Kodak Versamark DP5640 User manual

Brand: Kodak

Model: Versamark DP5640

Category: Print & Scan

Type: User manual

This manual is also suitable for

Versamark DS5600 Series

Printing Systems

Operator Guide

0114332-603

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.

Versamark DS5600 Series Printing Systems Operator Guide

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

reproduced without a written agreement from Eastman Kodak Company. 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.

Eastman Kodak Company 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. Eastman Kodak Company 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 Eastman Kodak Company. is provided without warranty or

representation of any kind, and Eastman Kodak Company will not be liable for any damages resulting from the use of such information.

Kodak and Versamark are trademarks of Eastman Kodak Company.

0114332-603 09/2010

Part Number Media Revision Date Description ECN

0114332-603 PDF 02 09/2010 Revision for CS150 Version 4.0.2.0 K10566

Previous Releases

Part Number Media Revision Date Description ECN

0114332-602

0114332-603

PDF

001 01/2008 Initial release with CS150 and CS150 UTS K7790

Operator Guide 3

Scope

This guide describes how to operate the Kodak Versamark DS5600 Series

Printing Systems. These printing systems produce letter-quality, variable

data images using continuous inkjet technology at up to 500 fpm

(150 mpm) with print resolutions of 240x240, 240x480, 300x300, or

300x600 dots per inch (dpi).

The DS5600 series printing systems can be used for business forms, tag

and label, direct mail, booklets, bar coding, numbering, addressing,

personalization, and billing statements with or without spot color. These

printing systems are modular and can be configured for web or sheet-fed

presses, collators, mail bases, folders, and a variety of other inline and

offline finishing equipment.

For DS5600 operation, the following system requirements apply to the

system components:

• Kodak Versamark CS150 System Controller Software Dashboard

Version 4.0.1.0 or higher

• Microsoft Windows XP Professional with Service Pack 2.0

• Ethernet-compatible narrow-format printers (with Compact DS Main

board installed)

• Ethernet-compatible wide-format print stations (with Compact DS

Main board installed)

• Fluid Controller Software Release 5.000 or higher

For additional information about the components used in the DS5600

series printing systems, see the following publications:

• Kodak Versamark CS150 System Controller Software Getting Started

Guide

• Kodak Versamark DP5222 and DP5340 Printing Systems Operator’s

Guide

The procedures in this guide should be performed only by an operator

who has received on-site training from Kodak.

Scope

4 DS5600 Series Printing Systems

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.

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.

This style Refers to

Ready

Text displayed by the software.

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.

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

Operator Guide 5

Contents

Chapter 1. Overview

DS5600 Configurations........................................................................................11

DS5600 Components ..........................................................................................13

System Controller..........................................................................................13

Print Stations.................................................................................................14

Printheads.....................................................................................................15

Fluid Containers............................................................................................15

System Operation................................................................................................16

Chapter 2. Operation

System Preparation.............................................................................................18

Startup Procedures..............................................................................................19

System Connections .....................................................................................19

Startup Sequence .........................................................................................20

Controller Operation ............................................................................................21

Menus and Screens ......................................................................................22

Device Configuration.....................................................................................24

Database Configuration ................................................................................25

Job Selection.................................................................................................26

Job Printing ...................................................................................................27

Using Online Help .........................................................................................30

Print Station Operation ........................................................................................31

Keyboard Controls ........................................................................................31

Screen Displays ............................................................................................32

Menu Screens........................................................................................ 32

Status Screens ...................................................................................... 33

Control Menu Procedures .............................................................................35

Service Menu Procedures.............................................................................37

Parameters Menu Procedures ......................................................................38

Pressure Adjustment ............................................................................. 39

Vacuum Adjustment............................................................................... 39

Stim Adjustment..................................................................................... 40

Stim Phase Adjustment ......................................................................... 40

Charge Voltage Adjustment................................................................... 40

Standby.................................................................................................. 41

Setup Menu Procedures ...............................................................................41

Chapter 3. Messages

Message Displays................................................................................................44

Message List........................................................................................................44

Chapter 4. Operator Maintenance

Daily Maintenance...............................................................................................47

Printhead Bottom Cover Cleaning.................................................................47

Printhead Cleaning........................................................................................47

Weekly Maintenance ...........................................................................................48

Printhead Air Filter ........................................................................................48

Cabinet Air Filter ...........................................................................................48

Operator Guide 7

Figures

Figure 1.1 DS5600 printing system configuration...........................................12

Figure 1.2 DS5600 components, single DT3 system......................................13

Figure 1.3 DT3 Print Station ...........................................................................14

Figure 1.4 Typical ink-jet printing system........................................................16

Figure 2.1 Connections, CS150 controller on DT3 cabinet.............................19

Figure 2.2 Network hub and power connections, DT3 print station................20

Figure 2.3 Main screen, CS150 software........................................................21

Figure 2.4 Diagnostics window.......................................................................22

Figure 2.5 Devices menu, Diagnostics screen................................................22

Figure 2.6 Select service setup window, CS150 software..............................24

Figure 2.7 Print job selection window .............................................................26

Figure 2.8 Database window ..........................................................................26

Figure 2.9 Configuring New Fields..................................................................27

Figure 2.10 Production window - after set up, CS150 ......................................27

Figure 2.11 Run window, CS150......................................................................29

Figure 2.12 Fluid controller software title screen..............................................31

Figure 2.13 Menu tree, DT3 print station software............................................32

Figure 2.14 Status screen layout......................................................................33

Figure 2.15 Printhead Ready status screen......................................................33

Figure 2.16 Control Menu, DT3 print station software......................................35

Figure 2.17 Parameters Adjustments screen, Control Menu............................35

Figure 2.18 Remote/Service Selection screen, Control Menu..........................35

Figure 2.19 Service Menu, DT3 print station software......................................37

Figure 2.20 Parameters Menu, DT3 print station software...............................38

Figure 2.21 Setup Menu, DT3 print station software ........................................41

Figure 3.1 Print station operator terminal screen display................................43

Figure 3.2 Display screen with sample messages..........................................43

Figure 3.3 Error message during startup........................................................44

Figure 4.1 Printhead air filter, DH6240 ...........................................................48

Figure 4.2 Cabinet filter, DT3 print station .....................................................48

Operator Guide 9

Tables

Table 1.1 Printhead performance ..............................................................15

Table 2.1 System status display summary ................................................34

Table 2.2 Control menu functions..............................................................36

Table 2.3 Service menu function ...............................................................37

Operator Guide 11

Chapter 1. Overview

This overview describes Kodak Versamark DS5600 Series Printing

Systems in the following sections:

• DS5600 Configurations

• DS5600 Components

Configuration descriptions describe the various combinations of

components that can make up a system.

Component descriptions identify the controller, printers, and print stations

used in the DS5600, and the system nomenclature.

DS5600 Configurations

The DS5600 series supports up to four printers and print stations in the

following combinations:

• Kodak Versamark CS150 System Controller with two Kodak

Versamark DP5600 Series Print Stations

• Kodak Versamark CS150 System Controller with one narrow-format

printer (Kodak Versamark DP5222 Printer or Kodak Versamark

DP5340 Printer) and two Kodak Versamark DP5600 Series Print

Stations

• Kodak Versamark CS150 System Controller with two narrow-format

printers (Kodak Versamark DP5222 Printer or Kodak Versamark

DP5340 Printer) and two Kodak Versamark DP5600 Series Print

Stations

• Kodak Versamark CS150 System Controller with three narrow-format

printers (Kodak Versamark DP5222 Printer or Kodak Versamark

DP5340 Printer) and one Kodak Versamark DP5600 Series Print

Station

The narrow-format printers support the following printheads:

• Kodak Versamark DH5222 Printheads, which has a 2.13" (5.41 cm)

print array and prints resolutions of 120x120 or 120x240 dpi

• Kodak Versamark DH5340 Printheads, which has a 1.07" (2.71 cm)

print array and prints resolutions of 240x240 or 240x480 dpi

The DP5600 series print station can support any of the following

printheads:

• Kodak Versamark DH5300 Printhead, which has a 2.77" (7.04 cm)

print array and prints resolutions of 300x300 or 300x600

• Kodak Versamark DH6300 Printhead, which has a 3.41" (8.66 cm)

print array and prints resolutions of 300x300 or 300x600

• Kodak Versamark DH6240 Printhead, which has a 4.27" (10.85 cm)

print array and prints resolutions of 240x240 or 240x480

12 DS5600 Series Printing Systems

Chapter 1. Overview

DS5600 Configurations

Figure 1.1 shows the different DS5600 series configurations.

Figure 1.1 DS5600 printing system configuration

Other system components such as the paper transport, cue sensor, tach

encoder, finishing equipment, and printhead mount(s) are dependent on

the specific combination installed.

The DS5600 series printing systems are identified as:

• Kodak Versamark DP5630 Printing System

Narrow-format printers and one or two DP5600 series print stations

with DH5300 Printheads

• Kodak Versamark DP5640 Printing System

Narrow-format printers and one or two DP5600 series print stations

with DH6240 Printheads

• Kodak Versamark DP5650 Printing System

Narrow-format printers and one or two DP5600 series print stations

with DH6300 Printheads

All configurations are compatible with the current model of the 38.5"

non-stitch printhead mount.

The specific installation and application requirements determine the other

system components required. This guide provides operating instructions

for a system with either narrow-format or wide-format printheads.

Note: The term DH6240 is used for the 4.27" printhead in some system

configurations, but that term is not used in this guide.

Second DP5600 series print station

CS150 on DS5600

CS150 on DS5000

DP5222

DP5340

2.13" DH5222

1.07" DH5340

DP5630

DP5640

DP5650

3.41" DH6300

2.77" DH5300

4.27" DH6240

Second, third and fourth printers

Operator Guide 13

Chapter 1. Overview

DS5600 Components

The DS5600 series has the following standard components:

• Kodak Versamark CS150 System Controller

• Network hub

• One printer or print station

• Printhead

• Umbilical

• Fluid containers

The system can include the following additional components:

• System enclosure (same used for the Kodak Versamark DS5000

Series Printing Systems)

• Computer mounting shelf (used only on a Kodak Versamark DT3 Print

Station)

• Second, third, or fourth narrow-format printer

• Second DT3 print station.

Each printer or print station supports one printhead. Each printhead prints

one color. Spot color printing is supported using multiple printheads.

Printheads cannot be stitched.

System Controller

When the system does not include a DP5000 series printer (also called a

narrow-format printer), the CS150 is mounted on a DT3 print station.

Figure 1.2 shows the system components of a system that does not have

a narrow-format printer.

Figure 1.2 DS5600 components, single DT3 system

Printhead

DT3 print station cabinet

CS150 System Controller

Umbilical

Network hub

PC shelf

Monitor

14 DS5600 Series Printing Systems

Chapter 1. Overview

DS5600 Components

Print Stations

The Kodak Versamark DP5600 Print Station is a new component used

only in the DS5600 Series Printing Systems.

The DP5600 consists of a fluid controller for the printhead (DH5300,

DH6240, or DH6300) and an operator terminal for the print station

controller software. When the CS150 is mounted on a Kodak Versamark

DT2 cabinet, the same computer serves as the operator terminal for both

the CS150 and the print station using a KVM (keyboard/video/monitor)

switch.

The DT3 cabinet (Figure 1.3) contains the entire fluid system for the

printhead, an internal fluid controller PC, and the Compact DS Main

Board with associated cables. The PC in the DT2 cabinet controls fluidic

and electronic operation of the print station and umbilical. The Compact

DS Main Board relays processes data received over the Ethernet from the

CS150 and transmits rasterized, fiberoptic image data to the printhead.

Figure 1.3 DT3 Print Station

Fluid cabinet

Monitor

Umbilical

Keyboard

Data Main Board

Printhead

Operator Guide 15

Chapter 1. Overview

DS5600 Components

Printheads

The printheads used in the DS5600 series have the performance

characteristics listed in Table 1.1.

Resolution is measured in dots-per-inch (dpi) along the print array for the

X axis and in the direction of substrate movement for the Y axis.

Maximum speed in feet-per-minute (fpm) was determined printing a 4-line

address with a 1-line Postnet barcode separated by 0.5-inch. Data

prepared in IJPDS format can be printed faster, but the actual speed at

which a given job can be printed is determined by the interaction of the

image data and the inter-document spacing. Simulated imaging can be

used to test the speed at which a job can be run.

For DS5600 operation, apply the following guidelines to printhead

mounting:

• Maximum height = 6 ft (183 cm) above the base of the printer cabinet.

• Minimum height = 2 ft (61 cm) below the base.

• For narrow-format printheads, the print array should be no more than

0.5 inch (1.27 cm) above the transport belt. Optimum print quality is

obtained with a printhead height of 0.125 inch (0.317 cm).

• For the DH5300 and DH6300 (wide format) printheads, the maximum

height is 0.1 inch above the transport belt.

• For the DH6240 printhead, the maximum height is 0.125 inch above

the transport belt.

Fluid Containers

The system requires external fluid containers for ink and replenisher fluid.

These containers can be any combination of the following types:

• 5.2 gallon (20 L) cubitainer

• 55 gallon (209 L) drum

• 275 gallon (1045 L) tote

Table 1.1 Printhead performance

Model

Print width Resolution (dpi)

Speed

(fpm)

Nominal Exact X axis Y axis

DH5340 1 inch 1.06 inch

(2.69 cm)

240

480

500

DH5222 2 inch 2.13 inch

(5.41 cm)

120

240

500

DH5300 4 inch 2.77 inch 300

300

600

500

DH6300 4 inch 3.41 inch

(8.66cm)

300 x 600 500

DH6240 4 inch 4.27 inch

(10.85cm)

240 x 240 500

16 DS5600 Series Printing Systems

Chapter 1. Overview

System Operation

The print station software monitors the level of ink stored in the internal

tank, which is automatically filled from the external supply as ink is used.

Replacing the external supplies can occur without stopping a job. You

must monitor the fluid supplies using the print station software and

replace the external ink or replenisher container when alerted by a “check

external fluid containers” message.

System Operation

The DS5600 series printing system uses data in the Native Input

Command Version 3 (NIC3) format for narrow-format printers (a system

with only DH6240 printheads can use IJPDS format data). The controller

processes job data and sends image data to the printers and print

stations over an RJ-45 Ethernet connection (Figure 1.4). This connection

uses a network hub mounted behind the CS150 computer.

The CS150 uses setup commands embedded in the NIC3 data to

automatically set job parameters. Alternatively, you can enter job setup

instructions at the CS150 operator terminal.

Figure 1.4 Typical ink-jet printing system

The job parameters and setup at the CS150 are applied to the data to

determine which part of the bit-mapped data goes to each printhead.

Embedded setup allows jobs to be run without any image positioning at

the controller, however, the CS150 software can be used to correct the

setup or make changes to it if needed.

In a DS5600 system, narrow-format printers operate with the CS150 just

like they do in a DS5000 series printing system. The presence of one or

two DT3 print stations does not change that relationship. The DT3 print

stations operate with the CS150 in the following manner:

• The CS150 serves the function of a Kodak Versamark CS220 System

Controller Software or Kodak Versamark CS400 System Controller

Software in a wide-format printing system such as the DS6240.

• The Compact DS Main Board in the DT3 functions as the Kodak

Versamark CD120 Data Station or Kodak Versamark CD130 Data

Station in a wide-format printing system.

• The DT3 print station software operates normally, monitoring all

aspects of fluid controller operation.

Operating procedures and controls are described in Chapter 2,

“Operation.”

CS160

Data

source

Data

station

Fluid

cabinet

Printhead

Controls and status

NIC3

Bit-mapped

data

Controls

and status

Umbilical

Fiberoptic

Print Station

Operator Guide 17

Chapter 2. Operation

Operation of a Kodak Versamark DS5600 Series Printing System consists

of the following procedures:

• System Preparation

• Startup Procedures

• Controller Operation

• Print Station Operation

The Kodak Versamark CS150 System Controller Software is used to

control the system. The CS150 can be used to control the fluid systems

and data systems of narrow-format printers, but not Kodak Versamark

DP5600 Series Print Stations. When a DP5600 print station is configured,

the Fluid Controller Software that runs on the computer in the DP5600

print station must be used to control that fluid system and printhead.

Note: If two DP5600 print stations are configured, each one must be operated

using its own operator terminal. The first DP5600 shares the operator

terminal of the CS150, but the second DP5600 has a separate operator

terminal.

The primary reference for all CS150 software procedures is the online

Help (see “System Preparation”).

Note: Systems ship with the current version of CS150 System Controller

software (Version 4.0.2.0 as of publication of this guide). Systems with

earlier versions of the software, including all versions called Kodak Versa-

mark Mailscape Software, may not be compatible with the DS5600 series

printing systems. Contact technical support for information on software

upgrades.

18 DS5600 Series Printing Systems

Chapter 2. Operation

System Preparation

Before the system can print, the following CS150 software procedures

must be completed:

• Set up production printers

• Configure databases

• Create print layouts

All these procedures are described in the CS150 online Help. Access this

information from any screen by selecting the Help button (shown below

on the production “Dashboard” screen). Open specific Help topics by

clicking on items in interactive lists or on the pull-down menus.

The final procedure in this sequence is production (see “Print Jobs”). All

production printers must be configured as devices in the CS150 software,

and each database to be used as a print source must be configured for

printing.

This configuration, which includes field and record definition as well as

print layout, is saved in a configuration file (*. bcf).

When the printers and databases are configured, a print job is started by

selecting a printer and loading a configuration file (*. bcf).

An optional CS150 module called Read and Image allows a CS150 user

with a camera system (or barcode reader, magnetic strip reader, or optical

character reader [OCR] and a production printing system) to personalize

print products based on a customer number. For convenience, this Help

refers to a camera system when discussing the Read and Image

capability.

Help button

Operator Guide 19

Chapter 2. Operation

Startup Procedures

The CS150 System Controller is primarily used with the Kodak Versamark

D-Series Printing Systems for applications that require bar coding,

numbering, addressing, and personalizing. The CS150 can operate up to

four printheads in various combinations (See “DS5600 Configurations” on

page11). The feature key for the CS150 software must match the number

and type of printheads being used.

Startup Procedures

Narrow-format printers should be powered-up normally before the

controller is started. For a system a with DS5000 series enclosure, startup

is done exactly the same as described in the Kodak Versamark CS150

System Controller Software Getting Started Guide. Review the following

procedures before starting the system initially:

• System Connections

• Startup Sequence

System Connections

For a system without a DS5000 series enclosure, check all the

connections to the controller mounted under the shelf on the DT3 cabinet

(Figure 2.1).

Figure 2.1 Connections, CS150 controller on DT3 cabinet

Monitor power

Data from controller

Data out to printer

PC power

KVM for CS150

Data from customer network

CS150 software key

KVM for DT3

KVM switch input

KVM switch

Data output

20 DS5600 Series Printing Systems

Chapter 2. Operation

Startup Procedures

The DS5600 series controller on the DT3 cabinet requires the following

connections:

• Input power

•Monitor

• Keyboard

•Mouse

• Feature key (see note below)

• Data source

One input from the customer data source is required. The data source

is typically a LAN or network drive.

• Network hub data connections

Each printer or print station must have an output cable from the

24-port Ethernet switch installed in the system enclosure or the DT3

shelf (Figure 1.2). Input to the hub is a connection to the system

controller. Hub connections are done at installation and should not be

changed unless a printer is added to the system or permanently

removed. A connected printer does not have to be used. Only printers

active in the current software configuration print.

Note: The CS150 software key (also called a “feature key”) is programmed for

the number of printheads and optional software features of the system. If

a feature is not active that is required, contact technical support.

Startup Sequence

Start the system using this sequence (Figure 2.1 and Figure 2.2):

• Power up the print station(s)

• Power up the narrow-format printer(s)

• Power up the network hub

• Power up the controller PC

Figure 2.2 Network hub and power connections, DT3 print station

Single Data input from controller

Up to four data outputs

DT3 cabinet power

DT3 input power,

PC and monitor power

CS150 power

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