Kodak VERSAMARK DP7122 User manual

Kodak Versamark, Inc.

K

ODAK VERSAMARK DP7122 Printer

Operator’s Guide

KODAK VERSAMARK DP7122 Printer

Operator’s Guide

Block 3 Mod 11

FCC Compliance Statement

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 man-

ual, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful inter-

ference, in which case the user will be required to correct the interference at his own expense.

Note: Good quality, shielded (braided shielded) cables must be used for the RS-232-C and Centronics interfaces.

Canadian EMI Compliance Statement

Le présent appareil numérique n’émet pas de bruits radioélectriques dépassant les limites applicables aux appareils numériques de la classe A

prescrites dans le Règlement sur le brouillage radioélectrique édicté par le ministère des Communications du Canada.

This digital apparatus does not exceed the Class A limits for radio noise emissions from digital apparatus set out in the Radio Interference Reg-

ulations of the Canadian Department of Communications.

EMI-CISPR 22/EN 55 022/CE Marking

Warning: This is a Class A product. In a domestic environment, this product may cause radio interference in which case the user may be

required to take adequate measures.

KODAK VERSAMARK

DP7122 Printer

Operator’s Guide

This document contains proprietary information of Kodak Versamark, Inc. or its licensors and is their exclusive property. It may not be

reproduced without a written agreement from Kodak Versamark, Inc. No patent or other license is granted to this information.

The software described in this document is furnished under a license agreement. The software may not be used or copied except as provided

in the license agreement.

Kodak Versamark, Inc. makes no warranty of any kind with regard to the contents of this document, including, but not limited to, the implied

warranties of merchantability and fitness for a particular purpose. Kodak Versamark shall not be liable for any errors or for compensatory,

incidental or consequential damages in connection with the furnishing, performance, or use of this document or the examples contained herein.

Information concerning products not manufactured by Kodak Versamark, Inc. is provided without warranty or representation of any kind, and

Kodak Versamark, Inc. will not be liable for any damages resulting from the use of such information.

Kodak and Versamark are trademarks of Eastman Kodak Company.

0114130-602

0114130-603 07/2004 Printed in U.S.A.

Part Number Medium Revision Date Description ECN

0114130-602

0114130-603

Print

PDF

002 07/2004 Revision for Block 3 and Field Mod 11 K4315

Previous Releases

0114130-602

0114130-603

Print

PDF

001 05/2004 Initial release- Block 1 SDP1019

iii

Scope

This guide describes operating, troubleshooting, and maintenance proce-

dures for the 7122 Printer. For information about connecting or discon-

necting fluid containers, or changing fluid-related filters, or adding or

replacing fluids, see the 7122 Printer

Changing Fluid Containers

document.

The 7122 is a modular, PC-driven, inkjet printer that can operate with

compatible

KODAK VERSMARK controllers as well as with user-designed

or third party controllers.

This guide assumes that the reader is the operator, who is responsible for

printing jobs, troubleshooting common printing problems, and performing

routine maintenance. The reader should have a basic knowledge of

computers and the printing environment in which the printer is being

used.

Mandatory Action: Consult Operator’s Manual

Read all safety information and operator procedures through before performing

any action.

Text Notations

iv

Text Notations

This manual uses the following typographical conventions.

Safety Notations

The following definitions indicate safety precautions to the operator.

Note: Information that needs to be brought to the reader’s attention.

Caution: A situation where a mistake could result in the destruction of data or

system-type damage.

!

WARNING

A potential hazard that could result in serious injury or death.

!

DANGER

An imminent hazard that will result in serious injury or death.

This style Refers to

Ready

Text displayed by the software.

go

Anything you type, exactly as it appears, whether referenced

in text or at a prompt.

ENTER

Special keys on the keyboard, such as enter, alt, and

spacebar.

[NEXT] Buttons and lights on the printer operator panel.

Save Software command buttons and sections of dialog boxes,

such as group boxes, text boxes, and text fields.

File → Open

A menu and a specific menu command.

ALT+F1

Pressing more than one key at the same time.

ALT, TAB

Pressing more than one key in sequence.

xx,yy

Variable in error messages and text.

jobfile.dat File names.

Service and Support

v

Service and Support

Technical equipment support is available 24 hours a day, 7 days a week.

Software and applications support is available 8:00 a.m. to 5:00 p.m.

EST/EDT, Monday through Friday.

Call for telephone or on-site technical support; to order parts or supplies;

to request documentation or product information.

Phone Fax

U.S.A., Canada, and

worldwide

+1-800-472-4839

+1-937-259-3739

+1-937-259-3808

Europe +41-21-806-0404 +41-21-806-1920

Asia/Pacific Rim +65-6744-6400 +65-6744-6700

Japan +81-3-3256-2613 +81-3-3256-2616

Updated service

information

http://www.kodakversamark.com

Customer support customer@kodakversamark.com

vii

Contents

Chapter 1. Getting Started

Safety Information............................................................................................. 1-2

Introduction....................................................................................................... 1-3

Printer Components.......................................................................................... 1-4

Printer......................................................................................................... 1-5

Operator Panel........................................................................................... 1-5

Printhead and Umbilical ............................................................................. 1-5

Fluid Compartment..................................................................................... 1-5

Supporting the Printhead.................................................................................. 1-6

Setting Up the Printhead................................................................................... 1-7

Determining Substrate Movement.............................................................. 1-7

Locating the Print Array.............................................................................. 1-7

Positioning Multiple Printheads.................................................................. 1-8

Determining Cue Distance and Cue Delay....................................................... 1-9

Tach Encoder............................................................................................. 1-9

Cue Sensor................................................................................................ 1-9

Cue Distance..................................................................................... 1-10

Cue Delay.......................................................................................... 1-10

Document and Image Lengths........................................................................ 1-11

Chapter 2. Basic Operation

Safety Information............................................................................................. 2-1

Operator Panel Functions................................................................................. 2-1

Panel Buttons............................................................................................. 2-2

Panel Lights ............................................................................................... 2-3

Operating Procedures....................................................................................... 2-3

Turning On the Printer................................................................................ 2-4

Bypassing the POC Test and Fluid System............................................... 2-4

Turning On the Fluid System When Idle .................................................... 2-4

Turning On the Fluid System When Bypassed.......................................... 2-5

Idle Time Guidelines .................................................................................. 2-5

Turning Off the Fluid System...................................................................... 2-5

Turning Off the Printer and the Fluid System............................................. 2-5

Clearing Errors........................................................................................... 2-5

Power Failure.................................................................................................... 2-6

Chapter 3. Troubleshooting

Printing Test Patterns....................................................................................... 3-2

Identifying Print Defects.................................................................................... 3-3

Buildup and Contamination........................................................................ 3-4

Ragged Print........................................................................................ 3-5

Crooked Jets........................................................................................ 3-8

Streakers ............................................................................................. 3-9

Open Jets ............................................................................................ 3-9

Voltage Defects........................................................................................ 3-10

Dark Defect........................................................................................ 3-10

Pickout............................................................................................... 3-10

Phase Defect............................................................................................ 3-11

Contents

viii

Setup Errors.............................................................................................. 3-11

Narrow Print ....................................................................................... 3-11

Elongation.......................................................................................... 3-12

Truncation .......................................................................................... 3-12

Miscellaneous Problems........................................................................... 3-12

Interference........................................................................................ 3-12

Irregular Gaps .................................................................................... 3-13

Single Line of Dots............................................................................. 3-13

Smears............................................................................................... 3-13

Distortion............................................................................................ 3-13

Improper Print Density........................................................................ 3-13

Chapter 4. Maintenance

Safety Information............................................................................................. 4-1

Required Tools and Supplies............................................................................ 4-2

Periodic Maintenance........................................................................................ 4-2

Cleaning the Printhead............................................................................... 4-2

Cleaning the Air Filter................................................................................. 4-3

Replacing the Mist and Fluid Filters............................................................ 4-3

Corrective Maintenance .................................................................................... 4-4

Cleaning the Bottom Cover......................................................................... 4-5

Catch Pan Installation................................................................................. 4-6

Standby Pan Installation............................................................................. 4-7

Wiping and Swabbing................................................................................. 4-8

Routine Cleaning.................................................................................. 4-8

Incident Recovery .............................................................................. 4-10

Glossary

Operator’s Guide xi

Figures

Figure 1.1 Safety label locations, 7122 printer and printhead...................... 1-2

Figure 1.2 Printer components (front view).................................................. 1-4

Figure 1.3 Printer components (rear view)................................................... 1-4

Figure 1.4 Printhead mount ......................................................................... 1-6

Figure 1.5 Substrate movement (7122 printhead)....................................... 1-7

Figure 1.6 Print array................................................................................... 1-7

Figure 1.7 Multiple printhead dimensions.................................................... 1-8

Figure 1.8 Tach encoder.............................................................................. 1-9

Figure 1.9 Cue sensor example................................................................... 1-9

Figure 1.10 Cue distance and cue delay ..................................................... 1-10

Figure 1.11 Document parameters.............................................................. 1-11

Figure 2.1 Operator panel buttons and lights............................................... 2-1

Figure 2.2 Printer - rear view ....................................................................... 2-6

Figure 3.1 Good test pattern........................................................................ 3-3

Figure 3.2 Seal, removed 7122 printhead eyelid......................................... 3-4

Figure 3.3 Slight raggedness, sample test pattern ..................................... 3-5

Figure 3.4 Buildup-caused missing print, sample test pattern..................... 3-6

Figure 3.5 Crooked jets, sample test image and test pattern ...................... 3-8

Figure 3.6 Slight streaker, sample test pattern............................................ 3-9

Figure 3.7 Open, sample test pattern .......................................................... 3-9

Figure 3.8 Slight dark defect, sample test pattern ..................................... 3-10

Figure 3.9 Slight pickout, sample test pattern ........................................... 3-10

Figure 3.10 Phase defect, sample test patterns .......................................... 3-11

Figure 3.11 Compressed test image, 120 ppi.............................................. 3-11

Figure 3.12 Elongated and truncated test image, 480 ppi........................... 3-12

Figure 4.1 Removing the air filter................................................................. 4-3

Figure 4.2 Bottom cover, printhead.............................................................. 4-5

Figure 4.3 Catch pan 0192385 for the 7122 printhead................................ 4-6

Figure 4.4 Catch pan installed, 7122 printhead........................................... 4-7

Figure 4.5 Standby pan (0194687) with grounding wire.............................. 4-7

Figure 4.6 Standby pan installed under 7122 printhead.............................. 4-8

Figure 4.7 Jet curtain, printhead running replenisher .................................. 4-9

Figure 4.8 Swabbing the 7122 printhead..................................................... 4-9

Figure 4.9 Eyelid edge, eyelid removing for cleaning................................ 4-11

Contents

Tables

xii Kodak Versamark DP7122 Printer

Tables

Table 1.1 Maximum distances............................................................... 1-11

Table 2.1 Operator panel buttons............................................................ 2-2

Table 2.2 Operator panel lights............................................................... 2-3

Table 2.3 Idle time guidelines.................................................................. 2-5

1 - 1

Chapter 1. Getting Started

This chapter provides the following introductory information:

• Safety Information

• Introduction

• Printer Components

• Supporting the Printhead

• Setting Up the Printhead

• Determining Substrate Movement

• Locating the Print Array

• Positioning Multiple Printheads

• Determining Cue Distance and Cue Delay

• Document and Image Lengths.

Before starting any printer procedure, read the safety information.

1 - 2

Chapter 1. Getting Started

Safety Information

Apply all of the following safety guidelines to 7122 operation.

• Follow all instructions in the Material Safety Data Sheets shipped with

the ink and replenisher. The ink and replenisher used in the 7122

printer are regulated materials in the classifications shown at left.

Transportation, storage, handling, and disposal must be done in

accordance with all applicable local, State, and Federal regulations.

The labels below identify hazards related to handling ink and

replenisher.

• Note the safety labels on the printer that identify hazards and

describe mandatory safety precautions (see Figure 1.1). Take

appropriate safety precautions at all times.

• Note the safety label symbols listed below; these warning symbols

are used on the printer and printhead for general reference, and in

the text to identify hazards related to specific procedures or actions.

Figure 1.1 Safety label locations, 7122 printer and printhead

Warning: Electrostatic Sensitive Devices

Avoid generating static electricity. Static can ignite ink, replenisher, or vapor.

Strictly follow all grounding instructions.

Warning: Flammable Material

Never expose the printer, printhead, ink, replenisher or vapor to a heat source or

ignition source.

Warning: General Danger

Read all safety information and operator procedures through before performing

any action.

Warning: Irritant

Avoid contact with all fluids, ink and replenisher.

Safety labels

1 - 3

Chapter 1. Getting Started

Introduction

• Verify that the installation location has sufficient airflow and

ventilation. The 7122 printer produces 160 cubic feet per hour of

exhaust, and that exhaust contains 50 parts per million of solvent

(MEK). The recommended ventilation is a 400 cubic feet per minute

intrinsically safe blower fan (non-sparking).

Introduction

The 7122 printer has the following characteristics:

• Printhead size: two inches

• Vertical resolution (dpi): 120

• Horizontal resolution (dpi): 120 or 240

Vertical resolution is along the width of the printhead array and is fixed.

Horizontal resolution is in the direction of substrate movement and can be

set to one of two values. Resolution is measured in dots per inch (dpi).

The printer is capable of printing 100-percent variable data at a print

speed of up to 1000 fpm, depending on the application.

After installation, basic setup procedures must be performed before

printing can begin. Along with a brief overview of the printer components,

this chapter describes the required setup procedures, which include

supporting the printhead, setting up the printhead, positioning multiple

printheads, and determining cue values.

Mandatory Action: Consult Operator’s Manual

Read all safety information and operator procedures through before performing

any action.

Mandatory Action: Wear Eye Protection

Avoid contact with all fluids, ink and replenisher.

Prohibition: No Smoking

Never expose the printer, printhead, ink, replenisher or vapor to a heat source or

ignition source.

Warning: Do Not Move the Printer

Once the printer has been installed, make sure that the casters remain locked and

that the printer remains in place. Moving the printer could cause fluid connections

to separate.

1 - 4

Chapter 1. Getting Started

Printer Components

The printer contains the following components (Figure 1.2 and Figure

1.3):

• Printer

• Operator panel

• Printhead with attached umbilical

• Fluid containers.

Figure 1.2 Printer components (front view)

Figure 1.3 Printer components (rear view)

Note: Your fluid containers make differ from those shown above. See the 7122

Printer

Changing Fluid Containers

document for details.

Umbilicals

Printhead

Operator panel

Umbilicals

Replenisher container

Ink container

1 - 5

Chapter 1. Getting Started

Printer Components

Printer

The printer, which includes all of the components within the printer

cabinet, accepts print data and commands that determine job setup and

control printer functions. The printer receives this information from a

controller and translates it into a bitmapped format that is sent to the

printhead through the umbilical.

Operator Panel

The five buttons appearing across the top of the operator panel control

printer operations, such as powering the printer and fluid system on and

off, opening and closing the eyelid, and cleaning the printhead. The seven

lights appearing across the bottom of the panel report operating

conditions such as low fluid levels, errors, and the detection of tach and

cue signals.

Printhead and Umbilical

The printhead contains the print array, a row of holes (orifices) from which

the jets of ink are formed. The 7122 printhead provides a 2.13 inch (5.41

cm) print width.

A covering, called the eyelid, protects the print array from damage and

dust and keeps fluids from leaking during printer startup and shutdown.

The printhead contains an eyelid heater which maintains the proper eyelid

temperature.

Note: Once it opens, the eyelid remains open at all times including during

Standby. The eyelid closes only during startup and shutdown. Because

the eyelid remains open, the Standby pan should be placed under the

printhead whenever the printer is idle (see “Standby Pan Installation” in

Chapter 4).

The standard 12 ft (3.6 m) umbilical connects the printhead to the fluid

system. The umbilical contains the fluid tubes and electrical cables that

transfer ink and data between the fluid system and the printhead.

Fluid Compartment

Note: Use only fluids approved by Kodak Versamark, Inc.

The fluid compartment contains the ink and replenisher tanks.

Replenisher maintains the relative concentration of ink to replenisher. A

light on the operator panel comes on when a fluid container is low. Fluid

containers are stored behind the printer. Optional ports in the front door

allow fluid containers to be placed in front of the printer, but the fluid

supply lines must be rerouted.

1 - 6

Chapter 1. Getting Started

Supporting the Printhead

The printhead support must hold the printhead steady to protect it from

vibration. The support must hold the printhead within 0.250 to 0.375 inch

of the substrate (6-10 mm), and support the weight of the printhead and

umbilical. Optimum print quality is obtained by keeping the printhead as

close as possible to the substrate.

Refer to the installation instructions shipped with the printhead mount for

assembly and installation instructions. The printhead mount holds the

printhead over a label base or document transport (Figure 1.4).

Figure 1.4 Printhead mount

1 - 7

Chapter 1. Getting Started

Setting Up the Printhead

Proper printhead setup helps to ensure print quality.

Determining Substrate Movement

Figure 1.5 illustrates normal and reverse substrate movement.

Figure 1.5 Substrate movement (7122 printhead)

Locating the Print Array

To locate the position of the print array (jets) relative to the edges of the

printhead housing (covers), locate the dot indentation on the seam of the

printhead cover (see Figure 1.6). Use the location dot to correctly position

the printhead over the mailbase or transport.

Figure 1.6 Print array

Normal substrate movement

Reverse substrate movement

Front of printhead

Rear of printhead

Print array location dot

1 - 8

Chapter 1. Getting Started

Setting Up the Printhead

Positioning Multiple Printheads

Position multiple printheads as closely together as possible. The most

downstream printhead (the last printhead to print) must finish printing

before the next substrate passes under the cue sensor. (See the section

“Determining Cue Distance and Cue Delay” in this chapter.)

The following dimensions need to be considered:

• Feedstroke - the substrate length plus the distance between

substrates

• Cue distance - the distance between the cue sensor and the print

array of each printhead

• Image length - the length of the image being printed.

For proper positioning, feedstroke must be equal to or greater than

the cue distance for each printhead plus the image length.

You can further verify accurate printhead positioning by ensuring that the

distance between substrates is equal to or greater than the cue distance

for the most downstream printhead.

Figure 1.7 diagrams the positioning dimensions.

Figure 1.7 Multiple printhead dimensions

Distance between substrates

Feedstroke

Cue

sensor

Image

length

Cue

distance

Substrate direction

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Kodak VERSAMARK DP7122 User manual

Kodak VERSAMARK DP7122 User manual

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