Gerber InkJet Printer, CAT UV Owner's Manual

Gerber CAT | UV ™

Ink Jet Printer

Owner’s Guide

Gerber CAT | UV Print Modes

Imperial Metric

Print Modes

635 x 360 DPI

Performance 1 Bi-Directional 408 6 38 7 Performance 1 Uni-Directional 269 8 25 11

635 x 720 DPI

***Performance 2 Bi-Directional 165 13 15 18 Production 1 Bi-Directional 137 16 13 22 Production 1 Uni-Directional 109 19 10 27 Production 2 Bi-Directional 91 23 8 33 Production 2 Uni-Directional 67 31 6 44

1058 x 720 DPI

Quality 1 Bi-Directional Quality 1 Uni-Directional Quality 2 Bi-Directional Quality 2 Uni-Directional

SPEED

Foot2 / Hour

70 56 39 28

Minutes to Print

4 x 8 Foot Board **

34 7 42 37 5 53 53 4 76 75 3 106

PRINT SPEED

/ Hour *

Meter

Minutes to Print

3 x 1.5 Meter Board **

*NOTE: Based on Full Table Printing ** NOTE: Based on start of print to end of print within +/- 10% ***NOTE: Print mode to be released.

♦ Warranty

Please see Product Specifications for required operating environment and consult your Owner’s Guide for required preventative maintenance procedures.

♦ Additional Documentation

Further documents, and updates to current documentation, will be available with each new firmware release. For the most up-to-date literature, contact your Gerber Service

iii

representative or check the eService Document Library which can be accessed from the Support section of the Gerber web site: www.gspinc.com

This document may not be reproduced by any means, in whole or in part, without written permission of the copyright owner.

This document is furnished to support the Gerber CAT|UV Ink Jet Printer. In consideration of the furnishing of the information contained in this document, the party to whom it is given assumes its custody and control and agrees to the following:

The information herein contained is given in confidence, and any part thereof shall not be copied or reproduced without written consent of Gerber Scientific International, Inc.

This document or the contents herein under no circumstances shall be used in the manufacture or reproduction of the article shown and the delivery of this document shall not constitute any right or license to do so.

Information in this document is subject to change without notice.

Printed in USA

Gerber CAT|UV, GerberCAT, Cold Fire Cure Technology, FastFacts, OMEGA, Support First, and Matched Technology System are trademarks and GSP is a registered trademark of Gerber Scientific Products. Onyx and PosterShop are registered trademarks and ProductionHouse is a trademark of Onyx Graphics. X-ACTO is a registered trademark of Hunt Corporation. Anticon is a registered trademark of Milliken & Company. Firefox is a registered trademark of Mozilla. Microsoft, Internet Explorer, Windows, Windows XP, Windows Vista, and Windows 7 are registered trademarks of Microsoft in the USA and other countries.

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FCC Compliance

Warning: Changes or modifications to this unit not expressly approved by the party responsible for compliance could void the user’s authority to operate the equipment.

NOTE: This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to Part 15 of the FCC rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference in which case the owner will be required to correct the interference at their own expense.

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

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

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Contents

Quick Print Checklist...................................................................................................................9

Chapter 1: Introduction........................................................................................................... 10

In this manual.........................................................................................................................................11

Conventions used in this booklet ........................................................................................................11

Safety information .................................................................................................................................12

Electrical...............................................................................................................................................12

Ink handling and disposal.................................................................................................................12

Printer ventilation...............................................................................................................................13

Personal precautions ..........................................................................................................................13

UV lamp precautions .........................................................................................................................13

Technical support ..................................................................................................................................13

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

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

UV bulb technology...............................................................................................................................15

UV ink technology.................................................................................................................................16

Storing inks and materials....................................................................................................................16

UV ink storage.....................................................................................................................................16

Material storage ..................................................................................................................................17

Gerber CAT | UV control panel ..........................................................................................................17

Main control panel..............................................................................................................................18

Auxiliary keypad................................................................................................................................18

Control Panel keys..............................................................................................................................19

Exploring the printer's menu system..................................................................................................22

Status..........................................................................................................................................22

Setup..........................................................................................................................................22

Calibration ................................................................................................................................23

Maintenance..............................................................................................................................23

The Gerber CAT | UV web pages.......................................................................................................23

Powering the printer .............................................................................................................................24

Sleep/Idle mode ....................................................................................................................................24

Emergency Stop .....................................................................................................................................25

Chapter 3: Setting up the Gerber CAT | UV ......................................................................... 27

Networking your Gerber CAT | UV printer .....................................................................................27

Setting fixed (static) network addresses..........................................................................................27

Setting the IP Address and Subnet Mask of your computer.........................................................29

Viewing the current network settings.................................................................................................33

Chapter 4: Loading Inks and Materials ............................................................................... 34

Loading the inks.....................................................................................................................................34

Checking the ink level........................................................................................................................35

Replacing ink pouches when ink remains in the reservoir...........................................................35

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Replacing an ink pouch when the reservoir is empty ...................................................................37

Preparing the material...........................................................................................................................38

Choosing a material type...................................................................................................................38

Normalizing material.........................................................................................................................39

Cleaning the material .........................................................................................................................39

Loading the Flat Bed..............................................................................................................................42

Printer/graphic orientation...............................................................................................................42

Adjusting the UV shield for rigid material .....................................................................................44

Uniform Print Gap & Elimination of Gap Between Prints............................................................45

Understanding Flat Bed printing margins......................................................................................47

Loading roll material in the Roll-to-Roll configuration....................................................................48

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

Using the material roller....................................................................................................................49

Loading roll material into the printer..............................................................................................50

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

Removing material from the winding unit and printer ................................................................53

Understanding Roll-to-Roll printing margins................................................................................54

Chapter 5: Printing Jobs on the Gerber CAT | UV .............................................................. 55

Using RIP software and profiles..........................................................................................................55

Print mode options ................................................................................................................................55

Printing a job – Instructional overview...............................................................................................56

Canceling a job .......................................................................................................................................57

Flat Bed Printing ....................................................................................................................................58

Printing on the Flat Bed .....................................................................................................................58

Printing a full bleed Flat Bed job ......................................................................................................59

Printing double-sided, full-bleed......................................................................................................60

Roll-to-Roll Printing ..............................................................................................................................63

Choosing a print mode for Roll-to-Roll printing............................................................................63

Printing a single Roll-to-Roll job.......................................................................................................64

Printing multiple Roll-to-Roll jobs in Continuous mode ..............................................................65

Automatic printer operations...............................................................................................................67

UV lamp warm-up..............................................................................................................................67

Sleep/Idle mode .................................................................................................................................67

Automatic spitting to clear the nozzles ...........................................................................................67

User-selectable modes...........................................................................................................................68

UV lamp automatic shut-off or Continuous mode ........................................................................68

Lamp Delay mode ..............................................................................................................................68

Lamp Spec mode.................................................................................................................................69

Large Field mode ................................................................................................................................70

Step Blending mode ...........................................................................................................................71

Chapter 6: Printer Maintenance........................................................................................... 72

Required maintenance supplies...........................................................................................................72

Gerber CAT | UV Regular Preventive Maintenance........................................................................74

Daily maintenance.................................................................................................................................76

Tips for Clean Heads procedure.......................................................................................................76

1) What is the purpose of the Clean Heads procedure?................................................................76

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

plate?.....................................................................................................................................................76

3) How can I be sure my clean was effective?.................................................................................76

4) Why do I lose nozzles? ..................................................................................................................76

Clean Heads Procedure......................................................................................................................78

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End of Day Clean................................................................................................................................82

Emptying and cleaning the waste ink tray......................................................................................83

Weekly maintenance .............................................................................................................................86

Cleaning the flat bed ..........................................................................................................................86

Cleaning the head access door..........................................................................................................86

Monthly maintenance ...........................................................................................................................87

Purging ink lines to remove air.........................................................................................................87

Six month maintenance.........................................................................................................................93

Cleaning the table rails.......................................................................................................................93

Cleaning the Roll-to-Roll grit wheels...............................................................................................93

Cleaning the Roll-to-Roll rubber drive wheels...............................................................................94

As-Needed Maintenance ......................................................................................................................95

Periodic Maintenance Process to correct angled nozzles..............................................................95

Cleaning individual color printheads..............................................................................................98

Cleaning the roll-to-roll platen..........................................................................................................99

Cleaning the ink drawers...................................................................................................................99

Cleaning the Maintenance Shelf Mat ...............................................................................................99

Cleaning the X axis belts....................................................................................................................99

Cleaning the outside of the Gerber CAT | UV...............................................................................99

Preparing a printer that will not be used for up to two weeks......................................................100

Steps for preparing the Gerber CAT | UV for two weeks of idle time.....................................100

Steps for restarting the Gerber CAT | UV after two weeks of idle time...................................100

Shutting down the printer for more than two weeks .....................................................................100

Steps for shutting down the Gerber CAT | UV ...........................................................................100

Steps for restarting the Gerber CAT | UV ....................................................................................100

Steps for shutting down your Gerber CAT|UV...........................................................................101

Steps for restarting your Gerber CAT | UV..................................................................................108

vii

Chapter 7: Gerber CAT | UV Web Pages ............................................................................. 117

Accessing the Gerber CAT | UV web pages....................................................................................117

Home page............................................................................................................................................118

System Status page ..............................................................................................................................119

System Settings page...........................................................................................................................120

Changing the printer name .............................................................................................................120

Changing the System Log Level.....................................................................................................120

Numeric units....................................................................................................................................121

Language............................................................................................................................................121

Lamp Delay .......................................................................................................................................121

Lamp Spec Mode ..............................................................................................................................121

Large Field.........................................................................................................................................121

Step Blending ....................................................................................................................................121

Network Settings .................................................................................................................................122

Using Static Settings.........................................................................................................................122

Other settings ....................................................................................................................................123

Job Status page .....................................................................................................................................123

Diagnostics page ..................................................................................................................................125

Version Information .........................................................................................................................126

View System Log ..............................................................................................................................127

View Satellite Log.............................................................................................................................128

Sensors................................................................................................................................................129

Configuration Info page...................................................................................................................131

USB Test page....................................................................................................................................132

Statistics..............................................................................................................................................133

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Error History page............................................................................................................................134

Calibration web page ..........................................................................................................................135

X Gantry Adjustment .......................................................................................................................136

Calibrating the location of a printed image (Print Pos Offset Front and Side) ........................137

Calibrating Image Quality...............................................................................................................139

Update page..........................................................................................................................................144

Loading firmware upgrades............................................................................................................144

Contacts web page...............................................................................................................................147

Chapter 8: Troubleshooting.................................................................................................. 148

Printer issues ........................................................................................................................................149

Printer will not turn on ....................................................................................................................149

Printer is stuck on “Gerber” screen at power-up .........................................................................149

Printer is stuck on “Check the Shelf” screen.................................................................................149

Printer is stuck on “Warming” screen ...........................................................................................149

Job will not print ...............................................................................................................................149

Winder does not roll up the material.............................................................................................150

Material jams when printing...........................................................................................................150

Quality of printed output ...................................................................................................................152

Missing nozzles.................................................................................................................................152

Banding in the flat bed prints..........................................................................................................152

Banding in roll-to-roll prints ...........................................................................................................153

Missing or angled nozzles...............................................................................................................153

The print is blurred...........................................................................................................................155

Smearing or fading in the print.......................................................................................................155

Color balance is different between software and print ...............................................................156

Small text quality is poor.................................................................................................................156

The ink forms small puddles on the print.....................................................................................156

Image easily scratches off the material ..........................................................................................156

Print is not cured...............................................................................................................................157

First few inches (50-100cm) of the job is not curing.....................................................................157

Job data errors ......................................................................................................................................158

Data errors, interruptions, and pauses during printing..............................................................158

Job Status & Common Printer Messages ..........................................................................................159

Error Messages.....................................................................................................................................162

Running the control panel screen test...............................................................................................165

Checking network connections..........................................................................................................165

Pausing a job due to data starvation.................................................................................................166

Restoring Factory Default Settings....................................................................................................166

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Printer Menu Tree – Rev A Version ....................................................................................168

APPENDIX ................................................................................................................................. 169

Yearly Maintenance Requirements ...................................................................................................169

General site requirements...................................................................................................................170

Size and weight.................................................................................................................................170

Ambient conditions ..........................................................................................................................170

Power requirements .........................................................................................................................171

Printer orientation.............................................................................................................................172

Locating the serial number..............................................................................................................172

Computer and software requirements...........................................................................................172

Index .......................................................................................................................................... 174

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Quick Print Checklist

After you have setup your Gerber CAT|UV for the first time, use this checklist to help guide you through the steps required for getting the machine ready for printing. Refer to the page numbers provided next to each step for more information.

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

(Replace ink pouches if necessary).

panel

2 Clean the heads (When LED is lit before printing).

3 Prep the material

(Normalize and clean for best results).

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

Roll (Single or Continuous) or Flat).

5 Load the material

(Flat Bed or Roll-to-Roll).

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

downs for roll-to-roll material.

Using your selected RIP software

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

8 Select the appropriate material profile and page size.

9 Select one of the available print modes.

10 Send the job to the printer.

11 Press Run Job to begin printing your job.

p. 19

p. 78

p. 39

p. 38

p. 42 or p. 48

p. 44 or p. 48

Consult RIP software instructions

p. 56

12 UV Lamp warm-up

13 Job will begin printing.

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(If lamps are not to proper temperature).

p. 15

p. 56

Chapter 1: Introduction

Thank you for purchasing the Gerber CAT|UV™, an outdoor-durable, UV-cured ink jet printer with flat bed and optional roll-to-roll capabilities. The Gerber CAT|UV’s versatile printing methods allow shops to meet diverse customer needs. For applications that require printing on flexible materials, such as banner, vinyl, and backlit materials, shops can print via the roll-to-roll configuration. The printer has a generous flatbed which accommodates large jobs with ease. It can print on rigid materials such as foam board, corrugated plastic, polycarbonate, expanded PVC, aluminum, or MDO, as well as flexible materials such as banner, vinyl, and backlit. In addition, you have the option of printing full-bleed.

The Gerber CAT|UV variety of materials which meet the following standards:

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

♦ Maximum rigid or roll material width is 64" (1.6m/162.6cm). ♦ Maximum rigid material thickness is 1" (25.4mm). ♦ Maximum rigid material length for the roll-to-roll configuration is 120" (3m/304.8cm). ♦ Maximum rigid material length for the flatbed-only configuration is 100"

(2.5m/254cm).

♦ Maximum rolled material thickness is 0.030" (0.76mm). ♦ Minimum rolled material width is 24" (61cm). ♦ Minimum sheet size is 12" x 12" (30.5cm x 30.5cm).

The Gerber CAT|UV printheads use multiple-drop technology to provide vivid colors and an expanded color gamut. The printer has several print modes to maximize throughput or quality. The printing rate varies based on the selected print mode and the chosen material profile (as determined by the RIP software). For best results, use Gerber-qualified materials. For the most current information available, see gspinc.com/applications.

Gerber’s exclusive GerberCAT™ ultraviolet ink set includes four colors – Magenta, Cyan, Yellow, and Black, which achieve an outstanding color gamut and brilliant hues. The cationic inks are cured using Gerber's proprietary Cold Fire Cure™ technology. This low energy, low temperature cure creates a mechanical bond between the ink and the substrate, providing better abrasion resistance and eliminating adhesion loss which can occur with vinyl graphics. The low-temperature cure also greatly expands the range of materials that can be printed by the Gerber CAT|UV. Heat sensitive plastic, vinyl, fabric, and paper-based materials can be printed using Gerber's Cold Fire Cure and GerberCAT inks without concern over ink adhesion or material damage.

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Chapter 1

Introduction

In this manual

The following chapters introduce you to the Gerber CAT|UV, describe the printing process, and show you how to maintain your printer for maximum quality output.

Chapter 1: Introduction provides details on how to use this manual and important customer service and safety information.

Chapter 2: Product Overview provides details of the general product features and requirements and describes the control panel and menu structure as well as the startup sequence.

Chapter 3: Setting up the Gerber CAT|UV directs you in setting up the Gerber CAT|UV to run on a network and other user-controlled options.

Chapter 4: Loading Inks and Materials directs you in loading the Gerber CAT|UV ink and installing both flexible and rigid materials.

Chapter 5: Printing Jobs on the Gerber CAT|UV describes how to print on either flexible or rigid material with RIP software.

Chapter 6: Printer Maintenance details cleaning and purging of printheads as well as the daily, weekly and monthly maintenance procedures.

Chapter 7: Gerber CAT|UV Web Pages describes the onboard web interface program that can be used to check on the printer's current status and ink status, to view or change system and network settings, view message logs, assist in diagnostics, and to install new firmware.

Chapter 8: Troubleshooting highlights potential printing problems and provides possible solutions. The Messages section list common messages that may display on your control panel screen and their meaning.

Menu Tree provides a visual layout of the Gerber CAT|UV printer's menu.

Appendix includes General Site Requirements and Yearly Maintenance Requirements.

Conventions used in this booklet

The following conventions are used in this booklet:

WARNING: A warning statement contains information which, if not followed, could result in electrical shock hazard.

CAUTION: A caution statement contains information which, if not followed, could result in personal injury or equipment damage.

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

TIP: A tip contains a suggestion to make your task easier or to remind you of something that may appear elsewhere in the booklet.

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Chapter 1

Introduction

Safety information

Electrical

WARNING: Observe these safety precautions to avoid possible electrical shock hazard when using the Gerber CAT|UV.

♦ Use the correct power cord; do not use a damaged power cord. ♦ Use an outlet with a ground terminal or electric shock can occur. ♦ Turn printer off and unplug it from the power source before servicing. ♦ Unplug any communications cables before servicing. ♦ Never open covers affixed by screws unless directed by Gerber service personnel. Doing so

may result in electric shock or damage to the printer.

♦ Remove any electrostatic charge from your clothing or body by touching a metal part of the

printer before servicing. Electronic components (such as memory) may malfunction if exposed to electrostatic charge.

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

carpeting.

Ink handling and disposal

CAUTION: Observe these general safety precautions when operating the Gerber CAT|UV

CAUTION: Use impervious gloves to protect your hands. Nitrile gloves of no less than 8 mils have proven impervious for one hour of exposure. Gloves should be disposed of after one hour of exposure time. Wear safety goggles to protect your eyes.

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

will damage the printer.

♦ Consult the GerberCAT ink MSDS for proper handling, disposal, and safety

recommendations. Also consult local laws and regulations.

♦ Do not open ink pouches. Ink could get on your skin or in your eyes. ♦ When handling ink pouches and waste ink, be careful that the ink does not get on your skin

by wearing impervious nitrile gloves. If it does, wash your skin with soap and water for 15 minutes. Seek medical attention if symptoms occur.

Ink Jet Printer.

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

and wash them separately with soap and water.

♦ If ink gets in your eyes, immediately rinse your eyes with copious amounts of water for at

least 15 minutes and seek medical attention immediately.

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Chapter 1

Introduction

♦ Dispose empty ink pouches, waste ink, wipes, and used swabs according to local laws and

regulations.

Printer ventilation

CAUTION: Observe these general safety precautions when operating the Gerber CAT|UV

♦ Do not obstruct printer exhaust fans.

Ink Jet Printer.

Personal precautions

CAUTION: Observe these general safety precautions when operating the Gerber CAT|UV

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

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

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

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

Ink Jet Printer.

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

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

UV lamp precautions

UV WARNING

Exposure to UV light can be dangerous to eyes and skin and should be avoided. Never operate the Gerber CAT|UV with any of the covers removed. Never operate the printer with the rubber light shields (flaps) missing or damaged. Contact Gerber if any of the rubber light shields (flaps) need to be replaced.

Technical support

If you have questions regarding using, maintaining, or troubleshooting the Gerber CAT|UV please contact your Gerber distributor or Gerber Service.



phone: 800-828-5406 / 860-643-1515, ext. 8602 fax: 860-871-3862



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e-mail: gspservice@gspinc.com

www.gspinc.com

Chapter 1

Introduction

Additional sources of information

Gerber FastFacts™ provides answers to technical and service questions. FastFacts are available on the Gerber web site: www.gspinc.com under “Support.”

Electronic versions of this manual and other documentation are available from the eService Document Library which can be accessed from the Gerber web site: www.gspinc.com under “Support.” You must sign up for a free customer account to access the eService location.

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Chapter 2: Product Overview

UV bulb technology

UV WARNING

The Gerber CAT|UV uses Cold Fire Cure UV technology to instantly and safely cure inks using low energy and low heat. The UV lamps run the full length of the gantry (approximately 65"/165cm) and provide a very specific wavelength of UV light which cures the GerberCAT inks. The lamps are enclosed to ensure that the user is protected from exposure to UV radiation.

The UV bulbs require a short warm-up cycle before printing if they are not at operating temperature. When the lamps reach their operating temperature, the cooling fans automatically turn on to maintain the proper temperature. Gerber CAT|UV lamps do not require a cool down cycle before re-striking.

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Chapter 2

Product Overview

UV ink technology

CAUTION: Use only GerberCAT inks. Substituting any other inks will void the warranty. Each color ink pouch must be installed into the corresponding colorcoded pull-out ink drawer.

GerberCAT cationic ultraviolet inks have very little odor and require no special ventilation. Gerber's patent-pending, Cold Fire Cure technology dries the ink immediately and the printed material may be handled or cut directly after printing.

Although printhead capping is not required on the Gerber CAT|UV, there is a parking station which is used when it is not printing for extended periods. The parking station travels with the gantry and blocks stray light from the printhead nozzle plates.

Graphics created by the Gerber CAT|UV are outdoor-durable for up to three years. However, environment and application will determine the ultimate outdoor life span and may result in outdoor durability of greater or less than three years.

GerberCAT inks are specifically designed for use with the Gerber CAT|UV printer. The inks come in four colors: Magenta (M), Cyan (C), Yellow (Y), and Black (K). The eight printhead system dedicates two printheads per ink color.

The ink is supplied in one liter pouches that are used to refill the Gerber CAT|UV ink reservoirs. Four color-coded ink drawers contain receptacles to accept the ink pouches.

Storing inks and materials

Store GerberCAT inks and qualified materials as instructed for the best quality output when printing. Improper storage of inks or materials will negatively effect overall print quality.

UV ink storage

GerberCAT inks have a shelf life of approximately 12 months from date of manufacture when stored as recommended. Note the “Use by” date printed on the pouch and properly dispose of according to MSDS.

The operating temperature and humidity range of the Gerber CAT|UV is smaller than the storage range for the ink pouches. If ink is stored outside of the operating temperature range, wait for the ink to normalize before using it.

♦ Temperature: 41° F to 86° F (5° C to 30° C) ♦ Humidity: 30% - 70% non-condensing

NOTE: The guaranteed term of ink is 12 months from date of manufacture when it is kept or used without exposing air at 77°F (25°C). Note the “Use by” date printed on the pouch.

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Chapter 2

Product Overview

Material storage

See manufacturer’s material-specific documentation for recommended handling and storage requirements and/or gspinc.com/applications for Gerber-qualified materials. General material storage and handling suggestions follow:

♦ Do not use creased, damaged, torn, curled, bowed, or warped material. ♦ Do not leave material loaded in the roll-to-roll unit of the printer for an extended

period of time. The pinch wheels may damage it, or the material may curl resulting in misalignment, jams, or decreased printing quality.

CAUTION: When printer is set to Lamp Delay mode ON, ensure no material is present in the roll-to-roll area or on the flatbed area, whichever is not being used, as damage may occur to the material and/or printer hardware due to extended lamp exposure when the beam rests in these locations.

Tip: Gerber recommends cleaning rigid material with IP Surface Cleaner or 99% Isopropyl Alcohol and wiping it away evenly with a lint-free cloth. This cleans the surface and improves the output quality of the print.

Gerber CAT | UV control panel

The Gerber CAT|UV has two control panels for ease of use: the main control panel and the auxiliary keypad. The main control panel is located on the printhead gantry, rotates 180° and has an adjustable viewing angle for ease of use.

Most controls needed to load material, print jobs, and clean the printheads are located on keys on the main control panel. The printer's menu system which contains printer status, calibration, and maintenance tasks is also accessed from the main control panel by pressing the MENU key. The printer's Menu system is not necessary for day-to-day operation of the Gerber CAT|UV.

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Chapter 2

Product Overview

Main control panel

Printer Ready

BACK ENTER

SHIFT / PAUSE RUN JOB CANCEL

CLEAN LOAD

HEADS SLEW UNLOAD

ROLL

TO FLAT INK ROLL BED MENU LEVEL

Single z z Cont. z

Screen interface for status messages, printer progress, and setup controls.

Navigational keys for screen interface. If the printer's Menu is activated, these controls also navigate through the sub-menus for printer setup, calibration, status, and maintenance.

Operational keypad used to load material, move the gantry, print jobs, control the vacuums, and to clean the printheads.

Auxiliary keypad

The auxiliary keypad is located near the origin of the flat bed and provides basic controls for loading jobs and cleaning the printheads.

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Chapter 2

Product Overview

Control Panel keys

The Screen shows menus, instructions, system and job status, and messages. An icon in the lower right corner indicates the type of message or sub-menu.

The SHIFT/PAUSE key is serving as a “shift” key, being used in conjunction with other keys as a shortcut to initiate desired events. Which key is present is dependent on revision level at time of manufacture. See table at the end of this section.

RUN JOB begins printing the job at the printer or the next job to arrive if in Roll-to-Roll Continuous mode.

The RUN JOB key also can be used in conjunction with the SHIFT/PAUSE key start the NOZZLE OUT built-in test job.

To move through menus:

♦ BACK moves up through the menu tree ♦ ENTER moves down through the menu tree. ♦ Y Z Directional navigation keys move side to

side when text is displayed.

The CANCEL key aborts a job after the carriage completes the current right to left swipe.

If the carriage is moving left to right, the system will complete the next right to left pass.

If the gantry is moving it completes its current step.

If the gantry is performing large moves at the beginning or end of the job, it will stop at the current location.

Once movements have been completed, the screen shows the Job Canceled message.

The carriage moves to the park position.

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Chapter 2

Product Overview

The CLEAN HEADS yellow LED blinks to indicate that it has been four hours since the last Clean Heads procedure when the printer is active or after two hours when the printer is idle. Press the CLEAN HEADS key to begin the cleaning sequence. The gantry moves to the front of the table and the carriage moves to the maintenance shelf location. Follow the instructions on the screen. The Clean Heads procedure timer automatically resets and the LED goes out when the cleaning sequence is completed.

In addition, this key can be used in conjunction with the SHIFT/PAUSE key as a shortcut to initiate the End of Day Clean procedure.

Use the SLEW key to move the gantry along the table on the X axis (front to back).

Press the LOAD/UNLOAD key to prepare the printer for loading or unloading material. When Rigid is selected the table vacuum is enabled or disabled when pressing LOAD/UNLOAD depending on its current state.

The LOAD/UNLOAD key also can be used in conjunction with the SHIFT/PAUSE key to turn on the table vacuum whenever desired, without the gantry returning to the home position.

For printers equipped with the Roll-to-Roll option: When Roll-toRoll is selected, the roll-to-roll vacuum is enabled or disabled depending on its current state. When in Roll-to-Roll mode the user is given the option of turning the vacuum on after the job is received (if it is currently disabled.)

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The ROLL TO ROLL key is not active for printers without the rollto-roll option.

Press the ROLL TO ROLL key to begin the loading sequence for rolled material. Press again to toggle the selection between Single and Continuous printing. The LED lights indicating the choice. The gantry moves into position near the roll-toroll assembly. The operator loads and aligns the material and adjusts the hold-down devices. The material is ready for printing.

Press the FLAT BED key to begin the loading sequence for rigid material. The Flat LED lights. Operator loads and aligns the material and adjusts the sliding UV shield. The operator turns on the flat bed vacuum using the LOAD/UNLOAD key. The material is ready for printing.

Pressing the FLAT BED key a second time enables full-bleed printing and the LED blinks.

Flat is the default mode at printer start-up and the only mode available for flatbed-only printers.

Front Panel Key Short Cuts

Press the MENU key to enter the menu system of the printer. This is not normally required for printing but provides access to printer Status, Setup, Calibration, and Maintenance menus.

Press the INK LEVEL key to display the Ink Level screen which graphically shows the estimated amount of ink remaining in each pouch.

The Ink Level LED is solidly lit when the ink level of any pouch is low. The LED blinks when a pouch is empty.

Key Short Cut Purpose

While holding down SHIFT/PAUSE key, press CLEAN HEADS key While holding down SHIFT/PAUSE, press LOAD/UNLOAD While holding down SHIFT/PAUSE, press RUN JOB While holding down SHIFT/PAUSE, press RUN JOB and LEFT at the same time

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Start END OF DAY CLEAN procedure Toggle table vacuum on/off

Start NOZZLE OUT built-in test job

Start ANGLED NOZZLE built-in test job

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Exploring the printer's menu system

The printer's menu system displays on the control panel screen and is used for printer status, setup, calibration and maintenance. This menu system is not necessary for day-to-day operation of the Gerber CAT|UV. When navigating through the sub-menus, an icon displays on the bottom right corner of the screen to indicate your location within the menu structure.

Status

Major sub-menus from the menu system are briefly described below.

Tip: For a graphical representation of the printer's menu structure, refer to the appendix at the end of this manual.

Status

The Status section of the printer's menu displays the printer's Firmware Version.

Setup

The Setup section of the printer's menu provides access to UV lamp controls as well as displaying the Network Configuration settings. To change the network settings, you must use the Gerber CAT|UV web pages. See the “Network Settings” on page 122 for detailed instructions.

♦ Lamp Delay mode allows the user to

completing a job when printing on Flat Bed or Roll-to-Roll. See page 68 for detailed instructions.

♦ Lamp Spec

mode is a special UV lamp setting that may be helpful for certain materials that

need extra heat to cure ink. Lamp Spec mode activates the UV lamps at a higher temperature than normal and warms the material prior to the start of the job. See page 69 for detailed instructi

ons.

♦ Large Field mode improves the print quality of large solid areas of color, especially light

blue or green. Once Large Field is enabled it remains active until disabled by the operator. Large Field can also be controlled from the System Settings web page. See page 70 for detailed instructi

ons.

♦ Step Blending improves the print quality of images and large text only by hiding excess

banding in the x-axis. By default, Step Blending is disabled. Once step Blending is enabled it remains active until disabled by the operator. Step Blending can also be set on the System Setting web page. See page 71 for detailed instructions.

set the UV lamps to remain on for 10 minutes after

♦ IP Address ♦ Subnet Mask ♦ DH

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CP (not currently active)

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♦ MAC Address

Calibration

The Calibration section of the printer's menu provides access to Park Position Cal as well as a number of Test Jobs.

♦ Test Jobs

♦ Nozzle Out Job ♦ Angled Nozzle Job ♦ Production Horizontal Align Job ♦ Quality Horizontal Align Job ♦ Mechanical Align Job ♦ Print Position Job

♦ Park Position Cal to calibrate the park position of the printhead carriage.

Maintenance

The Maintenance section of the printer's menu allows access to printhead maintenance functions including:

♦ Clean Heads procedure is used to clean the printheads by pushing a small quantity of ink

through the nozzles. It must be done whenever the LED is lit before printing. See page 78 for detailed instructi

ons.

♦ End of Day Clean procedure must be done at the end of each print day. See page 82 for

detailed instructi

ons.

♦ Purge to remove air from the ink system by pushing a large quantity of ink through the

nozzles. See page 87 for detailed instructions.

♦ Inspect Noz

zles allow lowering of the maintenance shelf for viewing and cleaning of the

area around the printheads.

♦ Clear Ink Lines to remove all ink from the printer. See page 101 for detailed instructions. ♦ Fill Ink Lines to initially load ink when the system is new o

r after ink has been removed

from the system. See page 111 for detailed instructions.

The Gerber CAT | UV web pages

The Gerber CAT|UV has an onboard interface program that can be accessed directly from any connected user computer via an internet browser (such as Microsoft® Internet Explorer® 6.0 or higher or Mozilla Firefox® 2.0 or higher). This program can be used to check on the printer's current status, ink status, view or change system and network settings, view message logs, assist in diagnostics, and to install new firmware. To access the web pages you will need the following:

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♦ A user computer with an internet browser either directly connected to the machine or

connected to a network which is connected to the machine. (See section “Networking the GERBER CAT|UV” for more information). The computer does not have to be connected to the internet to access the printer web pages.

♦ The printer’s IP Address which can be viewed in the Setup section of the printer menu.

Enter the IP Address as the web address in the internet browser.

For detailed information on using the Gerber CAT|UV web pages, see “Using the Gerber CAT|UV web pages” beginning on page 68.

Powering the printer

The power switch is located on the left side of the printer. Ethernet connections are located under the printer near the power switch.

When the power switch is turned on the Gerber CAT|UV will automatically initiate the following procedures during the initial startup:

♦ Firmware starts up and internal diagnostics occur (the working icon displays). When the

Gerber CAT|UV is powered on the internal firmware starts up just like a computer. The control panel screen displays the name of the printer and the firmware version that is currently installed. The printer then proceeds with a series of internal diagnostics to test the operation of various components including sensors, fans, ink system, lamps and network connections. If there are any internal issues, a message displays after the startup sequence is complete. See “Messages” on page 159.

♦ Carriage moves to the

home position within the gantry.

♦ Gantry moves to the home position at the front of the printer. ♦ The firmware version displays. ♦ The Printer Ready message displays. ♦ The Clean Heads LED blinks as a reminder to run the Clan Heads procedure which pushes

ink through the nozzles to clear them.

NOTE: It is required that you leave the Gerber CAT|UV powered on at all times in order to maintain ink vacuum. Do not turn the printer off, even for extended periods of down time. If the printer will not be in user for longer than two weeks, you must follow the special procedures described in “Shutting down the printer for more than two weeks” on page 100.

Sleep/Idle mode

After 10 minutes of idle time

When the Gerber CAT|UV is idle for 10 minutes it will automatically go into idle mode. When in idle mode, the UV lamps, vacuum blowers, and roll-to-roll fans turn off and the gantry rises

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to its home position. During the first two hours of idle mode, the printer will maintain proper printhead temperature and spit ink every 5 minutes to ensure that the printer is prepared to print.

After two hours of idle time

When the

printer has been idle for two hours, the printer enters sleep mode and the printhead heaters automatically turn off and the printer ceases to spit ink. The Clean Head LED blinks to indicate that you must perform the Clean Heads sequence before printing.

Every thirty minutes when the printer is in sleep mode the Gerber CAT|UV automatically reestablishes vacuum pressure to ensure that no excess ink drips from the printheads.

Emergency Stop

There are two emergency stop button located on either end of the gantry. Press either button to immediately shut down the UV lamps and abort printing.

A message displays asking the operator to

Check the Shelf, Access Door or

Press ENTER when done

To release E-Stop and return printer to normal condition, twist E-Stop button in clockwise direction until it returns to original position.

Maintenance shelf and head access door emergency stop

Lowering the maintenance shelf or opening the printing. Use care when accessing either of these areas. When any of these actions causes an emergency stop, a message displays asking the operator to

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Check the Shelf, Access Door or E-Stops.

head access door will also cancel a job which is

Check the Shelf, Access Door or E-Stops.

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Check the Shelf, Access Door or

Press ENTER when done

Once the operator has corrected the condition and pressed ENTER, the motors of the printer perform a homing sequence.

NOTE: If the power is restored or the condition corrected before the

E-Stop message displays, the printer displays a Motor Power Cycled! message.

Check Shelf, Access Door, or

CAUTION: During maintenance procedures, always wait for printer prompts before lowering the maintenance shelf or opening the head access door. Performing either of these actions prior to the prompts will cause an emergency stop and require you to redo maintenance procedures from the beginning.

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Chapter 3: Setting up the Gerber CAT | UV

This chapter describes general information on setting up your Gerber CAT|UV including how to connect the printer to the network and how to configure your computer and printer to communicate with each other.

Networking your Gerber CAT | UV printer

The Gerber CAT|UV is a network device and your computer must have a 100/1000 Mbps autoswitch network interface board installed to communicate with the printer. Gerber supplies a CAT 5E Ethernet cables to connect the printer to the network or for direct connection to a computer. (The Gerber CAT|UV is also compatible with a CAT 6 Ethernet cable.)

Tip: If your computer is not on a network you can create your own network with a separately purchased network switch and connect one or more devices to your computer. Your computer must have a 100/1000 Mbps auto-switch network interface board and you will need to obtain a 100/1000 Mbps Ethernet switch with several ports. Use straight-through Category 5E or Category 6 Ethernet cables with RJ45 connectors: one to connect the Gerber CAT | UV to the switch, and one to connect the computer to the switch. The Ethernet switch, network interface board, and additional cables are readily available at local computer stores.

Tip: When a live network cable is plugged into the computer, the RJ45 jack LED will light.

Setting fixed (static) network addresses

When the Gerber CAT|UV arrives from the factory, it is set to use fixed (static) network addresses. You will need to obtain and assign the correct addresses in order for the computer to be able to communicate with the printer. The static network addresses are set in the Network Settings web page. If necessary, you will also configure your computer's IP Address and Subnet Mask as described in “Setting the IP Address and Subnet Mask of your Computer” on page 29.

The IP Address of the computer and Gerber CAT|UV should should be identical for the computer and the printer. In a single LAN environment leave the Gateway address as the default setting (000.000.000.000)

CAUTION: Use care when entering addresses for the equipment. Entering incorrect addresses could damage the network. In a large existing network, obtain the correct addresses for the computer and the Gerber CAT|UV administrator or IT professional.

be unique. The Subnet Mask

from the network

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CAUTION: The device ID number (last octet or last two octets depending on the type of network) of each device's IP Address must be unique. It can not be the same address as any other computer or equipment in the network or it will cause problems for the network.

NOTE: You must power-cycle the system after changing the settings in the NETWORK SETTINGS web page in order for them to take effect.

Tip: The default settings of the Gerber CAT | UV are: IP Address: 192.168.000.050, Gateway:

000.000.000.000, and Subnet: 255.255.255.000.

To set the network addresses of the Gerber CAT | UV

1 Open a web browser on a computer connected to the Gerber CAT|UV. (The internet

connection does NOT have to be active.)

2 Enter the IP address for the specific Gerber CAT|UV that you wish to access as a web

address in the web browser. (Do not use any slashes or colons.)

3 Press Enter and the Home page should appear on your web browser. There are links

on the Home page that connect you to other Gerber CAT|UV web pages.

4 Click the Network Settings link to open the Network Settings page.

5 Enter an IP Address of the Gerber CAT|UV in the field.

6 Enter a Subnet Mask address in the field. The default Subnet Mask of 255.255.255.000

is normally acceptable for most networks. The Subnet Mask should be the same for the computer and the printer.

7 Enter a Gateway address in the field. The Gateway address can be left at the default

setting of 000.000.000.000 in a single LAN environment. If you are connected across multiple LANs, contact your network administrator for the correct address.

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8 Click the Change Settings button to accept the new values.

9 The printer prompts you power-cycle the system in order for it to update and utilize

the newly entered values.

Setting the IP Address and Subnet Mask of your computer

When using Fixed network settings, the default IP address of the Gerber CAT|UV is

192.168.000.050 and the default Subnet mask is 255.255.255.000. The following procedure uses

192.168.000.001 for the computer's IP address and 255.255.255.000 for the Subnet mask. Use the procedure that matches your configuration: Windows® Vista, Windows 7, or Windows XP.

To set the IP Address and Subnet Mask for Windows Vista and Windows 7

NOTE: You must be logged on as an Administrator to configure network settings in Windows Vista or Windows 7.

1 Click Start > Control Panel to open the Control Panel dialog box. Your display might

look different if you are in Classic View. You can switch between Classic and Category View under Control Panel Home on the left side of the window.

2 Click Network and Internet to open the Network and Internet dialog box.

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3 Click Network and Sharing Center.

4 Click the Manage network connections task on the left side of the screen to open the

Network Connections screen.

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+ 149 hidden pages

Gerber InkJet Printer, CAT UV Owner's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual