: 800-828-5406 / 860-643-1515, ext. 8602

fax: 860-871-3862



e-mail: [email protected]

www.gspinc.com

Additional sources of information

Gerber FastFacts provides answers to technical and service questions. FastFacts are available

on the Gerber web site: www.gspinc.com under “Support.”

Electronic versions of this manual and other documentation are available from the eService

Document Library which can be accessed from the Gerber web site: www.gspinc.com under

“Support.” You must sign up for a free customer account to access the eService location.

15

4/29/10 Rev G

Chapter 2:

Product Overview

General requirements

The following sections provide an overview of Gerber Solara ion size, weight, and

recommended operating conditions.

Size and weight

You must have enough room to maneuver the packed Gerber Solara ion to its final location

where you can unpack and assemble it.

CAUTION: The Gerber Solara ion is packaged in several crate assemblies that vary

based on the printer’s configuration. The customer is responsible for providing

appropriate equipment (fork lift or palette jack with extended forks) for unloading

and moving the system into place. If a loading dock is not available, you must have

a forklift capable of unloading the system from the back of the delivery truck. The

fork lift must be able to lift 1,100 lbs. (499kg) and needs extended forks which are at

least 8 feet (2.5m). If this equipment is not available or the system requires

movement to an upper floor, riggers or special equipment will be required. This is

the responsibility of the customer.

Crate # Flatbed-only Configuration Crated Size Crated Weight

1 140" long x 35.25" wide x 78" high (356cm cm x 89cm x 198cm) 1,043 lbs. (473kg)

2 119" long x 35.25" wide x 52" high (302cm x 89cm x 132cm ) 850 lbs. (386kg)

Flatbed-only Configuration Uncrated Size Uncrated Weight

147" long x 104" wide x 52" high (373cm x 264cm x 132cm) ~1,000 lbs. (454kg)

Crate # Roll-to-Roll Configuration Crated Size Crated Weight

1 140" long x 35.25" wide x 78" high (356cm cm x 89cm x 198cm) 1,100 lbs. (499kg)

2 119" long x 35.25" wide x 52" high (302cm x 89cm x 132cm ) 850 lbs. (386kg)

3 75.5" long x 35.25" wide x 32" high (192cm x 89cm x 81cm) 280 lbs. (127kg)

Roll-to-Roll Configuration Uncrated Size Uncrated Weight

148" long x 104" wide x 52" high (376cm x 264cm x 132cm) ~1,000 lbs. (454kg)

CHAPTER 2

16

Product Overview

4/29/10 Rev G

Ambient conditions

The Gerber Solara ion 12 month product warranty requires the printer to be maintained in a

specific environment. If the system is operating outside of the environmental specifications, it

may result in system errors and/or shutdown. During the colder months of the year, especially

in dryer climates, be cognizant of the required environmental conditions (40% humidity

minimum/65F (18.5C) minimum). The operating environment must meet the following

conditions:

 Temperature: 65F to 75F (18.5C to 24C)

 Humidity: 40% - 60%, non-condensing

 Ventilation: no special ventilation required

 Avoid using printer near open windows, outside doors, or heating/cooling systems

 Protect printer and ink pouches from moisture, dust, drafts, and direct sunlight

 Noise level when operating vacuum table: ~77-78 Db

Note: Installations in which the Gerber Solara ion will be placed on carpeting require the use of

commercial or industrial rubber mats under and around the printer. This is to guard against

excessive static electricity potentially interrupting system operation.

Note: If you turn down the heat at night to a lower temperature than the specified operating

temperature, allow time for the printer and its internal components to warm to the proper

temperature before printing. Depending on the environment it may take several hours for the

dense metal components and ink in the system to warm to the specified operating temperature.

Power requirements

Gerber recommends that you leave the Gerber Solara ion powered on at all times. Do not turn

the printer off, even for extended periods of down time. If the printer will not be in use for

longer than two weeks, you must follow the special procedures described in “Shutting down

the printer to more than two weeks” on page 114.

Domestic: Dedicated 230/240 VAC circuit at 50-60Hz, single phase,

20 Amps continuous. Measured at the Solara ion: 230 VAC +/- 10%.

The Gerber Solara ion power cord comes with a NEMA 6-20P

plug and requires the matching NEMA 6-20R receptacle.

International: Dedicated 230/240 VAC circuit at 50-60Hz, single phase,

15 Amps continuous. Measured at the Solara ion: 230 VAC +/- 10%.

The Gerber Solara ion comes with a European CEE 7/7 plug and

requires the matching CEE 7 receptacle. These connectors can be

changed to meet local standards.

CHAPTER 2

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CAUTION: 208V lines, while seemingly within the specification range, are not

as robust as 230 V lines and are also subject to +/- 10% current fluctuations. These

below specification fluctuations of 208V lines do not to provide the Gerber Solara

ion with adequate power to consistently cure ink. You must provide a 230 V line.

WARNING: Make sure to connect the power cable only after all of the steps of the

installation procedure have been completed.

Printer orientation

Make note of the orientation of the printer. The end with the maintenance shelf is considered

the front of the printer and the control panel end of the gantry is the left side. Also note that the

right and left sides of the graphic file sent from the RIP software are reversed.

Locating the serial number

The printer serial number is located on the gantry. Slew the gantry all the way to the front

(maintenance shelf end) of the printer and look underneath and through the gantry track.

Maintenance shelf

Control panel

Orientation of

graphic sent

from RIP

software

Roll-to-Roll (if

so equipped)

Power switch

Ethernet

connections

under table

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Product Overview

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Computer and software requirements

The customer’s computer must have compatible RIP software installed to send print jobs to the

Gerber Solara ion. If the computer is not configured properly, if it does not have a network card,

or if the proper data cable is not used, you can run a test print on the Gerber Solara ion but you

cannot send jobs from the computer.

Gerber-authorized RIP software has been approved to work with the Gerber Solara ion and

GerberCAT inks and qualified materials. Following is a list of approved software at the time of

this document’s printing. Consult the GSP web site www.gspinc.com

for an up-to-date listing.

 Onyx® ProductionHouse™ Gerber Edition, Onyx® PosterShop™ Gerber Edition,

ImageRIP™ Plus by Onyx, or Gerber Solara ion Onyx Driver (necessary for existing

Onyx RIP owners version 6.5 or higher to ensure compatibility with the printer)

 ErgoSoft

 SAi Flexi™ or PhotoPrint™

 CADlink SignLab™

 Wasatch SoftRIP®

UV bulb technology

UV WARNING

Exposure to UV light can be dangerous to eyes and skin and should be avoided.

Never operate the Gerber Solara ion with any of the covers removed.

Never operate the printer with the rubber light shields (flaps) missing or damaged.

Contact Gerber if any of the rubber light shields (flaps) need to be replaced.

The Gerber Solara ion uses Cold Fire Cure UV technology to instantly and safely cure inks

using low energy and low heat. The UV lamps run the full length of the gantry (approximately

65"/165cm) and provide a very specific wavelength of UV light which cures the GerberCAT

inks. The lamps are enclosed to ensure that the user is protected from exposure to UV radiation.

The UV bulbs require a short warm-up cycle before printing if they are not at operating

temperature. When the lamps reach their operating temperature, the cooling fans automatically

turn on to maintain the proper temperature. Gerber Solara ion UV lamps do not require a cool

down cycle before re-striking.

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Product Overview

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UV ink technology

CAUTION: Use only GerberCAT inks. Substituting any other inks will void the

warranty. Each color ink pouch must be installed into the corresponding color-

coded pull-out ink drawer.

CAUTION: Use impervious gloves to protect your hands. Nitrile gloves of no less

than 8 mils have proven impervious for one hour of exposure. Gloves should be

disposed of after one hour of exposure time. Wear goggles to protect your eyes.

Dispose of used swabs, wipes, and gloves according to local laws and regulations.

GerberCAT cationic ultraviolet inks have very little odor and require no special ventilation.

Gerber's patent-pending, Cold Fire Cure technology dries the ink immediately and the printed

material may be handled or cut directly after printing.

Although printhead capping is not required on the Gerber Solara ion, there is a parking station

which is used when it is not printing for extended periods. The parking station travels with the

gantry and blocks stray light from the printhead nozzle plates.

Graphics created by the Gerber Solara ion are outdoor-durable for up to three years. However,

environment and application will determine the ultimate outdoor life span and may result in

outdoor durability of greater or less than three years. Laminating graphics increases durability.

GerberCAT inks are specifically designed for use with the Gerber Solara ion printer. The inks

come in four colors: Yellow (Y), Magenta (M), Cyan (C), and Black (K). The eight printhead

system dedicates two printheads per ink color.

The ink is supplied in one liter pouches that are used to refill the Gerber Solara ion ink

reservoirs. Four color-coded ink drawers contain receptacles to accept the ink pouches.

Storing inks and materials

Store GerberCAT inks and qualified materials as instructed for the best quality output when

printing. Improper storage of inks or materials will negatively effect overall print quality.

UV ink storage

GerberCAT inks have a shelf life of approximately 12 months from date of manufacture when

stored as recommended. Note the “Use by” date printed on the pouch and discard any ink

beyond that date.

The operating temperature and humidity range of the Gerber Solara ion is smaller than the

storage range for the ink pouches. If ink is stored outside of the operating temperature range,

wait for the ink to normalize before using it.

 Temperature: 41° F to 86° F (5° C to 30° C)

 Humidity: 30% - 70% non-condensing

Note: The guaranteed term of ink is 12 months from date of manufacture when it is kept or

used without exposing air at 77°F (25°C).

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Product Overview

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Material storage

See material-specific documentation for recommended handling and storage requirements.

General material storage and handling suggestions follow:

 Do not discard the original packaging. Use the box or plastic bag for material storage.

 Store material in a dry environment avoiding high temperature, high humidity, and

direct sunlight.

 The size of the material can change according to the temperature and/or humidity of

the working environment. Before using the material, “normalize” it in the working

environment for at least 24 hours.

 Printing before the material is normalized may cause jams due to material distortion

and may affect output quality.

 Do not use creased, damaged, torn, curled, bowed, or warped material.

 Material may have a printable side and a non-printable side. If you print on the wrong

side, blurring may occur.

 Do not touch the printable side of material before printing. Moisture or oil from hands

can affect the printing quality. Wear cotton gloves when handling materials.

 Do not leave material loaded in the roll-to-roll unit of the printer for an extended

period of time. The pinch wheels may damage it, or the material may curl resulting in

misalignment, jams, or decreased printing quality.

Tip: Gerber recommends cleaning rigid material with IP Surface Cleaner or 99% Isopropyl

Alcohol and wiping it away evenly with a lint-free cloth. This cleans the surface and improves

the output quality of the print.

Gerber Solara ion control panel

The Gerber Solara ion has two control panels for ease of use: the main control panel and the

auxiliary keypad. The main control panel is located on the printhead gantry, rotates 180 and

has an adjustable viewing angle for ease of use.

Most controls needed to load material, print

jobs, and clean the printheads are located on

keys on the main control panel. The printer's

menu system which contains printer status,

calibration, and maintenance tasks is also

accessed from the main control panel by

pressing the MENU key. The printer's Menu

system is not necessary for day-to-day

operation of the Gerber Solara ion.

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Gerber Solara ion Owner's manual

Gerber Solara ion Owner's manual

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