Prosper S10
Printer
Operator’s Guide
0114379-603
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.
European Union Statement
Please consult www.kodak.com/go/REACH for information about the presence of substances included on the candidate list according to article
59(1) of Regulation (EC) No. 1907/2006 (REACH).
© Eastman Kodak Company, 2009. Kodak, Versamark, and Prosper are trademarks of Kodak.
This document contains proprietary information of Kodak or its licensors and is their exclusive property. It may not be reproduced without a
written agreement from Kodak. 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 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 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 is provided without warranty or representation of any kind, and Kodak will not be liable for any damages
resulting from the use of such information.
All other trademarks are property of their respective owners.
0114379-603 English Original 6/17/09
Kodak Prosper S10 Printer Operator’s Guide
Part Number Media Revision Date Description ECN
0114379-603 PDF 003 06/2009 Initial Release. K9364
Previous Releases
Part Number Media Revision Date Description ECN
0114379-603 PDF 002 04/2009 Second draft with technical review changes included. K9236
0114379-603 PDF 001 02/2009 Preliminary draft for Beta systems. K9092
Operator’s Guide 3
Scope
This Operator’s Guide is about the Kodak Prosper S10 Printer, which
includes the Kodak Prosper S10 Print Station, umbilical, Kodak Prosper
S10 PIC Box, and Kodak Prosper S10 Jetting Module.
Included is an overview of the printer, operator procedures, and
maintenance procedures. Operator procedures are given for the print
station and PIC box.
The Kodak Prosper S10 Imprinting System is a modular product, and each
module has one or more documents that guide safe operation. As neces-
sary, refer to these guides.
• Kodak Prosper S10 Imprinting System Overview—describes the
printing system, each module, and available options.
• Kodak Prosper S10 Imprinting System Glossary—lists and defines
all technical terms that an operator needs to know.
• Kodak Prosper S10 Imprinting System Basic Operations Guide—
has procedures to remove, install, and wipe the printhead, and to
swab and clean the eyelid.
• Kodak Prosper S10 Jetting Module Replace and Pack Guide—
has procedures to purge, remove, pack, unpack, install, and fill a
jetting module.
• Kodak Versamark CS410 System Controller Operator’s Guide—
has procedures to operate and maintain the system controller,
and to set up and operate its software.
• Kodak Versamark DC3800 Printhead Carriage Operator’s
Guide—has procedures to operate and maintain the carriage and
its printhead mounts.
4 Kodak Prosper S10 Printer
Scope
Text Notations
This manual uses the following typographical conventions.
Safety Notations
The following definitions indicate safety precautions to the operator.
!
DANGERDANGER
Indicates an imminently hazardous situation which, if not avoided, will
result in death or serious injury.
WARNING
Indicates a potentially hazardous situation which, if not avoided, could
result in death or serious injury.
CAUTION
Indicates a potentially hazardous situation which, if not avoided, could
result in minor or moderate injury.
CAUTION
Indicates a situation which, if not avoided, could result in damage to data
and/or property.
NOTE
Indicates important information that will help avoid a problem and/or make
a task easier to accomplish.
This style Refers to
Ready
Text the software displays.
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.
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.
STOP Controls on equipment.
Operator’s Guide 5
Scope
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 +41-22-354-1400 +41-22-354-1480
Asia/Pacific Rim +65-6744- 6400 +65-6744-6700
Japan +81-3-5621-2220 +81-3-5621-2221
Updated service
information
http://graphics.kodak.com
Customer support
U.S.A and Canada
US-GDT-TechSupport@kodak.com
Customer support
worldwide
US-GDT-
Parts Ordering US-GDT-custo[email protected]
Operator’s Guide 7
Contents
Chapter 1. Overview
Operator Procedures...........................................................................................10
Power Distribution................................................................................................10
Fluid System........................................................................................................10
Ink .................................................................................................................10
Smart Card Reader................................................................................ 11
Ink Card Messages................................................................................ 11
Replenisher Fluid ..........................................................................................11
Storage Fluid.................................................................................................12
Waste Fluid ...................................................................................................12
Vacuum System...................................................................................................12
Ink Temperature Control System.........................................................................12
Control and Monitoring System ...........................................................................12
Umbilical..............................................................................................................13
Prosper S10 PIC Box...........................................................................................13
Prosper S10 Jetting Module.................................................................................14
Chapter 2. Printer Operation
Power Procedures...............................................................................................15
Turn On the Print Station ..............................................................................15
Turn Off the Print Station ..............................................................................16
Correct Print Defects ...........................................................................................16
Fluid Container Replacement..............................................................................17
Ink Container.................................................................................................17
Replenisher and Storage Fluid Containers ...................................................19
Discard the Waste Fluid................................................................................20
Discard Guidelines................................................................................. 20
Safety Procedures................................................................................. 20
Waste Container ...........................................................................................21
Clean the PIC Box...............................................................................................23
Clean the PIC Box Lower Surface.................................................................23
Chapter 3. Printer Maintenance
Inspection ............................................................................................................27
Print Station...................................................................................................27
Umbilical........................................................................................................27
Cleaning...............................................................................................................28
Clean the Print Station ..................................................................................28
Clean the Print Station Cooling Fan Filters...................................................28
Filter Replacement...............................................................................................30
Replace Print Station Cooling Fan Filter.......................................................30
Replace PIC Box HEPA Filter.......................................................................31
Replace PIC Box Printhead Air Filter............................................................33
Replace Dry Shutdown Valve Filter...............................................................35
Glossary
Operator’s Guide 9
Chapter 1. Overview
The Kodak Prosper S10 Printer is a module of the Kodak Prosper S10
Imprinting System, that accepts data in bitmap format as input and makes
printed images on a substrate, as output. Images can have fixed text,
variable text, and graphics. The substrate can be a continuous web or
separate pieces of material. The S10 Printer has these components:
• Kodak Prosper S10 Print Station
• Umbilical (one per PIC box)
• Kodak Prosper S10 PIC Box (one per jetting module)
• Kodak Prosper S10 Jetting Module (one per PIC box)
The print station (Figure 1) includes power distribution, a fluid system,
vacuum system, and a control and monitoring system. Each print station
controls one or two PIC boxes. The system controller is the operator
interface for the print station.
Components in the print station supply ink pressure and vacuum for the
jetting module. The fluid system sends ink, fluids, and control signals
through the umbilical to the jetting module. The umbilical is a flexible,
insulated housing that contains fluid lines, power and signal cables, and
one fiber optic cable.
Figure 1 Prosper S10 Printer
Print
Station
PIC
Umbilicals
(40 ft/12.2 m)
Boxes
10 Kodak Prosper S10 Printer
Chapter 1. Overview
Operator Procedures
Operator Procedures
The operator can do these procedures at the print station and PIC boxes:
• Turn power on and off
• Clean the PIC boxes
• Replace external ink, replenisher, storage, and waste fluid containers
• Replace some filters
Power Distribution
The input power for the print station is supplied through a power cord to a
bulkhead power connector/Electro Magnetic Interference (EMI) filter.
From the power plug/EMI filter, the input power is connected to a circuit
breaker. The circuit breaker has two functions:
• On/Off switch
• Electrical protection
Fluid System
The Prosper S10 fluid system is used for these functions:
• Supply ink and replenisher fluids to the ink tank and storage fluid
to the storage fluid tank.
• Heat/cool the ink supplied to the PIC box/jetting module.
• Circulate ink or storage fluids between the print station and the
PIC box/jetting module.
• Remove waste fluid from the system.
These fluids are used for printing and maintenance of the printing system:
• Kodak Prosper S10-0010 Pigment Black Ink
• Kodak Prosper S10-0011 Replenisher Fluid
• Kodak Prosper S10-0012 Storage Fluid
The operator will replace only external fluid containers. Contact a Kodak
service technician for maintenance on the internal fluid tanks and
components.
Ink
The external ink supply container is connected by a fluid line to a fitting on
the rear of the print station. The ink container is usually a 5 gallon (20 liter)
container or 55 gal. (208 L) drum. The ink type data is sent to the printer
by the ink card, that is put into the smart card reader behind the print
station front door.
Operator’s Guide 11
Chapter 1. Overview
Fluid System
Smart Card Reader
The print station gets ink data from the smart card reader, which it uses to
implement the Ink Compatibility Assurance Program (ICAP). The ink card,
supplied with each ink container, inputs the data into the control and
monitoring system. The primary function of the ink card is to track/monitor
ink use and make sure that only approved ink is used in the print station.
The ink card inputs this ink data:
• Type
•Container Size
• Batch Number
• Date of Manufacture
• Expiration Date
The ICAP system uses the data from the ink card and the flow meter
output to monitor fluid use. The ink card inputs the container size into the
control and monitoring system. As the flow meter monitors ink usage, the
system records when the ink supply will run out (based on the flow meter
data), and alerts the operator at the system controller. The ink card can be
recycled to a local recycling system after it has been used.
Ink Card Messages
These ink card messages are related to the ink card and/or smart card
reader and are shown on the system controller:
• CARD VOLUME EMPTY—The control and monitoring system
senses that the ink supply is gone.
• INK CARD NOT INSTALLED—The control and monitoring
system does not sense an ink card in the smart card reader.
• INCORRECT INK ATTACHED—The ink data input from the ink
card does not match the ink selected by the operator on the
system controller.
• INK SHELF LIFE EXPIRED—The ink expiration date has passed.
• INK FILL WARNING—The control and monitoring system senses
these three conditions:
• Flow meter FS1 does not sense fluid flow
• Ink fill valve V22 is open
• Vacuum pump P2 is operational
• CARD NOT READABLE—The control and monitoring system
cannot access/read the ink card installed in the smart card
reader.
Replenisher Fluid
Replenisher fluid dilutes the ink so that the ink matches the data from the
ink card. The replenisher fluid supply container is connected by a fluid line
to a fitting on the rear of the print station. The replenisher fluid container
usually is a 5 gal. (20 L) container or 55 gal. (208 L) drum. The
replenisher fluid moves through an inline filter to the replenisher fluid fill
valve and then into the ink tank.
12 Kodak Prosper S10 Printer
Chapter 1. Overview
Vacuum System
Storage Fluid
Storage fluid is used to purge (clean) the printing system. The storage
fluid supply container is connected by a fluid line to a fitting on the rear of
the print station. The storage fluid container is usually a 5 gal. (20 L)
container. The storage fluid moves through an in-line filter to the storage
fluid fill valve and then into the storage fluid tank.
Waste Fluid
Waste fluid from system operations is collected in an internal tank. A float
switch in the internal tank sends a signal to the waste pump to move the
fluid to an external container. The external waste container is usually a
15 gal. (56.8 L) or 55 gal. (208 L) drum.
Vacuum System
The vacuum system has a Variable Frequency Drive (VFD) controller,
vacuum pump and its related components of a mist filter, vacuum drying
valve, vacuum bleed valve, fluid tanks, and interconnecting fluid lines.
The vacuum system is used to pull fluids into the print station from the
external fluid containers and to assist in the circulation of fluid between
the print station and the PIC box/jetting module.
Contact a Kodak service technician for maintenance on the vacuum
system.
Ink Temperature Control System
The ink temperature control system is used to heat/cool the ink so that it
maintains a temperature of 86°F ± 9°F (30°C ± 5°C). The system has a
power supply, thermoelectric control Printed Circuit Board (PCB), and
thermoelectric heating/cooling module.
Contact a Kodak service technician for maintenance on the ink
temperature control system.
Control and Monitoring System
The control and monitoring system is made up of PCBs. The PCBs
monitor signals from the transducers and sensors in the fluid system.
These components give control signals to the different valves and pumps.
The state of the control signals is dependent on commands from the
software, input from the system controller, or input from transducers and
sensors.
Contact a Kodak service technician for maintenance on the control and
monitoring system.
Operator’s Guide 13
Chapter 1. Overview
Umbilical
Umbilical
The umbilical is a flexible, insulated housing that contains fluid lines,
power and signal cables, and one fiber optic cable. There can be one or
two umbilicals for each print station. One umbilical connects the print
station to one PIC box.
An umbilical has ink, storage, duct drain, catcher, and cross flush fluid
lines. There are three electrical cables: an 8-position data
communications cable (for the PIC data PCB), a 6-position data
communications cable (for the PIC fluid control PCB), and a power cable
(for the PIC fluid PCB). The fiber optic cable carries the print data (RIP)
from the data station to the jetting module. Each umbilical is 40 feet
(12.2 meters) long.
Contact a Kodak service technician for maintenance on the umbilical.
Prosper S10 PIC Box
The PIC box has two major assemblies: the Electronic Printhead Interface
Controller (E-PIC) and the Air Control Module (ACM). The E-PIC has
many assemblies contained in a frame. The ACM is one complete
assembly.
The PIC box has a top cover that shields and protects the umbilical
connections, printhead air filter, and dry shutdown valve (vacuum bleed)
filter. The cover is mounted over the handle/umbilical bracket. The handle
is used to carry the PIC box and the umbilical bracket is used to secure
the umbilical to the PIC box.
The PIC box has a 3-sided cover that goes over the downstream side of
the E-PIC. The upstream side of the E-PIC has a High Efficiency
Particulate Air (HEPA) filter assembly.
The ACM has two covers. One cover has a cut out for the door. The door
panel behind it, is raised/lowered when the jetting module is installed/
removed. The second cover goes around the other three sides.
The PIC box has two primary functional groups: electric and fluidic. The
electric group has the PIC fluid control PCB, PIC data PCB, and cooling
fans/blowers. The fluidic group has the fluid manifold and valves. The
jetting module takes the output of the electric and fluid groups and
develops ink drops that are put on the substrate to make text/images.
Operators will do maintenance for the HEPA filters, printhead air filter, and
the dry shutdown valve (vacuum bleed) filter. Contact a Kodak service
technician for other maintenance on the PIC box.
14 Kodak Prosper S10 Printer
Chapter 1. Overview
Prosper S10 Jetting Module
Prosper S10 Jetting Module
The jetting module is used to apply ink onto the substrate. It has a
maximum printing width of 4.16 inches for one jetting module and 16.64
inches for four jetting modules. It is made of a silicon wafer assembly
(nozzle plate), a rigid flex assembly, a fluid filter, and a fluid manifold with
inlet and outlet ports.
The jetting module can be easily damaged, so it must be carefully
handled at all times. The jetting module frame has three ball centering
recesses to help accurately position the jetting module in the ACM. The
jetting module slides into the jetting module carriage assembly on the
ACM-jetting modules interface slides. It must be inserted correctly and
carefully to make sure the rigid flex connector pads connect to the Data
Interface Board (DIB) and the fluid inlet and outlet are correctly positioned
for correct fluid flow.
See Kodak Prosper S10 Jetting Module Replace and Pack Guide for
procedures on how to replace, pack, install, uninstall, and clean the jetting
module.
Operator’s Guide 15
Chapter 2. Printer Operation
This chapter gives common operator procedures for the S10 Printer:
• Turn the power on and off
• Correct Print Defects—See Kodak Prosper S10 Imprinting System
Basic Operations Guide
• Replace the fluid containers—See “Fluid Container
Replacement” on page17
• Clean the PIC box—See “Clean the PIC Box” on page23
Power Procedures
This section gives the procedures to turn the print station on and off.
Turn On the Print Station
1. If necessary, turn the power on for the print tower(s).
a. If the printing system has a transformer, turn the main switch on.
b. Turn the main switch on at the print tower(s) infeed power
cabinet.
NOTE
The power-on cycle is several minutes long.
2. Turn the power switch on at the print station (Figure 2).
3. Select
Ack Error to reset system controller and/or jetting module
errors.
Figure 2 Power switch
Power switch
16 Kodak Prosper S10 Printer
Chapter 2. Printer Operation
Correct Print Defects
Turn Off the Print Station
1. Select a jetting module (1A, 1B, and so on).
2. Select Shut Down.
3. Select each remaining jetting module and do step 2 again.
CAUTION
Do not turn print station power off until shutdown cycle is complete.
4. When the jetting modules of a print station show “ALLOFF”, turn the
power switch off at the print station (Figure 3).
Figure 3 Power switch
Correct Print Defects
See Kodak Prosper S10 Imprinting System Basic Operations Guide for
examples and procedures on how to correct print defects.
Power switch
Operator’s Guide 17
Chapter 2. Printer Operation
Fluid Container Replacement
Fluid Container Replacement
This section gives the procedures to replace the ink, replenisher, storage,
and waste fluid containers. Follow all safety procedures in this section.
Ink Container
CAUTION
If it is necessary to change the usual ink to a different type of ink, contact
Kodak technical support to schedule a flush procedure.
CAUTION
Make sure to replace the empty container with ink of the same type and
color.
CAUTION
If the ink card is missing, damaged or unreadable, use a new ink
container and card. Contact Kodak technical support to get a replacement
for the damaged ink card.
1. Open the new ink container.
a. Remove the envelope from the container.
b. Remove the ink card from the envelope (Figure 4).
Figure 4 Ink card
Horizontal mark
Gold contact
Sample ink card can
look different from
the actual ink card.
18 Kodak Prosper S10 Printer
Chapter 2. Printer Operation
Fluid Container Replacement
2. Open the print station front door (Figure 5).
a. Remove the expired ink card and recycle it in a local recycling
system.
b. Insert the new ink card (the gold square contact faces out) into
the smart card reader, until the black horizontal marks do not
show.
c. Close the print station front door.
Figure 5 Ink card and smart card reader
CAUTION
Make sure to disconnect the supply line before the cap/feed tube are
removed from the empty container. The internal tank will empty of all
fluids and the print station will shut down. “INK TANK EMPTY” will show
on the system controller.
3. At the empty ink container, push the quick-disconnect button to
disconnect the supply line from the empty ink container (Figure 6).
a. Remove the cap/feed tube from the empty ink container. Do not
disconnect the feed tube from the cap.
b. Discard the empty container; follow all applicable regulations for
waste fluid. Use the solid cap from the new ink container to seal
the empty ink container.
Figure 6 Empty ink container
Ink card
Smart card
reader
Quick disconnect button
Cap/feed tube
Supply line
Operator’s Guide 19
Chapter 2. Printer Operation
Fluid Container Replacement
4. At the new ink container, remove the solid cap from the new ink
container (Figure 7).
a. Install the cap/feed tube from the empty ink container.
b. Push the quick disconnect/supply line onto the cap until it clicks.
5. Correct or apply any system controller messages.
Figure 7 Full ink container
Replenisher and Storage Fluid Containers
The replenisher and storage fluids are different from each other. Replace
the containers in the same way.
CAUTION
Make sure to disconnect the supply line before the cap/feed tube are
removed from the empty container. Air can be drawn into the fluid system
and cause print defects.
1. At the empty container, push the quick-disconnect button to
disconnect the supply line from the empty container (Figure 8).
a. Remove the cap/feed tube from the empty container. Do not
disconnect the feed tube.
b. Discard the empty container; follow all applicable regulations for
waste fluid. Use the solid cap from the new ink container to seal
the empty ink container.
Figure 8 Empty container
Cap/
Cap
Quick disconnect/
supply line
feed tube
Quick disconnect button
Cap/feed tube
Supply line
20 Kodak Prosper S10 Printer
Chapter 2. Printer Operation
Fluid Container Replacement
2. At the new container, remove the solid cap from the new container
(Figure 9).
a. Install the cap/feed tube from the empty container.
b. Push the quick disconnect/supply line onto the cap until it clicks.
3. Correct or apply any system controller messages.
Figure 9 Full container
Discard the Waste Fluid
Use the guidelines and procedures in this section to correctly discard the
waste fluid that is a by-product of flushing the jetting module. Carefully
read and follow these guidelines and procedures.
Discard Guidelines
Before all waste fluids are discarded, contact your local wastewater
management authorities for data on how to discard ink and ink-related
waste in your location. Then contract with a local waste handler to collect
and remove all waste fluids.
A Material Safety Data Sheet (MSDS) is shipped with each ink or fluid.
The MSDS gives the wastewater management authority or waste handler
data for the best procedure to discard the waste fluids.
Safety Procedures
Make sure and follow the standard safety procedures when handling
waste fluid or any chemical materials.
• Wear protective clothing, gloves, and eye protection.
• Prevent contact with skin or clothes.
• Wipe up spills immediately to prevent permanent surface stains.
Cap/
Cap
Quick disconnect/
supply line
feed tube
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