Kodak Versamark DS5600 Series, Versamark DP5630, Versamark DP5640, Versamark DP5650 Operator's Manual

0114332-603

Versamark DS5600 Series

Printing Systems

Operator Guide

FCC Compliance Statement

This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to Part 15 of the FCC Rules. These
limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment.
This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instruction 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 own expense.

Note: Good quality, shielded (braided shielded) cables must be used for the RS-232-C and Centronics interfaces.

Canadian EMI Compliance Statement

Le présent appareil numérique n’émet pas de bruits radioélectriques dépassant les limites applicables aux appareils numériques de la classe A
prescrites dans le Règlement sur le brouillage radioélectrique édicté par le ministère des Communications du Canada.

This digital apparatus does not exceed the Class A limits for radio noise emissions from digital apparatus set out in the Radio Interference Reg­ulations of the Canadian Department of Communications.

EMI-CISPR 22/EN 55 022/CE Marking

Warning: This is a Class A product. In a domestic environment, this product may cause radio interference in which case the user may be
required to take adequate measures.

Versamark DS5600 Series Printing Systems Operator Guide

Part Number Media Revision Date Description ECN

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

Previous Releases
Part Number Media Revision Date Description ECN

0114332-602
0114332-603

© Kodak, 2010. All rights reserved.

This document contains proprietary information of Eastman Kodak Company or its licensors and is their exclusive property. It may not be
reproduced without a written agreement from Eastman Kodak Company. No patent or other license is granted to this information.

The software described in this document is furnished under a license agreement. The software may not be used or copied except as provided in
the license agreement.

Eastman Kodak Company makes no warranty of any kind with regard to the contents of this document, including, but not limited to, the implied
warranties of merchantability and fitness for a particular purpose. Eastman Kodak Company shall not be liable for any errors or for
compensatory, incidental or consequential damages in connection with the furnishing, performance, or use of this document or the examples
contained herein. Information concerning products not manufactured by Eastman Kodak Company. is provided without warranty or
representation of any kind, and Eastman Kodak Company will not be liable for any damages resulting from the use of such information.

Kodak and Versamark are trademarks of Eastman Kodak Company.
0114332-603 09/2010

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PDF

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

Scope

This guide describes how to operate the Kodak Vers am ar k DS5600 Series
Printing Systems. These printing systems produce letter-quality, variable
data images using continuous inkjet technology at up to 500 fpm
(150 mpm) with print resolutions of 240x240, 240x480, 300x300, or
300x600 dots per inch (dpi).

The DS5600 series printing systems can be used for business forms, tag
and label, direct mail, booklets, bar coding, numbering, addressing,
personalization, and billing statements with or without spot color. These
printing systems are modular and can be configured for web or sheet-fed
presses, collators, mail bases, folders, and a variety of other inline and
offline finishing equipment.

For DS5600 operation, the following system requirements apply to the
system components:

• Kodak Versamark CS150 System Controller Software Dashboard
Version 4.0.1.0 or higher

• Microsoft Windows XP Professional with Service Pack 2.0

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

• Ethernet-compatible wide-format print stations (with Compact DS
Main board installed)

• Fluid Controller Software Release 5.000 or higher

For additional information about the components used in the DS5600
series printing systems, see the following publications:

• Kodak Versamark CS150 System Controller Software Getting Started

Guide

• Kodak Versamark DP5222 and DP5340 Printing Systems Operator’s
Guide

The procedures in this guide should be performed only by an operator
who has received on-site training from Kodak.

Operator Guide 3

Scope

!

WARNING

!

DANGER

Text Notations

Safety Notations

Note: Information that needs to be brought to the reader’s attention.

Caution: A situation where a mistake could result in the destruction of data or

This manual uses the following typographical conventions.

This style Refers to

Ready

go

ENTER

[NEXT] Buttons and lights on the printer operator panel.

Save Software command buttons and sections of dialog boxes,

File  Open

ALT+F1
ALT, TAB

xx,yy Variable in error messages and text.
jobfile.dat Fil e names.

Text displayed by the software.
Anything you type, exactly as it appears, whether referenced

in text or at a prompt.
Special keys on the keyboard, such as enter, alt, and

spacebar.

such as group boxes, text boxes, and text fields.
A menu and a specific menu command.

Pressing more than one key at the same time.
Pressing more than one key in sequence.

The following definitions indicate safety precautions to the operator.

system-type damage.

Service and Support

A potential hazard that could result in serious injury or death.

An imminent hazard that will result in serious injury or death.

Technical equipment support is available 24 hours a day, 7 days a week.
Software and applications support is available 8:00 a.m. to 5:00 p.m.

EST/EDT, Monday through Friday.

Call for telephone or on-site technical support; to order parts or supplies;
to request documentation or product information.

Phone Fax

U.S.A., Canada, and
worldwide

Europe [phone] [phone]
Asia/Pacific Rim [phone] [phone]
Japan [phone] [phone]

[phone]
[phone]

[phone]

4 DS5600 Series Printing Systems

Contents

Chapter 1. Overview

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

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

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

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

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

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

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

Chapter 2. Operation

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Chapter 3. Messages

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

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

Chapter 4. Operator Maintenance

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

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

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

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

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

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

Operator Guide 5

Figures

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Operator Guide 7

Tables

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

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

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

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

Operator Guide 9

DS5600 Configurations

Chapter 1. Overview

This overview describes Kodak Ve rs a ma rk DS5600 Series Printing
Systems in the following sections:

• DS5600 Configurations

• DS5600 Components

Configuration descriptions describe the various combinations of
components that can make up a system.

Component descriptions identify the controller, printers, and print stations
used in the DS5600, and the system nomencla tu re .

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

• Kodak Versamark CS150 System Controller with two Kodak
Ve rs am ar k DP5600 Series Print Stations

• Kodak Versamark CS150 System Controller with one narrow-format
printer (Kodak Versamark DP5222 Printer or Kodak Versamark
DP5340 Printer) and two Kodak Versamark DP5600 Series Print
Stations

• Kodak Versamark CS150 System Controller with two narrow-format
printers (Kodak Versamark DP5222 Printer or Kodak Versamark
DP5340 Printer) and two Kodak Versamark DP5600 Series Print
Stations

• Kodak Versamark CS150 System Controller with three narrow-format
printers (Kodak Versamark DP5222 Printer or Kodak Versamark
DP5340 Printer) and one Kodak Versamark DP5600 Series Print
Station

The narrow-format printers support the following printheads:

• Kodak Versamark DH5222 Printheads, which has a 2.13" (5.41 cm)
print array and prints resolutions of 120x120 or 120x240 dpi

• Kodak Versamark DH5340 Printheads, which has a 1.07" (2.71 cm)
print array and prints resolutions of 240x240 or 240x480 dpi

The DP5600 series print station can support any of the following
printheads:

• Kodak Versamark DH5300 Printhead, which has a 2.77" (7.04 cm)
print array and prints resolutions of 300x300 or 300x600

• Kodak Versamark DH6300 Printhead, which has a 3.41" (8.66 cm)
print array and prints resolutions of 300x300 or 300x600

• Kodak Versamark DH6240 Printhead, which has a 4.27" (10.85 cm)
print array and prints resolutions of 240x240 or 240x480

Operator Guide 11

Chapter 1. Overview

Second DP5600 series print station

CS150 on DS5600

CS150 on DS5000

or

DP5222

or

DP5340

2.13" DH5222
or

1.07" DH5340

DP5630
DP5640

or

DP5650

3.41" DH6300

2.77" DH5300

4.27" DH6240

or

Second, third and fourth printers

DS5600 Configurations

Figure 1.1 shows the different DS5600 series configurations.

Figure 1.1 DS5600 printing system configuration

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

Other system components such as the paper transport, cue sensor, tach
encoder, finishing equipment, and printhead mount(s) are dependent on
the specific combination installed.

The DS5600 series printing systems are identified as:

• Kodak Versamark DP5630 Printing System
Narrow-format printers and one or two DP5600 series print stations

with DH5300 Printheads

• Kodak Versamark DP5640 Printing System
Narrow-format printers and one or two DP5600 series print stations

with DH6240 Printheads

• Kodak Versamark DP5650 Printing System
Narrow-format printers and one or two DP5600 series print stations

with DH6300 Printheads

All configurations are compatible with the current model of the 38.5"
non-stitch printhead mount.

The specific installation and application requirement s determin e the other
system components required. This guide provides operating instructions
for a system with either narrow-format or wide-format printheads.

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

12 DS5600 Series Printing Systems

DS5600 Components

Printhead

DT3 print station cabinet

CS150 System Controller

Umbilical

Network hub

PC shelf

Monitor

Chapter 1. Overview

DS5600 Components

The DS5600 series has the following standard components:

• Kodak Versamark CS150 System Controller

• Network hub

• One printer or print station

• Printhead

• Umbilical

• Fluid containers
The system can include the following additional components:

• System enclosure (same used for the Kodak Versamark DS5000

Series Printing Systems)

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

Station)

• Second, third, or fourth narrow-format printer

• Second DT3 print station.
Each printer or print station supports on e printhead. Each printhead print s

one color. Spot color printing is supported using multiple printheads.
Printheads cannot be stitched.

System Controller

When the system does not include a DP5000 series printer (also called a
narrow-format printer), the CS150 is mounted on a DT3 print station.
Figure 1.2 shows the system components of a system that does not ha ve
a narrow-format printer.

Figure 1.2 DS5600 components, single DT3 system

Operator Guide 13

Chapter 1. Overview

Fluid cabinet

Monitor

Umbilical

Keyboard

Data Main Board

Printhead

DS5600 Components

Figure 1.3 DT3 Print Station

Print Stations

The Kodak Ve rs am ar k DP5600 Print Station is a new component used
only in the DS5600 Series Printing Systems.

The DP5600 consists of a fluid controller for the printhead (DH5300,
DH6240, or DH6300) and an operator terminal for the print station
controller software. When the CS150 is mounted on a Kodak Versamark
DT2 cabinet, the same computer serves as the operator term inal for bo th
the CS150 and the print station using a KVM (keyboard/video/monitor)
switch.

The DT3 cabinet (Figure 1.3) contains the entire fluid system for the
printhead, an internal fluid controller PC, and the Compact DS Main
Board with associated cables. The PC in the DT2 cabinet controls fluidic
and electronic operation of the print station and umbilical. The Compact
DS Main Board relays processes data received over the Etherne t from the
CS150 and transmits rasterized, fiberoptic image data to the printhead.

14 DS5600 Series Printing Systems

Chapter 1. Overview

DS5600 Components

Printheads

The printheads used in the DS5600 series have the performance
characteristics listed in Table 1.1.

Table 1.1 Printhead performance

Model

DH5340 1 inch 1.06 inch

DH5222 2 inch 2.13 inch

DH5300 4 inch 2.77 inch 300

DH6300 4 inch 3.41 inch

DH6240 4 inch 4.27 inch

Print width Resolution (dpi)
Nominal Exact X axis Y axis

240

(2.69 cm)

(5.41 cm)

(8.66cm)

(10.85cm)

240xx
120

120xx

300xx
300 x 600 500

240 x 240 500

240
480

120
240

300
600

Speed
(fpm)

500

500

500

Resolution is measured in dots-per-inch (dpi) along the print array for the
X axis and in the direction of substrate movement for the Y axis.

Maximum speed in feet-per-minute (fpm) was determined printing a 4-line
address with a 1-line Postnet barcode separated by 0.5-inch. Data
prepared in IJPDS format can be printed faster, but the actual speed at
which a given job can be printed is determined by the interaction of the
image data and the inter-document spacing. Simulated imaging can be
used to test the speed at which a job can be run.

For DS5600 operation, apply the following guidelines to printhead
mounting:

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

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

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

0.5 inch (1.27 cm) above the transport belt. Optimum pr int quality is
obtained with a printhead height of 0.125 inch (0.317 cm).

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

height is 0.1 inch above the transport belt.

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

the transport belt.

Fluid Containers

The system requires external fluid cont ainers for ink and replenisher fluid.
These containers can be any combination of the following types:

• 5.2 gallon (20 L) cubitainer

• 55 gallon (209 L) drum

• 275 gallon (1045 L) tote

Operator Guide 15