HP 0706124 User Manual

DisplayMaker Legacy Mach 12

User Manual

Part Number 0706124 Rev B

1

Legal notices

© Copyright 2008 Hewlett-Packard Development Company, L.P.
The information contained herein is subject to change without notice. The only warranties for HP

products and services are set forth in the express warranty statements accompanying such
products and services. Nothing herein should be construed as constituting an additional warranty.
HP shall not be liable for technical or editorial errors or omissions contained herein.

Printed in the US
For additional technical support and user documentation please refer to:

www.hp.com/go/graphicarts

2

Caution

SEVERE DAMAGE TO THE PRINTHEAD
CARRIAGE CIRCUIT BOARD AND PRINT­HEAD WILL OCCUR IF A PRINTHEAD IS
REMOVED WHILE POWER IS SUPPLIED TO
THE PRINTHEAD. Repairing this damage will

require a service call and replacement of the print­head carriage circuit board and printhead at cus­tomer expense.

To avoid electrical damage to the printhead carriage
circuit board and printhead:

Follow the instructions in the DisplayMaker Mach
12 User Manual to replace printheads.

DO NOT remove any printhead without first pressing
the Carriage or Prime keys on the control panel.
Pressing the Carriage key will move the printhead
carriage to the center of the platen; pressing the
Prime key will move the carriage out of the service
station to the prime position. Pressing either key will
cut power to the printheads, allowing you to safely
remove and replace printheads.

DO NOT disable the “cover open” switches on the
top cover or prime access door. When the printer
detects that either of these doors is open, it cuts
power to the printheads, making it safe to remove
and replace printheads. If these switches are dis­abled, the printer can no longer detect whether the
doors are open, making electrical damage more
likely.

iii

Revision Log The following is a list of major changes and additions that have

been made to this manual since it was first released.

See the accompanying Release Notes for specific changes to the
software and hardware between manual updates.

Release Date Description

May 2001 Manual first released.
Mar 2002 Chapter 1: Added description of new dryer

system.
Chapter 2: Expanded description of ATTN
messages. Documented many revisions to the
menu.
Chapter 3: Revised procedure “Selecting a Print
Mode.” Added new information about switching
between ink sets. Revised procedure “Installing
Ink for the First Time in a New Printer.” Enhanced
procedure “Replacing an Ink Tube” with new
illustrations.
Chapter 4: Replaced manual media feed calibra­tion procedure.
Chapter 5: Added top cover maintenance
information.
Appendix B: Added troubleshooting information
on banding and using the isolation test print.
Revised recovery procedure for error W-MD-4
Media Advance/Drive Too Slow.

iv

Regulatory Statements

FCC-A 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 user will be required to correct the
interference at his or her own expense.

This equipment must be installed exactly as instructed in this
manual using only the components supplied. If a supplied com­ponent ever needs to be replaced, it must be replaced with the
same part supplied by the manufacturer. It is your responsibility
to follow these instructions in order to maintain compliance
with the FCC regulations. Changes or modifications not
expressly approved by ColorSpan Corporation could void your
authority to operate this equipment. In particular, this device
must be operated with shielded cables to maintain FCC
compliance.

A booklet is available from the Federal Communications Com­mission entitled, How to Identify and Resolve Radio-TV Interfer-
ence Problems (#004-000-00345-4). Write to the U.S. Government
Printing Office, Washington, DC 20402.

DOC (Canada) This digital apparatus does not exceed the Class A limits for

radio noise for digital apparatus set out in the Radio Interference
Regulations of the Canadian Department of Communications.

Normes de Sècuritè (Canada)

Le présent appariel numérique n’émet pas de bruits radioélec­triques dépassant les limites applicables aux appareils numériques
de la Classe A prescrites dans le réglements sur le brouillage
radioélectrique édictés par le Ministére des Communications du
Canada.

v

Telecommunications

Network Statement

The ColorSpan VideoNet port on this device is not intended to
be connected to a public telecommunications network. Connec­tion of this device to a public telecommunications network in a
European Community Member State will be in violation of
national law implementing Directive 91/263/EEC on the
approximation of laws of the Member States concerning tele­communication terminal equipment, including the mutual rec­ognition of their conformity.

Der VideoNet port ist nicht dafür vorgesehen an ein öffentliches
Telefonnetz angeschlossen zu werden. Der Anschluß dieses
Gerätes an ein öffentliches Telefonnetz in einem Mitgliedstaat
der EU, verstößt gegen nationale Gesetze zur Ausführung der
Direktive 91/263/EEC, die sich mit der Annäherung von
Gesetzen von Mitgliedstaaten beschäftigt, betreffend Tele­kommuniktionsanlagen und die gegenseitige Anerkennung
ihrer Konformität.

vi

About This Manual Read this manual to unpack, set up, and use the ColorSpan

DisplayMaker Mach 12 digital color printers.

◆ Chapter 1 shows you how to unpack and assemble the
printer, and introduces you to its main features.

◆ Chapter 2 shows you how to use the control panel.

◆ Chapter 3 shows you how to install ink and media.

◆ Chapter 4 shows you how to calibrate the printer.

◆ Chapter 5 shows you how to maintain the printer.

◆ Appendix A shows you how to troubleshoot common

printing problems.

◆ Appendix B lists the printer’s technical specifications.

For further information, refer to the following ColorSpan
documentation:

◆ Quick Start Guide - START HERE to set up and install a brand
new ColorMark print server, and connect and configure
printers to it.

◆ DisplayMaker Mach 12 Site Preparation Guide - explains how to
prepare your site for the printer’s arrival and installation.

◆ DisplayMaker Mach 12 Watch Me First - a multimedia “how-
to” guide on CD-ROM (available on VHS cassette from
MacDermid ColorSpan Technical Ser vices).

◆ ColorSpan Print Server Documentation - the System Control
User Guide and Printing Tools User Guides shows you how to

print and RIP files through the ColorSpan print server. If the
printer is connected to a non-ColorSpan print server (RIP),
refer to the documentation that accompanies the server.

◆ Release Notes and Update Notes - late-breaking information,
update descriptions, and update instructions.

Further information about all ColorSpan products is also avail­able over the Internet at the ColorSpan World Wide Web site at
http://www.colorspan.com.

vii

Conventions This manual uses the following informational conventions:

Note

Hinweis

Caution

Vorsicht

WARNI N G

WARNU N G

Other WARNING symbols used:

A special technique or information that may help
you perform a task or understand a process.

Ein Hinweis beschreibt eine spezielle technik zur
Lösung einer Aufgabe oder enthällt Informationen,
die Ihnen eine Prozedur näher erläutert.

Alerts you to something that has the potential to
cause damage to hardware, software, or data.

Dieses Feld weist auf einen Umstand hin, der einen
Hardware-oder Software-Schaden oder Datenverlust
verursachen könnte.

Alerts you to something that has the potential to
cause physical harm to you or others around you.

Eine Warnung auf weist auf einen Umstand hin,
durch den Ihnen und anderen Personen ein phy­sischer Schaden erwachsen könnte.

Electrical Hazard

Vorsicht steht unter Spannung

Lifting Hazard

Vorsicht beim Anheben

viii

TABLE OF CONTENTS

Revision Log .............................................................................................. iv

Regulatory Statements............................................................................... v

FCC-A ..................................................................................................... v

DOC (Canada)....................................................................................... v

Telecommunications Network Statement............................................. vi

About This Manual .................................................................................. vii

Conventions ............................................................................................ viii

1

2

Getting Started

Operating Requirements ....................................................................... 1-2

Electrical ............................................................................................. 1-2

Environmental.................................................................................... 1-2

Important Operating Notes ............................................................... 1-3

Safety Warnings................................................................................. 1-4

Unpacking and Assembly ...................................................................... 1-5

Unpacking.......................................................................................... 1-5

Parts List ......................................................................................... 1-6

Stand Assembly.................................................................................. 1-7

Final Assembly ................................................................................... 1-8

Connecting to Power ....................................................................... 1-13

Connecting to the Print Server ........................................................ 1-14

Power-Up Sequence......................................................................... 1-15

What’s Next?.................................................................................... 1-15

Workflow Overview ............................................................................. 1-16

Parts Overview ..................................................................................... 1-17

Special Features ................................................................................... 1-21

Performance Features ...................................................................... 1-21

Ease-Of-Use Features ....................................................................... 1-21

Using the Control Panel

Overview................................................................................................ 2-2

Ready Screen...................................................................................... 2-2

Front Page.......................................................................................... 2-2

Menu.................................................................................................. 2-2

User Assistance................................................................................... 2-3

Front Page.............................................................................................. 2-5

Navigation Keys ..................................................................................... 2-9

Menu.................................................................................................... 2-10

Calibrate Printer............................................................................... 2-10

Printer Configuration ....................................................................... 2-11

Table of Contents ix

Print Settings ................................................................................ 2-11

Printer Options............................................................................. 2-13

Reset All Defaults ......................................................................... 2-15

Service Printer .................................................................................. 2-16

User Diagnostics .......................................................................... 2-16

Service Tests ................................................................................. 2-16

Calibrations .................................................................................. 2-17

Home Head.................................................................................. 2-17

Measure Media Width ................................................................. 2-17

New Carriage ............................................................................... 2-17

Prime Bars .................................................................................... 2-17

Disable Media Sensor .................................................................. 2-18

Warnings & Actions ......................................................................... 2-18

Menu Tree............................................................................................ 2-19

Front Page ........................................................................................ 2-19

Calibrate Printer ............................................................................... 2-19

Configure Printer.............................................................................. 2-20

Service Printer .................................................................................. 2-20

Warnings & Actions ......................................................................... 2-21

3

Installing Ink and Media

Variable Mode Printing .......................................................................... 3-2

Ink System Overview.............................................................................. 3-4

Spare Ink and Printheads ................................................................... 3-6

Selecting a Print Mode........................................................................... 3-7

Switching Between Ink Sets ................................................................. 3-10

Installing Ink for the First Time in a New Printer................................. 3-12

Replacing Ink System Components ..................................................... 3-17

Replacing an Ink Reservoir in an Idle Printer................................... 3-17

Replacing an Ink Reservoir During Printing (“Hot Swapping”)...... 3-18

Replacing a Printhead ...................................................................... 3-19

Replacing An Ink Tube..................................................................... 3-20

Loading Media ..................................................................................... 3-24

Loading 72-Inch Media ................................................................... 3-29

Takeup Options................................................................................ 3-30

Linearization..................................................................................... 3-30

Dryer Operation............................................................................... 3-31

Cutting and Unloading Media............................................................. 3-32

x Table of Contents

4

Calibrating the Printer

AutoSet................................................................................................... 4-2

Manual Calibrations .............................................................................. 4-3

Media Feed Calibration ..................................................................... 4-4

34-Inch/12-inch Calibration .......................................................... 4-5

Double Lines Calibration ............................................................... 4-6

Manual Bidirectional Registration ..................................................... 4-7

Manual Head Registration ............................................................... 4-10

Manual Jet Mapping........................................................................ 4-13

Report Individual Bad Jets ........................................................... 4-15

Clear Individual Bad Jets ............................................................. 4-16

View Current Bad Jets .................................................................. 4-16

Clear All Bad Jets.......................................................................... 4-17

Jet Status Lines ................................................................................. 4-18

Zero Registration Data..................................................................... 4-18

Auto Calibrations ................................................................................. 4-19

AutoTune ............................................................................................. 4-20

Quality Check Mode........................................................................ 4-20

Calibration Summary ........................................................................... 4-21

Linearization ........................................................................................ 4-23

5

Maintaining the Printer

Maintenance Schedule .......................................................................... 5-2

Cleaning Ink Jets.................................................................................... 5-3

Evaluating Printhead Performance After Cleaning ............................ 5-4

Cleaning Jet Outs............................................................................... 5-4

Cleaning the Service Station .................................................................. 5-5

Printing Prime Bars ................................................................................ 5-7

Manual Priming ..................................................................................... 5-8

Cleaning the Top Cover....................................................................... 5-10

Purging the Printheads ........................................................................ 5-11

Cleaning the Encoder .......................................................................... 5-13

Cleaning the Carriage Rail................................................................... 5-14

Technical Specifications

A

Specifications ......................................................................................... A-2

Supported Ink and Media.................................................................. A-4

Supplies and Accessories ....................................................................... A-5

Table of Contents xi

B

Troubleshooting

Troubleshooting Checklist ..................................................................... B-2

Diagnostics............................................................................................. B-4

Banding.................................................................................................. B-9

Stitch Banding.................................................................................... B-9

Edge Banding..................................................................................... B-9

Supply-Loop Banding ...................................................................... B-10

Texture Banding............................................................................... B-11

Swath Edge Banding........................................................................ B-11

MacDermid ColorSpan Technical Services........................................... B-12

Help From Your Reseller .................................................................. B-12

Help From ColorSpan ...................................................................... B-12

If All Else Fails................................................................................... B-12

Index

xii Table of Contents

CHAPTER 1

Getting Started

This chapter shows you how to get started using your printer. It includes
these topics:

◆ Operating Requirements (page 1-2)

◆ Unpacking and Assembly (page 1-5)

◆ Workflow Overview (page 1-16)

◆ Parts Overview (page 1-17)

◆ Special Features (page 1-21)

Getting Started 1-1

Operating
Requirements

Environmental ◆ Make sure the room is well ventilated, with a temperature

Choose a location for the printer before you unpack it. Keep the
following requirements in mind:

Electrical ◆ See “Connecting to Power” on page 1-13 for detailed power

requirements.

◆ Use the supplied power cords. Plug them directly into a
grounded electrical outlet. Do not lengthen either power
cord with an extension cord; the resulting voltage drop
could damage the printer.

◆ The supply cord for the primary dryer serves as a discon­nect. The socket-outlet shall be installed near the equipment
and shall be easily accessible.

◆ Make sure the line voltage does not vary more than 10
percent from the voltage marked on the back of the printer.
Install a voltage regulator or similar device if the power
source is not stable.

◆ Unplug the printer during power failures. Wait for the power
to return before plugging it back in.

◆ Connect the print server to a separate circuit from the
printer.

between 60° and 90° F (16° to 32° C). The relative humid­ity should be between 30 and 60 percent, non-condensing.
Optimal printing and drying occurs within these ranges.
Printing slows automatically to aid drying in high humidity
conditions.

◆ Store media and ink in an area with similar temperature and
humidity conditions as the printer.

◆ Keep the ventilation slots under the dryer tube free of any
blockage. This will allow the output dryer fans to properly
dry the printer output.

◆ Locate the printer close enough to the print server (RIP) so
that they can be connected with the required cable.

◆ Locate the printer on a flat, level surface.

◆ Locate the printer where its normal operating noise will not

disturb quiet work areas.

1-2 Operating Requirements

◆ DO NOT install the printer near humidifiers, refrigerators,
fans, water faucets, heaters or similar equipment.

◆ DO NOT install the printer in areas where the temperature
changes abruptly, such as near air conditioners or in the path
of direct sunlight.

◆ DO NOT expose the printer to flames, dust or solvent
chemicals.

Refer to Appendix B for detailed specifications.

Important Operating

Notes

◆ Wear cotton gloves (provided with each roll of ColorSpan
media) when loading media to prevent fingerprints that
could show after printing.

◆ Protect the media at all times from creases and tears, and
ensure that the media is cut cleanly. Do not rest or store a
media roll on end, or you could cause edge creases that
could strike the printheads during printing.

◆ Always use a lint-free cloth moistened with plain water to
clean the printhead.

◆ DO NOT touch the printhead’s ink jet nozzles (the metal
plate on the bottom of the printhead) with your fingers. Any
contaminants could clog the ink jet nozzles.

◆ DO NOT touch the electrodes on the back of the ink print­head. This could result in a faulty electrical connection,
which would cause jets to misfire.

◆ DO NOT clean the printhead surfaces with a dry cloth or
paper towel.

◆ DO NOT set heavy objects on the power cord or printer
cable; do not bend the cables or force them into contorted
positions.

◆ DO NOT place heavy objects anywhere on the printer.

Operating Requirements 1-3

Safety Warnings

WARNI N G

WARNU N G

WARNI N G

WARNU N G

WARNI N G

WITH THE POWER SWITCH IN THE OFF POSITION, POWER
MAY STILL BE SUPPLIED TO THE PRINTER COMPONENTS.
To completely cut power from the printer, you must unplug
the power cords from the power outlets.

WENN DER NETZSCHALTER IN OFF POSITION STEHT,
WIRD DEN KOMPONENTEN TROTZDEM STROM
ZUGEFÜHRT. Um den Drucker komplett stromfrei zu
machen, müssen Sie den Netzstecker ziehen.

The printer is too heavy to be lifted safely by one person.
At least two persons are required to lift the printer.

Der Drucker ist zu schwer für eine Person. Mindestens 2
Personen sind erforderlich um den Drucker anzuheben.

THE PRINTER ELECTRONICS ASSEMBLY CONTAINS A LITH­IUM BAT TERY DEVICE. THERE IS A DANGER OF EXPLOSION
IF THE BATTERY IS INCORRECTLY REPLACED. The battery
must be replaced only by ColorSpan authorized personnel,
and must be replaced only with the same or equivalent
type. Dispose of this lithium battery device in accordance
with local, state (or province), and Federal (or country)
solid waste requirements.

WARNU N G

WARNI N G

WARNU N G

DIE ELEKTRONIK DES DRUCKERS ENTHÄLT EINE LITHIUM
BATTERIE. ES BESTEHT EXPLOSIONSGEFAHR WENN DIESE
UNSACHGEMÄSS AUSGEWECHSELT WIRD. Die Batterie
darf nur durch einen ColorSpan authorisierten Technicker
ausgewechselt werden und muss mit dem gleichen oder
einem gleichwertigen Typ Batterie ersetzt werden. Bitte
entsorgen Sie die Lithium Batterie gemäss Ihren Landes­oder Bundesgesetzen.

Moving parts. Keep fingers away from media path.

Bewegliche Teile, Verletzungsgefahr.

1-4 Operating Requirements

Unpacking and
Assembly

This procedure assumes that the printer is in its final location.
See the Site Preparation Guide for moving and unpacking hints.

WARNING

WARNUNG

Note

The printer is too heavy to be lifted safely by one
person. At least two persons are required to lift the
printer.

Der Drucker ist zu schwer für eine Person. Mindes­tens 2 Personen sind erforderlich um den Drucker
anzuheben.

If you will be installing a ColorSpan Print Server, set
it up now and power it on. This will allow the server
to perform its automatic one-time new system check
while you unpack and assemble the printer.

Unpacking 1. The printer is delivered to your site packed in one cardboard

box, attached to a plywood platform on two wooden pallets.
Examine the shipping packaging for shipping damage.

Report any damage or apparent rough handling immediately
to the shipper.

2. Remove the Unpacking and Assembly diagram, Watch Me
First CD-ROM, and other documents from the outside of the
box, and set them aside for reference.

You can use the Unpacking and Assembly diagram for refer­ence during the unpacking and assembly process. The
Watch Me First CD-ROM contains useful “get t ing started”
information, including a demonstration of unpacking,
assembly, and set up.

3. Remove the bands that secure the box to the pallet and open
the top flaps of the box.

4. Carefully cut the corners of the outer box and remove it from
the pallet.

5. Remove the packing material from the printer.

6. Remove the stand crossbar, which is packed on top of the
printer.

7. Remove the ink tray boxes, stand leg boxes, and accessory
boxes, which are packed together in the center of the pallet.

8. Remove the cardboard shipping end caps from each end of
the printer.

Unpacking and Assembly 1-5

9. Remove the media spools, which are packed together under
the printer module.

Do not remove the printer module from the pallet at this
time. The printer rests on two shipping supports. You will
use these supports and two assembly supports to help
assemble the printer.

Note

Replacement shipping packaging and instructions
are available from MacDermid ColorSpan Technical
Services (phone: [phone]).

10. Refer to the following list to verify that you received all of the
parts and accessories.

Notify ColorSpan immediately if you are missing any of the
components listed below.

Parts List

Main Box Outside of Box:

Stand Leg Box

Ink Tray Box

Accessory Box

◆ “Watch Me First” CD-ROM

◆ Unpacking & Assembly Diagram

◆ Declaration of Conformity

Inside of Box:

◆ Printer Module

◆ (1) Stand crossbar

◆ (2) Media spools with collets

◆ (1) Stand leg box

◆ (1) Ink tray box

◆ (1) Accessory box

◆ (2) Stand legs

◆ (2) Ink trays

◆ (18) Black Phillips head screws

◆ (4) Silver Phillips head screws

◆ (2) Red-headed bolts

◆ (1) Service station

◆ (1) Ink maintenance kit: manual priming

bulb, purge clip, drain bottle

◆ (1) Fill system assembly

◆ (2) Spare ink tubes

(11) Color Map print mode cards

◆

◆ (1) White point reference chip

◆ (1) Screwdriver

◆ (1) Hex wrench

◆ (1) VideoNet or Ethernet cable

◆ (3) U.S. domestic power cords

◆ (2) European power cords

◆ (3) International power plug adapters

◆

Documentation, warranty, and software
license agreement

1-6 Unpacking and Assembly

Stand Assembly 1. Locate the stand legs  and , and the crossbar .

2. Using the Phillips head screwdriver and eight of the screws
provided, assemble the stand.

Start by positioning the two stand legs upright, at approxi­mately the width of the crossbar. Align the holes on the
crossbar with the holes in the stand legs, and secure them
with the screws.

Fig. 1-1. Stand assembly

Unpacking and Assembly 1-7

Final Assembly 1. Remove the two red-headed bolts from the right-hand ship-

ping support.

Fig. 1-2. Remove the red-headed bolts

2. Locate the assembly supports

The assembly supports are mirror images of each other; the
foam pad should be positioned toward the ends of the
printer.

3. Align the assembly supports

➍.

 with the shipping supports

, at the rear of the pallet as shown.









Fig. 1-3. Assembly supports , shipping supports 

1-8 Unpacking and Assembly

4. Thread one of the red-headed bolts that you removed from
the shipping support
the pallet.

The pallet contains a threaded nut that will accept the bolt.
Tighten the bolt hand-tight.

5. Attach the other assembly support to the pallet with the
other red-headed bolt.

 through the assembly support into

WARNING

WARNUNG

6. With two to four persons, roll the printer onto its back, on the
assembly supports.

The printer is now resting entirely on the assembly sup­ports. The right-hand shipping support is trapped with the
printer and will roll with it.

The printer is too heavy to be lifted safely by one
person. At least two persons are required to lift the
printer.

Der Drucker ist zu schwer für eine Person. Mindes­tens 2 Personen sind erforderlich um den Drucker
anzuheben.

Fig. 1-4. Roll the printer onto its back

Unpacking and Assembly 1-9

7. Remove the right-hand shipping support from the printer,
and bolt it to the pallet as shown, using the two red-headed
bolts provided. Do not remove the bolts from the rear sup-

ports.

Note that the “tower” of the support is now at the front of
the pallet.

Fig. 1-5. Shipping supports reversed and bolted

8. Lift the left-hand shipping support from the pallet, reverse it,
and replace it into its guides on the pallet.

The “tower” of the support is now at the front of the pallet.

1-10 Unpacking and Assembly

9. Gently tip the assembled stand on its back, and set it down
on top of the shipping supports as shown in Fig. 1-6.

Fig. 1-6. Assemble the printer module and stand

10. Using the two silver Phillips head screws provided, attach the
stand to printer module.

The silver screws are required to establish an electrical
ground connection between the printer and stand.

11. Press the caster locks down to prevent the printer from
rolling.

12. With the aid of one or more persons, carefully rotate the
assembled printer upright.

Be ready for the printer’s center of gravity to shift, so you
can tip the printer to its upright position in a controlled
manner.

13. Unlock the casters and roll the printer to its final location.
Then lock down the casters.

14. Locate the printer on a flat, level floor, with all four wheels of
the stand resting stationary on the floor. The printer must
remain stationary and level for proper ink flow and best print
quality.

15. Locate and connect the profiler docking station cable on the
left end of the printer, and connect it from the left-hand ink
tray to the port on the printer.

Unpacking and Assembly 1-11

16. Locate and connect the profiler docking station cable from
the right-hand ink tray to the port on the printer.

17. Using ten of the screws provided, attach the ink trays

➌ and

➍.

The right and left trays are mirror images of each other. Posi­tion the trays so that the inks load from the front.

Insert and tighten the screws most of the way, insert and
drop the trays into place onto the screws, then tighten the
screws the rest of the way.

➍

➌

Fig. 1-7. Attach the ink trays,

connect docking station cable

18. Remove the shipping bands from the long black chain con­nected to the printhead carriage.

19. Remove the foam block that immobilizes the carriage for
shipping.

20. Place the white point reference chip into the circular cutout
on the platen, near the left end.

To reach the white point cutout, you will need to reach
inside the left endcap.

1-12 Unpacking and Assembly

21. Install the service station by inserting it into the rectangular
cutout inside the right endcap (behind the control panel).

Position the service station so that the edge with the word
“FRONT” is closest to the front of the printer. Slide the ser­vice station fully to the left end of the cutout.

22. Join the connector on the twisted wires from the takeup
motor to the connector on the electronics assembly.

The connector on the electronics assembly is on the side of
the electronics enclosure, near the takeup spool bracket.

Connecting to Power The printer has separate power inputs for the printer and dryer

heaters. Each cord will only fit into its corresponding inlet on
the printer. The printer can be operated with one or both inlets
connected to power. See Appendix A, Technical Specifications,
or refer to the Site Preparation Guide, for detailed power require­ments.

Refer to Fig. 1-8 for the locations of the printer power inlets.

The print server may be connected to the same circuit as the
printer if the circuit’s amperage is sufficient for both devices.
Refer to the print server’s documentation for its amperage
requirement. Consult a qualified electrician if you have any
doubt as to how the circuits in your facilit y can accommodate
the printer and print server.

WARNING

WARNUNG

Unpacking and Assembly 1-13

WITH THE POWER SWITCH IN THE OFF POSITION,
POWER MAY STILL BE SUPPLIED TO THE PRINTER
COMPONENTS. To completely cut power from the
printer, you must unplug the power cords from the
power outlets.

WENN DER NETZSCHALTER IN OFF POSITION
STEHT, WIRD DEN KOMPONENTEN TROTZDEM
STROM ZUGEFÜHRT. Um den Drucker komplett
stromfrei zu machen, müssen Sie den Netzstecker
ziehen.

Connecting to the

Print Server

Connect the printer to the print server with the included
VideoNet (for ColorSpan print servers) or Ethernet cable (non­ColorSpan RIPs). See Fig. 1-8.

Refer to the print server (RIP) documentation for further instruc­tions on connecting the printer to the print server.

Fig. 1-8. Power and RIP connections

1-14 Unpacking and Assembly

Power-Up Sequence Turn on the power switch to observe the typical power-up

sequence:

1. The control panel backlight illuminates. Move the contrast

lever (located to the right of the control panel screen) up and
down until the control panel graphics and messages are easily
visible.

2. The printer runs a series of self-tests, and reports any errors it

finds.

3. The camera searches for the location of the installed media’s

home and far edges. If media is installed, this data tells the
printer the width of the installed media. If no media is installed,
the printer will prompt the user to load media when the next
print job is sent to the printer.

4. The control panel displays the status screen.

Fig. 1-9. Initial status screen after first power-up

What’s Next? ◆ To familiarize yourself with the printer, refer to the remain-

der of this chapter.

◆ To proceed with installation, see Chapter 3, Installing Ink
and Media.

◆ For a complete description of using the control panel, see
Chapter 2, Using the Control Panel.

Unpacking and Assembly 1-15

Workflow Overview When the printer is connected to a ColorMark Pro print server,

here is how a typical print job progresses from the client work­station to the printer. If you are using a non-ColorSpan RIP, refer
to the documentation that accompanies it for details.

1. The operator sends a file to be printed from a client
workstation.

2. The print job is received by the print server.

Once it reaches the print server, the print job may be reprior­itized, combined with other jobs, re-routed, or otherwise
manipulated. Refer to the print server online help or manual
for instructions.

3. The print server RIPs the job.

The raster image processing (RIP) process translates the
PostScript language data that comprises the print job into
the data required by the printer.

4. The server sends the image to the printer for printing.

1-16 Workflow Overview

Parts Overview

16

4 5 6

7

8

9

10

11

16

1

1

12

2

14

3

15

17

3

13

21

18

19

20

Fig. 1-1. Major parts of the printer

Parts Overview 1-17

Index Description

1 End cap (two places) — includes removable end covers

for maintenance access.

2Stand — supports the printer.
3 Casters (four places) — enables easy location of the

printer, can be locked in place.

4Encoder strip — allows precise positioning of the print-

head carriage across the length of the platen.

5 Main carriage drive belt — moves the carriage across

the length of the platen.
Transport chain (not shown) — supports the ink sup-

ply tubes that carry ink from the ink reservoirs to the
printheads.

6Top cover — protects the user from the rapid motion of

the printhead during printing. A safety interlock switch
stops printing and cancels the print if the cover is
raised.

7Platen — supports the media under the printheads

during printing.

8 Printhead carriage — carries the printheads, digital

imaging sensor, and photodiode across the length of
the platen. (See also detail in Fig. 1-2. and Fig. 1-3. on
page 1-20.)

9 Media out sensor — detects whether media is loaded.
10 Service station (behind access door) — catches excess

ink from the printheads, wipes and caps the printheads
to prevent drying and clogging while not in use.

11 Prime access door — provides access to the carriage for

9

manually priming the printheads. A safety interlock
switch stops printing and cancels the print if the cover
is raised.

12 Control panel — displays messages and allows control

of certain printer operations. Includes a contrast adjust­ment lever and audio feedback.

13 Electronics module — contains the printer’s power

supply and control electronics. Includes a humidity
sensor to enable the printer to compensate for high­humidity conditions by slowing the speed of printing.

14 Pinch rollers (12 places) — grip the media during

loading and printing.

1-18 Parts Overview

Index Description

15 D r ye r t u b e — carries air blown from the dryer fans to

the printed output.

16 Ink reservoir tray (two places) — holds ink reservoir

boxes.

17 Takeup gearbox — powers the takeup spool to auto-

matically take up printed output.

18 VideoNet port — connects printer to print ser ver.
19 P o we r i n l e t s — connects printer and the dryer’s heater

to electrical power.

20 Standby power switch — places printer in standby

mode (to disconnect from power, disconnect power
cord).

21 Media advance switch — enables user to manually

advance media during loading.

22 Printhead carriage lock lever (two places) — locks

and unlocks the printhead assembly, for tilting it to the
upright position and returning it to the printing posi­tion.

23 Printhead cover (three places) — secures the print-

heads to the carriage.

24 Printhead cover latch (three places) — locks the print-

head cover in place.

25 Printhead (replaceable, up to twelve places) —

delivers ink to the media.

26 Digital image sensor — detects the location of printed

pixels for precise alignment of the printheads.

27 Photodiode — enables the creation of color transforms

without an external spectrophotometer (requires print
server support), and the linearization of existing trans­forms.

Parts Overview 1-19

22

23

23

23

25

24

Fig. 1-2. Printhead carriage, printhead covers open

26

27

Fig. 1-3. Printhead carriage, tilted position for

cleaning and accessing ink tubes

22

1-20 Parts Overview

Special Features The printer has many advanced features to help you produce the

best printed output with the least effort.

Performance Features ◆ AutoSet Calibration — uses a high-resolution digital imag-

ing sensor to automatically align printheads in the x-y
directions and bidirectionally for precise positioning of ink jet
pixels, also compensates for lost or misfiring jets by using
substitute jets without slowing printing speed.

◆ AutoTune — can run AutoSet at user-defined intervals, for
highest quality during unattended printing. Optionally, if
print quality falls below a user-defined level, printing stops
until the problem is corrected.

◆ Onboard linearization — uses the onboard photodiode to
linearize output over the entire density range (with print
server or RIP support).

◆ Integrated heated dryer — dries output as it prints. Option­ally, the dryer fan may be turned off to avoid streaking on
poly and film media.

◆ Humidity sensor — slows printing in high humidity condi-
tions to ensure drying, and alerts the user when the ambi­ent humidity is outside of optimal range.

Ease-Of-Use Features ◆ Modular ink deliver y system — the ink system consists of

three components—ink reservoir, ink tube, printhead—each of
which can be replaced independently of the others as
needed.

◆ Tilt-up print-head carriage — printhead carriage tilts up for
easy access to the ink tubes, printheads, and image sensors.

◆ Manual priming system — recovers clogged ink jets without
removing the printhead from the printer.

◆ Manual air purging system — recovers printheads that are
disabled due to too much air being introduced.

◆ Integrated bidirectional takeup system — takes up printed
output onto a spool for extended unattended printing. Out­put may be wound image-side out or image-side in.

◆ Media width sensing — automatically detects the width and
position of the media loaded, for precise image placement.

◆ Simplified control panel inter face — Front Page screen pre­sents frequently-used functions, with recommended preset
configurations. A menu provides access to less-frequently
used functions and troubleshooting help.

Special Features 1-21

◆ User assistance — control panel features online help, interac­tive procedures, and diagnostics to assist the user “on-the­fly,” reducing training and troubleshooting time.

1-22 Special Features

CHAPTER 2

Using the Control Panel

This chapter describes the functions of the control panel.

◆ Overview (page 2-2)

◆ Front Page (page 2-5)

◆ Navigation Keys (page 2-9)

◆ Menu (page 2-10)

◆ Menu Tree (page 2-19)

Using the Control Panel 2-1

Overview The touch-screen control panel shows you the printer’s current

status, and enables you to interact with the printer when chang­ing media and ink, respond to an error condition, or configure
options. There are three main control panel screens:

◆ Ready (Status) Screen

◆ Front Page

◆ Menu

Ready Screen When you press the Online/Offline button from the Front Page

screen, the printer goes online and the Ready or Status screen
appears. The Ready screen displays the current status of the
printer and any currently printing job. It displays when the
printer is online (communicating with the print server) and
either ready to print or printing.

Fig. 2-1 Ready screen

Front Page When you press the Online/Offline button from the Ready

Screen, the printer goes offline and the Front Page screen
appears. This screen is the top level of the printer’s menu sys­tem. It provides access to the most frequently-used off line func­tions. For details, see “Front Page” on page 2-5.

Menu When you press the Menu key on the Front Page screen, the

Menu appears. The Menu provides access to advanced configura­tion options. For details, see “Menu” on page 2-10.

2-2 Overview

User Assistance The control panel provides various forms of online user

assistance:

The ? button provides an explanation of the current function,
with some guidance for what to do next.

The ATTN (Attention) key blinks on the control panel when the
printer detects an error condition, potential error condition, or
when you make a change that suggests recalibration or other
action to ensure best print quality. There are three types of
AT TN messages:

◆ Actions — the printer has detected an error condition that
stopped printing or will prevent printing from starting. You
must correct the error before the printer will be ready to
print. When the printer senses that the error condition has
been addressed, the Action will be deleted the next time the
ATTN key is pressed.

◆ Warnings — the printer has detected a condition that, if left
unaddressed, could result in substandard prints or a condi­tion that will require an action before printing can continue.
Any action on your part is optional, printing is not inter­rupted for a Warning message.

◆ Changes — the printer has detected a change to the inks,
media, or printer that could affect print quality. Pressing the
ATTN key displays a message that suggests the actions to
perform for optimal print quality, such as recalibration. You
can dismiss the message with or without actually perform­ing the suggested action, although ignoring the messages
could result in substandard output quality. Printing is not
interrupted for a Change message.

When the printer issues one of these messages, the ATTN key
will blink, and an alert beep will sound. Press the ATTN key to
display a list of message titles, and select a title to display a
detailed cause-and-recovery screen.

If you choose to not correct a Warning or Change condition and
resume printing, the AT TN key will remain displayed, but will
not blink until the printer issues a new Warning, Action, or
Change message. The messages can be dismissed by correcting
the condition, or by pressing the applicable key on the detail
screen.

Overview 2-3

Tip See page 2-12 for instructions for choosing an

Expert or Novice mode for displaying these mes­sages (Expert mode routes most messages to the
Actions & Warnings menu), and for disabling or
enabling the audible alarm.

2-4 Overview

Front Page The Front Page provides access to the most frequently-used

printing and maintenance f unctions. For advanced config ura­tion options, press the Menu key (see “Menu” on page 2-10 for
instructions).

Fig. 2-2. Front Page

◆ Printer Name — displays the name of the printer as defined
on the print server.

◆ Online/Of fline — returns the printer to the Ready screen.

Front Page 2-5

◆ Media & Ink — displays a listing of the media and ink cur-

rently installed in the printer. Press the p and C keys to
highlight “Media” or one of the inks, then press B (Pro-
ceed) to display information about the selection. From this
screen, you can press the m and q keys to scroll between
screens. Press B (Proceed) to return to the list, then z
(Menu Out) to display the Front Page screen.

Fig. 2-3. Media info, ink info screens

2-6 Front Page

◆ Status — displays the status of all user-configurable options.
Press { (Page) to scroll between pages. To change an
option, go to the Printer Configuration section of the menu.

Fig. 2-4. Status page 1

◆ Advance Media — press the p key to advance the media for-
ward. When you press and hold the p key, the media moves
faster. You can also press the Media Advance switch on the
rear of the printer, below the left profiler docking station, to
advance the media. Press the C key to advance the media
back onto the supply spool. When you press and hold the C
key, the media moves faster.

◆ Menu — displays the complete printer menu for access to
advanced configuration options (see “Menu” on page 2-10
for instructions).

◆ AutoSet — performs a “one touch” calibration of the printer:
bidirectional and head-to-head alignment of printheads, and
AutoJet substitution mapping of deflected or missing jets.
See “AutoSet” on page 4-2 for instructions.

◆ Prime Bars — fires all jets by drawing a set of lines called
prime bars. This is a good way to inspect and prepare the
jets for printing after they have been idle for more than a few
hours. Choose Quick Prime Bars for most primes, or
Detailed Prime Bars when you want to locate individual
missing jets that AutoSet may have missed, so you can map
them manually under Calibrate Printer - Manual Calibra-
tions - Manual Jet Mapping (see “Manual Jet Mapping” on
page 4-13 for instructions).

Front Page 2-7

◆ Print Mode — interactively assists you in installing print­heads in the correct positions, and setting the number of
print passes. See “Selecting a Print Mode” on page 3-7 for
instructions.

◆ Carriage — moves the carriage out of the service station so
you can load or clean the printheads and ink tubes, clean the
image sensors, and remove the service station.

◆ Prime — moves the printhead carriage to the priming posi-
tion, so that one or more printheads can be manually
primed (see “Manual Priming” on page 5-8 for instructions).

◆ Media Unload — when unloading media, prints the calcu-
lated amount of media remaining on the roll for reference
(on the lower right edge). If using the takeup, cut the media
from the takeup spool before pressing the Media Unload key
(see “Cutting and Unloading Media” on page 3-32). When
removing the partial roll from storage and re-loading on the
printer, the user can report this value to the printer during
the Media Load operation.

◆ Media Load — causes the printer to measure width of the
media installed in the printer, checks for proper media posi­tioning on the platen (for good vacuum contact), asks the
user to enter the amount remaining on the supply roll, asks
the user to select a takeup option. See “Loading Media” on
page 3-24 for instructions.

◆ AT TN (Attention) — blinks on the control panel when the
printer detects an error condition, potential error condition,
or when you make a change that requires recalibration or
other action to ensure best print quality. See “User Assis­tance” on page 2-3 for further details.

2-8 Front Page

Navigation Keys The following table shows you how to move through the menu

system and perform printer control functions.

Key Description

v

C p

x w

z E

m q

B

{

r

| ~

n

o

s

A

}

t

D y

Display Menu — displays the printer menu.

Menu Up/Down — moves the menu highlight up and

down the menu.
Menu Top/Bottom — moves the menu highlight to the

top or bottom for the menu.
Menu Out, Menu In — moves to the next higher menu

in the hierarchy, or selects the highlighted option.
Back/Forward — moves between pages or screens, or

selects printheads to calibrate.

Proceed — initiates the selected function.

Page — switches between pages of a multi-page screen.

Help — displays a summary description of the high-

lighted menu options.
Pause/Resume — pauses or resumes printing during a

calibration.

Cancel — cancels the current menu function or choice.

Continue (error screen) — proceeds to the next step in

a troubleshooting dialog.
Ignore (error screen) — specifies “ignore” in a trouble-

shooting dialog.
Retry (error screen) — specifies “retry” in a trouble-

shooting dialog.
Reboot Printer (error screen) — specifies “restart

printer” in a troubleshooting dialog.
Information (error screen) — displays further informa-

tion about the error.
Yes/No (error screen) — indicates a Yes or No in a trou-

bleshooting dialog.

Navigation Keys 2-9

Menu The menu has three main sections:

◆ Calibrate Printer (see below)

◆ Printer Configuration (page 2-11)

◆ Service Printer (page 2-16)

◆ Warnings & Actions (page 2-18), shown in Expert Messages

Mode only

This section explains each of the functions on the printer menu.

Calibrate Printer For details on these options, see Chapter 4, Calibrating the

Printer.

◆ Manual Calibrations — allow you to calibrate the media
feed advance accuracy, and perform the various compo­nents of the automatic AutoSet calibration visually, without
the printer’s digital imaging sensor. Inaccurate judgments by
the operator during these tests could result in substandard
output. In most cases, use AutoSet instead. See “Manual Cal­ibrations” on page 4-3 for instructions.

◆ Auto Calibrations — enables you to run a portion of the
AutoSet calibration, to save time. See “Auto Calibrations” on
page 4-19 for instructions.

◆ AutoTune — schedules AutoSet to run automatically after a
certain number of prints have printed. See “AutoTune” on
page 4-20 for instructions.

◆ Calibration Summary — prints summary information with
the AutoSet calibration test patterns, or transmits registra­tion or jet data to a log file on the print server. “Calibration
Summary” on page 4-21 for details.

2-10 Menu

Printer Configuration Printer Configuration enables you to set many options that con-

trol how the printer operates.

Print Settings

◆ Top Gutters — allows you to turn on or off the gutter pat­tern at the top edge of the print, which shows data about
the print such as date and time printed and print mode, plus
write-in blanks for other data.

Color set reported in the print job

Job name

Media name from the print server/RIP

Ink type

Print mode selected at control panel:
Heads per color, number of passes,
direction of printing, HQ mode,
ink color set

Fig. 2-5. Top gutter data

◆ Side Gutters — sets the side gutter pattern to narrow,
medium, or wide sizes, or disables them. Side gutter pat­terns help keep the ink jets open by firing ink through them
in a pattern outside the printed image area.

◆ Takeup Direction — sets the direction of the takeup motor
for Image Inside or Image Outside takeup.

◆ Takeup Control — enables and disables the takeup system.

Date and time printed

Embedded software version

Printer

◆ Platen Vacuum Control — turns on the vacuum fans, then
allows you to raise or lower the speed of the vacuum fans.
Raise the speed if the media is rising of f the platen, lower the
speed if the media is buckling or wrinkling.

Menu 2-11

◆ Head Height — sets the height of the printhead to Normal
(0.050 inches/1.27 mm) or Custom. Use Normal unless the
media is curling or the printhead carriage is striking the
media. Lower settings reduce ink overspray, but increase the
chances of the printhead striking the media. When the head
height is 0.070 inches (1.78 mm) or higher, do not run
AutoSet, run the manual calibrations instead.

◆ Space Between Prints — sets the blank space between print
jobs, between 0 and 10 inches (25 cm).

◆ Right and Lef t Margin — sets the amount of blank space for
the right and left margins, between 0 and 5 inches (13 cm).

◆ Service Station — sets the printhead service station cycle:
every 30 seconds, spit-and-wipe (default); or every 30 sec­onds with spit only. The service station cycle helps keep the
ink jets open when not printing by expelling ink and
(optionally) wiping the jets.

◆ Drying Delay — select the printer’s preprogrammed algo­rithm for slowing the print speed when the ambient relative
humidity is excessive, or specify a custom drying delay in
seconds per print swath. A longer delay allows the output to
remain under the dryer longer, which ensures adequate dry­ing under higher ambient relative humidity.

Printing automatically occurs at a speed that ensures that the
output will be dry before it reaches the takeup spool,
depending on the level of ambient relative humidity.

To increase the media advance speed, you can specify a man­ual drying delay. If you specify a manual drying delay inter­val that will be insufficient to dry the output, the printer will
display a warning message on the control panel. Be aware
that if you override this warning without increasing the dry­ing delay, you should not use the takeup system, and take
care to remove output from the printer before it reaches the
floor, and store it flat until it dries. Using the takeup to collect
wet output, or allowing wet output to pile on the floor,
would likely result in ruined prints.

◆ Units — sets English or metric units of measure for data dis-
played by the control panel.

◆ Expert/Novice Messages — Novice mode presents Warn-
ings & Changes (alerts that do not prohibit printing) and
Actions (conditions that require user intervention before
printing can proceed). Expert mode presents Actions only,
presents fewer “press Proceed” prompts after an Action has
been addressed, and does not require you to press Proceed

2-12 Menu

after manually winding back a service loop. The default is
Novice mode.

When in Expert mode, active Warnings, Changes, and
Actions can be displayed by selecting Warnings & Actions
from the menu, since Warnings will not cause the ATTN icon
will appear in Expert mode. See “User Assistance” on page 2­3 for further information about Actions and Warnings. See
“Warnings & Actions” on page 2-21 for further information
about this menu option.

◆ Audible Alarm — when enabled and one or more Actions are
pending, sounds a beep until the ATTN key is pressed.

◆ Service Station Spits — adjusts the number of times ink is
expelled (“spit”) during a single service station visit. The set­tings are 1 through 10. To reduce the number of missing or
misfiring jets, increase this setting.

◆ SS Overspray Delay — when enabled, this setting will pause
the printhead carriage in the service station area briefly
(approximately one second) before exiting, to eliminate fine
overspray on the right side of prints (nearest the service sta­tion).

Printer Options

◆ Dryer — turns the dryer fans on or off. Disable the dryer fan
to avoid streaking output on poly media and films.

◆ Print White Space — when enabled (on), the printhead car­riage always travels the width of the media, even when there
is a white (blank) space in the image. When disabled (off),
the printhead remains in its home position and the media
advances past white spaces in the image.

◆ Quality Check — when enabled, the printer determines the
number of misfiring or not firing ink jets that are not being
replaced by other jets. If this number exceeds a maximum
value, an error occurs. This can give the operator a chance to
print anyway, or cancel printing so the problem can be
resolved.

◆ Attended Mode — user must press B (Proceed) to

acknowledge the error and print the job (if one is pend­ing), or y (Cancel) to cancel printing.

◆ Unattended Mode — no user acknowledgment of errors

is required. When a quality check fails, print jobs are sent
to the ColorSpan print server’s Attention queue with a
disposition of “Uncalibrated Printer” (this feature may
not be supported on non-ColorSpan print servers).

Menu 2-13

◆ OFF — no quality check is per formed, all jobs will print.

◆ Print Position — positions the print in the horizontal (x-axis)

direction, either in the center or flush right.

◆ Media Supply Loop — the supply loop is the slack portion of
the media between the platen and supply spool. When the
media is backed up to reduce the amount of blank
(unprinted) space between print jobs, the result is a supply
loop. A supply loop can cause printing anomalies if not
removed. The printer provides three options to handle the
supply loop:

◆ Prevent Supply Loop — use this mode to ensure opti-

mal quality and speed (see Tip below). The media is not
backed up and no supply loop is created. Prints will
move completely through the dryer before the next print
begins.

◆ Allow Supply Loop — use this mode for optimal print-

ing speed or to manually remove the supply loop after
each print. Prints will move completely through the
dryer, then the media is backed up, and the user is
prompted to remove the supply loop by manually
rewinding the slack portion onto the supply spool. Print­ing resumes after the user presses the Proceed key, or
after 60 seconds, whichever occurs first.

◆ Unattended Supply Loop — use this mode to remove

the supply loop as in Allow Supply Loop mode, or the
printer will do it and printing proceeds as in Prevent
Supply Loop mode. Printing proceeds as in Allow Supply
Loop, but if the user does not press Proceed after 60 sec­onds, the media is advanced to its location after drying
and printing proceeds.

Tip

2-14 Menu

Use the ColorSpan print server’s MediaSaver or N-Up
features to group separate print jobs into a single
job. This conserves media and speeds printing by
eliminating the blank space between jobs, without
creating a supply loop.

Reset All Defaults

◆ Restore All Defaults — restores all Printer Configuration set­tings to their factory default values, and zeroes all registra­tion data. After running this option, all calibration values
must be reestablished by running AutoSet.

◆ Zero Platen Width — sets the platen width to zero, which
forces the printer to measure the platen on the next power
up.

◆ Measure Platen — measures the platen width.

Menu 2-15

Service Printer User Diagnostics

User Diagnostics presents an interactive troubleshooting pro­gram to diagnose problems before calling MacDermid
ColorSpan Technical Services. It walks you through a series of
tests and checks for certain printer functions. The printer asks
you to make observations or run simple tests to help it diagnose
problems and suggest corrective actions. It has the following
sections:

◆ VideoNet Status

◆ Head Statistics

◆ Carriage Motion

◆ VideoNet Connection

◆ Calibration

◆ Error History

◆ Actions and Warnings List — table of all actions and warn-

ings with cause and recovery. This is an abbreviated version
of the table on page B-5.

◆ Log Error History

Service Tests

These tests are for factory, service, and technical support use.

◆ Control Panel Test — tests the functionality of the control
panel display.

◆ Spit and Wipe Jets Test — tests the functionality of the ser­vice station by firing ink (spit) and drawing the printheads
over the service station wipers (wipe).

◆ Takeup Test — tests the functionality of the takeup system.

◆ Print Test — the user selects one of the twelve printheads to

test, then the printer begins firing that printhead continu­ously until canceled by the user. The test can help to iden­tify an intermittently failing printhead.

◆ Profiler Test — identifies and verifies profilers in each posi­tion. The printer will report the profiler number, color, and
ink percentage remaining. Particularly useful when the
printer is connected to a non-ColorSpan RIP that cannot dis­play profiler status.

◆ Vacuum Fan Test — runs the platen vacuum fans to test for
correct operation.

2-16 Menu

◆ Dryer Test — runs the dryer heater assembly to test for cor­rect operation.

◆ Print Image on Image Sensor — the printer prints a small set
of lines which are scanned by the digital image sensor. Then
the printer prints an enlargement of the image as the sensor
captured it.

◆ Horizontal Dot Accuracy — for factory/service use only.

◆ Vertical Dot Accuracy — for factory/service use only.

◆ Isolation Print Test — for factory/service use only.

◆ Pod Test — for factory/service use only.

Calibrations

These calibrations are performed at the factory. If any of them
are detected as out-of-specification, a message is displayed on
the control panel, recommending that you perform the applica­ble calibration:

◆ Head Height — re-homes the head height to the known
highest reference point, or if New Carriage was previously
selected (see below), recalibrates the known highest refer­ence point

◆ Media Sensor — locates the platen to establish the “media
out” head height

◆ White Point — reads the white point reference chip in the
platen to establish a white point for the photo diode.

Home Head

Recalibrates the home position of the printhead carriage. If the
printhead carriage will not return to the service station between
prints, select this option. Cycling the power off and on will also
run the Home Head function.

Measure Media Width

Measures the width of the media.

New Carriage

Reinitializes the head height so that it can be recalibrated (see
“Calibrations,” above.

Prime Bars

Prints a wide-swath version of the prime bars.

Menu 2-17

Disable Media Sensor

If the media sensor is malfunctioning, disable it to continue
printing. Note that with the media sensor disabled, the printer
will not be able to detect when there is no media in the printer.

Warnings & Actions When in Expert mode, active Warnings, Changes, and Actions

can be displayed by selecting Warnings & Actions from the
menu, since Warnings will not cause the ATTN icon will appear
in Expert mode. This option does not appear in Novice mode.

See “User Assistance” on page 2-3 for further information about
Actions and Warnings. See page 2-12 for a description of the
Expert/Novice Messages mode.

2-18 Menu

Menu Tree

Calibrate Printer Manual Calibrations

Front Page Online/Offline

Media & Ink

Status

Advance Media

Menu

AutoSet

Prime Bars

Print Mode

Carriage

Prime

Media Unload

Media Load

Media Feed
Manual Bidi Registration
Manual Head Registration
Manual Jet Mapping
Jet Status Lines
Default Registration Data

Auto Calibrations

AutoBidi Calibration
AutoH2H Calibration
Auto Bidi & H2H Calibration
AutoJet Calibration

AutoTune

Calibration Summary

AutoSet Summary
Log Head Registration Data
Log Jet Data

Menu Tree 2-19

Configure Printer Printer Settings

Top Gu tters
Side Gutters
Takeup Direction
Takeup Control
Platen Vacuum Control
Head Height
Space Between Prints
Right and Left Margin
Service Station
Drying Delay
Units
Expert/Novice Messages
Audible Alarm
Select Pen Temperature
Service Station Spits
SS Overspray Delay

Printer Options

Dryer
Print White Space
Quality Check
Print Position
Media Supply Loop

Reset All Defaults

Restore All Defaults
Zero Platen Width
Measure Platen

Service Printer User Diagnostics

VideoNet Status
Head Statistics
Carriage Motion
VideoNet Connection
Calibration
Error History
Warnings and Actions List

2-20 Menu Tree

Log Error History

Service Tests

Control Panel Test
Spit and Wipe Jets
Takeup Test
Print Test
Profiler Test
Vacuum Fan Test
Dryer Test
Print Image on Image Sensor
Horizontal Dot Accuracy
Vertical Dot Accuracy
Isolation Print Test
Pod Test

Calibrations

Head Height
Media Sensor
White Point

Home Head

Measure Media Width

New Carriage

Prime Bars

Disable Media Sensor

Warnings & Actions (Shown in Expert mode only)

Menu Tree 2-21

2-22 Menu Tree

CHAPTER 3

Installing Ink and Media

This chapter describes:

◆ Variable Mode Printing (page 3-2)

◆ Ink System Overview (page 3-4)

◆ Selecting a Print Mode (page 3-7)

◆ Installing Ink for the First Time in a New Printer (page 3-12)

◆ Replacing Ink System Components (page 3-17)

◆ Loading Media (page 3-24)

◆ Cutting and Unloading Media (page 3-32)

Installing Ink and Media 3-1

Variable Mode
Printing

The printer uses these techniques to vary the quality of a print
and speed of printing:

◆ Direction — for fastest print speed, the printheads fire ink
bidirectionally, when the carriage travels in both directions.
To reduce certain banding effects, the printheads can be set
to fire only when the carriage is moving to the left.

◆ High quality (HQ) — when enabled, reduces certain band­ing effects.

◆ Color Set — ink sets may contain one each of a different
color, two each of a different color, varying densities of cer­tain colors, or combinations. Using two sets of colors speeds
printing, while using multidensity inks creates smoother
transitions between light tones, and increases the perceived
resolution of the print.

◆ Jet Replacement — jets on the printhead that are misfiring or
not firing at all can be replaced with alternate jets. Ideally,
every pixel called for in a print is printed. In reality, some
pixels are not printed because the ink jets tend to become
partially or completely clogged with ink, which reduces print
quality. AutoJet mapping substitutes an otherwise unused jet
for a missing or deflected jet.

◆ Passes — number of times the printhead passes over a given
area of the image. A greater number of passes makes a
greater number of substitute jets available, but slows print­ing speed.

Print quality (apparent resolution and smooth gradients) is
improved by:

◆ Increasing the number of passes (see “Selecting a Print
Mode” on page 3-7)

◆ Increasing the number of different ink colors (and/or
densities); see “Selecting a Print Mode” on page 3-7

◆ Printing in HQ mode (see “Selecting a Print Mode” on page
3-7)

◆ Printing unidirectionally (left only); see “Selecting a Print
Mode” on page 3-7

◆ Selecting “Do not print white space” under Configure
Printer - Printer Options - Print White Space (see “Printer

Options” on page 2-13)

◆ Using MediaSaver (ColorSpan Print Server feature) to group
jobs together, eliminating the drying delay between jobs

3-2 Variable Mode Printing

Print speed is increased by:

◆ Reducing the number of passes (see “Selecting a Print
Mode” on page 3-7)

◆ Reducing the number of different colors or using smaller ink
sets (four or six colors instead of eight or more)

◆ Printing with two heads per color (see “Selecting a Print
Mode” on page 3-7)

◆ Printing bidirectionally (in both directions); see “Selecting a
Print Mode” on page 3-7

◆ Printing in non-HQ mode (see “Selecting a Print Mode” on
page 3-7)

◆ Printing in low relative humidity to avoid drying delays

◆ Disabling the service station overspray delay under Config-

ure Printer - Printer Settings - SS Overspray Delay (see
page 2-13)

Variable Mode Printing 3-3

Ink System Overview The printer’s ink system consists of three main components:

◆ Ink reservoir — a plastic box containing the ink supply and
an electronic profiler, which specifies the ink type, color, and
amount remaining. The profiler plugs into a connector on
the ink tray, allowing it to communicate with the printer and
print server. The reservoir is self-contained and seals auto­matically for easy handing.

◆ Ink tube — carries the ink from the reservoir to the print-
head, self-sealing on both ends for ease of handling.

◆ Printhead — delivers the ink to the media.

Each of these components can be replaced independently of the
others. This enables you to consume the ink from two or more
reservoirs before replacing the printhead when an excessive
number of clogged jets cannot be recovered with priming or
cleaning. The ink tubes need not be replaced unless you switch
ink types (for example, from a dye ink to a pigmented ink, or to
a different set of colors), or if a tube becomes damaged.

Fig. 3-1. Ink system components

3-4 Ink System Overview

The ink system also includes a labeling system to help keep the
components of each ink color together:

◆ Color Map Cards — lists all of the supported ink sets, fits in
plastic sleeve inside the printer’s top cover for easy reference
during installation and printing.

Fig. 3-2. Color Map card

◆ Ink Type Label — used to identify the ink type used in each
ink tube.

◆ Ink Tube Number Label — used to label each end of each ink
tube (ink reservoir end and printhead end) from 1 to 12; cor­responds to the factory-labeled ink tray positions 1 to 12.

Fig. 3-3. Ink type and ink number labels

Ink System Overview 3-5

Spare Ink and Printheads For maximum productivit y and minimum down time,

ColorSpan recommends stocking extra ink reservoirs and print­heads. When the ink supply runs low, or a printhead needs to be
replaced, having spares will ensure that printing can resume as
quickly as possible.

Since ink and printhead usage will vary depending on the
amount and types of printing you do, experience will help you
determine how to stock an efficient spare inventory. For exam­ple, in a “2x6” configuration (two six-color sets of ink),
ColorSpan recommends stocking t wo six-color sets of ink reser­voirs, plus six printheads (one for each color). Both ink reser­voirs in a pair tend to run out of ink at the same time, so two
spares per color would allow you to continue printing with a
minimum of delay. The printheads tend to need replacement
one at a time, so one spare per color would be sufficient most of
the time.

Tip

To clean a printhead with jet-outs, see “Cleaning Ink
Jets” on page 5-3.

Printhead Handling Tips

◆

DO hold the printhead by the plastic body only.

◆ DO clean the printheads with a clean lint-free cloth moistened

with plain water.

◆ DO NOT touch the ink jet nozzles on the bottom of the printhead.

◆ DO NOT touch the electrodes on the back of the printhead. The

printhead is fired by an electrical signal. The electrodes that carry
this signal are easily contaminated.

◆ DO NOT set the printhead down anywhere before you install it.

◆ DO NOT wipe the printhead with any fiber-cellulose material,

such as a paper tissue.

◆ NEVER APPLY ISOPROPYL ALCOHOL ON THE PRINTHEAD OR

SERVICE STATION. USE PLAIN WATER. Alcohol reacts with pig­mented inks, rendering the printhead unusable. To clean ink clogs,
see “Cleaning Ink Jets” on page 5-3.

3-6 Ink System Overview

Selecting a Print Mode Before installing ink, report to the printer how you will use the

ink you will install (the “print mode”). This is necessary because
although the printer can detect which inks are installed, a given
ink set may be usable in several different modes.

For example, consider an installation of two six-color (C2M2YK)
sets of ink. By changing the color map selected at the control
panel, and without moving or removing any of the ink reser­voirs or printheads, these twelve inks may be used as:

◆ 2 six-color ink sets

◆ 1 six-color ink set

◆ 2 four-color ink sets

◆ 1 four-color ink set

See “Switching Bet ween Ink Sets” on page 3-10 for further
details.

To configure the print mode:

1. From the Front Page screen on the control panel, press the
Print Mode key.

The control panel displays the Current Selection screen. This
shows the current settings for the options you are about to
specify.

2. Press the B (Proceed) key.

The control panel displays the Print Direction menu.

3. Press the C and p keys to select the BiDi or Left Only print
direction, then press the D key.

The control panel displays the Select Heads Per Color menu.
For both options, you can also specify a High Qualit y (HQ)
mode.

4. Press the C and p keys to select the number of printheads
per color you plan to use, then press the D key.

The Select Ink Type menu appears.

5. Press the C and p keys to select the ink type, then press the
D key.

Selecting a Print Mode 3-7

The control panel displays the Select Color Map screen. At
the top of this screen are the color sets that are valid for the
number of heads per color you selected. At the bottom of
the screen is a schematic diagram showing the placement of
the printheads in the printhead carriage.

Fig. 3-4. Select Color Map screen

Printhead Positions

159

2610

3711

4812

Ink Colors

CCyan
mC Medium Cyan
lC Light Cyan
MMagenta
mM Medium Magenta
lM Light Magenta
Y Yellow
KBlack
xxx Ignored/Not used

Ink Type (Suffix)

e Endura•Chrome
p Perma•Chrome

3-8 Selecting a Print Mode

6. Press the C and p keys to select the color map you will use.

The color map diagram changes with your selection.

7. Press D to continue.

The control panel displays the Select Passes menu.

8. Press the C and p keys to select the number of print passes
you want to use.

A higher number of passes produces the best print quality,
but a lower number of passes will increase print speed. The
default is 8 passes.

9. Press D to continue.

The Front Page screen appears. The print mode is now
selected. If you changed the number of passes by more than
one pass, you should run a Media Feed Calibration (see
“Media Feed Calibration” on page 4-4) and Head-to-Head
registration (“Auto Calibrations” on page 4-19) before print­ing.

10. Install the Color Map card that corresponds to the mode you
selected into the plastic sleeve on the printer’s top cover.

Refer to the Color Map card to help you load inks into the
correct locations. See the figure on page 3-5 for an illustra­tion of a Color Map card.

Selecting a Print Mode 3-9

Switching Between Ink
Sets

The inks are located in specific numbered locations on the
printer for optimal print and color quality. The software ignores
ink positions that are not needed for a print mode, so any ink
(or no ink) can be present in these positions. This provides flex­ibility while minimizing the need to swap or reposition inks. For
example, by loading a 2x6 C2M2YK ink set, you can switch
between 2x6, 1x6, 2x4, and 1x4 print modes at the control
panel without moving or changing any inks (see below).

1 x 6

2 x 6

2 x 4

1 x 4

C = Cyan, mC = Medium Cyan
M = Magenta, mM = Medium Magenta
Y = Yellow
K = Black

Fig. 3-5. Possible modes with a 2x6 ink set

3-10 Switching Between Ink Sets

Switching between eight-color and six-color modes, however,
does require switching ink(s):

1 x 6

1 x 8

2 x 6

C = Cyan, mC = Medium Cyan, lC = Light Cyan
M = Magenta, mM = Medium Magenta, lM = Light Magenta
Y = Yellow
K = Black
CX = Change Ink

Fig. 3-6. Possible modes with a 1x8 ink set

Caution

When changing ink colors, if you change the print­head and reservoir without changing the existing ink
tube, ink from the reservoir will mix with the differ­ent ink in the ink tube, producing a third color. When
you change ink colors, you must replace the existing
printhead, tube, and reservoir with the printhead,
tube, and reservoir containing the new ink color.

The printer will display an error if you install a print­head and/or reservoir in the wrong position for the
selected ink set, but it cannot detect whether the ink
tube does not match the other components.

Since inks of different dilutions are very difficult to
visually discern in the ink tubes, be sure to label all
components and replace them one color at a time, as
described in “Replacing Ink System Components” on
page 3-17.

Switching Between Ink Sets 3-11

Installing Ink for the
First Time in a New
Printer

When you receive a new printer, numbered empty ink t ubes are
preinstalled at the factory. This prepares the printer to accept ink
reservoirs and printheads with any ink type or color set. It also
avoids introducing air into the ink, which would occur gradually
if ink tubes filled with ink were installed and stored unpressur­ized (without an ink reservoir connected).

During the ink installation process, you will displace the air
inside the ink tube with ink before you connect the tube to the
printhead.

Caution

1. On the printer’s Ready screen, press the Online/Offline key.

The Front Page screen appears.

2. On the control panel Front Page screen, press the Carriage
key.

The printhead carriage moves to the center area of the platen
so you can load the printheads.

3. Open the printer’s top cover.

4. If desired, label the ink tubes at the reservoir end.

Referring to the Color Map card, affix the labels showing the
ink color and ink type onto the ink tubes at the reservoir
end. This will identify the ink used in each tube, and help
reconnect any tubes that are removed and stored to the cor­rect ink reservoir and printhead.

Always fill an empty ink tube with ink before con­necting it to a printhead. Connecting an empty ink
tube to a printhead will result in enough air to be
introduced to cause the printhead to fail. This condi­tion may be recoverable by purging the cartridge of
air (see “Purging the Printheads” on page 5-11 for
instructions), and then priming them (see “Manual
Priming” on page 5-8).

3-12 Installing Ink for the First Time in a New Printer

5. If not pre-assembled, insert the drain tube into the connec­tion on top of the drain bottle.

Fig. 3-7. Assembling the drain tube to the top

of the drain bottle.

6. Place the drain bottle on the floor and tape the drain tube to
the dryer tube, providing a descent from carriage-level to the
drain bottle.

Fig. 3-8. Placing the drain bottle

Installing Ink for the First Time in a New Printer 3-13

7. Referring to the Color Map card, place an ink reser voir into its
numbered position (1 through 12) in the ink tray.

Be sure to insert the profiler into its port in the ink tray.
Work with the ink reservoir, tube, and printhead that corre­spond to one position at a time. This will help prevent cross­connecting components.

8. Referring to the Color Map card, affix the labels showing the
ink color and ink type onto the connectors of the ink supply
tube (see Fig. 3-3 on page 3-5).

9. Open one of the carriage covers to expose the printhead
slots.

Release the cover by pressing its latch at the front of the
carriage.

10. Insert the needle end of the drain tube into the nozzle end of
the supply tube that is located in the printhead slot in the
carriage assembly (see Fig. 3-9).

This will allow air to escape from the supply tube.

Fig. 3-9. Connecting the drain bottle tube to the supply tube

11. Connect the ink supply tube into its corresponding fitting on
the ink reservoir.

The ink will begin to flow from the reservoir toward the ink
bottle. The ink will displace the air in the tube, filling it
with ink. To ensure that the drain tube needle does not slip
out of the ink tube, hold the drain tube needle in place dur­ing the fill process.

3-14 Installing Ink for the First Time in a New Printer

12. As soon as you see ink flowing into the drain tube, pinch the
drain tube and remove it from the nozzle end of the ink tube.

By pinching the drain tube, a vacuum is formed between the
pinched tube and the end of the needle, keeping any resid­ual ink from draining from the needle as it is removed.

Fig. 3-10. Removing the drain tube

13. Wipe clean the needle end of the drain tube, and set it aside,
keeping the ink inside from spilling out.

14. Remove the packaging from a printhead that contains the
same ink as the ink reservoir.

Remove the tape covering the electronic contacts, and
remove the plug from the ink inlet. Do not touch any of the
metallic electronic contacts.

15. Install the printhead into the carriage.

Install the printhead into the correct position. You can use
the built-in handle to help position the printhead.

16. Repeat steps 7 through 15 for each ink tube you want to fill.

17. Close and latch the carriage cover(s).

18. Close the printer’s top cover.

On the control panel Front Page screen, press the B (Pro­ceed) key to park the printhead carriage into the service sta­tion.

See “Loading Media” on page 3-24 for media loading
instructions.

Installing Ink for the First Time in a New Printer 3-15

After installing one or more printheads, always run AutoSet. See
“Front Page” on page 2-5 for instructions on running AutoSet
from the Front Page screen.

3-16 Installing Ink for the First Time in a New Printer

Replacing Ink System
Components

This section shows you how to replace the individual compo­nents in the ink system:

◆ Replacing an ink reservoir in an idle printer

◆ Replacing an ink reservoir during printing (“hot swapping”)

◆ Replacing a printhead

◆ Replacing an ink tube

Replacing an Ink Reservoir

in an Idle Printer

Replace an ink reservoir when there is insufficient ink to print,
or when you want to use a different color or type of ink. If you
replace an ink reservoir with the same color and type of ink,
there is no need to replace the printhead and ink tube.

Caution

When installing ink tubes, avoid placing excessive tension on
the tube end connected to the printhead. Excessive tension may
cause kinking and blockage of the ink flow, and could cause the
tube to separate from its connector, resulting in an unrestricted
flow of ink from the tube.

1. Remove the ink reser voir from the ink tray. Do not disconnect
the ink tube at this time.

This disconnects the profiler, which is built into the ink res­ervoir, from its port on the back of the tray. The printer
detects that the profiler has been disconnected, but will not
report an error condition unless you try printing.

2. Install the new ink reservoir into place in the ink tray. Care­fully connect the profiler into its port at the back of the tray.

If you install ink of a different color or type than was origi­nally installed, the printer will report this as an error mes­sage on the printer control panel.

When switching to a new ink color or ink type,
replace the ink reservoir, printhead, and ink tube as a
matched set. Failure to do so will contaminate the
ink system and compromise performance or output
quality.

3. Disconnect the ink tube from the old ink reservoir, and con­nect it to the new ink reservoir.

Replacing Ink System Components 3-17

Replacing an Ink Reservoir

During Printing (“Hot

Swapping”)

You can replace an ink reservoir during printing (“hot swap”)
only with an ink reservoir of the same color and ink type.

Caution

1. Place the new ink reservoir near the reservoir to be replaced.

2. Remove the ink reser voir from the ink tray. Do not disconnect
the ink tube at this time.

This disconnects the profiler, which is built into the ink res­ervoir, from its port on the back of the tray. The printer
detects that the profiler has been disconnected, but will not
report an error condition unless you fail to connect the new
ink reservoir to the profiler docking station within ten
seconds.

3. Install the new ink reservoir into place in the ink tray. Care­fully connect the profiler into its port at the back of the tray.

Do this promptly. Since the printer keeps track of ink used,
the longer it takes for you to replace the ink reservoir, the
less accurate this “count” will be. If you install ink of a dif-
ferent color or type than was originally installed, the printer
will report this as an error message on the printer control
panel, and printing will stop.

When switching to a different ink color or ink type,
wait for printing to finish, then replace the ink reser­voir, printhead, and ink tube as a matched set. Fail­ure to do so will contaminate the ink system and
compromise performance or output quality.

4. Disconnect the ink tube from the old ink reservoir, and con­nect it to the new ink reservoir.

Connect the new ink reservoir within five seconds, or the
printhead may deprime, which will damage printed output.

3-18 Replacing Ink System Components

Replacing a Printhead Replace a printhead when the printer:

◆ When the printer can no longer compensate for missing or
deflected jets by increasing the number of print passes, and
you cannot recover these jets (see “Cleaning Ink Jets” on
page 5-3 for instructions).

◆ When the number of passes required increases print times to
unacceptable levels.

◆ When switching ink color or type.

To replace a printhead:

1. Wait for the printer to stop printing.

2. From the ready screen, press the Online/Offline button.

The Front Page screen appears.

3. Press the Carriage button.

The printhead carriage moves out of the service station.

4. Open the top cover.

5. Open the carriage cover of the printhead that you want to
replace.

Press the cover’s latch at the front of the carriage.

6. Remove the printhead from the carriage by lifting the print­head straight up.

Use the printhead handle to help you lift it up.

7. Install the new printhead into the carriage.

Remove the tape covering the electronic contacts, and
remove the plug from the ink inlet.

8. Close and latch the carriage cover.

9. Close the top cover.

10. On the control panel, press the B (Proceed) key to park the
printhead carriage into the service station.

11. Run an AutoSet calibration.

Replacing Ink System Components 3-19

Replacing An Ink Tube

To ink trays

From printheads

Fig. 3-11. Ink tube routing

Replace an ink t ube when switching ink colors or t ypes, or if the
ink tube leaks. You need not replace an ink tube when you
change an ink reservoir and/or printhead without changing ink
color or type, if the tube is functioning normally.

Each of the ink tubes is routed to a specific ink tray position, to
enable the replacement of individual tubes without crossing or
tangling with other tubes.

Caution

Tip

3-20 Replacing Ink System Components

Always remove and replace ink tubes one at a time,
to ensure correct routing of the tube. Although the
printer can detect the proper placement of the ink
reservoirs and printheads, it cannot detect whether
the ink tubes are routed correctly. Incorrectly routed
ink tubes would likely mix inks in the printhead, and
cause printing problems.

Wear protective gloves during this procedure to pro­tect your hands from ink stains.

1. Wait for the printer to stop printing.

2. From the ready screen, press the Online/Offline button.

The Front Page screen appears.

3. Press the Carriage button.

The printhead carriage moves out of the service station.

4. Open the printer top cover.

5. Disconnect the ink tube you are replacing at the carriage end.

Some slack is necessary to avoid kinking the ink tube when
you disconnect it from the printhead in step 9.

6. Depress the lock levers to unlock the printhead assembly, and
swing the carriage up to expose the printheads.

7. Disconnect the ink tube from the ink reservoir.

The tube automatically seals when you disconnect it. This
prevents ink from spilling out.

8. Carefully remove the ink tube from its clips, beginning at the
ink tray end.

9. Disconnect the ink tube from the printhead.

Unless the tube is damaged, you can store the tube, with the
ink inside, for future use. Be sure that it is properly labelled
with position number and ink type.

10. Install the new tube into its guides, beginning from the print­head end, but do not connect the empty tube to the print-

head yet.

Beginning at the printhead end ensures that the slack por­tion of the tube is at the ink tray end. Be sure to route the

Replacing Ink System Components 3-21

Tube guides inside the tube chain

Fig. 3-12. Location of tube guides

tubes through the guide behind the carriage top cover for
printheads 1, 2, and 3.

Ink tray

Tube guides along rear of printer

Caution

Ensure that the ink tubes will not be pinched or sev­ered when the top cover is closed.

11. Connect the new ink tube to the ink reservoir.

Fig. 3-13. Connecting the ink tube to the reservoir

3-22 Replacing Ink System Components

Caution

12. Connect the other end of the tube to the drain bottle, and
place the bottle on the printer platen or floor.

As ink begins to move through the ink tube from the ink
reservoir, the air in the tube is displaced with ink. The
greater the distance between the drain bottle and the ink
reservoir, the faster the ink will flow.

Always fill an empty ink tube with ink before con­necting it to a printhead. Attempting to print with an
empty ink tube connected to a printhead will result
in enough air to be introduced to cause the print­head to fail. This condition may be recoverable by
purging the cartridge of air (see “Purging the Print­heads” on page 5-11 for instructions).

Tip

13. When ink has reached the end of the ink tube and begins
dripping into the drain bottle, remove the supply tube from
the drain bottle.

The ink tube automatically seals in the ink.

14. Label the new ink tube with the ink color on the connector to
the ink reservoir, and with the tube number (1 through 12)
on the connector at both ends.

Proper labeling will help ensure that the tubes are always
connected to the right ink reservoirs and printheads. This
will help reduce the possibility of reconnecting tubes to the
wrong printheads.

15. Connect the new ink tube to the printhead.

16. Swing the printhead assembly down into the printing posi­tion, and push the printhead assembly down into position
until it engages the lock levers with a click.

17. Close the printer top cover.

18. On the control panel Front Page screen, press the B (Proceed)
key to park the printhead carriage into the service station.

If the ink does not begin flowing, try disconnecting
and reconnecting the ink tube to the ink reservoir,
and reposition the drain tube needle within the ink
tube nozzle.

Replacing Ink System Components 3-23

Loading Media Wear cotton gloves during this procedure, or handle the media

only by its very outside edges. This will prevent skin oils from
being deposited on the media, which could render output qual­ity unacceptable.

Tip

Caution

Home side (toward control panel)

Fig. 3-14. Installing media roll and collets onto the spool

1. Ensure that the fixed collet (with the metal pin) is in the
proper location on the supply spool.

The collet is designed to accommodate 2-inch and 3-inch
cores.

For best results, use genuine ColorSpan media.

Do not store or rest a media roll on either end before
loading it onto a spool. This could result in an inden­tation on the edge of the media, which can be struck
by the printhead carriage during printing.

Far side

◆ If you are loading media with a 2-inch core, set the col-

let into the outside (closest to the home side) hole of the
spool. This is how the collet is installed at the factory.

◆ If you are loading media with a 3-inch core, set the col-

let into the inside hole (closest to the far side) of the
spool.

2. Tighten the pin with the hex wrench included with the
printer.

3. Load the media roll onto the spool.

3-24 Loading Media

4. Load and secure the other collet against end of media roll.

The far-side collet does not have a metal pin. Push the collet
into the core, and friction will hold it in place.

5. From the rear of the printer, load the media and spool into
the printer’s supply spool holder.

Press the home side of the supply spool into the home side
holder (on the left from the rear of the printer), then swing
the far side of the supply spool into the far side holder (on
the right).

6. With your right hand, feed the leading edge of the media
into the printer’s pinch rollers and hold it in place until the
following step.

If loading 72 inch media, see “Loading 72-Inch Media” on
page 3-29.

Note

7. With your left hand, press the Media Advance button to
advance media a few inches (several centimeters).

The Media Advance button is located to the left of the
installed supply spool, on the rear of the printer next to the
Big Ink pack tray and electronics enclosure.

8. While holding the left collet stationary, press the Media
Advance button a few seconds, until the media web is tight
with no wrinkles.

Ensure that the right and left edges of the media web are
perpendicular to the sides of the printer, that the tension
appears uniform across the media web, and that the media is
not unrolling unevenly (“telescoping”) from the supply
spool.

Note

The printer automatically locates the right and left
edges of the media, so it is not necessary to align
the media edges to a reference mark on the platen.

These checks ensure that the tension is uniform
across the width of the media. This is critical to
trouble-free printing.

Loading Media 3-25

9. On the Front Page screen of the control panel, press the Load
Media key.

The control panel prompts you to press the B key to load
media, or n to cancel.

10. Press the B key to proceed.

The control panel prompts you to advance the media.

11 . P r e s s t h e p key to advance the media past the front edge of

the platen.

12 . Pr e ss th e B key to proceed.

This causes the printer to measure the width of the media.

The control panel displays a numeric keypad.

Fig. 3-15. Numeric entry screen

13. Enter the length of the media roll (if it is a new roll) or the
length remaining (if it is a partially used roll), and press the
Enter key to continue.

To skip this step, press Esc or Enter without entering a value.
The printer will not track the amount of media remaining
on the roll, and it will be unable to display a warning when
the amount of media runs low. The media length will dis­play a s “undefined.”

3-26 Loading Media

14. The control panel asks whether you want to use the takeup
system.

See “Take u p O pt i ons ” on page 3-30 for details on using the
takeup system.

◆ If you will be printing without using the takeup system,

or if you will be performing a Media Feed Calibration,
press the n key to skip loading the takeup. See “Media
Feed Calibration” on page 4-4 for instructions.

◆ To use the takeup system, press the B key.

15. Press and hold the p key until the end of the media reaches
past the takeup spool.

16. Load an empty media core onto the takeup spool, and load
the core and spool into the printer’s takeup spool holder.

See steps 3 through 5 for detailed instructions.

17. Grasping the middle of the media web, pull straight back and
tape the middle of the web to the takeup core.

Note

18. Add a small amount of slack (a “supply loop”) to the media,
to prevent the takeup from pulling the takeup spool out of
the printer.

19. Press the B key to continue.

The control panel displays an informational message sug­gesting that you perform a Media Feed calibration.

20. Press the B key to perform a Media Feed calibration, or n to
skip the calibration.

See “Media Feed Calibration” on page 4-4 for instructions.

You are now ready to begin printing. The printer will verify
that the media is wide enough for each print job it receives.

Be sure that the direction you wrap the media
around the takeup spool is consistent with the direc­tion specified in the Takeup Control option of the
menu (see “Takeup Options” on page 3-30 for
details). The default direction is Image Outside
(printed image facing out).

Loading Media 3-27

Tip

The media should be consistently tensioned across its
width when attached to the takeup spool. Ensure
that the web is straight and smooth from side to side.
If necessary, a cardboard core from a roll of masking
or other graphic arts tape can be slipped over the
spool holder to hold it in place.

Loading the media onto a takeup spool that already
has some media on it will change the weight of the
spool and make it more difficult to inadvertently pull
off the media during printing.

3-28 Loading Media

Loading 72-Inch Media The width of the 72-inch media makes it impossible for most

persons to load it by grasping its left and right edges at the same
time. Follow this procedure to more easily load 72-inch wide
media.

Wear cotton gloves during this procedure, or handle the media
only by its very outside edges. This will prevent skin oils from
being deposited on the media, which could render output qual­ity unacceptable.

1. With your right hand, grasp the media at the center of its
leading edge, and pull it forward into the center grip rollers.

2. While continuing to hold the center of the leading edge of
the media in place, grasp the left edge of the media with
your left hand.

3. Pull the left edge of the media into the leftmost grip rollers.

4. Hold the media in place with your left hand.

5. Grasp the right edge of the media with your right hand, and
pull it into the rightmost grip rollers.

6. With both hands, feed the media web evenly into all grip roll­ers.

7. Press the Media Advance button to finish loading the media.

8. Verify that the media web is even and unwrinkled across its
width.

9. When loading the media onto the takeup spool, ensure that
the media is tightly wound onto the spool across its width.

Uneven or excessive tension may cause the spool to pull out
of the left spool holder.

Loading Media 3-29

Takeup Options You can enable and disable the takeup system at the control

panel. See Takeup Control under “Print Settings” on page 2-11
for details.

◆ When enabled, before each print job the takeup system
automatically detects whether any media is attached to the
takeup spool and operates the takeup motor as needed.

◆ When disabled, the takeup motor will not operate, and will
not attempt to detect whether media is attached to the
takeup spool.

When printing one print at a time, you may choose to not use
the takeup system at all. In this case, advance the media, cut the
finished print from the roll, then back up the media for the next
print. (To advance and back up the media using the control
panel, see “Front Page” on page 2-5).

Caution

You can also configure the takeup system so it winds the image
facing to the inside or outside of the spool. This is useful if your
laminator or other finishing equipment has a certain require­ment for its supply spools. See Takeup Control under “Print Set­tings” on page 2-11 for instructions.

If you do not use the takeup system, the software
assumes that you are cutting individual prints as
they are printed. If you send a large number of jobs
to the printer without the takeup system loaded,
and allow printing to continue unattended, the
prints will pile onto the floor.

Linearization When changing media types, you should perform a color cali-

bration or linearization (if supported by the RIP). This compen­sates for the differences between medias that affect color
accuracy. For further information, see “Linearization” on page 4-

23.

When replenishing the media supply with the same type of
media, relinearization is unnecessary unless print color quality
has changed noticeably.

3-30 Loading Media

Dryer Operation As the printed output advances past the dryer outlets, the dryer

blows air over the output to dry it. The print will continue to
advance until the trailing edge of the print has passed under the
dryer. The print remains stationary for twenty seconds, then will
reverse or advance according to the supply loop option selected
(see page 2-14). To cancel the twenty-second delay, press the n
(Cancel) key.

The printer’s relative humidity sensor enables the printer to
adjust the media advance speed to ensure adequate drying.
Higher relative humidity will result in slower printing. You can
customize this feature from the control panel; for instructions,
see page 2-12.

Relative
Humidity Printer Action

0–29% Low humidity warning displayed, jets may drop out

and media may lift from the platen
30–59% Optimal, no warning or drying delay
60–79% High humidity warning displayed, media advance is

delayed automatically as humidity increases
> 80%

Action displayed, printing stops. User must specify a

manual drying delay to proceed with printing (see

Drying Delay under “Print Settings” on page 2-11)

Caution

Loading Media 3-31

Output on polyester films can be streaked by the
dryer air flow. To avoid this, you can disable the
dryer fan from the control panel. For instructions,
see “Printer Options” on page 2-13.

Cutting and
Unloading Media

1. Press the p key on the Front Page screen to advance the

printed portion of the media past the cutter anvil (on the
front edge of the platen).

2. From the front of the printer, place a utility knife blade in the
cutter channel and draw the cutter across the media.

Support the trailing edge of the media as you cut it from the
supply spool.

3. On the Front Page screen of the control panel, press the
Unload Media key.

4. The control panel prompts you to press B to unload media,
or n to cancel.

5. Press B to continue.

The control panel asks if you want to print the calculated
length of media remaining on the supply spool onto the
media for reference. When reloading the media later, the
control panel will prompt you to enter this value so it can
continue to track the amount of media remaining.

6. Press B to print the length remaining, or n to skip printing.

7. As desired, take the single print or takeup spool with printed
output to your finishing area, and re-load the takeup system.

3-32 Cutting and Unloading Media

CHAPTER 4

Calibrating the Printer

This chapter explains how to calibrate the printer for the best possible
output:

◆ AutoSet (page 4-2)

◆ Manual Calibrations (page 4-3) — Media Feed, Manual BiDi Registra-

tion, Manual Head Registration, Manual Jet Mapping, Jet Status
Lines, Default Registration Data

◆ Auto Calibrations (page 4-19) — AutoBiDi Calibration, AutoH2H
(Head-to-Head) Calibration, AutoBiDi & H2H Calibration, AutoJet
Calibration

◆ AutoTune (page 4-20)

◆ Calibration Summary (page 4-21)

◆ Linearization (page 4-23)

Calibrating the Printer 4-1

AutoSet AutoSet is an advanced printer calibration feat ure that uses an

onboard digital imaging sensor and sophisticated software to
detect and compensate for variations in ink jet printing. It can
be initiated by the user or run automatically at specified inter­vals (AutoTune). AutoSet is designed to be a “one-button” cali­bration, the only calibration you need to run in most cases for
superior quality output.

When you press the AutoSet key on the Front Page control panel
screen, these functions are performed automatically:

◆ Bidirectional Registration — ensures that every working jet
fires a pixel at precisely the same location, regardless of the
carriage’s direction of travel.

◆ Head-to-Head Registration — ensures that the printheads
are in alignment relative to each other.

◆ AutoJet substitution mapping — detects and disables indi­vidual ink jets that are misfiring or not firing at all. During
subsequent printing, the printer compensates for these jets
by using other jets in their place, ensuring maximum print
quality without reducing print speed.

Note

Note

Tip

4-2 AutoSet

Clean printheads produce the best printed output
and accurate calibration patterns.

AutoSet does not work with transparent media. In
this case, you should run AutoSet on a white media
that is similar in thickness to the clear media, then
switch to the transparent media; or manually run
the calibrations under the Calibrate Printer menu
using the transparent media.

If the printhead carriage head height is set to 0.070
inches (1.78 mm) or higher, do not run AutoSet. For
best accuracy, run the manual calibrations instead.
For instructions on running the manual calibrations,
see “Manual Calibrations” on page 4-5.

Manual Calibrations When you run the calibrations from this menu, you evaluate the

calibration test patterns visually and enter the calibration values
via the control panel. In most cases, AutoSet is more accurate
and should be used instead (see “AutoSet” on page 4-2).

Note

If you decide to manually calibrate the printer, first clean the
printhead jets as described in “Cleaning Ink Jets” on page 5-3.

The Manual Calibration menu consists of these options:

◆ Media Feed (page 4-4) — enables you to calibrate the
printer’s media advance accuracy by printing and visually
inspecting your choice of test patterns.

◆ Manual BiDi Registration (page 4-7) — prints bidirectional
registration patterns and allows you to report which pattern
is the most precise.

◆ Manual Head Registration (page 4-10) — precisely aligns
the printheads relative to each other, for accurate colors and
precise registration of images.

◆ Manual Jet Mapping (page 4-13) — enables you to detect
and report nonfiring or misfiring ink jet nozzles, which
enables the printer to “fill in” for them.

◆ Jet Status Lines — prints a quick test pattern that shows
which jets are out.

Manually performing the component calibrations of
AutoSet is time-consuming and can be error-prone,
but is necessary when the head height is 0.070
inches (1.78 mm) or greater, or when calibrating
transparent media. (There is no automatic media
feed calibration, so you must always perform it
manually.)

◆ Default Registration Data — sets all registration data to
zero.

After calibration and jet mapping, perform a linearization, or
color calibration (as supported by your print server or RIP). For
further information, see “Linearization” on page 4-23.

Manual Calibrations 4-3

Media Feed Calibration This calibration allows you to calibrate the accuracy of the

media feed process. You perform this calibration when loading
media, or later if prints requiring very accurate length (for exam­ple, output that will be tiled) are found to be the wrong length.

To perform this procedure, it is helpful to have a magnifying
glass or printer’s loupe to examine the test patterns.

◆ Before performing a Media Feed calibration, print the Prime
Bars and clean the ink jets to get the maximum number of
jets working.

◆ After performing a Media Feed calibration, run AutoSet.

1. If you will be performing this calibration with a new roll of
media, advance the media to the floor, back it up to the
platen, and remove the supply loop (see page 2-13).

This will remove the advance error that would be introduced
by the tighter winding at the beginning of a new roll of
media.

2. Press the v (Menu) key from the Front Page screen on the
control panel to display the menus.

3. Press the E (Menu In) key display the Calibrate Printer menu.

4. Press the p key to highlight Manual Calibration.

5. Press the E (Menu In) key.

6. Press the E (Menu In) key to select the Media Feed option.

The following prompt appears:

Press Proceed to print pattern
Press Cancel to adjust without printing

7. Press the Proceed key to print a test pattern, or Cancel to skip
printing.

If you press Cancel, to go step 13.

When you press Proceed, you can choose between the fol­lowing calibrations:

◆ 34-Inch (900 mm) Calibration — prints two reference

marks along the direction of media feed; measure the
distance between the marks to determine advance
accuracy.

◆ 12-Inch (305 mm) Calibration — same as previous cali-

bration, uses less media but may be less accurate.

4-4 Manual Calibrations

◆ Double Lines — alternate method for use when a refer­ence measuring stick is not available

8. Select one of the options and press the E (Menu In) key to

continue.

9. Follow the applicable procedure below.

34-Inch/12-inch Calibration

10. Press the B key to continue.

The printer asks whether you want to print the media feed
calibration.

11. Press the B key to continue.

The printer prints the calibration marks, and prompts you to
adjust the advance.

Fig. 4-16. Media Feed Calibration pattern

12. With a metal yardstick, measure the distance between the
marks.

A measuring stick with 1/64 inch markings works best.

13. Adjust the media feed advance using the control panel.

You can increase the advance by pressing the C key, or
decrease it by pressing the p key.

14. Press B (Proceed) to save the advance value you entered.

15. Press B (Proceed) to return to the menu.

Manual Calibrations 4-5

Double Lines Calibration

Use this calibration if an accurate measuring stick is not avail­able.

The panel prompts you to select a printhead to calibrate.

16. Scroll through the printhead numbers to the printhead you

want to calibrate, then press the B key.

A menu appears listing the pattern versions plus a cancel
option:

◆ Fine

◆ Medium

◆ Coarse

◆ Cancel Calibration

Begin with the Coarse pattern, and repeat this procedure
with the Medium and Fine versions for the best results.

17. Select a pattern and press the B key to proceed.

If prompted, remove the supply loop (see page 2-13). The
pattern you selected prints.

18. Examine the patterns with a high-power mangifier.

Fig. 4-17. Good advance and bad advance in media advance calibration patterns

19. Select the pattern with the straightest line of pixels, and enter
the pattern number.

4-6 Manual Calibrations

Manual Bidirectional

Registration

Bidirectional registration is a method to align each of the print­heads so that dot placement is accurate in both directions along
the X axis (along the direction of print head travel).

The bidirectional registration pattern consists of a series of verti­cal lines. Half the pixels in this pattern are printed in one direc­tion, half of them in the other direction. When the pixels are
accurately aligned, the pattern is clear. When the dots are not
aligned, the pattern appears fuzzy and ill-defined.

Tip

There are three bidi patterns from which to choose:

◆ Fine — allows 0.25 pixel adjustments

◆ Medium — allows 0.5 pixel adjustments

◆ Coarse — allows 1 pixel adjustments

For the most precise image reproduction, perform these calibra­tions one after the other, starting with Coarse, then Medium,
then Fine.

1. Press the v (Menu) key from the Front Page screen on the

control panel to display the menus.

2. Press the E (Menu In) key display the Calibrate Printer

menu.

3. Press the p key to highlight Manual Calibrations.

4. Press the E (Menu In) key.

5. Press the p key to highlight Manual BiDi Registration.

6. Press the E (Menu In) key to select the option.

7. Press B (Proceed).

The control panel displays this prompt:

AutoSet incorporates an automatic version of this
calibration. Try AutoSet first before running this
manual calibration (see “AutoSet” on page 4-2 for
details).

Print a manual bidi registration page?

8. Press B (Proceed).

9. Press the p key repeatedly to highlight the Fine, Medium, or

Coarse option.

Manual Calibrations 4-7

10. Press B (Proceed).

The printer prints the calibration pattern you selected.

11. When the calibration page has printed, the control panel dis­plays this prompt:

Bidi registration

Head 1: 0

12. Examine the BiDi Registration pattern for the current head,
and determine which pattern is the closest to perfectly
aligned.

Use a printer’s loupe to select the pattern, since the lines in
the patterns may be difficult to discern.

+2 0 -2+4+6

Fig. 4-18. BiDi Registration pattern.

13 . P r e s s t h e C or p control panel keys repeatedly until the

number next to the pattern that is closest to aligned perfectly
is displayed.

For example, if pattern +2.0 is the closest aligned, press the
C key to change the display to:

HEAD-1 +2.0

If a printhead is extremely out of alignment, there may be
no pattern in alignment. Since the black vertical bars are
nominally five pixels apart, you can add +5 or -5 to a pattern
number to shift the colored bars right or left by one black
bar. Alternatively, you can perform the BiDi Registration
repeatedly, which will move the head in smaller increments,
until the head is aligned.

14 . P r e s s B (Proceed).

The control panel message increments the head number by
one.

4-8 Manual Calibrations

15. Repeat steps 12 through 14 for each of the twelve heads.

When you have entered registration values for all heads, the
control panel displays this message:

Registration Successful

Manual Calibrations 4-9

Manual Head Registration The printer creates images by firing dots of ink onto a sheet of

media. Precise positioning of each dot is essential for optimal
print quality. This is possible only if you register all printheads
in the printhead assembly to each other in both the X (along the
length of the platen) and Y (along the length of the media) direc­tions.

This is a two-part process:

◆ Print a registration pattern.

◆ Enter the X and Y registration data for each head.

Tip

1. Press the v (Menu) key from the Front Page screen on the
control panel to display the menus.

2. Press the E (Menu In) key display the Calibrate Printer
menu.

3. Press the p key to highlight Manual Calibration.

4. Press the E (Menu In) key.

5. Press the p key to highlight Manual Head Registration.

6. Press the E (Menu In) key to select the option.

The control panel asks whether you want to print a manual
head-to-head calibration page.

7. Press the B key.

The control panel displays a menu to allow you to select a
Fine, Medium, or Coarse registration pattern.

8. Press the p and C keys to select a pattern, then press the B
key.

If you have a calibration pattern from a recent print, you
can use it to calibrate the heads. Press n (Cancel) and go to
step .

AutoSet incorporates an automatic version of this
calibration. Try AutoSet first before running this
manual calibration (see “AutoSet” on page 4-2 for
details).

4-10 Manual Calibrations

If you need to print a new calibration pattern, press B (Pro-
ceed). The printer prints a calibration page.

X-direction patterns Y-direction patterns

Fig. 4-19. Head-to-Head Registration patterns

When the calibration page has printed, the control panel
displays this prompt:

Take readings from left side of pattern.

9. Press the B key.

The control panel displays this message:

X Direction Registration

Head 2: +0

10. Examine the X direction pattern (in the left-hand group of
patterns) for the current head, and determine which pattern
of colored and black lines are the closest to perfectly aligned.

Use a printer’s loupe to select the pattern, since the lines in
the patterns may be difficult to discern otherwise.

+0

+1

+2

Fig. 4-20. Sample head calibration patterns.

In this example, pattern “+1” is aligned the closest,

so “+1” would be entered.

11. Press the C or p control panel keys repeatedly until the
number next to the pattern that is closest to aligned perfectly
is displayed.

Manual Calibrations 4-11

For example, if pattern +2 is the closest aligned, press the C
key to change the display to:

X REG

HEAD-1 +2

If a printhead is extremely out of alignment, there may be
no pattern in alignment. Since the black vertical bars are
five pixels apart, you can add +5 or -5 to a pattern number
to shift the colored bars right or left by one black bar. Alter­natively, you can repeatedly perform an X calibration, which
will move the head in smaller increments, until the head is
aligned.

12 . Pr e ss B (Proceed).

The control panel message increments the head number by
one.

13. Repeat steps 10 through 12 for each of the heads.

When you have entered registration values for all the heads,
the control panel displays this message:

Take readings from right side of pattern.

14 . P r e s s t h e B key.

Y Direction Registration

Head 2: 0

X registration is complete. You are now ready to begin Y reg­istration.

15. Examine the Y registration pattern (in the right-hand group
of patterns) for the current head, and determine which pat­tern of colored and black lines are the closest to perfectly
aligned.

16 . P r es s t h e C or p control panel keys repeatedly until the

number next to the pattern that is closest to aligned perfectly
is displayed.

17 . P r e s s B (Proceed).

The control panel message increments the head number by
one.

18. Repeat steps 15 through 17 for each of the Y patterns.

When you have entered registration values for all of the pat­terns, the control panel displays this message:

Registration successful.

4-12 Manual Calibrations