Kodak Prosper S10 User manual

Brand: Kodak

Model: Prosper S10

Category: Ink cartridges

Type: User manual

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).

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.

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-

[email protected]

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

Station

PIC

Umbilicals

(40 ft/12.2 m)

Boxes

10 Kodak Prosper S10 Printer

Chapter 1. Overview

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

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

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

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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Kodak Prosper S10 User manual

Brand: Kodak

Model: Prosper S10

Category: Ink cartridges

Type: User manual

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Kodak Prosper S10 User manual

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