Gerber InkJet Printer, CAT UV Owner's Manual

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Gerber CAT | UV ™

Ink Jet Printer

Owner’s Guide

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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

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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

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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

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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

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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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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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5 Right click the Local Area Connection and choose Properties to display the Local Area

Connection Properties dialog box.

6 Select Internet Protocol Version 4 (TCP/IPv4) and then click Properties. The following

dialog box displays.

7 Choose Use the following IP address to activate the address fields.

8 Enter 192.168.0.1 for the IP address of your computer.

9 Press Tab to automatically enter the correct Subnet Mask (255.255.255.0).

10 Do not enter a Default Gateway if using direct connection, or unless instructed by your

network administrator.

11 Click OK to save the settings and exit the Properties dialog box.

To set the IP Address and Subnet Mask for Windows XP

1 Click Start > Settings > Control Panel.

2 Double-click the Network Connections icon.

3 Double-click the Local Area Connections icon to open the Local Area Connections

Properties dialog box.

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4 Click Internet Protocol (TCP/IP) in the list.

5 Click Properties to open the Internet Protocol (TCP/IP) Properties dialog box.

6 Click Use the following IP address:

7 Enter 192.168.0.1 for IP Address.

8 Press Tab to automatically enter the correct Subnet Mask (255.255.255.0).

9 Do not enter a Default Gateway if using direct connection, or unless instructed by your

network administrator.

10 Click OK to save the settings and exit the Properties dialog box.

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Viewing the current network settings

You can view the current network settings (IP Address and Subnet Mask) and the factory assigned MAC (media access control) address for the Gerber CAT|UV on through the printer’s Menu system. You can only view the network settings in the printer’s Menu system. To change settings, use the Gerber CAT|UV web pages. See “Network Settings” on page 122.

To view the current network settings in the Menu system

NOTE: The following screens are examples only; your settings may be different.

1 From the main control panel press the MENU key. The

Status screen displays.

Status

2 Press the Y or Z key until the

Delay

screen.

Setup screen displays. Press ENTER to display Lamp

Setup

3 Press the Y or Z key until the

IP Address screen displays. Press ENTER.

IP Address

192.168.0.50

4 Press the Y or Z key to display the rest of the network settings including

DHCP, and MAC Address.

Subnet Mask,

NOTE: DHCP is currently disabled.

Subnet Mask

255.255.255.000

MAC Address

00-50-C2-2D-34-58

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DHCP

Disabled

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Chapter 4: Loading Inks and Materials

This chapter describes how to load the four GerberCAT ink colors and install both flexible and rigid material into the Gerber CAT|UV.

Loading the inks

CAUTION: Do not disassemble the ink pouches. When handling ink pouches and waste ink, be careful that the ink does not get on your skin. If ink gets on your skin, wash your skin with soap and water for 15 minutes. Seek medical attention if irritation persists.

CAUTION: If your clothing comes in contact with uncured ink, remove any contaminated clothing and wash them separately with soap and water.

CAUTION: 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.

CAUTION: Waste ink, empty pouches, used swabs, wipes and gloves must be disposed according to local laws and regulations. Consult the MSDS sheets and local codes for proper disposal.

Gerber CAT|UV uses four GerberCAT ink colors: Cyan (C), Magenta (M), Yellow (Y), and Black (K), supplied in one liter pouches. The ink pouches are installed in color-coded ink drawers that fill the four internal reservoirs.

Gerber CAT|UV monitors ink usage and tracks the level in the ink pouches and ink reservoirs. Pouches can be removed and replaced during printing and do not have to be empty when removed and can be reinstalled later. Inks should be replaced when they are past the “Use by” date noted on the pouch whether or not they are installed in the Gerber CAT|UV.

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CAUTION: You should not open the ink drawer more than 10 times per pouch as excessive opening and closing can damage the pouch and cause ink leakage in the drawer. Use care when closing ink drawers; they have sensitive sensors which can cause errors when handled roughly.

Checking the ink level

Press the INK LEVEL key on the control panel to display the graphical Ink Level screen to view the status of the ink pouches. In the following example the Cyan (C) is 75% full; Magenta (M) is full; Yellow (Y) is 25% full; and the Black (K) pouch is empty and needs to be replaced. Press CANCEL to return to the Printer Ready screen.

Ink Level

NOTE: All ink levels are approximate.

C M Y K

Replacing ink pouches when ink remains in the reservoir

When a pouch level is low, the Ink Level LED is solidly lit on the Gerber CAT|UV control panel indicating that you will need to replace the pouch soon. The Ink Level LED blinks when a pouch is empty.

Pouches can be replaced while a job is printing. The printer will continue to print as long as the ink in the reservoir remains above the low level. You may wish to replace a partially empty pouch with a full pouch before printing a large job. Partial pouches can be reinstalled for use later.

Receiving an “INK Empty – Replace Pouch” message

Occasionally you may g Check to ensure that you installed the pouch correctly, and then you may update the amount without opening and closing the drawer again. For example you can now select “No Change” without having to open and close drawer. If the “INK Empty – Replace Pouch” message continues to display after several attempts to update the pouch amount, seek technical assistance.

et an “INK Empty – Replace Pouch” after replacing an empty pouch.

Always print a Nozzle Out test print after getting the “INK Empty – Replace Pouch” message. If you were printing a job prior to receiving the message you can continue printing as long as the Nozzle Out test print looks good. If you were performing a maintenance procedure such as a head clean or purge, assume that the procedure did not complete correctly. Repeat the maintenance procedure after replacing the pouch and then print a Nozzle Out test print to ensure that the printheads are functioning well. If necessary repeat the maintenance procedure until the test print is acceptable.

To replace an ink pouch

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eyes. Dispose of used swabs, wipes, and gloves according to local laws and regulations.

1 Open the color-coded ink pouch drawer located on the side of the Gerber CAT|UV.

You should not open the ink drawer more than 10 times per pouch as excessive opening and closing can damage the pouch and cause ink leakage in the drawer

CAUTION: Do not attempt to open the ink pouch drawer when the printer is actively printing and the gantry is moving towards the drawer. If the gantry is within 4" (10.16cm) of the drawer, the printer will stop and abort the job to avoid the gantry contacting the open drawer when printing.

2 Unsnap the spout from the drawer clip and remove the pouch (The pouch does not

have to be completely empty and can be reinstalled later).

3 Wipe up any dripped or spilled ink from the bottom of the ink drawer with an all-

purpose wipe and dispose of wipe according to local laws and regulations. It is normal to have drips of ink from the ink pouch located in the drawer above.

CAUTION: Always match the color of the ink pouch to the color-coded ink drawer.

4 Place a new ink pouch in the ink drawer and snap the spout onto the receptacle

drawer clip.

CAUTION: Dispose of empty pouches and used wipes according to local laws and regulations. Consult the MSDS and local codes for proper disposal.

5 Close the ink drawer and the control panel screen prompts the user to estimate the

amount of ink in the pouch which was just inserted. The choices are No Change, 100% Full, 75% Full, 50% Full, 25% Full, and Low. The default selection is No Change.

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NOTE: The screen to choose the amount of ink in the pouch will only display when the printer is in the Printer Ready mode. It will not display while actively printing.

Cyan Ink Pouch Contents:

No Change

6 Use the YZ keys to select the appropriate amount and press ENTER to accept. The

printer resets the counter that tracks ink usage (unless No Change was selected). The

Printer Ready screen displays.

Replacing an ink pouch when the reservoir is empty

If the low pouch is not replaced when the Ink Level LED is solidly lit, the reservoir level will eventually fall below the low ink level. When this happens, the Ink Level LED will begin to blink indicating that an ink pouch is empty. If the pouch is allowed to run completely dry the following screen displays during a job or when an operator attempts to start a new job.

BLACK empty

You must replace the empty pouch to continue. The system will begin filling the reservoir as soon as the ink drawer is closed. Printing can commence when the reservoir level exceeds the low sensor.

Tip: In the event of an ink reservoir failing to fill, the amount of ink remaining in the pouch is no longer set to zero. The ink pouch status will remain as it was prior to the fill failure.

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Preparing the material

The Gerber CAT|UV is a flat bed printer with an optional roll-to-roll configuration.

When printing on rigid or flat material you will use the printer's flat bed and vacuum system. The gantry containing the printheads travels along the length (X-axis) of the printer. The printheads move left and right within the gantry along the width (Y-axis).

When printing on roll material such as vinyl you can use the roll-to-roll configuration (if so equipped), which makes use of both the roll material loader bar and the automatic winder unit. The roll-to-roll configuration uses eight pinch and grit wheels to grip and pull the material through the printer's roll-to-roll assembly.

When printing, fans under the material create a vacuum to hold the material firmly against the printer's flat bed or roll-to-roll platen to maintain its position during printing. By choosing either the FLAT BED or ROLL-TO-ROLL key on the control panel, the correct vacuums are enabled when pressing the LOAD/UNLOAD key.

NOTE: When printing long material that crosses into roll-to-roll area, material MUST be taped down to ensure it does not bend upward and cause hardware and/or printhead damage.

Choosing a material type

The Gerber CAT|UV is a true flat bed ink jet printer with optional roll-to-roll capabilities which can print on a variety of uncoated materials up to 64" (162.6 cm) wide and 1" (25.4mm) thick. It is versatile enough to meet your graphic needs including outdoor signage, indoor signage, Point of Purchase displays, banners, backlit displays, and reflective signage. Compatible materials are divided into two categories:

♦ Roll (which refers to vinyl, banner, textiles, or flag in rolled or sheet versions) ♦ Rigid (which refers to a flat substrates including PVC, styrene, corrugated plastic,

aluminum, acrylic, glass, MDO, plywood, and sign foam)

The material must meet the following standards:

2.5m/254cm).

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♦ 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).

NOTE: It is recommended that Gerber-qualified materials be used to obtain the best results. See gspinc.com/applications for more information.

CAUTION: The Material size must be set in the RIP and the user must be careful to load the correct

Gerber CAT|UV does not detect material size (length or width).

size material to accommodate the job.

When printing on roll stock using a printer that is equipped with the roll-to-roll option, there must be a ½" (13mm) border on either side of the job to accommodate the material hold down devices. Take this border into consideration when planning your prints. See “Understanding printing margins” on page 47.

Rigid sign blank material must be flat within 0.

03" (0.76mm). Warped material may jam in the

printer. Material that is bowed upward will contact the print carriage.

When printing on rigid substrates you have the option of full bleed printing which allows the Gerber CAT|UV to print a job larger than the sign blank, resulting in the printed area extending beyond the edges of the material.

covered under warranty. In order to ensure print and printer-favorable conditions are met for each print, adhere to the related requirements starting on page 45.

NOTE: It is

recommended that you use only Gerber-qualified materials for the Gerber CAT|UV. Printer problems that may occur due to use of materials other than those recommended by Gerber are not covered by the Gerber CAT|UV warranty. See gspinc.com/applications for a current list of qualified materials.

Normalizing material

The size of material can change depending on the temperature and/or humidity of the working environment. For the best print-to-cut registration, “normalize” the material in the working environment for at least 24 hours before printing.

If the substrate has been stored in a location with temperature and humidity that is far beyond the recommended range for the Gerber CAT|UV, or for the substrates themselves, be aware that substrates deep within a stack of material may take longer to normalize than the surface pieces.

Cleaning the material

Substrate manufacturers provide important information on usage, storage, cleaning, and disposal, as well as application tips for their materials. Review these documents and follow the instructions before printing. See gspinc.com/applications and the manufacturer’s website for the most current information and instructions.

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NOTE: It is possible to turn on the table vacuum to hold material for cleaning purposes without the gantry moving to the table origin. To do so, depress and hold down the PAUSE key while additionally depressing the LOAD/UNLOAD key.

Cleaning rigid substrates

Some substrates such as

corrugated plastic, polycarbonate, expanded PVC, and painted aluminum require cleaning prior to printing to remove dust or debris which is often attracted by static electricity.

To clean rigid material

1 Liberally spray a lint-free cloth with IP surface cleaner or 99% isopropyl alcohol until

the cloth is saturated.

NOTE: Gerber does NOT recommend using 60% rubbing alcohol, 70% isopropyl alcohol, or other common cleaners because they may leave a residual film on the substrate.

2 Wipe the substrate in a fluid motion in one direction, pushing the dirt off the edge of

the substrate. The alcohol should be apparent on the surface.

3 Do not wipe the substrate using a circular motion which can result moving the dirt

around into swirled patterns which may be visible after printing.

4 Wait until the cleaning solution fully evaporates before loading or printing on the

substrate. Complete evaporation of the solution may take several minutes to several hours. Refer to the substrate’s product bulletin for specific instructions.

Cleaning rolled material

Flexible substrates

are both rolled and sheet materials of many types including vinyl, banner, paper and textiles. Due to the variety of flexible substrates, Gerber recommends following the manufacturer’s specifications for storage and cleaning. Following are instructions for preparing vinyl for printing.

NOTE: Only use blank un-printed material or slew the used roll material beyond the printed area before beginning the job.

To clean roll material

CAUTION: Never clean vinyl material with alcohol, only clean vinyl with distilled water.

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1 Wipe the material with a clean, lint-free cloth moistened with distilled water. Allow

the material to dry completely before printing.

2 Prior to loading material into the printer, wipe the ends of the roll with a tack cloth to

remove any dirt or dust.

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Loading the Flat Bed

When printing on rigid or flat material you will use the printer's flat bed. Gerber recommends that you properly prepare the material by making sure it contains no rough edges and that the surface to be printed on has been wiped clean of any dust and debris. See “Cleaning the material” on page 39.

Rigid sign blank material must be flat within 0.

03" (0.76mm). Warped material may jam in the printer. Material that is bowed downward will scrape the platen. Material that is bowed upward will contact the print carriage. If the material has curled edges that are not pulled against the table with the vacuum, use a light adhesive tape to secure the material to the table and prevent head strikes or damage to the gantry.

You can print jobs up to 10' (304.8cm) long. However, when printing materials in excess of 9' (274.3cm), in which a portion of the media comes to rest on the roll-to-roll platen which is not part of the vacuum table, you must reinforce this area.

CAUTION: You must reinforce material crossing into the roll-to-roll platen area by taping it down. This will keep materials from bowing at that end and prevent possible hardware and/or printhead damage.

For jobs shorter than 9' (274.3cm) with a printer equipped with a roll-to-roll unit, or shorter than

100" (2.5m/254cm) when using a flatbed-only printer, the material will rest fully on the table,

therefore no tape is necessary unless there are curled material edges. You may use a light adhesive tape to secure the edges of material to the table and prevent head strikes or damage to the gantry.

Printer/graphic orientation

It is important to understand the position of the graphic sent from the RIP software and its orientation on the flatbed table. The flatbed portion of the table with the maintenance shelf is considered the front of the printer. Note that the left and right sides of the printer and the graphic are reversed (see diagram below).

NOTE: Orientation may vary depending on the Rip software used.

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NOTE: The Gerber CAT|UV does not detect material size (width or length). Material size must be set in the RIP. When loading material, you must verify that there is sufficient material for the completion of the job.

To load material onto the Flat Bed

1 Use the LOAD/UNLOAD key to ensure that the vacuum is off before attempting to

load rigid media. Use the slew keys to move the gantry into a position for easy material loading.

2 Press the FLAT BED key on the control panel. The Flat LED lights to indicate the

choice. The FLAT BED is selected by default when using a flatbed-only printer and the Flat LED is lit to indicate that it is active.

Tip: The FLAT BED key toggles between normal Flat Bed mode and full-bleed printing. When the LED blinks, full-bleed is enabled. See page 59 for more information on printing in full-bleed mode.

3 Place the rigid material onto the

table and align it to the table origin alignment

guidelines which are a series of closely spaced holes along the edges of the table.

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Alignment Guidelines

RIGHT SIDE

M A I N T E N A N C E

S H E L

Printing Origin

LEFT SIDE

4 Press the LOAD/UNLOAD key to turn on the table vacuums. You can use the

auxiliary keypad or the main control panel. If the vacuum does not completely pull down the material, tape the edges of the material to the table using a light adhesive tape.

5 The gantry moves to the front of the system, near the table origin

6 The printer checks the location of the sliding UV shield and prompts you to

shield to its parked position

if it is not there. Grasp the UV shield handle and slide it all

Slide the UV

the way to the left. Press ENTER on the keypad when the shield is in the correct position. See next section below for more information.

Slide UV shield to its park

7 The printer automatically measures the material thickness and sets the print gap

between the printheads and the material to the proper height.

8 Press ENTER on the control panel to return to the

Printer Ready message.

Adjusting the UV shield for rigid material

The Gerber CAT|UV comes with a sliding UV shield that protects the printer from overexposure to UV light. Material hold-down devices are not required for rigid material.

Once the rigid material is loaded on the flat bed, grasp the UV shield by the handle and position it so that the right edge of the handle aligns with the right edge of the rigid material. The shield is not used to help hold down the material when printing, but to protect the printer against over-exposure to UV light. The UV shield can move up and down the entire length of the carriage gantry to adjust to varying material widths.

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Line up this edge of sliding UV shield handle with right edge of material.

Uniform Print Gap & Elimination of Gap Between Prints

If the material is thicker than 0.035" (0.9mm) it will ask the user to position the sliding UV shield adjacent to the right hand side of the board to prevent UV light reflecting off the table back into the heads. The diagram below shows both the correct and the incorrect use of the shield.

covered under warranty.

CORRECT

Carriage motion

INCORRECT

Carriage motion

Reflected UV

Carriage

Print heads

UV lamps

UV shield

Board

Carriage

Print heads

UV lamps

UV shield

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Board

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Similarly, avoid arranging boards on the table with gaps. Leaving gaps between boards will result in UV light reflecting back into the print head and causing nozzle blockages. Sacrificial material (waste material) should be used to fill any gaps.

NOTE: Sacrificial material should be the same thickness as the board to be printed. Thicker material might strike the carriage whereas thinner material will allow UV light to reflect back into the print heads.

INCORRECT

Carriage motion

CORRECT

Carriage motion

Carriage

Print heads

Reflected UV

Print heads

Reflected UV

UV lamps

UV shield

Board

UV lamps

UV shield

Sacrificial material

Board to be printed

Arrange the boards on the table in order to avoid gaps and prevent reflected UV light by using sacrificial material or butting the boards next to each other. Irregular shapes will need to be used within fitted templates. Any sacrificial material must be the same thickness as the board to be printed (see diagram below showing the table as viewed from above).

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–

Loading Inks and Materials

Sacrificial material

Board to be printed

INCORRECT CORRECT CORRECT

Table Fron

Viewed from above

Understanding Flat Bed printing margins

NOTE: The Gerber CAT|UV does not detect material size (length or width). Material size must be set in the RIP and the user must be careful to load the correct size material to accommodate the job.

CAUTION: Incorrect arrangement of boards on the table, or adjusting or modifying the print gap can result in UV light being reflected into the print heads causing nozzle blockages. These failures are not print and printer-favorable conditions are met for each print, adhere to the related requirements starting on page 45.

The Gerber CAT|UV is

able to print on a wide variety of materials at widths ranging from 12"

(30.5cm) to 64" (162.6cm).

The printing margins vary depending on the type of material used.

For rigid material, it is possible to print completely to the edges.

covered under warranty. In order to ensure

NOTE: To achieve maximum print width of 64”, full bleed mode must be utilized. See page 59.

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Loading roll material in the Roll-to-Roll configuration

Roll material refers to rolled or flexible sheet material. The rolled or sheet material can be made of many different materials as long as it is qualified for use with the Gerber CAT|UV. When printing on roll material it is recommended that you use the optional roll-to-roll configuration which includes a winder.

Using rolled material effectively involves the following steps:

♦ Loading roll material onto a material roller ♦ Loading roll material into the printer ♦ Loading and removing material from the

winding unit

NOTE: The Gerber CAT|UV does not detect material size (length or width). Material size must be set in the RIP and the user must be careful to load the correct size material to accommodate the job. The smallest acceptable roll material width is 24"(61cm).

Using material hold-down devices for roll material

When equipped with the roll-to-roll option, the Gerber CAT|UV comes with two material hold-down devices for vinyl and other non-rigid materials. Position the hold-down devices over the edges of the roll material for optimum printer performance and to keep your roll material from curling and jamming. Slide the hold-down devices along the grooves in the platen to move them. First, locate the right hold-down at the right edge of the printer. Slide the material under the hold-down so that it covers ¼” (6mm) of the material. Position the left hold-down until it covers ¼” (6mm) of the left edge of the material.

Left hold down device

Right hold down device

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Using the material roller

Printers with the roll-to-roll hardware are equipped with the roll feed/take-up roll system which maintains proper positioning of the material during printing. When loading roll material onto a material roller, place the roll on a flat surface.

CAUTION: Never load a roll of material onto a roller standing on end as it can damage the material and the roller.

CAUTION: Material rolls can be heavy. Maximum roll weight is 100 lbs./45.36 Kg. Take care when lifting and loading the material rolls.

CAUTION: Be careful not to pinch your fingers in the roll feed system when loading the material.

To load roll material onto the material roller

1 Remove the material supply axle from the assembly and then remove the left core

flange from the axle.

Core flange

Thumbscrew

2 Lay the roll of material on a flat horizontal surface and insert the material supply axle

into the roll. Insert the axle until the material tube fits firmly against the fixed right core flange.

NOTE: Make sure that the material is properly oriented when inserting the roller so that the material enters the printer print side up. From the back of the printer, the adjustable flange will be at the left end of the roll.

3 Insert the left core flange onto the axle until it fits firmly against the material tube.

4 Tighten the white thumbscrew to hold the flange in place. Do not over-tighten the

thumbscrew.

5 Standing at the roll-to-roll end of the printer, hold the material roll loaded on the roller

with the adjustable flange to the left and place it on the printer.

NOTE: The material on the supply roll must not be slack to insure proper media feed. Re-roll around the supply roll if necessary. Also check the tension on the feed roll brake.

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Loading roll material into the printer

When loading the roll material the hold-down devices keep the edges of the material from curling or interfering with carriage motion. The following procedure applies to both sheet and roll-fed material.

NOTE: You can not slew the material in the reverse direction (down) when roll-to-roll printing.

To load roll material into the printer

1 The sliding UV shield is not required for roll-to-roll printing. Grasp the handle and

slide the shield all the way to the right to its home position.

2 Press the ROLL-TO-ROLL key on the control panel. The Roll-to-Roll Single LED lights,

the system beeps three times, and the gantry moves into the loading position approximately 12" (30.5cm) from the roll-to-roll assembly. The displays when the movement is complete.

Printer Ready screen

3 Open the pinch wheels by pushing down on the material load lever to open the pinch

wheels.

4 For rolled material, feed the material around the dancer bar and over the roll-to-roll

platen. Feed the leading edge of the material between the pinch wheels and the grit wheels.

Dancer Bar

5 Ensure material is squarely aligned and is at least halfway into hold downs.

6 Close the pinch wheels by pulling up on the material load lever.

7 Press the LOAD/UNLOAD key on the control panel to prepare the printer for

printing. The vacuums are turned on or off depending on their current state. If the rollto-roll vacuum is turned off, you can enable it after the job is received at the printer. See "Printing a single Roll-to-Roll or Flat Bed job” on page 64.

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8 The right edge of the material should be approximately ¼" (6mm) underneath the right

hold-down which is located at the far right edge of the platen.

Right material hold-down device

Slide the left hold-down so that it is ¼" (6mm) over the material to ensure that the

material does note curl or bend during printing.

Left material hold-down device

9 If you are using the winding unit for roll stock, continue with the procedure “Using

the winding unit.”

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Using the winding unit

Printed material may be immediately wound onto a take-up roll making unattended operation possible.

Once material is loaded, the winding unit operates automatically during printing. A material sensor monitors the length of printed material and activates the winding unit as required. When the printed material loop passes in front of the sensor, the winding unit turns on and winds the excess material onto the take-up roll.

To load material on the winding unit

1 If the winder has been previously activated it may attempt to wind the material while

you are trying to tape it onto the roller. Press and hold the winder switch for two seconds in either direction (Wind or Unwind) to disable the automatic winding mechanism.

Winder switch

2 Press the slew key on the control panel to move the roll material until it is near the

take up roll.

NOTE: You can not slew the material backward/down through the roll-to-roll mechanism.

3 Secure the material to the take-up roll with tape, attaching the material to the roll in

the center first, and then at either end.

4 Press the winder switch in either direction to activate the winder.

5 Continue printing as normal. The material will form a loose loop when printing. The

winding unit automatically activates when the loop of material passes in front of the sensors. When the slack material is wound around the take-up roll, the winding unit automatically stops.

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Removing material from the winding unit and printer

The optional Roll-to-Roll system is equipped with a cut-off blade groove along the width of the platen for easy removal of printed material from the supply roll.

Cut-off blade groove

To unload roll material from the winder and printer

1 Using a hand-held, cut-off blade in the blade groove (or a pair of scissors), carefully

cut the printed material off of the supply roll. You can cut off the material using a hand-held XACTO® knife in the cut-off groove which is located along the width of the roll-to-roll platen.

2 Use the forward/up SLEW key to move the printed material through the printer.

NOTE: You can not slew the material backward/down through the roll-to-roll mechanism.

3 Press the LOAD/UNLOAD key on the control panel to turn off the Roll-to-Roll

vacuum fans.

4 To remove the print from the take-up roll, press and hold the winder switch in the

unwind direction until the taped edge of the print is visible (Pressing and holding the switch disarms the automatic winding control).

5 Un-tape the printed material from the take-up roll.

6 Manually wind up the remaining rolled media onto the supply roll core.

7 To remove the unprinted material from the supply axle, remove it from the printer and

set it on a flat surface.

8 Loosen the thumbscrew and remove the left core flange from the material supply axle.

9 Remove the rolled media from the right core flange and off of the material supply axle.

10 Reinstall the left core flange onto the supply axle and return the axle to its position on

the printer.

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Understanding Roll-to-Roll printing margins

covered under warranty. In order to ensure

The Gerber CAT|UV is

able to print on a wide variety of materials at widths ranging from 12"

(30.5cm) to 64" (162.6cm).

The printing margins vary depending on the type of material used. When using a printer equipped with a roll-to-roll option, the material hold-down devices are installed ¼" (6mm) over the roll (vinyl) material edges to keep the edges from curling during printing. A printing margin of ¼" (6mm) is added from the edge of the shield, making the total margin ½" (12mm) on each side of the material, resulting in a maximum printing width of 63" (160cm) for rolled material. See the detailed illustration that follows.

Rolled material

Left

Material

Hold-down

Device

ROLLED

MATERIAL

Right Material Hold-down Device

Total material used in printing margins:

1 inch (25mm)

½” (12mm)

Total Margin

AUTOMATIC

PRINTING

MARGIN

¼” + ¼” = ½” 6mm + 6mm = 12mm

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Chapter 5: Printing Jobs on the Gerber CAT | UV

This chapter describes how to print jobs on the Gerber CAT|UV including choosing the print mode, viewing job information, starting and stopping jobs.

Using RIP software and profiles

The quality of the RIP (raster image processing) software can be very important when printing photo-realistic images. Gerber-authorized software has been approved to work with the Gerber CAT|UV and Gerber inks and materials. Following is a list of approved software at the time of printer introduction. Consult the GSP web site www.gspinc.com for an up-to-date listing.

♦ Onyx® ProductionHouse™, Onyx PosterShop™, or Gerber CAT|UV Onyx Driver

version X10 or higher (to ensure compatibility with the printer)

♦ ErgoSoft ♦ Caldera™

Gerber-authorized RIP software employs carefully engineered color profiles to produce crisp images and smooth tonal transitions. Be sure to choose the correct device profile for the material and print quality that you have chosen. Using the wrong device profile can result in shifting colors and unsatisfactory results. If you are using a material that does not have a profile available, use a profile for a similar material. It is recommended that you print a small “test” job to verify the expected results before printing large jobs.

Print mode options

The Gerber CAT|UV can set to print in several print modes. Refer to the chart on the following page for estimated print speeds and printing direction. Values shown are derived from printing on vinyl material.

When choosing the print quality, you make a choice of speed vs. quality. The highest quality printing uses the slowest speed. Choosing the correct print quality for the job is dependent on the type of results that you require and the intended viewing distance.

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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

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.

Printing a job – Instructional overview

Printing a job is done in a three simple steps: 1) loading the material, 2) sending the job to the printer from RIP software, and 3) running the job from the printer.

To print a job

1 To print a job, first press the LOAD/UNLOAD key once you have properly cleaned

and positioned the material. The

Loading material

2 Send the job from your RIP software to the printer.

Ready - <job name>

Loading material screen displays.

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3 Press the RUN JOB key (if using Flat Bed, slide light shield to edge of material).

Printing - <job name>

Canceling a job

Cancel a job by pressing the CANCEL key on the control panel. You can clear other jobs in the queue by pressing the CANCEL key as the jobs are received.

To cancel a job

1 To abort a job, press the CANCEL key while the job is running. The

wait . . .

screen displays.

Canceling job. Please

Canceling job. Please wait . . .

2 Multiple jobs sent to the printer are cleared from the queue one at a time by pressing

CANCEL as the jobs are received.

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Flat Bed Printing

This section covers all printing-related information for the Flat Bed selection.

Printing on the Flat Bed

Printing job setup is quick and easy. The Gerber CAT|UV automatically sets the proper lamp height and print gap for the loaded material without user intervention.

CAUTION: The distance between the substrate and the printhead is very small and slight variations in material thickness or even wrinkles in masking tape can cause head strikes or damage to the job.

When printing on material that has severely curled edges, the vacuum table may not completely pull down the material. Tape the material to the table using a light adhesive tape to prevent head strikes or other damage to the gantry from contact with the material. Ensure that the tape is wrinkle-free.

When using the flat bed feature of a printer, you can print jobs up to 10' (304.8cm) long. However, when printing materials in excess of 9' (274.3cm), in which a portion of the media comes to rest on the roll-to-roll platen, it is highly recommended that you reinforce the roll-toroll platen area material by taping down the last foot. This will keep materials from bowing in this area and prevent the possibility of head strikes that could ruin the job or the printheads.

For jobs shorter than 9' (274.3cm), the material will rest fully on the table, and therefore no tape is necessary unless the material has curled edges. If so, use a light adhesive tape to secure the edges to the table.

CAUTION: Incorrect arrangement of boards on the table, or adjusting / modifying the print gap can result in UV light being reflected into the print heads causing nozzle blockages. These failures are not

covered under warranty. In order to ensure print and printer-favorable conditions are met for each print, adhere to the related requirements starting on page 45.

NOTE: Rigid sign blank material must be flat within 0.03" (0.76mm). Warped material may jam in the printer. Materi

al that is bowed upward will contact the print carriage.

To run a single Flat Bed job

1 Press the FLAT BED key. The ROLL-TO-ROLL key is not active for

flatbed-only printers.

2 Load the material on the printer table. See the appropriate “Loading

the material” sections in Chapter 4.

3 Send the job from your RIP software to the printer. When the job is

received at the printer, the screen displays the

Ready: job name message.

Ready - <job name>

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4 Verify that the correct material is loaded on the printer and press the RUN JOB key on

the control panel.

5 The screen prompts you to

Slide UV shield next to the material if the material is thicker

than 0.040" (1mm). Grasp the UV shield handle and slide the shield until the right edge of the handle is aligned with the right edge of the material. This will properly position the shield in relation to the material so the thickness can be properly measured.

Slide UV shield next to the material

Line up right edge of sliding UV shield handle with edge of material.

Tip: If the lamps are not at proper operating temperature the Warm Up screen with progress bar displays. See “UV lamp warm-up” on page 67.

6 After completing the

job, the

Job Complete message displays, the printheads return to

the park position, the lamps turn off, and the printer beeps.

Job Complete

The screen then displays the

Printer Ready message. When the next job is received, you

will need to press the RUN JOB key to begin printing.

Printing a full bleed Flat Bed job

When in FLAT BED mode the Gerber CAT|UV has the ability to print full bleed which prints a job which is larger than the sign blank, resulting in the printed area extending beyond the edges of the material. To activate full bleed mode press the FLAT BED key a second time until the LED blinks. Pressing the FLAT BED key toggles between normal rigid printing (steady LED), and full bleed printing (blinking LED).

Since printing in full bleed mode extends the job beyond the perimeter of the substrate, protect the printer’s flat bed with tape or other masking material around all four edges of the material to prevent the job from being printed directly on the table. The material used to protect the table should be approximately the same height as the substrate on which you are printing. Thicker

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material will cause carriage strikes. Thinner masking material is acceptable as long it is within 1/16" (1.6mm) of the substrate thickness.

CAUTION: It is imperative that sacrificial material of the same thickness be used around print job to absorb excess ink to avoid damage to the printheads from ink spray and/or reflected UV causing ink cure on printheads.

covered under warranty. In order to ensure print and printer-favorable conditions are met for each print, adhere to the related requirements starting on page 45.

IMPORTANT: Make sure that thicker materials used to protect the fla

t bed are firmly secured in place. If the vacuum alone is not enough to hold down the protective materials, then use tape to secure their placement. This will prevent the protective material from shifting during printing.

Tip: If ink does contact the table when printing in full bleed mode, carefully remove the ink with a straight edge razor blade. It should lift off easily if you remove it promptly. The longer the ink remains on the table, the stronger it adheres, and the more difficult it can be to remove. After removing ink, spray the area with isopropyl alcohol and wipe it clean.

Printing double-sided, full-bleed

To print double-sided, full bleed jobs

1 Measure the sign blank to make sure that you know the exact height and width of the

substrate. In this example the sign blank is exactly 18" (457.2mm) wide and exactly 24" (609.6mm) high.

2 In the RIP, adjust the width and height so

that they are 0.75" (19.05mm) larger than the exact width and height of sign blank that you measured.

3 In your design program, resize the job by

0.75" (19.05mm) in each direction. For example, an 18" x 24" (457.2mm x 609.6mm)

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job would be resized to 18.75" x 24.75" (476.25mm x 628.65mm) to allow the printing to go 0.375” (9.52mm) beyond the sign blank on all sides.

4 Load the sign blank by aligning it to the table alignment marks/holes. Press the

LOAD/UNLOAD key on the printer when finished.

5 In order to protect the job from printing directly on the table, you need to protect the

printer’s flat bed with tape and scrap material that is at least 1/2" (12.7mm) wide. Standing in front of the printer, apply masking tape on the front and left side of the printer around the edges of the sign blank. Use scrap material on the right and back sides.

The scrap material must cover the full width and length of the sign blank so that there are no gaps between the sign blank and the masking tape or scrap material. The scrap material used to protect the table on the sides of sign blank should be approximately the same height as the substrate on which you are printing in order to properly protect the print heads.

NOTE: Thicker scrap material will cause carriage strikes. Thinner scrap material is acceptable as long as it is within 1/16" (1.6mm) of the substrate thickness.

Left side

of Printer

Masking

tape

Front of Printer

6 Using the new page size, send the job to the printer and start printing by pressing the

RUN JOB key in the GERBER CAT|UV. When the GERBER CAT|UV asks you to move the UV shield, move the UV shield so that it is aligned with the scrap material, not the substrate’s edge.

NOTE: It is important to align the UV shield with the scrap material so that the printer does not inadvertently print on the shield and result in ink build-up that can cause head strikes.

material

Scrap

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7 When the first side is complete, flip the

sign blank over left to right (if the top of the job is located at the front of the printer as shown in the previous illustration). Place the sign blank in the same location as the first side, completely inside the masking tape and scrap material. Repeat printing on this side.

8 Remove all masking tape and scrap

material so that the ink does not build up too high and scratch the heads.

NOTE: The scrap material on the back and right sides of the sign blank should be removed after every job; the masking tape at the edges of the table can be used a few times since it is thinner than the sign blank. Just be sure to remove and replace the tape whenever the ink buildup starts to approach the height of (or is higher than) the sign blank on which you are printing.

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Roll-to-Roll Printing

This section covers all printing-related information for the Roll-to-Roll selection.

Choosing a print mode for Roll-to-Roll printing

There are two modes for printing roll-to-roll jobs: Single and Continuous (Cont.). Print mode selection is controlled by the ROLL-TO-ROLL key on the control panel and is not active on flatbed-only printers. Press the ROLL-TO-ROLL key repeatedly to toggle between Single and Continuous mode.

Single mode

Use Single mode to run one job at

a time. Single mode allows you to:

♦ Change material between jobs ♦ Advance the material before the next job

After a job prints, the Gerber CAT|UV waits for you to begin the next job when it is received at the printer (see “Printing a single Roll-to-Roll job” on page 64).

Tip: You

can print a job in Single mode to verify printed output, and then switch to Continuous

mode to continue printing multiple jobs that you plan to print on the same rolled material.

Continuous mode

Continuous mode is designed for printing multiple jobs on the same material using the rollto-roll option. In Continuous mode, you must begin the first job, but subs

equent jobs start without operator initiation when they are received at the printer as long as the printer is in Printer Ready mode. When one job finishes, the next job begins immediately on the same material loaded in the printer. When all jobs that have been sent are completed, the printer waits for another job and begins printing as soon as it is received (See “Printing multiple Rollto-Roll jobs in Continuous mode” on page 65).

In continuous mode the

operator is not prompted to turn on the platen hold-down vacuum at the start of a job. The operator must turn the vacuum on or off as appropriate using the LOAD/UNLOAD key.

At the end of the first job printed in Continuous mode the lamps and vacuum (if it is active) will remain on for 10 minutes to enable the next job to start quickly. If the next job arrives after the 10 minute period the lamps will initiate the warm-up sequence prior to printing. The vacuum does not automatically resume and must be manually turned on using the LOAD/UNLOAD key.

Exiting Continuous mode (by either choosing Single or Flat Bed) automatically turns off the lamps and vacuum if they are currently on.

If a job does not start when running in Continuo

When the Gerber CAT|UV is printing in Continuous mode, the next job will not begin if one of the following conditions occurs:

♦ The CANCEL key is pressed

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♦ The printer has been removed from Printer Ready mode, for instance the INK LEVEL

key has been pressed

♦ An ink pouch needs to be replaced ♦ A system error occurs ♦ The printer mode is switched from Single to Continuous mode after the job has

completed (The printer checks the mode immediately after a job completes).

If any of the above conditions occur, correct the situation and begin the job manually. The Gerber CAT|UV will begin printing when it receives the job as long as there is material loaded and the ink pouches are not empty.

Printing a single Roll-to-Roll job

Job setup is quick and easy. The Gerber CAT|UV automatically sets the proper lamp height and print gap for the loaded material without user intervention.

NOTE: The distance between the substrate and the printhead is very small and slight variations in material thickness or even wrinkles in masking tape can cause head strikes or damage to the job.

CAUTION: Adjusting or modifying the print gap can result in UV light being reflected into the print heads causing nozzle blockages. These failures are not covered under warranty. In order to ensure print and printer-favorable conditions are met for each print, adhere to the related requirements starting on page 45.

To run a single Roll-to-Roll job

1 Press the ROLL-TO-ROLL key on the control panel until the

Single LED lights (the ROLL-TO-ROLL key toggles between Single and Cont. mode).

2 Load the material in the printer (see instructions starting on

page 48).

3 Send the job

job is received at the printer, the screen displays the

from your RIP software to the printer. When the

Ready: job name message.

Ready - <job name>

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4 If the vacuum is off, the following message displays giving you the option to turn the

vacuum on before printing. Press ENTER to turn on the vacuum and CANCEL to leave the vacuum off (CANCEL will not abort the job from this screen).

Roll to Roll Vacuum Fans

ENTER = Vacuum CANCEL = No

5 Verify that the correct material is loaded in the printer and press the RUN JOB key on

the control panel.

Tip: If the lamps are not at proper operating temperature the Warm Up screen with

progress bar displays. See “UV lamp warm-up” on page 67.

6 After completing the

job, the

Job Complete message displays, the printheads return to

the park position, the lamps turn off, and the printer beeps.

Job Complete

The screen then displays the

Printer Ready message. When the next job is received, you

will need to press the RUN JOB key to begin printing.

Printing multiple Roll-to-Roll jobs in Continuous mode

Continuous mode lets you run several jobs in Roll-to-Roll mode without having to press Run Job between each one. When one job finishes, the next job begins immediately on the same material loaded in the printer. When all jobs that have been sent are completed, the printer waits for another job and begins printing as soon as it is received. Continuous mode is designed for

printing multiple jobs on the same rolled material.

In continuous mode the operator is not prompted to turn on the platen holddown vacuum at the start of a job. The operator must turn the vacuum on or off as appropriate using the LOAD/UNLOAD key.

For complete details on Continuous mode, see “Continuous mode” on page 63.

To print multiple Roll-to-Roll jobs

1 Press the ROLL-TO-ROLL key on the control panel until the Cont. LED lights. The

ROLL-TO-ROLL key toggles between Single and Cont. mode (The ROLL-TO-ROLL key is not active for flatbed-only printers).

2 Load the material in the printer. See instructions starting on page 48.

3 Send the job

from your RIP software to the printer. When the job is received at the printer, the screen displays the printing.

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Ready: job name message and the estimated duration of

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Ready - <job name>

4 Turn on (or off) the vacuum as required for the material being printed using the

LOAD/UNLOAD key.

5 Verify that the correct material for all the jobs you wish to print is loaded in the printer

and press the RUN JOB key on the control panel. The first job begins printing and the

Printing - <job name> screen displays.

Printing - <job name>

6 After completing the job, the screen returns to

Printer Ready. When the next job is

received it will begin printing automatically. If you send another job to the printer while it is actively printing, it will begin as soon as the current job is done.

The UV lamps and vacuum (if it is active) remain on for 10 minutes after a job is

completed and then will automatically shut off. If the next job arrives after the 10minute period the lamps will initiate the warm-up sequence prior to printing. The vacuum does not automatically resume and must be manually activated using the LOAD/UNLOAD key.

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Automatic printer operations

There are some behavioral characteristics of the Gerber CAT|UV that you should be aware of before printing a job.

UV lamp warm-up

The lamps are turned on only before starting a job. The UV bulbs require a short warm-up cycle if they are not at the proper operating temperature. When the lamps are in the warm-up phase the progress bar will appear on the screen estimating the amount of time required to warm the lamps to the proper operating temperature.

Warm Up - <job name>

70%

When they have reached their operating temperature, the cooling fans automatically turn on to maintain the proper temperature.

NOTE: The UV lamps do not require a cool down phase before re-striking.

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 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 it goes into 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 should perform the Clean Heads procedure before printing (see page 78).

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.

Automatic spitting to clear the nozzles

Every five minutes while the printer is active, the Gerber CAT|UV clears the printhead nozzles by spitting a small amount of ink in the waste ink tray. If the printer is printing when spitting is scheduled, it pauses at the end of a swipe and moves the carriage to the spitting location and clears the printheads. After spitting, printing resumes.

When the printer has entered idle mode, it continues to spit for the first two hours. After two hours it ceases to spit ink and you must run the Clean Heads procedure upon resuming printing operations.

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User-selectable modes

There are some optional tools that can be utilized to enhance print output speed and quality that you should be aware of before printing a job.

UV lamp automatic shut-off or Continuous mode

The UV lamps are designed to automatically turn off upon completion of a job. When a printer is equipped with the optional Roll-to-Roll unit, it can be set to run Roll-to-Roll jobs in Continuous mode. In Continuous mode the lamps remain lit so that the next job can run immediately after it is received. If there is no job in the queue, the lamps and fans will shut down after a delay of 10 minutes. See “Choosing a print mode for Roll-to-Roll printing” on page 63.

Lamp Delay mode

Lamp Delay mode allows the user to set the UV lamps to remain on for 10 minutes after completing a job when printing in Flat Bed or Roll-to-Roll areas. This saves time by removing wait time for lamp warm up. The user can immediately run jobs back to back. Lamp Delay mode is set in the Setup section of the printer Menu or on the System Settings web page. The default setting is off.

Once Lamp Delay mode is activated, pressing the CANCEL key will not turn off the lamps. When a user performs a maintenance function the lamps are turned off, but Lamp Delay remains enabled. Lamp Delay can be disabled (and the lamps turned off) in the Setup menu or from the System Settings web page.

When Lamp Delay is activated and utilized for flatbed printing, the gantry parks at the back of the printer (opposite the maintenance shelf) between jobs. This is to ensure that the UV lamps do not damage any loaded material. Note that when the gantry moves to its park position it may unexpectedly knock off items that may be located there. Do not use the printer as a table to store items.

When Lamp Delay is activated and utilized for roll-to-roll printing, the gantry parks in the flatbed area of the printer between jobs. This is to ensure that the UV lamps do not damage any material in the roll-to-roll area. Do not use the printer as a table to store items.

NOTE: Do not leave material on the flatbed area when using Lamp Delay mode and printing roll-to-roll jobs. Do not leave material in the roll-to-roll area when using Lamp Delay and printing flatbed jobs. Damage may occur to printheads, other hardware and/or material.

Immediately before printing a job, the lamps will turn off temporarily while the printer is sensing the material height. The lamps will automatically turn back on and there may be a short warm-up cycle.

When Lamp Delay mode is activated in Flat Bed or Roll-to-Roll single mode, you must still press the RUN JOB key in order to start the next job.

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To activate Lamp Delay Mode from the printer’s menu

1 From the main control panel press the MENU key. The

Status screen displays.

Status

2 Press the Y or Z key until the

Setup screen displays.

Setup

3 Press ENTER to display the

Lamp Delay screen.

Lamp Delay

ON OFF

4 Use the arrow keys to select

OFF and then press ENTER.

ON and then press ENTER. To disable Lamp Delay, select

Lamp Spec mode

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 for 45-60 seconds prior to the start of the job. The lamp warm-up cycle is longer when the printer is set to Lamp Spec mode.

Lamp Spec mode is set in the Setup section of the printer Menu or on the System Settings web page. The default setting for Lamp Spec Mode is Normal.

NOTE: Lamp Spec mode may or may not increase the curing success of some materials. Use Gerber-qualified materials for the best results.

To activate Lamp Spec mode from the printer’s menu

1 From the main control panel press the MENU key. The

Status screen displays.

Status

2 Press the Y or Z key until the

Setup screen displays.

Setup

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3 Press ENTER to display the Lamp Delay screen.

Lamp Delay

4 Press the arrow keys until the

Lamp Spec Mode screen displays and then press ENTER.

Lamp Spec Mode

Normal High

5 Use the arrow keys to select

select

Normal and then press ENTER.

High and then press ENTER. To disable Lamp Spec Mode,

Large Field mode

Large Field located in the Setup menu improves the print quality of large solid areas of color, especially light blue or green. By default, Large Field is disabled and the printer is set to normal mode which enhances details and small text in a print. Once Large Field is enabled it remains active until disabled by the operator. Large Field mode can also be set on the System Setting web page.

To activate Large Field mode from the printer’s menu

1 From the main control panel press the MENU key. The

Status screen displays.

Status

2 Press the Y or Z key until the

Setup screen displays.

Setup

3 Press ENTER to display the

4 Press the arrow keys until the

Lamp Delay screen.

Large Field screen displays and then press ENTER.

Large Field:

On Off

5 Use the arrow keys to select

select

Off and then press ENTER.

On and then press ENTER. To disable Large Field mode,

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Step Blending mode

Step Blending located in the Setup menu improves the print quality of images and large solid area of color 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.

To activate Step Blending mode from the printer’s menu

1 From the main control panel press the MENU key. The

Status screen displays.

Status

2 Press the Y or Z key until the

Setup screen displays.

Setup

3 Press ENTER to display the

Lamp Delay screen.

Lamp Delay

4 Press the arrow keys until the

Step Blending screen displays and then press ENTER.

Step Blending:

On Off

5 Use the arrow keys to select

mode, select

Off and then press ENTER.

On and then press ENTER. To disable Step Blending

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Chapter 6: Printer Maintenance

Regularly performing recommended maintenance tasks will help keep the Gerber CAT|UV running at peak performance. This chapter describes required daily, weekly, and monthly printer maintenance. Following is a chart of maintenance terms, their definition and intended usage. See the Regular Preventive Maintenance Chart on page 74 for an overview of all necessary maintenance procedures.

Required maintenance supplies

Head cleaning supplies

♦ Daily Maintenance Solution ♦ Fisher Scientific foam-tipped swabs ♦ Anticon® Gold heavy-weight, clean room wipes ♦ All-purpose wipes ♦ Impervious nitrile gloves at least 8 mils thick ♦ Safety glasses ♦ Waste ink tray sponge

Term Definition Intended Usage

Clean Heads Procedure

Purge Ink is pumped from the pouch

A small amount of ink is pumped from the pouch through the nozzles. May be referred to as a “prime”.

through the nozzles and the purge valve.

Routine maintenance. If there are a few missing and/or misfiring nozzles in each head.

To remove trapped air in a printhead or if there are many missing nozzles in a specific head. Also used if you are filling an ink line (embedded in the “fill ink line” procedure), or replacing a head or reservoir assembly.

End of Day Clean

Periodic Daily Maintenance Solution and As needed in order to maintain healthy

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Daily Maintenance Solution is swabbed on all heads at the end of the day after all printing is complete.

Printheads are cleaned using Daily Maintenance Solution to remove debris and ensure printhead health overnight.

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Maintenance Process

Gerber Clean Solution are applied followed by a Clean Heads Procedure whenever angled nozzles are occurring in order to recover angled nozzles.

nozzles. See page 95.

Daily Maintenance Solution

Gerber Clean Solution

All Purpose wipes

Anticon® Gold heavyweight, clean room wipes

Fisher Scientific foam-tipped swabs

250ml bottle Use with Anticon-covered swabs to clean

the printheads whenever the LED is lit (after two hours of idle time and after four hours of printing time) and during the End of Day Clean procedure.

125 ml bottle Use with foam-tipped swab as part of the

Periodic Maintenance Process on an asneeded basis (whenever angled nozzles are prevalent).

56 count package Use in the waste ink tray to absorb excess

ink.

300 count package Use with Daily Maintenance Solution to

wipe the printheads during Clean Heads Procedure and End of Day procedures. Anticon wipes are the only wipes that should ever touch the printheads.

50, 250 or 500 count package

Use for cleaning the printheads. These non-scratching, lint free swabs are the only swabs recommended for the GERBER CAT|UV printhead.

Waste ink tray sponge

CAUTION: It is very important to use only Gerber-recommended wipes and swabs when cleaning the printheads. Use of any other wipes and swabs could damage the printheads. Be aware that damage caused by use of unapproved swabs or wipes will not be covered under the standard 12 month warranty for the Gerber CAT|UV or a Gerber Service Contract. Always use new, clean wipes and swabs. Never reuse wipes and swabs. Never substitute paper towels for wipes. Dispose of used swabs and wipes according to local laws and regulations.

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A sponge that resides in the waste ink tray to capture ink mist and prevent spitting form adversely affecting printheads and prints.

Protection of printheads, prints, and absorption of ink spits.

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Gerber CAT | UV Regular Preventive Maintenance

Following is a chart of recommended regular maintenance to be performed by the owner to ensure continued print quality and trouble-free operation. Refer to specific instructions on recommended maintenance procedures in this manual.

Action Daily Weekly Monthly 6

Months

Perform a Clean Heads procedure whenever the Clean Heads LED is flashing before printing. Check and clean the waste ink tray as needed.

Perform an End of Day Clean procedure at the end of the print day.

Clean ink from the top of the sliding UV shield.

Clean ink from the right side plate and the side plate between the waste ink tray and the table.

Perform a Periodic Maintenance Process.

Discard and replace the waste ink tray sponge

At every

Clean

Heads

Procedure

As needed (roughly every 40 hours of print time)

Months

Clean Roll-to-Roll platen (if so equipped) and Flatbed table.

Clean the Head Access Door.

Clean ink drips from the ink drawers when you replace ink bags.

Clean the table rails.

Clean the Roll-to-Roll grit wheels (if so equipped).

Clean Roll-to-Roll rubber drive wheels with alcohol (if so equipped).

Replace rubber light shields as needed.

Replace Maintenance Shelf Mat as needed.

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At ink

change

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User-Replaceable Consumable items

• Daily Maintenance Solution

• GerberClean Solution

• Impervious nitrile gloves at least 8 mils thick

• Fisher Scientific foam-tipped swabs

• Anticon Gold heavy-weight, clean room wipes

• All-purpose wipes

• Waste ink tray sponge

• GerberCAT Ink Cyan 1 Liter Pouch

• GerberCAT Ink Yellow 1 Liter Pouch

• GerberCAT Ink Black 1 Liter Pouch

• GerberCAT Ink Magenta 1 Liter Pouch

• GerberCAT Flush 1 Liter Pouch

• IP Surface Cleaner

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Daily maintenance

NOTE: The Clean Heads Procedure and End of Day Clean only need to be performed when the printer is being utilized.

Tips for Clean Heads procedure

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

♦ To maintain consistent nozzle performance. ♦ To introduce a small amount of Daily Maintenance Solution to the nozzle plate to prevent

ink from curing or adhering to the nozzle surface.

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

♦ As light as possible while still making contact.

o Effectively, you are trying to wick the excess ink off the surface of the nozzle

plate. You ARE NOT trying to scrub the nozzle surface. The printhead nozzle plate is a very sensitive coated surface. Excessive pressure can result in scratches to the printhead surface or removal of the protective coating, which can result in lost or angled nozzles that will negatively affect print quality. The most effective way to hold the Anticon wipe-covered swab is with 2 fingers. Holding the swab with more fingers makes it more likely you will apply excessive pressure to the

nozzle plat

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

♦ You should print a nozzle out test print after every 4 hour clean.

o You should check for any new missing nozzles based on your previous nozzle

out pattern. There are 4,096 nozzles in your printer, each with a distinct line on your nozzle print pattern. You want to make sure that you have as many nozzles as possible firing.

4) Why do I lose nozzles?

Reasons for temporary loss of nozzles include:

♦ Wiping too hard with the Anticon wipe-covered swab. ♦ Using too much Daily Maintenance Solution on the surface of the Anticon wipe-covered

swab.

♦ NOT covering Fisher brand foam-tipped swab with Anticon wipe as per this manual’s

specific instructions.

♦ Printing too long between cleans. ♦ Not performing an End of Day Clean.

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♦ Ingesting air into the heads through nozzles that have dropped out for the reasons

listed above.

These temporary losses of nozzles can normally be recovered by repeating a Clean Heads

procedure.

For losses of large number of nozzles, especially adjacent nozzles, it may be necessary to perform a purge. For example, a normal clean pushes ink through the heads for a few seconds, while a purge pushes ink through the heads for several more seconds. This should only be necessary to dislodge large amounts of air.

Reasons for permanent loss of nozzles include:

• Wiping debris from the underside of the carriage into the nozzles.

o You must be careful when wiping the printhead during normal maintenance.

Any dust, lint, or debris around the nozzle surface can plug a nozzle if it is drawn into the nozzle while you are wiping. You need to keep the area around the nozzles clean using a new Fisher Brand foam tip swab and Daily Maintenance Solution. You should never re-use a swab or drag a swab through debris on the underside of the carriage and then allow that swab to touch the nozzle surface.

• Scratching the anti-wet coating on the nozzle plate using excessive wiping pressure.

o Think of the nozzle plate as a very sensitive surface and be sure to wipe very

gently. The point is to make contact with the printhead surface to wick away ink, not to scrub debris off the surface. Use only two fingers on the Anticon wipe-covered swab and concentrate on making contact to wick ink away, not to scrub the surface.

• Allowing too much UV exposure to the underside of the carriage. This can happen

when...

o Failing to use your sliding shield correctly o Not placing your rigid material in the ‘home’ position o Printing on non-rectangular material o Leaving gaps between material blanks on the printer surface o Using mismatched thickness of sacrificial material. It should be the same

thickness as the board to be printed (see page 45).

o Printing on

mirrored surfaces

o Forcing print gap height higher than actual target substrate height.

• Reusing swabs and wipes

• Allowing missing nozzles to go un-recovered for several days of printing.

• Skipping Clean Heads Procedure and End of Day Clean.

• Using the wrong swabs and/or wipes (use ONLY Gerber approved Fisher Brand foam

tip swabs and Anticon® Gold heavy-weight, clean room wipes). Ensure they are covered with an Anticon wipe when the procedure calls for it.

WARNING: Permanent nozzle loss due to any of the above mentioned userinduced failure modes is not covered under warranty.

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CAUTION: It is imperative that the End of Day Clean is performed to prevent ink buildup. A Clean Heads procedure must be performed whenever the Clean Heads LED is blinking. Perform this simple maintenance procedure to maximize printhead life and ensure high quality prints.

NOTE: The Clean Heads LED will flash whenever there is a power cycling. Please do not ignore the flashing of this message when it is actually time to clean the heads.

NOTE: At any time, if you notice ink drips on the table or print, inspect the left and right side plates to see if ink has dripped in these locations, and remove any drips or cured ink immediately.

Clean Heads Procedure

Perform a Clean Heads procedure whenever the Clean Heads LED is lit before printing in order to clear

the nozzles by pushing ink through the printhead nozzle plates. The UV bulbs will turn off and the printheads will move to the maintenance location before cleaning begins. The Clean Heads command is located in the Maintenance section of the printer's menu but can be easily accessed using the CLEAN HEADS key on the control panel.

After cleaning the printheads, wipe the nozzle plates with an Anticon-covered swab moistened with Daily Maintenance Solution as described in the following procedure. It is critical that you follow the instructions exactly, using only the amount of Daily Maintenance Solution that is recommended, or you could cause printhead problems. When wiping is complete, print a Nozzle Out Job to verify that all of the nozzles are functioning.

If there are missing (clogged) nozzles you can clean all of the printheads again, or clean only the color printheads that have missing nozzles.

The UV shield and the side plates should be checked and cleaned during every Clean Heads procedure. This procedure should be done after you have completed the Clean Heads procedure and before you lift the Maintenance Shelf.

The Clean Heads procedure timer automatically resets after cleaning all of the printheads.

Required Clean Heads procedure cleaning supplies

♦ Daily Maintenance Solution ♦ Fisher Scientific foam-ti

pped swabs

♦ Anticon Gold heavy-weight, clean room wipes ♦ All-purpose wipes ♦ Impervious nitrile gloves at least 8 mils thick ♦ Safety glasses ♦ Waste ink tray sponge

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NOTE: Both job length and material thickness affect the frequency of Clean Heads procedures required to maintain healthy printheads: shorter length jobs and/or thicker materials will increase the frequency of need for Clean Heads procedures due to greater UV exposure to the printheads under these conditions. Be sure to monitor the Clean Heads LED and perform a Clean Heads procedure whenever the LED is flashing in order to maintain healthy printheads.

1 From the main or auxiliary control panel press the CLEAN HEADS key to begin the

cleaning sequence. This procedure pushes a small quantity of ink through all of the printheads to clear the nozzles.

2 The printhead carriage moves to the maintenance location and the screen prompts you

Remove the Head Access Door. Press ENTER when done. Set the door aside on an all-

to purpose wipe.

3 The printer prompts you to

Check Waste ink Tray. Remove the

waste ink tray and empty ink if necessary. Do not remove sponge unless required (see page 83).

CAUTION: Use caution not to spill ink out of tray sides as sponge may

randomly redirect ink flow when pouring into

waste container.

4 Slide the waste tray back in place to automatically begin the

cleaning sequence. The working icon displays during the cleaning sequence. Ink will drip from all of the printheads into the waste ink tray. The head cleaning process takes a few minutes and a series of three progress bars display sequentially as follows:

Please wait…, Head Cleaning, Please wait….

Head Cleaning

70%

5 When the Clean Heads procedure is complete, the system prompts you to

Access Door.

6 After the head access door is installed the screen prompts you to

printheads

Lower shelf and swab

Replace Head

7 Lower the Maintenance Shelf by pushing down in the middle of the shelf. Do not push

on either end of the shelf as it causes the shelf to twist.

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8 Place 3-5 drops of Daily Maintenance Solution onto a new Anticon-covered swab.

CAUTION: It is critical that you only the specified drops of Daily Maintenance Solution to moisten each Anticon wipe-covered swab. Using more than the recommended amount will over-saturate the swab and may allow the printhead vacuum pressure to absorb excess solution into the printhead itself. If this happens, the extra solution will dilute the GerberCAT ink causing it not to cure properly during printing.

9 Use one side of an Anticon wipe-covered swab to clean the left-most printhead. Wipe

the printhead from back to front 2 times at a 45° angle, using light pressure, by holding the swab as close as possible to the middle of the stick, between the thumb and index finger as pictured below.

NOTE: There are two printheads for each color.

10 Reposition the Anticon wipe over the foam-tipped swab so that a new, clean area is

located at the swab tip. Apply 3-5 drops of Daily Maintenance Solution and then wipe

the 2

printhead of the same color repeating the previous step.

CAUTION: Never reuse old swabs to clean the printhead. Never use the same Anticon-covered swab on two different color printheads.

11 Repeat the previous steps, using a new Anticon wipe-covered swab for each color set

of printheads. The printer prompts you to

NOTE: Prior to raising the Maintenance Shelf, be sure to complete previous procedure for all printheads prior to proceeding.

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Raise shelf when done.

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12 Dispose of wipes and swabs according to state and local laws and regulations.

13 Inspect the small, flat side plate between the waste ink tray and the table, and the

opposite side plate for cured ink. Occasionally ink may drip in these areas and will be cured by the UV lamps, creating small mounds of cured ink. As the carriage travels over this area it can contact the cured ink and damage the printheads.

Sliding UV Shield

14 Using your hand move the sliding UV shield toward the

center of the printer. Wipe any uncured ink off the UV shield with an all-purpose wipe. Clean any cured ink off the UV shield using a straight edge razor blade.

15 Wipe any uncured ink off the left and right side plates

with an all-purpose wipe. Clean any cured ink off the side plates using a straight edge razor blade. The screen prompts you to

Raise shelf when done. Be sure to follow

the entire procedure to completion before raising shelf.

Left side plate between waste tray and table Right side plate

16 Dispose of ink and wipes according to state and local laws and regulations.

17 Wipe down the side plates and sliding UV shield with an all-purpose wipe that has

been dampened with water. Dry them with a new wipe.

18 Raise the Maintenance Shelf and the printer returns to the home position and

automatically resets the Clean Heads procedure timer. The

Printer Ready screen

displays.

Tip: After a Clean Heads procedure, you can print a Nozzle Out test print to verify that all printhead nozzles are firing properly. The Nozzle Out job is available from the Calibration section of the printer’s Menu.

NOTE: A nozzle health is OK or not. If it is OK, proceed as normal. If NOT, check ink levels via front

Nozzle Out recommended message appears. Print a Nozzle Out job to determine if

panel (see page 35). Replace any empty pouches and repeat Clean Heads procedure. If none are empty and print quality of Nozzle

Out job is poor, seek technical assistance.

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End of Day Clean

CAUTION: All 8 heads MUST be cleaned at the end of every print day.

NOTE: A shortcut for Steps 1-4 below can be performed by first depressing and holding down the PAUSE key, and then depressing the CLEAN HEADS key at the same time.

1 From the main control panel press the MENU key. The

Status

2 Press the Y or Z key until the

Maintenance screen displays.

Status screen displays.

Maintenance

3 Press ENTER to display the

End of Day Clean

End of Day Clean screen.

4 Press ENTER and the gantry will move over the maintenance shelf and will prompt

you to

lower the Maintenance Shelf.

5 Lower the maintenance shelf. The screen now displays Raise shelf when done.

NOTE: Do not raise shelf until all heads have been swabbed with Daily Maintenance Solution.

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6 Put impervious nitrile gloves on both hands and put on safety glasses.

7 Place 3-5 drops of Daily Maintenance Solution onto a new Anticon-covered swab.

8 Wipe the left-most printhead from back to front 2 times at a 45° angle, using light

pressure, by holding the swab in the middle of the stick, between the thumb and index finger as pictured below.

NOTE: There are two printheads for each color.

9 Reposition the Anticon wipe over the foam-tipped swab so that a new, clean area is

located at the swab tip. Apply 3-5 drops of Daily Maintenance Solution and then wipe

the 2

printhead of the same color repeating the previous step.

CAUTION: Never reuse old swabs to clean the printhead. Never use the same swab on two different color printheads.

10 Repeat the previous steps for the remaining heads, moving from left to right, and

using a new Anticon-covered swab for each color set of printheads.

11 Dispose of swabs and wipes according to state and local laws and regulations.

12 Raise Maintenance Shelf when complete.

Emptying and cleaning the waste ink tray

When you need to empty the tray, remove the waste ink tray sponge, clean the waste ink tray, and install a new sponge.

To empty and clean the waste ink tray

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1 When prompted during the Clean Heads procedure, remove

the head access door and set it aside on an all-purpose wipe.

2 The printer displays

ENTER when done.

Check Shelf, Access Door, and E-stops. Press

3 Remove the waste ink tray by sliding it out. Removing the

waste ink tray temporarily suspends printhead spitting.

4 Empty the tray of any liquid ink into an appropriate disposal

container.

NOTE: Waste ink tray sponge should be replaced weekly.

CAUTION: Use caution not to spill ink out of tray sides as sponge may randomly redirect ink flow when pouring into waste container.

5 If it is REQUIRED to replace the waste ink tray sponge at this time, carefully remove

the saturated sponge and dispose of it according to state and local regulations and proceed with next Step below. If is NOT REQUIRED to replace the waste ink tray sponge at this time, proceed to Step 10.

6 Wipe out the tray with a clean all-purpose wipe. If cured ink is present, a putty knife

and/or razor blade can be used to carefully scrape it loose and then it can be discarded with the all-purpose wipes according to local, state, and federal regulations.

7 Thoroughly clean the exterior of the waste tray, paying special attention to the

topmost and rearmost surfaces of the tray, ensuring NO liquid ink is present.

Topmost surfaces

Rearmost surface

CAUTION: Ensure NO liquids are present on the rearmost surface/fin. Liquid ink on the rearmost surface WILL destroy waste tray sensor.

8 Dispose of ink-soaked wipes according to state and local laws and regulations.

9 Carefully install a new waste ink tray sponge into the waste ink tray so that it is fully

seated in the tray, below the top-most surface of the tray, and between the four sponge location marks on the edges of the tray.

Sponge

Topmost surfaces

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CAUTION: Ensure sponge is slightly recessed below height of top-most surface of waste tray, to ensure it does not come into contact with printheads.

10 Reinstall the waste ink tray.

11 Reinstall the head access door.

12 Press ENTER. The gantry homes itself and the

Printer Ready screen displays.

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Weekly maintenance

This section describes the recommended weekly maintenance.

Cleaning the flat bed

Each week you should carefully clean off any ink residue on the flat bed using a straight edge razor blade. Use care that you do not scratch the anodized surface of the flat bed. Use the SLEW keys to move the gantry out of the way to enable you to reach all areas.

Cleaning the head access door

The head access door is designed to trap tiny ink droplets that occur when the printhead spits to clear the nozzles. The head access door is located above the waste ink tray and is connected to the emergency stop circuit. To remove the head access door, reach under the door and pull forward firmly.

Whenever the head access door is removed the printer automatically cancels the current job, and turns off the motors and UV lamps. You should only remove the head access door when prompted or when the system is idle.

Inspect the head access door weekly. Wipe away any uncured ink with an all-purpose wipe. Cured ink can be scraped off with a razor blade.

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Monthly maintenance

This section describes the recommended monthly maintenance.

CAUTION: A Purge must be performed on all printheads once a month to ensure ink line and nozzle health.

Purging ink lines to remove air

Occasionally you may have air introduced in the system that must be removed or you may have several missing nozzles in a specific head that do not return when a Clean Heads procedure is performed. This is when a purge should be performed. When purging a specific ink color, both heads connected to that color reservoir are purged. You can also choose to purge all ink colors. When the color at a time.

The Purge command is located in the Maintenance section of the printer's menu.

All Colors option is chosen, the printer cycles through the purging sequence, one ink

CAUTION: It is required that only Gerber-recommended wipes and swabs be used when purging the printheads. Use of wipes and swabs other than what is recommended could damage the printheads. Always use new, clean wipes and swabs. Never reuse wipes and swabs. Never substitute paper towels for wipes.

NOTE: You must perform a Purge Procedure on all heads every 160 hours of print time or monthly, whichever comes first.

Required purge supplies

♦ Daily Maintenance Solution ♦ Fisher Scientific foam-ti

pped swabs

♦ Anticon Gold heavy-weight, clean room wipes ♦ All-purpose wipes ♦ 2mm, long handled, Allen wrench (supplied) ♦ Flashlight is recommended to assist in locating the valves and viewing the ink flow

To purge ink lines to remove air

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1 From the main control panel press the MENU key. The Status screen displays.

Status

2 Press the Y or Z key until the

Maintenance screen displays.

Maintenance

3 Press ENTER to display the

End of Day Clean

End of Day Clean screen.

4 Press the Y or Z key until the

Purge screen displays.

Purge

5 Press ENTER to display the Choose Color screen. Use the Y Z keys to select the

printhead color that you wish to purge. You may also select

All Colors to purge all of the

printheads during one procedure. When purging all colors, the messages differ slightly from those shown in this procedure.

Choose Color:

Cyan

6 Press ENTER to begin purging that color printhead. This

procedure will push ink through the printhead to clear air from the nozzles. The printhead carriage moves to the maintenance location and the screen prompts you to

Door. Press ENTER when done.

wipe and press ENTER.

7 The printer prompts you to

waste ink tray and empty ink if necessary. Do not remove sponge unless required (see page 83).

Set the door aside on a disposable

Check the Waste ink Tray. Remove the

Remove the Head Access

CAUTION: Use caution not to spill ink out of tray sides as sponge may randomly redirect ink flow

8 Slide the waste ink tray back in place. A

displays for approximately 1 minute. The printer then prompts you to

COLOR” Purge Valve 1. Press ENTER when done.

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when pouring into waste container.

Please wait… message and progress bar

Open “INK

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Open CYAN Purge Valve 1

Press ENTER when done

WARNING: Use care when opening the ink valves as it is easy to push the printhead carriage away from the waste ink tray causing ink to drip on the printer electronics and cause damage. The carriage should not move during this procedure. The bottom of the carriage has a shield, hold the shield in place with your fingers while turning the purge valve set screw. This will keep the carriage from moving. If it does move, pull it back with your fingers.

NOTE: If the carriage is not correctly parked above the waste ink tray, the printer prompts you to Move the Carriage to PARK position before Purge. Press ENTER when done. To move to PARK position, you must grab the carriage by the shield with your fingers and pull until it stops.

9 Open the first purge valve for the color you wish to purge using the 2mm Allen

wrench. Turn the wrench ¾ to one full turn counterclockwise to open the valve. You may find a flashlight helpful when locating the valves. Press ENTER when done.

10 The printer displays

flow of ink coming from the purge ports underside the purge block. It should be a consistent, rapid flow of drips to a steady stream. If NOT, there may be air in the line and/or blockage(s) in the purge block. Close the purge valve fully and re-open ¾ to 1 full turn using the Allen wrench. Check the ink flow again. If ink still does not flow in a steady stream, contact Gerber Service.

11 The printer then prompts you to

done.

After closing the first color valve and opening the second color valve, press

ENTER to begin the next purging sequence.

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Purging… Verify ink flow and a progress bar displays. Observe the

Close “INK COLOR” Valve 1. Open Valve 2. Press ENTER when

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Close CYAN valve 1. Open valve 2.

NOTE: The Front Panel may display

Press ENTER when done

Depressurizing, please wait... depending upon how quickly

valves are closed/opened and ENTER is pressed.

12 The printer displays

Purging… Verify ink flow and a progress bar displays. Observe the

13 After the selected printheads are purged, the screen prompts you to

valves. Press ENTER when done.

Using the 2mm Allen wrench, close all purge valves and

Close all purge

press ENTER when done.

Close all purge valves

Press ENTER when done

14 The screen prompts you to select another ink color to purge. If you wish to purge

another ink color, use the arrow keys to select

Yes. The Choose Color screen displays and

you can begin the purge sequence again with a different color. If you are done, select

No to continue.

Another Color?

Yes No

15 When all purging is complete the system prompts you to

ENTER when done

. Moisten a swab by applying 1 drop per side of Daily Maintenance

Clean the Purge Block. Press

Solution to clean the purge block, which is located directly under the purge valves. Be sure to swab the entire underside, not just the outer edge. Do this to remove any remaining ink and prevent it from dripping during printing and/or curing on the Purge Block. Press ENTER when done.

After purging, use a Daily Maintenance Solution-moistened swab to wipe the Purge Block directly under the valves.

16 Dispose of swab according to state and local laws and regulations.

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17 The printer now begins to calibrate the ink level and reestablishes ink pressure. This

process may take a few minutes and a progress bar displays during calibration with a

Please wait . . . message.

18 When finished, the system prompts you to

19 After the head access door is installed the screen prompts you to

printheads

Replace Head Access Door.

Lower shelf and swab

20 Lower the Maintenance Shelf by pushing down in the middle of the shelf. Do not push

on either end of the shelf as it causes the shelf to twist.

21 Place 3-5 drops of Daily Maintenance Solution onto a new Anticon-covered swab.

22 Wipe the left-most printhead from back to front 2 times at a 45° angle, using light

pressure, by holding the swab in the middle of the stick, between the thumb and index finger as pictured below.

NOTE: There are two printheads for each color.

23 Reposition the Anticon wipe over the foam-tipped swab so that a new, clean area is

located at the swab tip. Apply 3-5 drops of Daily Maintenance Solution and then wipe

the 2

printhead of the same color repeating the previous step.

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CAUTION: Never reuse old swabs to clean the printhead. Never use the same Anticon-covered swab on two different color printheads.

24 Repeat the previous steps for the remaining heads as required, moving from left to

right, and using a new Anticon-covered swab for each color set of printheads. The printer prompts you to

Raise shelf when done.

NOTE: Prior to raising the Maintenance Shelf, be sure to complete all steps for all printheads.

25 Dispose of wipes and swabs according to state and local laws and regulations.

26 Raise Maintenance Shelf when complete. After raising the maintenance shelf, the

printer returns to the home position. The

Printer Ready screen displays.

Tip: After a Purge, you can print a Nozzle Out test print to verify that all printhead nozzles are firing properly. The Nozzle Out job is available from the Calibration section of the printer’s Menu.

NOTE: A

Nozzle Out recommended message appears. Print a Nozzle Out job to determine if

nozzle health is OK or not. If it is OK, proceed as normal. If NOT, check ink levels via front panel (see page 35). Replace any empty pouches and repeat Clean Heads procedure. If none are empty and print quality of Nozzle

Out job is poor, contact Gerber Service.

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Six month maintenance

This section describes the recommended six month maintenance.

Cleaning the table rails

Every six months clean the two table rails from end to end with an all-purpose wipe moistened with isopropyl alcohol.

Cleaning the Roll-to-Roll grit wheels

Every six months, if the printer is equipped with a Roll-to-Roll unit, clean the Roll-to-Roll grit wheels with a stiff brush and adhesive remover to remove any vinyl adhesive or other residue that can be left behind by some materials.

To clean the Roll-to-Roll grit wheels

1 Press an emergency stop button to turn off power to the printer.

2 Clean the grit wheels from underneath the Roll-to-Roll platen using a stiff brush

dipped in the adhesive remover.

3 Access all surfaces of the grit wheels by rotating the grit wheel drive belt by hand.

Grit wheels Grit wheel drive belt

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Cleaning the Roll-to-Roll rubber drive wheels

Every six months, if the printer is equipped with a Roll-to-Roll unit, clean the Roll-to-Roll rubber drive wheels with an all-purpose wipe moistened with isopropyl alcohol. Clean both the upper and lower drive wheels on both sides of the printer.

Lower drive wheels with rubber inserts Upper drive wheels with rubber inserts

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As-Needed Maintenance

This section covers the maintenance procedures and cleanings with no pre-set intervals.

Periodic Maintenance Process to correct angled nozzles

This purpose of this process is to improve poor print quality by reducing angled nozzles.

NOTE: This process should only be performed as needed on print heads that exhibit angled nozzles. It is NOT intended to recover missing nozzles.

NOTE: The Angled Nozzle Job should be printed and observed to determine if angled nozzles exist. If angled nozzles are observed in M, C, or K colors, this process can be used to clean and help straighten these nozzles.

Materials needed

♦ Gerber Dail

y Maintenance Solution (DMS)

♦ Gerber Clean Solution (GCS) ♦ Gerber Foam-tip swab ♦ Gerber Anticon wipes ♦ 99% Isopropyl alcohol ♦ Protective gloves ♦ Safety glasses

CAUTION: Cleanliness of the foam tip swab surface is very important. Avoid pressing solid contaminates or cured ink that may be present around the nozzle plate into the nozzle holes.

Process overview

♦ Print Angled Nozzle job ♦ Identify print he

ad(s) with Angled Nozzle

♦ Apply Gerber Daily Maintenance Solution (DMS) – 3 cycles ♦ Apply Gerber Clean Solution (GCS) – 5 cycles ♦ Perform Clean Heads Procedure ♦ Print Angled Nozzle Job and evaluate results

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CAUTION: This procedure is for Cyan (C), Magenta (M), and Black (K) heads only. Do NOT perform on Yellow (Y) heads.

To determine print heads with angled nozzles

1 Go to Calibration > Test jobs > Angled Nozzle job.

2 Print the Angled Nozzle job and evaluate the nozzles. Only treat the print heads that

show angled nozzles. (remove shadow)

Missing nozzle

Angled nozzles

NOTE: The purpose of this procedure is to inhale the solutions into the print head nozzles to dissolve contaminants inside the print head. The solutions will be inhaled only while the saturated swab is touching the nozzle plate. Be sure to reapply solution on the swab before each touch to ensure it remains saturated.

3 Go to Maintenance > End of Day Clean and lower the shelf when directed.

To apply Daily Maintenance Solution (DMS)

NOTE: Use isopropyl alcohol in the event you spill DMS or ink on the shelf while cleaning.

1 Apply a minimum of 10 drops of DMS to a new foam-tipped swab.

NOTE: Use one swab for each print head, provided it does not have particles on the swab.

2 Touch one side of the foam-tipped swab to the front section of the nozzle area (see

photo below). Apply light pressure and hold for 2 to 3 seconds.

3 Add an additional 3-5 drops of DMS to re-saturate the foam-tipped swab. Touch the

foam-tipped swab to the middle section of the print head. Apply light pressure and hold for 2-3 seconds.

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4 Add an additional 3-5 drops of DMS to re-saturate the foam-tipped swab. Touch the

foam-tipped swab to the remaining section of the print head. Apply light pressure and hold for 2-3 seconds.

5 Repeat steps 1-4 for a total of three cycles for each print head requiring treatment.

To apply Gerber Clean Solution (GCS)

1 Apply a minimum of 10 drops of GCS to a new foam-tipped swab.

NOTE: Use one swab for each print head, provided it does not have particles on the swab.

2 Touch one side of the foam-tipped swab to the front section of the nozzle area (see

diagram above). Apply light pressure and hold for 2 to 3 seconds.

3 Add an additional 3-5 drops of GCS to re-saturate the foam-tipped swab. Touch the

foam-tipped swab to the middle section of the print head. Apply light pressure and hold for 2-3 seconds.

4 Add an additional 3-5 drops of GCS to re-saturate the foam-tipped swab. Touch the

foam-tipped swab to the remaining section of the print head. Apply light pressure and hold for 2-3 seconds.

5 Repeat steps 1-4 for a total of five cycles for each print head requiring treatment.

To complete the process

1 After finishing the Gerber Clean Solution steps above, wait 5 minutes with the shelf

down before continuing.

2 Raise the shelf after 5 minutes.

3 Perform the Clean Heads procedure (see page 78).

4 Print an An

gled Nozzle job. If new missing nozzles are created, perform a second

Clean Heads procedure.

5 If you see an improvement, but some angled nozzles remain, you may repeat this

process.

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Cleaning individual color printheads

You can choose to clean one or more color printheads by selecting Clean Heads from the Maintenance section of the Printer menu. When cleaning printheads by color, both printheads using that color ink will be cleaned. The Clean Heads procedure timer does not get reset unless all of the printheads are cleaned.

Required Clean Heads procedure cleaning supplies

♦ Daily Maintenance Solution ♦ Fisher Scientific foam-ti

pped swabs

♦ Anticon Gold heavy-weight, clean room wipes ♦ All-purpose wipes

To clean individual color printheads

Tip: You can access the All Color choice when choosing which printheads to clean, and clean all printheads at the same time.

1 From the main control panel press the MENU key. The

Status

Status screen displays.

2 Press the Y or Z key until the

Maintenance

3 Press ENTER to display the

End of Day Clean

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Maintenance screen displays.

End of Day Clean screen.

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4 Press the Y or Z key until the Clean Heads screen displays.

Clean Heads

5 Press ENTER to display the

Choose color screen. Use the Y or Z key until the correct

color displays.

Choose color:

Magenta

6 Press ENTER to select that color. From here follow the normal Clean Heads procedure

Step 3 on page 79.

Cleaning the roll-to-roll platen

Occasionally examine the roll-to-roll platen (if the printer is equipped with one) for a build-up of cured ink. Carefully remove the ink build-up with a straight-edge razor blade.

Cleaning the ink drawers

When ever you replace ink pouches wipe up any dripped or spilled ink from the bottom of the ink drawer with an all-purpose wipe and dispose of wipe according to local laws and regulations. It is normal to have drips of ink from the ink pouch located in the drawer above.

Cleaning the Maintenance Shelf Mat

As needed, the rubber Maintenance Shelf Mat can be sprayed lightly with isopropyl alcohol and then blotted dry with an all-purpose wipe.

NOTE: A color shift may be noticeable over time.

Cleaning the X axis belts

Periodically, the X axis belts along sides of printer should be checked for and cleared of any debris that may be present, using a soft lint-ree cloth. This will help ensure proper operation.

Cleaning the outside of the Gerber CAT | UV

As needed, the covers of the Gerber CAT|UV can be wiped down with a soft lint-free cloth to remove dust and fingerprints.

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100

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

Gerber strongly recommends that this procedure be performed if you will not use the Gerber CAT|UV for up to two weeks.

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

1 Perform a Clean Heads Procedure to make sure the heads are free of debris and

remain healthy when printer remains in idle state for a significant duration (see page

78).

2 Keep the printer powered on. Do not

time. This will help keep the ink lines filled and the vacuum pressure strong.

turn the printer off during the two weeks of idle

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

1 Perform a Clean Heads Procedure (see page 78). This is all you should need to make

sure dust has not settled on the heads while the printer sat idle.

2 Print a standard Nozzle Out test job to identify any printhead issues that may need to

be addressed. Print an Angled Nozzle test job for more detailed results.

3 Based on the Nozzle Out test job, purge only those individual heads that need to be

cleared (see page 87).

Shutting down the printer for more than two weeks

Gerber strongly recommends that the Gerber CAT|UV remain powered on even for short periods when it is not in use. This procedure should be performed if you need to shut down the Gerber CAT|UV for more than two weeks. The procedure is divided into two parts:

Steps for shutting down the Gerber CAT | UV

♦ Clearing ink from the ink lines ♦ Filling with GerberCAT Flush

Steps for restarting the Gerber CAT | UV

♦ Clearing GerberCAT Flush ♦ Filling with GerberCAT ink ♦ Purging each color ♦ Cleaning the heads ♦ Printing the Nozzle Out job

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Gerber InkJet Printer, CAT UV Owner's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual