Kodak VERSAMARK DS5110, DP5120, DP5240, DP5122 Operator's Manual

KODAK

VERSAMARK DS5110 Printer

Operator’s Manual

Kodak Versamark, Inc.

KODAK VERSAMARK

DS5110 Printer

Operator’s 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.

KODAK VER SA MARK DS5110 Printer

Operator’s Guide

Part Number Media Revision Date Description ECN

0114214-602
0114214-603

Print
PDF

001 07/2004 Revised manual format xxxxx

© Eastman Kodak Company, 2004. All rights reserved.

This document contains proprietary information of Kodak Versamark, Inc. or its licensors and is their exclusive property. It may not be
reproduced without a written agreement from Kodak Versamark, Inc. 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.

Kodak Versamark, Inc. 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. Kodak Versamark 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 Kodak Versamark, Inc. is provided without warranty or representation of any kind, and
Kodak Versamark, Inc. will not be liable for any damages resulting from the use of such information.

0114214-602
0114214-603 08/2004 Printed in U.S.A.

Scope

This guide describes operating, troubleshooting, and maintenance procedures for
the K

ODAK VERSAMARK DP5110 printer (DP5110).

This guide assumes that the reader is the operator, who is responsible for printing
jobs, troubleshooting common printing problems, and performing routine
maintenance. The reader should have a basic knowledge of computers and the
printing environment in which the printer is being used.

When other system components or system software programs are required to
complete a procedure, appropriate manuals are referenced.

Operator’s Guide iii

Text Notations

Safety Notations

This manual uses the following typogra phi ca l conv en tio ns .

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, such as

→ Open

File

ALT+F1
ALT, TAB

xx,yy

jobfile.dat File 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.

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 sequen ce .
Variable in error messages and text.

The following definitions indicate safety precautions to the operator.

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

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

damage.

!

WARNING

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

!

DANGER

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

iv

Service and Support

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

Monday through Friday.

Call for telephone or on-site tec hnical support; to order pa rts or supplies; to re quest
documentation or product information.

Phone Fax

U.S.A., Canada, and worldwide ([phone])

[phone]
Europe [phone] [phone]
Asia/Pacific Rim [phone] [phone]
Japan [phone] [phone]
Updated service information http://www.kodakversamark.com
Customer support [e-mail]

[phone]

Operator’s Guide v

Contents

Chapter 1. Getting Started

Printer Components ............................................................................. 1-2

Printer ............................................................................................ 1-2

Operator Panel .............................................................................. 1-3

Printhead and Umbilical................................................................. 1-3

Fluid Compartment ........................................................................ 1-4

Supporting the Printhead ..................................................................... 1-5

Setting Up the Printhead...................................................................... 1-7

Determining Substrate Movement................................................. 1-7

Locating the Print Array ................................................................. 1-7

Printing at 90° ................................................................................ 1-8

Positioning Multiple Printheads...................................................... 1-8

Determining Cue Distance and Cue Delay......................................... 1-10

Tach Encoder .............................................................................. 1-10

Cue Sensor.................................................................................. 1-11

Cue Distance......................................................................... 1-11

Cue Delay.............................................................................. 1-12

Document and Image Lengths........ ...... ....... ...... ....... ...... ................... 1-13

Operator’s Guide vii

Chapter 2. Basic Operation

Operator Panel Functions .................................................................... 2-2

Panel Buttons ................................................................................ 2-2

Panel Lights.................................................................................. 2-4

Operating Procedures .......................................................................... 2-5

Turning On the Printer ..................................................... ...... ....... . 2-5

Bypassing the POC Test and Fluid System................................... 2-6

Turning On the Fluid System When Idle........................................ 2-6

Turning On the Fluid System When Bypassed.............................. 2-6

Idle Time Guidelines...................................................................... 2-7

Turning Off the Fluid System ......................................................... 2-7

Turning Off the Printer and the Fluid System ................................ 2-7

Clearing Errors............................................................................... 2-7

Contents

Replacing Ink and Replenisher....... ....... ...... ........................................ 2-8

Moving the Printer................................................................................ 2-9

Power Failure..................................................................................... 2-10

Chapter 3. Troubleshooting

Printing Test Patterns .......................................................................... 3-2

Identifying Printing Problems............................................................... 3-3

Voltage Defects............................................................................. 3-3

Phase Defects............................................................................... 3-5

Dirty Printhead Components ......................................................... 3-6

Miscellaneous Problems..................................... ...... .............. 3 -9

Chapter 4. Maintenance

Required Tools and Supplies............................................................... 4-1

Daily Maintenance ............................................................................... 4-2

Cleaning the Printhead Bottom Cover........................................... 4-2

Cleaning the Printhead.................... ...... ....... ...... ....... ...... ....... ...... . 4-3

Periodic Maintenance .......................................................................... 4-4

Cleaning the Air Filter................................... ...... ....... ...... ....... ....... 4-4

Replacing the Mist Filter................................................................ 4-5

Corrective Maintenance....................................................................... 4-7

Cleaning the Printhead Catcher Bottom Plate............................... 4-7

Swabbing the Printhead................................................................ 4-8

Glossary

viii

Figures

Figure 1.1 Printer components .................................................... 1-2

Figure 1.2 Printhead mount......................................................... 1-5

Figure 1.3 Printhead mount stand ............................................... 1-6

Figure 1.4 Print array................................................................... 1-7

Figure 1.5 Printing at 90×............................................................ 1-8

Figure 1.6 Multiple printer dimensions......................................... 1-9

Figure 1.7 Tach encoder ........................................................... 1-10

Figure 1.8 Cue sensor example ................................................ 1-11

Figure 1.9 Cue distance and cue delay..................................... 1-12

Figure 1.10 Document parameters.............................................. 1-13

Figure 2.1 Operator panel buttons and lights.............................. 2-2

Figure 2.2 Ink and replenisher bottles......................................... 2-8

Figure 2.3 Printer - rear view..................................................... 2-10

Figure 3.1 Test pattern ................................................................ 3-1

Figure 3.2 Test print example...................................................... 3-2

Figure 4.1 Removing the printhead bottom cover ....................... 4-2

Figure 4.2 Cleaning the printhead bottom cover ......................... 4-3

Figure 4.3 Removing the air filter ................................................ 4-4

Figure 4.4 Removing the mist filter fitting.................................... 4-6

Figure 4.5 Replacing the mist filter.............................................. 4-6

Figure 4.6 Cleaning the catcher bottom plate.............................. 4-8

Operator’s Manual ix

Chapter 1. Getting Started

The DH5110 printhead is 1.0 inch (2.54 cm) wide. Vertical resolution is
fixed at 120 dpi and spans the width of the printhead array. Horizontal
resolution is in the direction of substrate movement and can be set to 120
or 240 dpi. Resolution is measured in dots per inch (dpi). The DS5110 is
capable of printing 100-percent variable data at a print speed of up to
1000 fpm.

After installation, basic setup procedures must be performed before
printing can begin. Along with a brief overview of the system components,
this chapter describes the required setup procedures, which include
supporting the printhead, setting up the printhead, printing at angles,
positioning multiple printheads, and determining cue values.

Operator’s Guide 1 - 1

Chapter 1. Getting Started

Printer Components

Printer Components

Umbilical

Printhead

Operator panel

Replenisher bottle

The printer contains the following components (Figure 1.1):

• Printer

• Operator panel

• Printhead with attached umbilical

• Fluid compartment.

Figure 1.1 Printer components

Ink bottle

Fluid compartment

Printer

The printer, which includes all of the components within the printer
cabinet, accepts print data and commands that determine job setup and
control printer functions. The printer receives this information from a
controller and translates it into a bitmapped format that is sent to the
printhead through the umbilical.

1 - 2

Chapter 1. Getting Started

Printer Components

Operator Panel

The five buttons appearing across the top of the operator panel control
printer operations, such as powering the printer and fluid system on and
off, opening and closing the eyelid, and cleaning the printhead. The seven
lights appearing across the bottom of the panel report operating
conditions such as low fluid levels, errors, and the detection of tach and
cue signals.

Printhead and Umbilical

Caution: To prevent damage to the printhead or printed circuit board components,

use the supplied wrist grounding strap when handling these components;
also, handle circuit boards only by edges free of connectors.

The printhead contains the print array , a row of holes (orifices) from which
the jets of ink are formed. The printhead provides a 1.06-inch (2.69 cm)
print width.

A covering, called the eyelid, protects the print array from damage and
dust and keeps fluids from leaking during printer startup and shutdown.

When the printer is idle, the eyelid should be closed. During printing, the
eyelid must be open to allow ink to reach the substrate.

The standard 12-ft (3.6576 m) or optional 24-ft (7.3152 m) umbilical
connects the printhead to the fluid system. The umbilical contains the fluid
tubes and electrical cables that transfer ink and data between the fluid
system and the printhead.

Operator’s Guide 1 - 3

Chapter 1. Getting Started

Printer Components

Fluid Compartment

Note: Use only Kodak Versamark-approved inks.

The fluid compartment, contains the ink and replenisher bottles.
Replenisher maintains the relative concentration of ink to water. A light on
the operator panel comes on when a fluid bottle or external ink container
is depleted and needs to be replaced.

The printer has quick-release couplings in the lines to the ink and
replenisher bottles to allow you to connect larger containers located
outside of the cabinet.

See Chapter 2 for fluid bottle and external container replacement
procedures.

1 - 4

Supporting the Printhead

Chapter 1. Getting Started

Supporting the Printhead

The printhead support must hold the printhead steady to protect it from
vibration. The support must also hold the printhead within 0.0 to 1.00 inch
(2.54 cm) of the substrate, and support the weight of the printhead and
umbilical. Printhead height restrictions vary from model to model.
Maximum printhead height is 1.0 inch (2.54 cm).

Two support options are available: the printhead mount and the printhead
mount stand. Refer to the installation instructions shipped with the
supports for assembly and installation instructions. The supports for the
one-inch and two-inch printheads vary only slightly. The printhead mount
holds the printhead over a label base or document transport (Figure 1.2).

Figure 1.2 Printhead mount

Operator’s Guide 1 - 5

Chapter 1. Getting Started

Supporting the Printhead

The printhead mount stand consists of an extendable arm, mounted on a
steel base with casters. The printhead mount stand provides a stable,
mobile printhead support (Figure 1.3).

Figure 1.3 Printhead mount stand

1 - 6

Setting Up the Printhead

Chapter 1. Getting Started

Setting Up the Printhead

Proper printhead setup helps to ensure print quality. Multiple printer
configurations and angle printing require certain restrictions or
considerations when positioning the printhead.

Determining Substrate Movement

The printhead has a series of dot indentations appearing on the sides of
the printhead cover to indicate the direction of normal substrate
movement. These dots decrease in size in the direction of normal
substrate movement.

Locating the Print Array

The printhead has a dot indentation on the seam of the printhead cover
which is the largest dot indentation. The seam indicates the location of the
print array (Figure 1.4).

Figure 1.4 Print array

Print array

Operator’s Guide 1 - 7

Chapter 1. Getting Started

Setting Up the Printhead

Substrate moving vertically

Print array

Printing at 90°

The printhead starts up, prints, and shuts down from all angular positions
between 6 ft (1.83 m) above and 2 ft (0.61 m) below the base plate of the
printer.

When printing with the substrate at a 90° angle to the ground, position the
printhead so that the front cover of the printhead faces the ground and the
print array faces the substrate, as shown in Figure 1.5.

Figure 1.5 Printing at 90°

Positioning Multiple Printheads

Position multiple printheads as closely together as possible. The most
downstream printhead (the last printhead to print) must finish printing
before the next substrate passes under the cue sensor. (See the section
“Determining Cue Distance and Cue Delay” in this chap ter.)

The following dimensions, shown in Figure 1.6, need to be considered:

• Feedstroke - the substrate length plus the distance between
substrates

• Cue distance - the distance between the cue sensor and the print
array of each printhead

• Image length - the length of the image being printed.
For proper positioning, feedstroke must be equal to or greater than

the cue distance for each printhead plus the image length.

1 - 8