Rena Mach 8 Operation Manual

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MACH 8

HIGH CAPACITY

DIGITAL COLOR PRINTER

& Automatic High Capacity Output Stacker (optional)

OPERATIONS MANUAL

Rev 05-30-14

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SAFETY PRECAUTIONS

THIS EQUIPMENT PRESENTS NO PROBLEM WHEN USED PROPERLY. HOWEVER, CERTAIN SAFETY RULES SHOULD BE OBSERVED WHEN OPERATING THE MACH 8 PRINTER.

BEFORE USING THE PRINTER, YOU SHOULD READ THIS MANUAL CAREFULLY AND FOLLOW THE RECOMMENDED PROCEDURES, SAFETY WARNINGS, AND INSTRUCTIONS:

 Keep hands, hair, and clothing clear of rollers and other moving parts.  DO NOT place hands/feet or other body parts under the Feed Table or Receiving Tray.  Avoid touching moving parts or materials while the machine is in use. Before clearing a jam,

be sure machine mechanisms come to a stop.

 Always turn off the machine before making adjustments, cleaning the machine, or performing

any maintenance covered in this manual.

 The power cord, supplied with the machine, should be plugged into a properly grounded,

easily accessible wall outlet near the machine. Failure to properly ground the machine can result in severe personal injury and/or fire.

 The power cord and wall plug is the primary means of disconnecting the machine from the

power supply.

 DO NOT use an adapter plug on the power cord or wall outlet.  DO NOT remove the ground pin from the power cord.  Do NOT use extension cords.  DO NOT route the power cord over sharp edges or trap it between furniture.  Avoid using wall outlets that are controlled by wall switches or shared with other equipment.  Make sure there is no strain on the power cord caused by jamming it between equipment,

walls or furniture.

 DO NOT remove covers. Covers enclose hazardous parts that should only be accessed by a

qualified service representative. Report any cover damage to your service representative.

 This machine requires periodic maint enance. Contact your authorized service representative

for required service schedules.

 To prevent overheating, do not cover the vent openings.  Use this equipment only for its intended purpose.

In addition, follow any specific occupational safety and health standards for your workplace or area.

This manual is intended solely for the use and information of Neopost USA, its designated agents, customers, and their employees. The information in this guide was obtained from several different sources that are deemed reliable by all industry standards. To the best of our knowledge, that information is accurate in all respects. However, neither Neopost USA, Inc. nor any of its agents or employees shall be responsible for any inaccuracies contained herein.

Memjet® is a registered trademark. All other trademarks ar e the pro per ty of their respective hold ers . All rights reserved. No part of t hi s book may be reproduced or transmitted in any form or by any means, electroni c or mechanical,

including photoc opying, recording, or any inform a t i on storage and ret rieval system, without permission in writing from the publisher

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TABLE OF CONTENTS

Table of Contents

SECTION 1 – Getting Acquainted 1

Front View 1 Rear View 2 Print Engine View 3 Ink Tank View 4 High Capacity Output Stacker (optional) 5

SECTION 2 – Installing the Printer 6

Transport Inspection 6 Tools Needed 6 Choosing the Location 6 Operating Conditions 7 Unpacking 7 Contents of Packagi ng 7 Removing the cardboard Shipping Insert and Shipping Tape 8 Leveling the Printer (Print Engine) 9 Checking the Tilt Readings 10 Connecting the Printer 11 Plugging in the Printer 11 Powering the Printer ON and OFF 11

Powering-Up the Printer: 11 Powering-Down the Printer: 11

Connecting to the Computer 12

Minimum Computer System Requirements 12

Installing the Printer Software (Driver & Toolbox) 13 Connecting the Printer via Network (Ethernet Port) 16 Installing the Ink Tanks 18 Ink Tank Anatomy 18 Procedure (Installing the Ink Tanks): 19 Installing the Printhead Cartridge 21 Printhead Cartridge Protective Pack aging 21 Procedure (Installing the Printhead Cartridge) 23 Installing/Removing the Head Media Guide 27

SECTION 3 –Installing the Output Stacker (optional) 29

Unpacking 29 Contents of Packagi ng 29 Connecting/Aligning the Output Stacker 29

SECTION 4 – Operating the Printer 30

MACH 8 Control Panel Functions 30 For The Print Engine: 30

Print Engine Status Light (LED) Indicators 31

For the Feed Table: 34

Feed Table: Status Light (LED) Indicators 34

Setting up the Feed 35 Printer Driver Properties 38 General Tab 38 Layout Tab 41 Import/Export Tab 43 Services Tab 43 Using the Printer Toolbox Utility 44 System Status 44 Ink Level Status 45

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TABLE OF CONTENTS

User Interface Menu 46 Diagnostics Menu 49 Ink Usage Menu 50 Network Configuration Menu 50 Service Menus 51 Printing 52 Printhead Cartridge Conditioning 52

Section 5 – Software Setup Information 53

General Software Setup Info 53 Adobe® Acrobat/Reader Setup Tips 53 Setting Up a Job in Microsoft Word® (2007) 54

SECTION 6 – Operating the Stacker (optional) . 55

Output Stacker Control Panel Buttons 55 Output Stacker Status Light (LED) Indicators 56 Output Stacker Setup 57

SECTION 7 – Operator Maintenance 58

Replacing the Ink Tanks 58 Cleaning Ink Tank Contacts & Prism 58 Ink Tank Storage & Shelf Life 59 Ink Tank Service Life 59 Ink Tank Disposal 60 Cleaning the Printhead Cartridge 60 From the M Series Driver: 60 From the Toolbox: 60 Manual Printhead Cleaning: 61 Replacing the Printhead Cartridge 62 Printhead Storage & Shelf Life 63 Printhead Service Life 63 Printhead Disposal 63 Inspecting & Cleaning the Lip of the Capping Station 64 Inspecting the Wiper Roller 65 Cleaning/Replacing Service Station Items 66 Removing the Service Stati on 66 Cleaning the Service Station 68

Wiper Roller Removal and Cleaning or Replacement 68 Wiper Motor Assembly Removal and Cleaning 69 Printing Platen and Capping Station Removal and Cleaning 70 Cleaning the Service Station Tray 70 Suggestion for High Volume Users: 70

Installing the Service Station 71 Still Experiencing Print Quality Issues? 74 Inspecting/Replacing the Waste Ink Tray 75 Replacing the Sheet Separators 76 Jams in the Printer 77 Removing Jammed Media 77 Cleaning the Printer Body 79 Cleaning the Feed Rollers and Forwarding Rollers 79 Cleaning the Feed Sensor 80 Cleaning Other Items inside the Print Engine 81 Grit Rollers (Media Transport Rollers) 81 Media (Paperpath) Sensors 81 Capping Station Lip 81 Paperpath Surfaces 81 Printing Platen Surface 81 Cleaning the Ink Revolver Couplings 83

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TABLE OF CONTENTS

PRINTER MAINTENANCE SCHEDULE 84 Preparing Printer for Transport 85 Local relocation 85 Remote relocation or shipping 85

SECTION 8 – Troubleshooting Guide 88

Print Quality Issues: 88 Examples of Print Quality Issues (including possible causes and solutions) 89

Air in Printhead Nozzle Area: 89 Clogged/Damaged/Dead Nozzles: 90 Color Mixing Issues: 91 Scuff Marks and Smudging Issues: 92 Fuzzy/Distorted Print 94

The Ink Tank(s) 95 The Printhead Cartridge 96 The Printer 98 Dots or Lines Printed on Media 98 Power Problems 98 Service Station Problems 99 Interface Communication Problems 100 Feeding Problems 101 Errors and Warnings 102 Printer Alert Window Messages 102 Toolbox System Status Messages 103

Appendix A – Specifications 107

MACH 8 Specifications 107 Optional High Capacity Output Stacker Specifications 107

Appendix B – Supplies and Optional Hardware 108

Obtaining Supplies, Service and Support 109 Warranty Registration 109

Appendix C – Quick Reference Info 110

Printer Control Panel LED Sequences 110 Driver Properties Printing Adjustments - Quick Reference 111

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TABLE OF CONTENTS

NOTES

______________________________________________________

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SECTION 1 – Getting Acquainted

SECTION 1

GETTING ACQUAINTED

Front View

Feed Table Controls – Raise and lower Feed Table for loading media. Print Engine Controls On/Off, Paper/Resume and Pause/Cancel Buttons. Storage Compartment – Holds media, ink and other supplies. Top Cover – Provides access to the Print Engine. Ink Tank Door – Provides access to the Ink Tanks and Service Station.

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SECTION 1

Feed Table Sensor

GETTING ACQUAINTED

Rear View

10.

Output Stacker Power Out – Connect power cord from optional High Capacity

Output Stacker here. Outlet is rated for 1A, 115VAC. Main Power Switch, Receptacle and Fuse– Plug in power cord here. Switch turns

main power ON/OFF. Fuse (2.5A, 250V, slow blow) provides over-current protection. (IMPORTANT: Use Control Panel ON/OFF button to power-down Print Engine before turning off main power.)

USB Port Connection – The USB cable, from the computer, attaches here. Network Connection – The network cable plugs in here. Stacker Interface Port – Stacker Interface Cable for the optional, Automatic High

Capacity Output Stacker connects here. Feed Rollers and Sheet Separators – Feeds and separates media; delivering one

piece at a time into the printing area. Skew Control Bridge – Adjust so the Skew Control Guide can be positioned near

the trailing edge of the media. Skew Control Guide– Adjust to the width of the media; to keep the media stack

square and control skew. Right Media Side Guide – Adjustable to fit different widths of media. Feed Table Extensions – Slide forward/back, using finger-hole, to support different

media widths. Slide one or both forward to support wider media. Slide one or both back to support narrower media. Tip: If Right Media Side Guide won’t move past a certain point; check to be sure the Feed Table Extensions and Separator Lockdown/Release Tabs, aren’t interfering with the guide.

11.

Feed Table – Load up to 5,000 sheets (10 reams). Raises and lowers with load. Media feeds from top of stack. Feed Table Sensor detects presence of media.

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SECTION 1

GETTING ACQUAINTED

Print Engine View

Ink Revolver Couplings – Connect the ink hoses to the Printhead Cartridge. The

Printhead Latch extends and retracts the couplings from the Printhead. Printhead Latch – When closed; the Ink Revolver Couplings extend/connect with the

Printhead Cartridge. When opened; the Ink Revolver Couplings retract/disconnect from the Printhead Cartridge, providing access for Printhead Cartridge installation/removal/replacement. (See #3 below).

WARNING! Never attempt to open the Printhead Latch manually, severe damage will

result. Use the Printhead Release button function in the Toolbox utility on your PC. Printhead Latch Release Button* – Initiates a Printhead Latch release cycle. If system

is primed with ink; a “System Deprime” cycle will occur before the Printhead Latch is released. Lightly press the button with a non-conductive tool.

*Similar function can be accessed through the Printer Toolbox User Interface screen on your computer. If you are replacing the printhead; it is best to use the “Release Pr inthead” button from the Toolbox utility.

Printhead Cartridge – Memjet Print Ink Channels Button* – Prints 5 bars (1 bar from each ink tank) to indicate how

well the Printhead Nozzles are working. Press the button with a non-conductive tool.

*Same function can be accessed throug h the Printer Toolbox Diagnostics screen on your computer.

Clamshell Latches – Lift both latches at the same time to release and swing open the

“clamshell” (top section of the Print Engine).

Do NOT open while the Printer is operating.

Do NOT let the Clamshell drop. Close it gently and then release the latches slowly. Make Sure the Clamshell is closed and locked before operating.

Printhead. Produces an 8.5" wide full color print area.

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SECTION 1

GETTING ACQUAINTED

Ink Tank View

(Behind the Ink Tank Door)

Ink Tank Securing Latches – Used to hold the Ink Tanks securely into the slots and against the electrical contacts within the print engine.

CAUTION! Before removing/installing Ink Tanks; please be sure to power-down the

Print Engine or press the “Replace Ink Tanks” button, in the Toolbox. If this rule is not followed damage to the Ink Tanks may result, rendering them unusable.

NOTE: Please be sure that both sides, at the bottom part of the latch, are engaged. Ink Tanks – Five Ink Tanks are used in the printer.

Cyan (C), Yellow (Y), Magenta (M), Black (K), Black (K) Waste Ink Tray – The purpose of this tray is to catch the waste ink produced by the

system. This tray is filled with absorbent material. This tray must be replaced when it becomes saturated. Please inspect routinely. The tabs located at the left and right sides

of the tray secure the tray to the print engine frame. Please be sure the tabs “click” into the frame, to secure the tray's position.

Service Station – Contains four major components.

- Wiper Roller Assembly - cleans the Printhead Cartridge of excess ink and debris.

- Capping Station - keeps the Printhead capped, hydrated and protected when not in use.

- Printing Platen - provides the base to support media during feeding and printing.

- Tray – holds all of the above components and captures the waste ink. The waste ink eventual makes its way from the Service Station Tray into the Waste Ink Tray.

Please refer to the “Operator Maintenance” section for information on how to properly maintain the Service Station and its components.

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SECTION 1

GETTING ACQUAINTED

High Capacity Output Stacker (optional)

Control Panel – UP button raises Receiving Tray. DOWN button lowers Receiving Tray. Pressing the same button a second time; stops the Tray at its current location.

Pressing both buttons simultaneously, for about 6 seconds, repositions the Tray to the “ready” position.

Main Power Switch, Receptacle and Fuse – Plug in power cord here. Switch turns main power ON/OFF. Fuse (2.5A, 250V, slow blow) provides over-current protection.

CAUTION: Disconnect power cord from Stacker before checking/replacing fuse. Interface Port– Stacker Interface Cable, from the MACH 8 Printer to the Output

Stacker, plugs in here. Stack Height Sensor– Senses the top of the paper stack, in Tray, and automatically

positions (raises or lowers) Tray as needed. Backstop Adjustment Knob – Locks and unlocks the Backstop for positioning. Backstop – Adjusts to accommodate media lengths from 5" to 13" long. Media Side Guide – Adjusts to accommodate media widths from 6.5” to 9" wide.

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SECTION 2 INSTALLING THE PRINTER

SECTION 2 – Install i ng t he Printer

Before using the MACH 8 Printer the following must be done:

• Choose a location for the Printer

• Unpack and assemble the Printer

• Remove the Service Station Transport Tab

• Position and Level the Printer (Print Engine)

• Plug in the Printer and connect it to the computer

• Install the Printer Driver

• Install the Ink Tanks

• Install the Printhead

• Setup the feed on the Printer

Transport Inspection

The printer is shipped in appropriate packaging so that, under normal shipping conditions, it reaches its destination without damage.

NOTICE: Report damage to the carrier. The carrier is l i able for any damage during transport. Transport and storage should take place under the following conditions:

- At temperatures between -25°C and +50°C (-13 °F to 122 °F).

- At a relative air humidity between 5% and 95%, non-condensing.

- At an atmospheric pressure between 70 kPa and 105 kPa. Exposure to conditions that are not permissible may lead to damage which is not externally visible.

IMPORTANT Please save the packaging materials for future use! It will be required if you ever need to ship the printer. Before shipping; please refer to the section titled “Preparing the Printer for Transport”.

Tools Needed

• Knife and scissors to open packaging

• Carpenters Level (9” or smaller)

• Protective, nitrile powder-free gloves should be worn to avoid getting ink on hands when

removing protective packaging materials fr om the ink coupling areas, the Ink Tank areas, and when installing/removing Printhead Cartridge and Ink Tanks.

• Distilled or de-ionized water

• Non-abrasive, lint free cloths

Choosing the Location

The Printer should be placed on a sturdy/level floor surface and it should be positioned at least 9 inches from any walls. Protect the Printer from excessive heat, dust, and moisture – avoid placing it in direct sunlight. Printer (Print Engine) Must be Level: Please refer to “Leveling the Printer (Print Engine)”, below, for details on why this is important and how to do this.

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SECTION 2

MACH 8 High Capacity Printer

Ink Tanks – Cyan, Magenta, Yellow, Black, Black

Printhead Cartridge

AC Power Cord

USB Cable

Operations Manual

Driver Software CD

Caster Adjusting Wrench

wrench

INSTALLING THE PRINTER

Operating Conditions

Operation should take place under the following conditions:

- At temperatures between +15°C and +35°C (59 °F to 95 °F).

- At a relative air humidity between 20% and 80%, non-condensing.

- At an atmospheric pressure between 70 kPa and 105 kPa.

- Printer and Print Engine should be protected from excessive environmental debris/dust.

- Printer must be placed on a sturdy floor surface.

- Printer (Printer Engine) must be leveled, using adjustable casters, front to back and left to right. Exposure to conditions that are not permissible may lead to damage which is not externally visible.

Allow the printer, printhead and ink tanks to acclimate to ambient temperature before using the printer.

Unpacking

Two or more people are required to lift the printer from its packaging. Remove the Printer and its parts from the carton. Remove all packing tape. Save the packaging in a safe place, for possible future use.

Contents of Packaging

NOTE: Items are shipped inside the Storage Compartment of the Printer.

The following items are included with your printer:

Note: Ink Tanks and Printhead Cartridges can be purchased through your Dealer/Distributor. See “Appendix B” for supplie s information.

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SECTION 2

CAUTION

INSTALLING THE PRINTER

Removing the cardboard Shipping Insert and Shipping Tape

WARNING! To avoid possible damage to the printer; do NOT plug-in, or power-up, the printer

until all shipping materials have been removed; as described below.

1. Open the Top Cover.

2. Carefull y release both latches (one on either side of

the Print Engine), and lift up with both hands, to gently swing open the Print Engine Clamshell.

TO PREVENT DAMAGE; HOLD ONTO (RELEASE) BOTH LATCHES WHEN OPENING AND CLOSING THE CLAMSHELL.

DO NOT FORCE/SLAM THE CLAMSHELL CLOSED. AFTER CARFULLY CLOSING THE CLAMSHELL, GENTLY

RELEASE BOTH LATCHES.

3. Remove the cardboard “Shipping Insert”

[A], by pulling up on both red tabs at the

same time. The “Shipping Insert” secures the Service Station duri ng printer transport.

4. Remove the Tape [B]. The tape wraps

around the underside of the Clamshell to secure the Head Media Guide. (If necessary, wipe off any tape residue from the Head Media Guide surface [C].)

5. Gently close and latch the Clamshell.

6. Close the Top Cover.

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INSTALLING THE PRINTER

Leveling the Printer (Print Engine)

IMPORTANT! It is critical that the Printer Engine is level front-to-back and left-to-right.

SECTION 2

Why is this Important?

The printer’s ink delivery systems, and w ast e i nk drainage system, depend on the Print Engine being level to perform properly. If this rule is not followed you will experience print quality issues and ink waste draining issues that could cause damag e t o the printer.

- Try to insure that the floor surface you are going to place the Printer on is sturdy, flat and level.

If the floor surface is not sturdy, flat and level then the printer should not be placed on it. Do NOT use the Toolbox utilities “Tilt” readings to level the Print Engine.

- Use an accurate level (i.e. bubble level), to check that the Print Engine is level (front to back and

left to right). It is not

acceptable to use your “cell phone app” to check level.

- Do NOT place shims/blocks under the C ast ers or frame.

If the Print Engine cannot be leveled at the current location, then the printer should be moved to a different location (floor surface) where it can be leveled.

Do NOT move the printer while the power is ON.

If you move the printer, please be sure to re-check that it is level before powering it on.

Use the following procedure to check and level the Print Engine.

1. Open the Top Cover.

2. Left to Right: Place a small level (9" or smaller) across

the front bridge of the Print Engine as shown [A]. (If level does not fit on front bridge, you can place the level on the rear bridge frame on the Print Engine.)

Adjust the casters as necessary to level the Print Engine.

(See Step 4) NOTE: Level must be placed on the Print Engine or Print

Engine frame (not on Printer Cabinet) to get an accurate reading.

3. Front to Back: Place the level on the Print Engine Side

Frame [B]. Adjust the casters as necessary to level the Print Engine

(See Step 4). NOTE: You may have to repeat Steps 2 & 3 to level the

Print Engine in bot h directions.

4. Adjusting Casters. Use t he wrench

the large nut on top of the caster [C]. Adjust the caster to the desired height, then tighten the nut so it snugs-up against the bottom of the Printer to lock the Caster in place. Then recheck level.

(included) to loosen

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SECTION 2 INSTALLING THE PRINTER

Checking the Tilt Readings

Once you have the Printer Driver installed, and the Print Engine has been powered-up for at least 15 minutes; you should return to this procedure to check the “Tilt” readings.

WARNING: You should NOT use the Toolbox utilities “Tilt” readings to level the Print Engine. However once you are sure the Print Engine has been properly leve l e d, as described on the previous page, it is important to routinely monitor the “Tilt” readings.

NOTE: When the Print Engine electronics are cold; the Tilt readings may not be accurate. You may see them fluctuate/change as the electronics warm-up. Please allow the Print Engine to remain powered-up for at least 15 minutes before checking/ adjusting.

1. Go to the Start Menu, All Programs, Memjet, M Series Driver,

then open the “Toolbox”.

2. When the Toolbox opens; on the User Interface screen, find

“Tilt”, in the status information along the left side.

You will see readings for Front-to-Back (FB) and Left-to-Right (LR). These readings should be “0” or very close to zero.

NOTE: The FB and LR orientations are in reference to the print engine, not the operator.

a. If the Tilt r eadings are (– 0.9 to 0.9) they will be shown in

black; indicating that the Print Engine is nearly level (within normal tolerances).

b. If the Tilt readings reach -1.9 or 1.9 they

will be shown in purple. This is a warning that the print engine is slightly out of level (out of norm a l tole r a nc e s ). Please recheck the level of the Print Engine.

c. If the Tilt readings reach -2.0 or 2.0 they

may be shown in red*; indicating that the Print Engine is too far out of level. Please stop using the printer and rec heck the level of the Print Engine.

NOTE: If you are sure the Print Engine is level, but the Tilt readings are still shown in purple or

red*; contact service support to have them verify level and possibly recalibrate the Tilt sensor.

* Character color may not change to red with some firmware versions. In this case monitor the

actual tilt reading. If it reaches -2.0 (or lower) or 2.0 (or higher); please stop using the printer and recheck the level of the Print Engine.

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CAUTION

Connecting the Printer

Plugging in the Printer

• Check to make sure the Main Power Switch [1] is in the OFF (0) position.

• Plug the power cord into the receptacle [1] at the rear of the Printer.

• Connect the other end of the Power Cord to a compatible AC Outlet that

supplies 100-120 volts AC, 60 Hz and provides earth ground.

• Plug the optiona l High Capacity Output Stacker into the receptacle [4].

DO NOT USE AN ADAPTER PLUG OR EXTENSION CORD TO CONNECT THE PRINTER TO THE WALL RECEPTACLE.

DO NOT USE OUTLETS CON TROL LED BY WALL SWITCHES. DO NOT USE AN OUTLET THAT SHARES THE SAME CIRCUIT

WITH LARGE ELECTRICAL MACHINES OR APPLIANCES.

Powering the Printer ON and OFF

Powering-Up the Printer:

SECTION 2

INSTALLING THE PRINTER

1. Turn ON the Main Power Switch [1].

2. Press the Control Panel’s ON/OFF Button.

Wait about 45 seconds for the print engine to power-up (ON/OFF button will illuminate).

Powering-Down the Printer:

1. Press the Control Panel’s ON/OFF Button.

Wait for the print engine to power-down (all Control Panel Buttons will turn OFF).

2. Turn OFF the Main Power Switch [1].

BEFORE POWERING OFF THE MAIN POWER SWITCH, ALWAY S POWER DOWN THE PRINT ENGINE, USING THE ON/OFF BUTTON.

IF THIS RULE IS NOT FOLLOWED DAMAGE TO THE PRINTHEAD AND OR INK SYSTEM CAN RESULT.

FOR BEST SYSTEM PERFORMANCE; IT IS RECOMMENDED TO KEEP THE PRINT ENGINE POWERED-UP (ON/OFF LIGHT ILLUMINATED) AT ALL TIMES.

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SECTION 2 INSTALLING THE PRINTER

Connecting to the Computer

The Printer connects to the computer through the USB port [2]. A Network port [3] is also provided; for connecting the printer to a network environment.

IMPORTANT: Do NOT connect the printer to the computer, until prompted to do so, during the printer driver installation process. See “Installing the Printer Software” section. Before installing the printer software (Toolbox and Driver); you should temporarily disable all Antivirus programs and Firewalls. In addition; you must be logged onto the system with full administrative privileges (admin rights).

Minimum Computer System Requirements

• Windows XP, Windows Vista, Windows 7 & *Windows 8/8.1

Supports 32 & 64 bit systems. You must have administrative privileges on the system.

• Pentium II, 2 GHz minimum (Pentium Dual Core, 2.5 GHz or better, is optimal)

• System memory – 2 GB minimum; or as recommended for your operating system.

• At least 10 GB free hard-disk space.

• Microsoft Internet Explorer 6.0 or higher.

• Java version 6. (If you have Java 7 or higher installed; you may need to load Java 6 also, or the

Toolbox may not open properly.)

• CD/DVD drive

• USB 2.0 port (ports will be identified as “USB2” or “Enhanced” in the Device Manager)

• Microsoft .Net Framework ve rsion 3.5 (for 32 bit systems) or Microsoft .Net Framework version 4

(for 64 bit systems) must be installed. Note: Even if you have a higher .NET Framework version installed; version 3.5 or 4 must also be installed, or the Toolbox will not open.

*Windows 8/8.1 is supported in “Desktop Mode” only. “Metro Apps” (applications for the Windows 8/8.1 environment only) are not supported.

How to check your system for the minimum system requirements, shown above: Right click on "My Computer" and select Properties. The system information, including Operating System, Processor Info and Memory info will be displayed under the "General" tab.

How to check your system for the versions of "Microsoft .NET Framework” installed.

From the Control Panel; open "Add or Remove Programs" and look for "Microsoft .NET Framework 3.5..." or "Microsoft .NET Framework 4..."in the list. You can obtain "Microsoft .Net Framework 3.5 or 4" via the Microsoft website. http://www.microsoft.com

How to check your system for the version of "Java" installed. From the Control Panel; open "Add or Remove Programs". Look for "Java(TM) ..." in the list. You can obtain Java from the following website: www.java.com There are also tools on the Java site to help you detect if you have java installed and what version is installed.

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SECTION 2

INSTALLING THE PRINTER

Installing the Printer Software (Driver & Toolbox)

For the Printer software to operate properly check that the computer system meets the minimum requirements. See section titled “Minimum Computer System Requirements”, on previous page.

NOTE: If you are updating the Digital Color Printer (M Series) printer software (printer driver and toolbox utility); please be sure to Uninstall the old software before installing the new sof t w are. Use the “Uninstall” feature found on your computer system under All Programs, “Memjet”, “M Series Driver”.

IMPORTANT: Before installing the Print er soft war e (Toolbox and Driver), you should temporarily disable all antivirus programs and firewalls. In addition, you must be logged onto the system with full

administrative privileges (admin rights). NOTE: Even if you plan to use the printer via an Ethernet Network Connection; your initial connection to

the printer must be done via USB; in order to access the Network Configuration Settings in the Toolbox.

Do NOT plug in the USB cable until prompted to do so.

PROCEDURE NOTE: This process may take up to 20 minut es t o complete; please be patient.

1. Disconnect the USB cable connection from the printer; if you plugged it in already.

2. Power-up the Printer. Turn ON the Main Power Switch, then press the Control Panel’s ON/OFF

button. Wait about 45 seconds for the print engine to power-up (ON/OFF button will illuminate).

3. Insert the CD, supplied with the printer, into your CD drive. If the “Launch Menu” window does

not automatically open in your browser. Locate and run the “MENU_LAUNCH.htm” file, located on the root directory of the CD.

4. When the Digital Color Printer Operation CD “Launch Menu” window opens on the computer

screen; Click “Install Printer Software”. NOTE: If you receive a Windows security or authorization warning, click on “YES” or “Continue

Anyway”. Tip: If you are unable to start the software installation using the button in the “Launch Menu”;

browse to the CD. Locate and open the Printer Drivers folder. Located and run “WinSetup.exe” to start the install.

5. The “Install Print er S oftware” window opens

on the computer screen.

Make sure the computer system meets the minimum requirements and you have followed the other instructions on the screen. Click “Install Printer Software” .

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SECTION 2 INSTALLING THE PRINTER

6. The License Agree men t window opens. Carefully

read the “Software License Agreement”. If you agree to the terms, check “I accept…” then click Next>.

7. After a few moments the “Printer Connections”

window opens. Click “Configure to print using

USB”. Then click Next>.

NOTE: Even if you plan to use the printer via an

Ethernet Network Connection; your initial connection to the printer must be done via USB; in order to access the Network Configuration Settings in the Toolbox.

8. After a few moments the “Installing Printer

Software” window opens and begins downloading the software.

9. As the software loads, the “Would You Like to

Install This Device Software?” window appears. Click Install.

10. The “Connect Device Now” window opens.

Connect the USB cable, from the computer to the printer, at this time.

Don’t click on either button (Back or Cancel). The software will automatically continue once it recognizes the printer (printer powered on and USB cable connected).

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11. The “Finished software installation” window

opens. Do not select (check) the Print Test Page as the Printer is not set up yet. If desired; you can select (check) the “Set this printer as the default printer” at this time. Then click Next>.

12. The M Series Driver welcome window will still

be open. Click Exit to close this window.

13. Restart the computer to complete the installation.

SECTION 2

INSTALLING THE PRINTER

The “M Series Driver” should now be available in your “Printer and Faxes” or “Devices and Printers” folder.

Tip: After you have completed printer setup installed, printhead cartridge installed, media feed setup); it is a good idea to print a test page from the printer driver to confirm that the printer driver and printer are communicating. This i s done by right-clicking on the “M Series Driver” and selecting “Properties” (Printer properties in Win7). Then click on the “Print Test Page” button.

(ink tanks

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SECTION 2 INSTALLING THE PRINTER

Connecting the Printer via Network (Ethernet Port)

PROCEDURE NOTE: This process may take up to 20 minutes to complete; please be patient.

1. If you haven’t already done so; install the Printer Software (M Series Driver and Toolbox), via USB,

by following the instructions in the previous section. Note: Initially the USB connection is needed in order to configure the printer’s internal network settings. Once the software installation is complete; you can proceed to the next step.

2. Open the M Series “Toolbox” utility.

To open the Toolbox utility; click on Start, All Programs, Memjet, M Series Driver, Toolbox. The Toolbox will open in a Web Browser (Example: Internet Explorer) window. Tip: If you receive warning that Windows Firewall has blocked some features of this program; please select Private Networks and then click on A l low Access.

3. From the User Interface win dow of the Toolbox; click on “Network Config”. Note: Your Toolbox

layout may look different than shown.

4. When the “Network Configuration” window appears; configure the printer's network settings as

needed. See example. Check with your IT support person for help with these settings. Be sure to click on “Submit” after entering new information. NOTE: The information shown on this page is just an example. You must use settin gs that are compatible with your network and settings that are not in direct conflict with other devices on the network.

AutoIP Network Tip: For network systems that automatically assign or obtain the IP Address; make sure the appropriate items (dhcp, bootp, autoip), for your particular network, are checked (selected).

Static IP Network Tip: Running "ipconfig", from the Command Prompt o f a computer that is being used on the same network, may help you define some of the information needed for this setup. In general you can use the same "Subnet Mask" and "Default Gateway" that are shown in the "Windows IP Configuration". However you need to provide a unique "IP Address" for the printer. For example if the "Windows IP Configuration", IP Address for your computer's connection is shown as 192.168.100.222 you may be able to use 192.168.100.223 for the printer; if this IP Address is not in use by some other device. If you want to check for an open IP Address you can ping the address before you save the settings and connect the printer. T y pe "ping [ip address]" (Example: ping 192.168.100.223) at the command prompt. An open IP Address will show "Request timed out".

An IP address that is in-use and working will show replies (Reply from 192.168.100.223:....)

Check with your IT support person for help with these settings.

5. Using a Cat5 network cable; connect the printer to your network via the Ethernet port.

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SECTION 2

INSTALLING THE PRINTER

6. Click on “Diagnostics”.

The “Diagnostics” window will open; displaying a lot of information about the printer. This information will include the Network Status and configuration settings.

7. If the “Network Status:” is shown

as “disconnected”; click on the refresh button in the browser window. If you have entered compatible network settings for your network and the printer; the "Ne t w or k Status:" line in the Diagnostics window should change from "disconnected" to "connected". I f the status doesn’t change to “connected” please contact you r I T support person for help with the network settings.

8. Run the Printer Software (M Series Driver) installation again; but this time choose "Add another

printer".

9. When prompted to choose the Printer Connection; select "Configure to print over the Network".

Then click Next.

The install program will search the network for printers. It should automatically locate the "M_Series" printer at the IP address provided by the network or that you configured in step 4. In this example the M_Series printer has the IP Address 192.168.100.251.

Note: If the driver install program cannot locate the printer automatically, then you will be presented with a window to enter the Host name and IP Address for the printer. Enter the IP Address for the printer and click Next (You do NOT need to enter a Host name). If the printer is found at the IP Address provided; the driver install will continue automatically (skip to 10). If the printer is not

found then, in general, you have not provided a valid IP Address or network configuration for the printer. In thi s case CANC EL the driver install and repeat from Step 2. Please obtain help from your IT support people.

10. Select the "M_Series" printer that is displayed. Then click Next.

11. When the “Finished software installation” window appears; displaying “Network Connection

Successful”; select if you want to “Print Test Page” or “Set this printer as the default printer”. Then click Finish. If selected, a test page will be sent to the printer to be printed. Tip: To help distinguis h bet w e e n mul ti pl e M-Series Drivers on your system; Open the “Printers and Faxes” (Devices and Printers) fold er. Then rename the network configured printer “M Series Driver (Network)” and the USB configured printer “M Series Driver (USB)”.

Opening (launching) the “Toolbox” utility over an Ethernet connection:

To open the Toolbox utility; click on Start, All Programs, Memjet, M Series Driver, Toolbox. If you have more than one copy of the M-Series Driver installed, you may be prompted to choose the device you want the Toolbox to connect to. Be sure to choose the proper device. Example: M-Series Driver - configured for USB. Suggestion: Rename to “M Series Driver (USB)” M-Series Driver (Copy 1) - configured for Ne t wo rk. Suggestion: Rename to “M Series Driver (Network)”

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SECTION 2

Before attempting to install or remove Ink Tanks; press the button labeled

be damaged, which will render the Ink Tank unusable.

WARNING!

The ink used in this system may be harmful if swallowed.

Discard unwanted printhead cartridges and empty ink tanks immediately.

INSTALLING THE PRINTER

Installing the Ink Tanks

The Digital Color Printer uses five Ink Tanks (two Black, one Cyan, one Magenta, and one Yellow). The Ink Tank is a delicate, precision device. Handle with extreme care to avoid damage.

Ink Tank Anatomy

Keep new and used printhead cartridges and ink tanks out of reach of children.

“Replace Ink Tanks” in the Toolbox, or Power-down the printer using the

ON/OFF button. If this rule is not followed the QA Chip on the Ink Tank may

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SECTION 2

INSTALLING THE PRINTER

Procedure (Installing the Ink Tanks):

This procedure assumes that you are installing Ink Tanks into a printer that doesn’t have any Ink Tanks installed. If you are replacing an empty Ink Tan k, please refer to the “Replacing the Ink Tanks” section.

Install the Ink Tanks as follows:

1. Power the Printer ON. Plug in the printer. Turn the printer’s Main Power Switch ON; then press

the control panel’s ON/OFF button. Wait about 45 seconds for the print engine to power-up (ON/OFF button will illuminate).

2. Open the M Series Toolbox. Go to All Programs, select the “Memjet” folder, select the “M

Series Driver” folder and Open the “Tool box”. Tip: If you receive warning that Windows Firewall has blocked some features of this program; please select Private Networks and then cl ick on Allow Access.

A web browser will open and display the “User Interface” screen. On the left side of the screen you will see information about the System Status and Ink levels. With no Ink Tanks installed all Ink status levels for “CKYMK”, will be displayed with a question mark (?) below each color position and the colors are not filled-in.

3. Click the button labeld “Replace Ink Tanks”, located in the Toolbox User Int erf ace screen.

This disconnects Printer communication with the Ink Tanks and allows safe installation and replacement.

Once the “Confirm” screen, shown to the right, displays, it is safe to install/remove Ink Tanks.

IMPORTANT: DO NOT until after

you have installed the Ink Tank(s)

press “Continue”

and closed the Ink Tank Latches.

4. Open the Ink Tank Doo r (hinged at

bottom).

5. Open the Ink Tank Securing Latches

[A].

6. Remove the new Ink Tank(s) f rom

packaging.

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SECTION 2 INSTALLING THE PRINTER

7. Insert the new Ink Tanks (label side up)

into their appropriate color slots CAUTION! Be sure each Tank is installed

into the proper color slot. If you force the Ink Tank into the wrong slot, you will contaminate the ink system and professional service will be required.

INSTALLATION TIP: To help insure that the Ink Tanks are properly seated; insert the Ink Tank into the appropriate Ink Station, then pull the Ink Tank back about an inch and push forward firmly. This will help insure that the “septum needles” penetrate the seals on the Ink Tanks.

8. Close and lock all three Ink Tank

Securing Latches. IMPORTANT: Make sure both sides of

the Latch are engaged at the bottom.

[B].

9. Click on the button labeled “Continue”, in the

Confirm screen of the Toolbox.

10. Watch the Toolbox screen on your computer. You should see all the ink

colors fill-in; if all the Ink Tanks are properly installed and recognized. If an Ink Tank color does NOT fill-in, and a question (?) mark or “out” condition is displayed below the ink color; this indicates that the printer does not recognize the Ink Tank (Unable to communicate with QA Chip) or the ink level sensor doesn’t see any ink in the Tank. Verify that the Ink Tank Securing Latches are fully closed and locked. Then click on the button labeled “Refresh Ink Levels”. If the ink color still does not fill in; the QA Chip contacts or Ink Level Prism may need to be cleaned. Please refer to the “Operator Maintenance” section for information on “Cleaning Ink Tank Contacts & Prism”.

Tip: Even new Ink Tanks can have dirty QA Chip con t act s. This is not always visible to the eye.

11. Close the Ink Tank Door.

NOTE: If a Printhead Cartridge is not installed, the Systems Status line in the Toolbox will display the

“MISSING PRINTHEAD message. To install the Printhead Cartridge; please proceed t o the section titled “Installing the Printhead Cartridge”.

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SECTION 2

The ink used in this system may be harmful if swallowed.

1 & 10

Handles

5 Foil vacuum bag

Nozzles protective tape

6 Cardboard packing box

3 & 8

Protective cover flaps

7 Cover retaining clip

Protective cover

9 Electrical contacts tape

ATTENTION

If you experienced fuzzy print quality or an abrupt failure in a particular area of nozzles on

perform this process for you.

INSTALLING THE PRINTER

Installing the Printhead Cartridge

The Digital Color Printer uses a single Memjet® printhead cartridge. The Printhead Cartridge is a delicate, pr ecision device. Handle with extreme care to avoid damage an d issues that could degrade print quality.

the previous printhead, we recommend that you have the service station inspected/cleaned and the wiper roller replaced before installing the new printhead. Failure to do so will increase the chance of damage to the new printhead. Service station maintenance and wiper roller replacement should only be performed by a qualified/trained person. Please contact your service representative to obtain training or to have them

Printhead Cartridge Protective Packaging

NOTE: Discard protective tape once it is removed . Do NOT reuse protective tape.

Keep all other packaging to store/dispose of old printhead cartridge.

Keep new and used printhead cartridges and ink tanks out of reach of children.

Discard unwanted printhead cartridges and empty ink tanks immediately.

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SECTION 2

CAUTION

• Use electrostatic discharge (ESD) handling precautions.

contaminants.

CAUTION

BUTTON ON THE PRINTER OR IN THE TOOLBOX.

INSTALLING THE PRINTER

• Hold the Printhead Cartridge by the handles ONLY.

• DO NOT touch the Ink Couplings, nozzle surface or electrical contacts.

• DO NOT unpack the Printhead Cartridge until the Printer is ready for

installation. Once unwrapped, delay in installing the Printhead can compromise print quality due to dehydration.

• DO NOT place an unwrapped Printhead on any surface before installing.

Protect the Printhead at all times from dust, fibers, dirt and other

DO NOT PRY OR MANUALLY LIFT THE PRINTHEAD LATCH OR THE LATCH WILL BREAK. ONLY OPEN THE LATCH USING THE PRINTHEAD RELEASE

NOTICE! Read this procedure, in its entirety, before proceeding!

Before you begin this process, you will need to obtain some deionized or distilled water and some lint free cloths. These items will be used to wet the printhead nozzles. NOTE: Do NOT use tap water or paper towels to w et or clean the printhead nozzles. Doing so may cause damage to the printhead cartridge and possible contamination to the ink system.

The printhead cartridge and ink supply must be within the operating temperature range ((+15°C to +35°C (59 °F to 95 °F)), before attempting to prime the cartridge with ink and starting to print. When stored at temperatures below the operating range it may take up to 3 hours for a cartridge in its packaging to reach operating temperature. NOTE: Additional packaging will increase the time needed to reach operating temperature.

Why is it necessary to wet the printhead nozzles? During the priming process a vacuum is created by the pump, to pull ink from the Tanks into the printhead and ink delivery system. If the printhead nozzles are dry (open); air is pulled in through the printhead nozzles causing the priming process to fail (pump is unable to create a vacuum). By wetting the printhead nozzles this creates a temporary “water seal”, which prevents air from getting pulled into th e prin t he a d during the priming process.

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SECTION 2

CAUTION

INSTALLING THE PRINTER

Procedure (Installing the Printhead Cartrid ge)

This procedure assumes that you are installing a Printhead Cartridge into a printer that does NOT have a Printhead Cartridge installed. If your pri nter already has a Printhead Cartridge installed, and you wish to replace the Printhead Cartridge; please refer to the section titled “Replacing the Printhead Cartr idge”.

1. Plug in the printer. Turn the printer’s Main Power Switch ON; then press the control panel’s

ON/OFF button. Wait about 45 seconds for the print engine to power-up (ON/OFF button will illuminate).

2. If the Printhead Latch [2] is closed; press the “Printhead

Latch Release” button [1]; as shown. Use a non-metallic item (example: plastic p en) to reach through the hole and lightly press the button.

The printer will run a routine and then the Printhead Latch [2] will release so it can be opened.

Note: The Printhead Latch [2] color may be blue or black.

WARNING! If the printhead latch fails to release do not

force the latch open. Severe damage will res ult.

Tip: You can perform this same function from your computer by clicking the “Printhead Release” button; found on the “User Interface” screen of the M Series “Toolbox” utility.

3. Open the Printhead Latch fully.

4. If present; Remove the Cap Protectors from the Ink Revolver

Couplings [3]. Save these items. They should be used to seal and protect the open ink system when a Printhead Cartridge is not installed.

NOTE: Before replacing or re-installing a Printhead Cartridge, please clean the Ink Revolver Couplings. See section titled “Cleaning the Ink Revolver Couplings”.

DO NOT PRY OR MANUALLY LIFT THE PRINTHEAD LATCH OR THE LATCH WILL BREAK. ONLY OPEN THE LATCH USING THE PRINTHEAD RELEASE BUTTON ON THE PRINTER OR IN THE TOOLBOX.

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SECTION 2

WARNING

INSTALLING THE PRINTER

5. [A] Carefully remove

the Printhead Cartridge from the foil packaging.

Tear at notch or cut end with scissors.

[B] Remove the protective plastic cover.

Hold the Printhead by the handle and unclip the

cover from the Printhead.

[C] Remove protective strip from the Printhead Electrical Contacts. DO NOT allow removed strip to touch the electrical contacts.

[D] Remove protective strip from the Printhead Nozzles. Hold the

Printhead by the handle. Pull the strip tab and slowly peel the strip from the Printhead.

DO NOT pull the strip at less than a 45° angle from the Printhead surface. DO NOT allow removed strip to touch the Printhead Nozzles.

TO AVOID ELECTRICAL SHOCK OR SHORTING

Before installing Printhead, make sure the contacts are DRY!

6. Carefully insert the Cartr idge into the compartment at an angle [4], with the Printhead surface

facing down and the Ink Couplings facing the Ink Revolver Couplings (ink hoses). Once it is seated, gently tilt the Cartridge forward until it snaps into an upright position [5].

DO NOT FORCE the Cartridge into position. DO NOT close the Printhead Latch at this time.

Page 31

Printhead Nozzle Area

CAUTION

DO NOT ALLOW THE CLAMSHELL TO DROP OR SLAM CLOSED.

WARNING: Be careful not to damage

media.

7. Open the Print Engine Clamshell; using with both hands.

8. Using a lint-free cloth soaked with deionized or distilled water,

wet the entire Printhead Nozzle area .

Be liberal with the amount of water you leave behind on the nozzles (the thin dark line on bottom of printhead cartridge). See images below.

the “star rollers” when wiping the printhead. These rollers are designed so they can roll across a wet image, without damaging the image. If the rollers are bent, they will not turn free; causing media feed issues (jamming) and possible damage to the image or

SECTION 2

INSTALLING THE PRINTER

9. Immediately after wetting the nozzles. Carefully close and latch the Print Engine Clamshell.

HOLD ONTO BOTH LATCHES WHEN OPENING AND CLOSING THE PRI NT ENGINE CLAMSHELL TO PREVENT DAMAGE.

10. Now close the Printhead Latch [6]. After a few

seconds the Printer will run a “priming routine” that fills the ink system and Printhead with ink.

WHAT TO EXPECT:

a. After closing the Printhead Latch there will b. Then you will hear the Service Station c. Then you will hear the ink pump start to d. At this time, ink should start flowing

be a ~15 second pause (no noise or motion).

move to the capping position.

run.

through all the tubes, in and out of the printhead. If you see this occurring, then the priming process is working.

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SECTION 2

CAUTION

SUPPORT FOR ASSISTANCE IF PROBLEMS PERSIST.

INSTALLING THE PRINTER

If ink doesn’t start filling all tubes during the first 5-seconds of the first ink pump cycle: Using deionized or distilled water; re-wet your lint-free cloth generously. Don’t wait for the pump to stop, open the clamshell and wipe along the Nozzles with the cloth, back and forth twice. Immediately after re-wetting the nozzles, carefully close the clamshell. The ink tubes should begi n filling. Tip: To save time; prepare a pre-wetted lint free cloth before you begin the priming process.

If you reach the end of the second pump activation cycle and the printhead still fails to prime or more of the ink tubes have not filled):

i. Release the printhead (using the Release Printhead feature from the Toolbox),

ii. Once the latch opens, carefully retract the latch fully.

iii. Release the printhead from the electrical contacts b y tilting it back; but don’t remove

the printhead.

iv. Tilt the printhead forward to reconnect it to the elect r i cal contacts.

v. Repeat the process from Step 7. See Caution below.

DO NOT REPEAT THIS PRIMING PROCEDURE MORE THAN TWICE IN A ROW.

AFTER TWO ATTEMPTS, LET THE PRINTER SIT FOR AT LEAST 1 - 2 HOURS

BEFORE YOU ATTEMPT TO PRIME THE PRINTER AGAIN. CONTACT TECHNICAL

(one

DAM AGE TO THE I NK SYSTEM MAY RESULT.

11. Once the printhead priming process is successful (all ink tubes are filled, in and out of the

printhead); it will take an additional 5 - 10 minutes for the printer to complete the process. During this time the printer will emit a number of chirps, whirrs and other noises.

12. Watch the Toolbox screen on your computer. Notice that

some of the information is in red. As the printer circulates ink and primes the system these fields should all turn black. This may take a few minutes.

NOTE: If any Ink Tank is less than 30% full, the Printhead Cartridge priming process may fail (not enough ink to completely fill the system). In this case you will need to replace the tank(s) containing low ink and repeat the printhead priming process. After the Printhead is primed, you can re-install the original Ink Tank(s) to use up any remaining ink. Please refer to the secti on titled “Replacing the Ink Tanks”.

13. When the printer stops processing, and all the fields in System Status are black, t he printer is ready

for use. When the printer is ready for use you will also observe the following printer Control Panel condition: ON/OFF button light ON, Paper/Resume light OFF, Pause/Cancel light OFF.

14. Close the top cover.

15. IMPORTANT! Whenever a printhead cartridge is installed o r re-installed, it must be conditioned

to perform properly . Before printing a live print-job; please refer to the section titled “Printhead Cartridge Conditioning”.

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SECTION 2

CAUTION

PRINT ENGINE CLAMSHELL TO PREVENT DAMAGE.

INSTALLING THE PRINTER

Installing/Removing the Head Media Guide

The Head Media Guide is used to flatten the media, as it enters under the printhead, to help redu ce media contact with the printhead.

If the media makes contact with the printh ead this may result in:

- Scuff Marks - black streaks deposited on surface of media

- Smearing/Smudging of wet image, which can also deposit additional ink on the printhead surface; increasing the chance for additional scuff marks. See section titled “Troubleshooting Guide” for more info on scuff marks and how to reduce.

This item is normally pre-installed in the printer. Please check to be sure the guide is securely installed before first use. In general the Head Media Guide can be used at al l times. If you are encountering print quality issues (image distortions, image not as sharp as expected); you can remove the Head Media Guide to see if this has an y effect. You may also need to remove this guide for cleaning purposes.

Items Needed for Install/Remove: Nitrile powder-free gloves, distilled water and lint free cloth.

Installation Procedure:

1. Open the Top Cover

2. Open the Print Engine Clamshell.

HOLD ONTO & RELEASE BOTH LATCHES WHEN OPENING AND CLOSING THE

3. [A] & [B] Start with the Head Media Guide positioned as sho wn in “A”.

Note: The “Tab”, on the end of the Guide, fits over the front side of the metal “Support” plate.

While lightly pressing up on the Guide; slide it to the left, until the cutouts in the Guide aligned with the ears on the back side of the metal “Support” plate. This will allow the Guide slide up closer to the printhead surface; as shown in “B”.

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SECTION 2

CAUTION

INSTALLING THE PRINTER

4. [C] Push the Guide to the right, to lock it

in place.

NOTE: While the Clamshell is still open, verify that the Head Media Guide is aligned with the Printhead Cartridge as shown in “C”.

5. Once the Head Media Guide has been

installed; Wipe the Printhead Nozzles end to end using distilled water and a damp lint-free cloth.

6. Carefull y close and latch the Clamshell.

Then close the Top Cover.

Removal Procedure:

1. Open the Top Cover

2. Open the Print Engine Clamshell.

HOLD ONTO & RELEASE BOTH L ATCHES WHEN OPENING AND CLOSING THE PRINT ENGINE CLAMSHELL TO PREVENT DAMAGE.

3. [A] & [B] Slide the Media Guide to the left and pull dow n on the Guide to release it from the

metal support.

[C] Remove the Guide from the Printer.

4. Once the Head Media Guide has been installed; Wipe the Printhead Nozzles end to end using

distilled water and a damp lint-free cloth.

5. Carefull y close and latch the Clamshell. Then close the Top Cover.

Page 35

INSTALLING THE PRINTER

Automatic High Capacity Output Stacker

AC Power Cord

Stacker Interface Cable (43-500-150) –

SECTION 3 –Installing the Output Sta cker

(optional)

The optional High Capacity Output Stacker is designed to work automatically with the MACH 8 Printer.

Before using the Output Stacker the following must be done:

• Unpack the Output Stacker

• Position, Connect Power and Interface the Output Stacker to the Printer

• Setup the Output Stacker to accommodate your media

Unpacking

Remove the Output Stacker and its cables from the carton. Remove all packing tape.

Contents of Packaging

SECTION 2

Connecting/Aligning the Output Stacker

1. Turn the Output Stacker’s Main Po w er Switch OFF (0).

2. Plug the power cord (provided) into the receptacle labeled

“Output Stacker Power Out” on the MACH 8. Plug the other end of the power cord into the Power receptacle on the Output Stacker.

3. Align Output Stacker with Printer Exit. Fit the alignment

peg on Printer into the slot on the Output Stacker [A].

Tip: You may need to turn the Casters, on bottom of the MACH 8 and Output Stacker, so they don’t interfere with the proper positionin g of the Output Stacker.

4. Connect the Stacker Interface Cable (provided) between the

Output Stacker and t he MACH 8 printer [B].

5. Verify that the printer’s Main Power Switch is ON (1).

6. Turn the Output Stacker's Main Power Switch ON (1).

The Receiving Tray will automatically move to the “ready” position–– (when Tray or top of media stack is about ¼” below the Stack Height Sensor).

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SECTION 4

PRINT ENGINE

OPERATING THE PRINTER

SECTION 4 – Operating the Printer

MACH 8 Control Panel Functions

There are 5 Buttons on the Control Panel of the MACH 8 to operate the Feed Table and the Print Engine.

For The Print Engine:

The 3 buttons on the right control the Print Engine: ON/OFF, PAPER/RESUME and PAUSE/CANCEL.

BUTTON FUNCTION(s)

Press to power-up or power-down the print engine. Note: The Main Power Switch must be ON, to power-up the Print Engine.

POWERING-UP: After pressing this button; it takes approximately 45 seconds for the

print engine to power-up. All lights blink simultaneously during power-up sequence. The ON/OFF button will change to a steady illumination condition, once the print engine is fully powered-up.

Tip: You can launch (open) the Toolbox utility after the lights come on.

ON/OFF

PAPER

RESUME

PAUSE

CANCEL

Please see “Print Engine Status Light (LED) Indicators” f or additional information.

POWERING-DOWN: Before turning off the printer, using the Main Power Switch; please be sure to power-down the print engine using this button. When the print engine has completed its power-down cycle, all lights in the control panel will turn off turn off the Main Power Switch. WARNING! If you need to Turn OFF/unplug the printer. Please be sure the Print Engine is powered-down (all LED’s out) before turning OFF the Main Power Switch. If this power-down process is not followed; printhead nozzle clogging and reduced head life may result. IMPORTANT: For best system performance, it is recommended to keep the print engine powered-up (ON/OFF light illuminated) at all times.

PAPER (Paper Feed Test): Before sending data to the printer; you can perform a paper feed test by pressing and holding this button for 5 seconds. A single piece will be fed.

RESUME: If a paper feed condition (paper jam, out of paper, etc.) was detected; clear the jam, reload media and press this button to resume printing. If the printer was paused using the PAUSE/CANCEL button, press this button to resume printing.

PAUSE: If you are in the process of printing and you want to pause the print job, press this button once. If the printer was paused, using the PAUSE/CANCEL button, press the RESUME button to resume printing.

CANCEL: If you want to cancel a paused print job, press this button again. The print job will be cleared from the printer and print queue in the driver. NOTE: In some cases you may need to manually clear (delete) the documents from the driver’s print queue.

. It is now safe to

Page 37

OPERATING THE PRINTER

Print Engine Status Light (LED) Indicators

The lights (LED’s), on these three control panel buttons, indicate the status of the Print Engine. Flashing SLOW = 1 time per second Flashing FAST = 3 times per second

NOTE: To obtain additional detail about the printer’s condition, please open the Toolbox utility. See “Errors and Warnings” for Additional Troubleshooting information. For a chart to hang near the printer, see “Quick Reference Info” (Appendix C).

Print Engine Status Light Indicator Chart

LED Sequence Print Engine Status

Print engine is powered-OFF (Powered-down)

Additional Details, Possible Solution or Action

In this condition, it is safe to turn the Main Power Switch OFF or ON.

IMPORTANT: For best system performance, it is recommended to keep the print engine powered-up (ON/OFF light illuminated) at all times.

SECTION 4

Print Engine is powered-ON and Ready

Print engine powering-up

Print engine powering-down

Paper Jam Detected Toolbox =

PAPERPATH_PAPERJAM

Any of the following conditions could exist: Paperpath: Entry : Yes Exit: Yes or Paperpath: Entry : No Exit: Yes or Paperpath: Entry : Yes Exit: No

Printer is Ready

It takes about 45 seconds for the print engine to power-up; after pressing the ON/OFF button.

TIP: You can launch (open) the Toolbox after the lights come on.

All lights blink simultaneously during powerdown sequence.

Wait until all lights go out before turning OFF the Main Power Switch.

Printer has detected that one or more of the media sensors are blocked (interrupted). Carefully remove jam and or clean all media sensors. Including the Feed Sensor. Make sure the clamshell is closed and latched.

If the Paperpath sensors are clear; the toolbox “Paperpath” line should change to Paperpath: Entry: No Exit: No No = not blocked (not interrupted) Yes = blocked (interrupted)

After you fix this condition you can;

- Press the RESUME button on the printer or press the “Clear Error” button in the Toolbox; to continue printing

- Press the CANCEL button to cancel the job Then manually clear job from the computer’s print queue; if needed.

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SECTION 4

Press RESUME, to resume printing.

increased.

OPERATING THE PRINTER

Print Engine Status Light Indicator Chart (continued)

LED Sequence Print Engine Status

Printing Paused PAUSE button was pressed.

Additional Details, Possible Solution or Action

Press the RESUME button to continue printing. Job can also be resumed by clicking on the “Clear Error” button in the Toolbox. Press the CANCEL button to cancel the job and clear the job from the computer’s print queue. Job can also be canceled by clicking on the “Cancel Job” button in the toolbox. NOTE: In some cases you may need to manually clear (delete) the documents from the driver’s print queue.

Out of Paper

Change in Paper Length detected Toolbox =

PAPERPATH_PAGE_SEQUENCE

Ink Tank(s) Empty Toolbox = INK_OUT_... Example: INK_OUT_YELLOW

Ink Tank(s) Missing Toolbox =

CARTRIDGE_MISSING_...

Example: CARTIRDGE_MISSING_Y

Printhead Not Primed Toolbox =

PRINTHEAD_UNPRIMED

Load Media.

Feed sensor has detected a change in paper length. This could be due to poor sheet separation (overlapping pieces) or paper that varies in length or a dirty/dust Feed sensor. Clean the Feed Sensor (sensor in feed section). Check/set paper feed and Media Thickness adjustment. Press RESUME, to resume printing. If problem persists call for Service; “double_pick_percent” may need to be

Press the “Replace Ink Tanks” button in the Toolbox and then replaced empty Ink Tank(s). Verify that Ink Tanks are seated firmly and latches are fully closed, before pressing the “Continue” button. TIP: If problem persists the Ink Tank contacts could be dirty/corroded (clean contacts), or the chip on the Tank may have been damaged by installing removing Tank without first pressing the “Replace Ink Tanks” button. If you are sure you followed the proper Ink Tank replacement procedure, you should call for Service.

Follow Printhead Priming procedures. If you continue to have trouble; check for kinked or pinched ink color tubes or call for Service.

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Paper is present on the Feed Table

edge is still in the Entry sensor.

Print Engine Status Light Indicator Chart (continued)

LED Sequence Print Engine Status

Printer is Performing Maintenance (Cleaning, Circulating Ink, etc..) Toolbox = MAINTENANCE_BUSY

Canceling Job. CANCEL key was pressed Toolbox = MECH_CANCELJOB

Hardware Error

Busy: Job Loading Wait for lights to stop blinking.

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OPERATING THE PRINTER

Additional Details, Possible Solution or Action

Wait for lights to stop blinking.

Cancel the print job and delete the job from the print spooler. Then cycle the Printer power and Output Stacker power (if attached). After powering-up the Print Engine, restart the job at the point the issue occurred.

(sensor covered), but it is not being

Paper Time-Out (Out of Paper) Toolbox =

PAPERPATH_FEED_TIMEOUT

received by the Print Engine. Check for jam in feed section and check feed setup. Press RESUME, to resume printing.

Tip: It is also possible to get this error if the media jams after reaching the Paperpath Exit sensor, and the trailing

See the “Toolbox System Status Messages” section for more details on Toolbox messages.

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For the Feed Table:

The Up and Down buttons control the Feed Table:

UP (Green Arrow): Press to raise the Table for loading and

positioning media. It will stop automatically when the media stack or Table reaches the Top Sensor. Or you can press again to stop manually at any time.

DOWN (Red Arrow): Press to lower th e Table for loading and positioning media. It will stop automatically when the table reaches the bottom of its travel. Or you can press again to stop manually at any time. TIP: If Feed Table won’t move; check to be sure Feed R oller Assembly is closed and latched. Contact Service Support to check Limit Switches.

Feed Table: Status Light (LED) Indicators

The lights (LED’s), on these two control panel buttons, indicate the status of the Feed Table.

Feed Table Status Light Indicator Chart

Feed Table Status

Additional Details, Possible Solution or Action

Top of media stack has made contact with the Feed

Feeder Ready

*Feed Table has reached its highest position; with no paper present.

**Feed Table is Lowering (moving down) automatically or Down button was pressed.

**Out of Paper or Feed Table at lowest position

Up button was pressed and Feed Table is Raising (moving up)

Roller Assembly and interrupted the top limit sensor. This is the “ready” position.

Feeder is ready. This condition will occur if you raise the Feed Table

until it tops-out (hits top limit switch), without any media on the Table.

Press DOWN button, to lower the Feed Table. Then load media and press the UP button.

NOTE: Condition can also occur if you run out of media while performing a paper feed test.

Press the DOWN button to stop the Feed Table or allow Table to stop automatically when it reaches the low limit sensor.

Load Media and press the UP button. Media is not seen by the “Feed Table Sensor”.

Load media and press the UP button. Feed Table reached low limit sensor.

Load media and press the UP button.

Press the UP button a second time to stop the Feed Table or allow Table to stop automatically when media stack or Table reaches high limit sensor/switch.

Main Power Switch is OFF. or Media present on Feed Table,

* If you power the printer on in this condition, the Table will automatically lower all the way. ** If you run out of media during a print job, the Table will automatically lower all the way and the job will be PAUSED automatically.

but Table is not at lowest or highest position.

Check/Turn ON Main Power Switch. If you are finished loading media; press the UP button.

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Setting up the Feed

1. Lower the F eed Table [A],

Press the “Down” Button, on the Control Panel, to lower the Feed Table.

2. Slide the Right Media Side Guide [C] , all the way to

the right. Tip: If you can’t move the guide all the way to the right,

the Feed Table Extensions [B] or Separator Lockdown/Release Tabs [G] might be in the way. In this case the Feed Table Extension may need to be retracted and the Separator Lockdown/Release Tabs may need to be released.

3. Adjust Feed Table Extensions [B] .

Slide the extension plates forward/back, using fingerhole, to accommodate/support the width of your media. Place a single piece of media on the Feed Table, as shown. If the media width covers a Feed Table Extension completely; slide if forward, so it is fully extended. If the media width doesn’t cover a Feed Table Ext ension completely; slide it back, so it is fully retracted.

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OPERATING THE PRINTER

4. Check/Adjust the Sheet Separators

Loosen the two Thumbscrews [D] and slide latches back [in direction of arrows]. Then open the Feed Roller Assembly [E]. Two of the Sheet Separators [F] have a Separator Lockdown/Release Tab [G] located below them.

Position a single piece of media, as shown.

If the media doesn’t completely cover the width of the separator, the separator must be locked down; so it doesn’t make contact with the feed roller causing premature wear. To lock the Separator(s) in the down position: While depressing the Separator(s) [F], push down on the corresponding Separator Lockdown/Release Tab [G]. This will lock the Separator(s) in the lower position.

If the media completely covers the width of the separator, the separator should be released; so it is up and can provide separation. To use/release the Separator(s): Push up on the Separator Lockdown/Release T ab(s) [G].

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SECTION 4 OPERATING THE PRINTER

5. Close and L atch the Feed Roller Assembly [E] .

While holding the Feed Roller Assembly down/closed, slide the latches forward [in opposite direction of

arrow] and tighten the two Thumbscrews [D].

6. Load Media

Place Media stack onto the Feed Table [A]. Make sure it is positioned to the left and as far forward as possible. Stack must be square and even.

7. Adjust the Right Media Side Guide [C].

Position the Right Media Side Guide to within 1/32" from the right edge of the media.

Tip: If Right Media Side Guide won’t move past a certa in point; check to be sure the Feed Table Extensions and Separator Lockdown/Release Tabs aren’t interfering with the guide. The Separator Lockdown/Release Tabs have been designed to interfere with the Right Media Side Guide if the Sheet Separator is not locked d own. This was done to reduce the chance of running narrow media with the Sheet Separators in the up position; making contact with the Feed Rollers, causing premature wear.

8. Adjust for Media Thickness. .

The Media Thickness Adjustment Knob [H] sets the uppermost stopping point of the Feed Table to accommodate single sheets of paper or heavier card stock/cardboard Normal/Thin Media (sheets of paper): Turn T hickness Adjustment Knob fully counter-clockwise unit it stops. Thick/Stiff Media (cardstock/cardboard): Turn Thickness Adjustment Knob fully clockwise until it stops.

The Thickness Indicator provides a quick visual check of the media thickness setting.

Down = Normal/Thin Media (Sheets of Paper) Up = Thick/Stiff Media (Card Stock, Cardboard)

Tip: If media gets stuck or

hesitates in the Separation/Feed Roller Assembly area, or makes excessive noise when transitioning through this area; try setting this adjustment for “Thick Media”. If you find that you are getting multiple feeds (doubles, overlapping pieces), try setting this adjustment for “Normal/Thick Media”.

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CAUTION

KEEP HANDS/FEET AND OTHER BODY PARTS OUT FROM UNDER

OPERATING THE PRINTER

9. Press and rel ease the “Up” Button. The Feed Table will

stop automatically when it reaches the “top” position.

10. Adjust the Skew Control Bridge [I].

Loosen the knob and adjust the Bridge so the rear edge of the Bridge is positioned about 1 or 2 inches in, from the trailing edge of the media stack. Then secure the knob. Tip: For media 5” or shorter in length; position the Bridge as close to Feed Roller Assembly as possibl e. For media 12” or longer in length; position the bridge as far back as possible (against stop).

11. Adjust the Skew Control Guide [J]

Loosen the knob and move the Skew Control Guide so it is making light contact with the side of the media stack. Then secure the knob.

NOTE: The Feeder may not feed larger and heavier media when the stack is full. The amount of media that can be stacked on the Printer is determined by the weight of the material. If this is the case, reduce the amount of media in the stack until the Feeder functions properly.

THE FEED TABLE. KEEP HANDS, HAIR AND CLOTHNG CLEAR OF MOVING PARTS.

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Printer Driver Properties

Valid for M Series Driver, version R13 The Printer Driver for the MACH 8 Printer works the same as any other Print er D r iver for Windows. It

does have some enhancements to help you maxi mi ze the ability of the Printer to print variable addressed pieces quickly and efficiently.

Once the job is set up, click File, then Print. The window on the right opens. Make sure the M Series Driver is the selected Printer. Clicking on P opens the “Properties” window.

roperties

General Tab

The General tab lets you select:

• Orientation – Portrait (default),

Landscape, Rotate 180° and Mirrored. Tip: Instead of changing this setting from “portrait” to “landscape”; experiment with the drop-down list of Media “Size” selections (i.e. “6 x 9 in – Portrait” or “6 x 9 in – Landscape”) to match the printed image orientation to the actual orientation of how the media is being fed into the printer.

• Page Buffering –

If Buffer is checked will be spooled before it is sent to the printer. This may increase the time it takes for the job to start printing, but it may also reduce the chance of the printer pausing to wait for data and or displaying “DATA_PATH_UNDERRUN” in the Toolbox.. Mask Optimization (checked is default) optimizes images for printing in most applications. NOTE: Some applications may display image boundaries when printed. If this occurs; try changing (unchecking or checking) the Mask Optimization selection.

; the entire print job

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MEDIA TYPE (media profile)

COMPATIBLE MEDIA (standard media styles)

• Copies – Lets you choose the number of copies to be printed.

NOTE: Driver has a limit of 32,767 copies. However, in some cases, copies are li mi t ed by the

software program. For example; Adobe Acrobat® limits copies to 999. Reverse Order – If un-checked

(default); the job will start printing with the first page. Printing starts as soon as the first page loads. If checked

, job will start printing from the last page. Since the entire job must be spooled, before

being sent to the printer, it may take awhile for the job to start printing.

• Media – Select Type and Size. Add Custom Size. o Type: Selecting the

appropriate Media Type (media profile) may help you achieve better color accuracy results.

Plain Paper

Chart at right provides some “standard media styles” and

Matte Coated Paper

their associated Media Type selection.

Premium Glossy Paper Premium Photo Paper Glossy

Tip: mColor (RIP and Workflow) software is available; if you require better

Glossy Paper

“color management” options. Please contact your Dealer /Distributor for more

Premium Matte Coated Paper

information on “mColor”.

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OPERATING THE PRINTER

Plain Paper Bright White Paper

Photo Paper Matte Presentation Paper Postcards Matte Brochure Matte Labels Matte Other Inkjet Paper Matte

Photo Paper Semi-gloss Photo Paper Gloss y Labels Glossy Postcards Gloss y Brochure Glossy

Premium Inkjet Paper Premium Photo Paper Matte

o Size: Select the media size you are using, from the pull-down list. If the size is not present

use the “Custom Sizes” feature. Tip: Selections are provided for “portrait” and “landscape” orientations. Experiment with these selections to match the printed i mage orientation to the orientation of how the media is being fed into the printer.

o Custom Sizes – Use to create and save “ custom media sizes”.

Range: Width: 3” min to 8.5” max. Height: 4.2” min to 30” max (Table supports 14.5”max).

NOTE: The security rights on some computer systems may prevent you from accessing or saving “Custom Sizes”. You may need “admin” rights to use this feature.

After defining a “custom media size”; enter your desired “Media Name” and press “Save”.

Tip: When defining the width of a “custom media size” that measures between 8.5 and 9 inches wide; please set the widt h value to 8.5” (max print width of printer).

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Media Orientation Tip: When defining a “custom media size”; be sure to set the dimensions to match the actual orientation of the media; as it is fed through the printer. Example: 5” x 7”, fed long-edge fist 5” x 7”, fed short-edge first

Oversize – Select this box to enable “full bleed” printing (printing off all edges of media). When “oversize” is selected the “custom media size” you define is increased by 0.13” in width and height; without affecting th e values shown in the “Custom Media Size” screen. IMPORTANT! In order to take advantage of this feature; the image you send must be slightly larger (normally1/8” wider and higher) then the “custom media size” you defined. Full Bleed Example: “Custom media size” defined as 5” W x 7” H and “oversize” selected. Media being fed measures 5” W x 7” H. Image being sent measures 5.125 W x 7.125 H. Full Bleed Tips: To avoid image expansion/distortion, please be sure to set/check the following:

- Layout Tab. “Resizing” should be set to “Original Size”.

- Adobe Acrobat. Select “Actual size” under “Page Sizing and Handling” in the Print box. You may also need to make changes to the “left adjustment” and “top adjustment” features, located in the “Layout Tab”; to align the image wit h the media, so it bleeds equally off all edges of the media.

, would have the custom dimensions 7” W x 5” H.

, would have the custom dimensions 5” W x 7” H.

Borderless Print – When using an image that is the exact same size as the media, this option can be selected to expand the image (21 dots in height and width); to help achieve “fullbleed” printing (printing off all edges of the media). NOTE: If you want to do “full-bleed” printing but don’t want the image expanded/distorted; please use the “Ov ersize” feature; as defined under “Custom Sizes” above.

• Color Selection – Select from Color, Compo si te Black or Black Only.

o Color: Selection provides full color printing using all five ink channels (CMYKK). o Composite Black: Selection uses all five ink channels (CMYKK), to generate the darkest

black print possible; for the selected print quality. Color images are printed in “grayscale”.

o Black Only: Selection uses only the native “K” (black) ink channels to print.

Images printed with this selection will be “gray” in color. This is the “native” “K” (black) ink color. If you want a darker black, please select “Composite Black”. Color images are printed in “grayscale” using only the “K” ( black) i nk channe ls. NOTE: Even if you select “Black Only” the system will still use a small amount of color ink (CMY) when performing head purge and head maintenance sequences. All Ink Tanks (CMYKK) must be installed and recognized as having ink available, or the printer will NOT function.

• Print Quality – Select Normal or Best. o Normal provides 1600 x 800 dpi at 12 ips (inches per second).

If you also select the Half Speed, box; media transport and printing is slowed to 6 ips, for higher print accuracy.

o Best provides 1600 x 1600 dpi, at 6 ips. Use when high quality images are required.

NOTE: The “Half Speed” selection is n ot available in the “Best” print quality mode.

• My Print Settings – Allows you to save or recall your custom Driver settings for various jobs.

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Layout Tab

Layout allows you change how the document prints without changing the original document.

• Resizing –

o Original Size – no changes o Custom Resize - lets you resize the

original as a % of normal size. The printer will print the document in the size you selected regardless of the size of the paper selected.

o Print on: Lets you specify the

particular size of paper that you want to print on regardless of the size of the original document. Checking “Scale to Fit” automatically resizes the document to fit on the new page size.

• Printing Adjustments –

Allows you to make minor changes to the print position and print area; in relationship to the media feed direction. You can also select the measurements t o be in Inches, Millimeters or Pixels (1mm = ~31 pixels).

NOTE: The values entered, in the following adjustments, do NOT override the values set in the Toolbox (User Interface and Service Menus - Printer Control Config). Instead, the values entered are added to or subtracted from the values set in the Toolbox. The range values (min and max), provided below, assume that the Toolbox values for “tof_adjustment” and “left_adjustment” are set to zero (0) and the Purge Bar Position in the Toolbox, User Interface screen, is set to zero (0). Exceeding these min or max values may cause the printer to print nothing (feed the media blank).

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o Left Adjustment – Lets you shift the printed image left or right.

Range: -3.01mm (-0.118 in) left to +200.02mm (7.875 in) right. Default = Zero (0) negative value = shift right (towards operator side) positive value = shift left (towards non-operator side) Zero (0) = left edge of media

o Top Adjustment - moves the image up or down on the media.

Range: -4.98mm (-0.196 in) up to +200.02mm (7.875 in) down. Default = Zero (0) negative value = shift up (towards leading edge) positive value = shift down (towards trailing edge) Zero (0) = leading edge of media.

o Max Page Width – Lets you limit how wide the actual print area will be. This feature can be

used to “cut-off” the right-side (operator side) of an image; at a set position. Range: +0.50mm (0.020 in) to 220.82mm (8.693 in). Default = +220.82mm (max print width of printer)

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SECTION 4 OPERATING THE PRINTER

o Purge Bar Position* – This feature allows you to adjust the purge bar location; to

account for the extra length needed to reach the actual gap between pieces. Range: -53.78mm (-2. 117 in) up to +200.02mm (7.875 in) down. Defa ult = Zero (0) negative value = shift up (purge sooner positive value = shift down (purge later) In normal operation, the printhead spits a small amount of ink into the gap between pieces; to keep the nozzles refreshed. For ir r egular-shaped pieces (like a cut-out or hole in the media), the Paperpath Entry sensor may “read” these “irregular areas” as the trailing edge; causing the printer to purge (spray a line of ink) onto the media. Tip: Optimally, this value should be set so the purge bar is positioned about 3 mm past the trailing edge of the media. NOTE: The value set should not exceed the physical gap that the “Paperpath Entry sensor” sees between pieces; minus at least 5 mm. Setting this value too large may cause blank (unprinted) pieces to be fed, purge bar printing on leading edge of next piece, and or “false” “PAPERPATH_FEED_TIMEOUT” conditions (with media stopping inside the print engine).

* See also “Purge Bar Position” in the “Using the Toolbox Utility” section.

See “Driver Properties Printing Adjustments - Quick Reference”, in Appendicies, for additional details.

• Watermark – Prints background text onto the media along with the original image.

A few selections (SAMPLE, Draft, COPY, and Confidential) are provided.

o First page only – When a watermark is selected; the “First page only” opt i on is available.

Selecting this option prints the watermark on the first page, but not subsequent pages. Un-checking this option prints the watermark on all pages.

o Custom – This button lets you create a new watermark or edit an existing watermark,

including font selection, color, size and printing angle.

• My Print Settings – Allows you to save or recall (select) your custom Driver settings for vari ous

jobs.

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Import/Export Tab

Import/Export is used to preserve any custom Watermarks, Media Sizes and/or Print Settings you may have developed for various jobs when you update the Printer firmware.

• Export – Used to save your custom media

sizes and/or watermarks, to a “holding file” (*.ini); before uninstalling/reinstalling/updating the M-Series Driver.

• Import – Used to import your custom

media sizes and/or watermarks, from a “holding file” (*.ini), after the M-Series Driver is re-installed or updated.

IMPORTANT!

BEFORE REMOVING/REPLACING/UPDATING THE M-SERIES DRIVER; USE THIS FEATURE TO EXPORT ANY CUSTOM MEDIA SIZES OR WATERMARKS YOU HAVE CREATED.

Services Tab

NOTE: The security rights/settings, on some computer systems, may prevent you from accessing the features on the “Services Tab”. These features can also be accessed via the Toolbox utility.

The Services Tab features allow you to:

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OPERATING THE PRINTER

• Print Configuration Page – Prints out

the current configuration of the Printer including current Firmware Version, Network Connection, printer Serial Number and more.

• Print Colorbar Page – Prints seven solid

blocks/bars of color to show how well the Printhead is mixing colors and printing

• Print Diagnostic Page – Shows basic

Printer information, memory, Network Settings, Event Log and RAM size.

• Clean Printhead Buttons:

Provide three levels of cleaning for the Printhead Cartridge. Use these features to help recover printhead nozzles that are not firing. Please see “Cleaning Buttons”, in the Toolbox, “User Interface Menu” section, for additional information and tips.

Quick Clean Printhead – Circulates ink, wipes and cleans the Printhead Cartridge. Normal Clean Printhead – Runs cleaning and wiping routine twice for better flushing and

cleaning. Full Clean Printhead – Runs the cleaning routine multiple times for the most thorough flushing

and cleaning of the Printhead.

• Wipe Printhead – Wipes and cleans excess ink from the Printhead Cartridge.

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Using the Printer Toolbox Utility

Once the Printer Driver is installed you have access to the Printer Toolbox (Embedded Web Server). The Toolbox lets you monitor the job, ink usage, perform diagnostic checks, print reports and run maintenance tasks on the Printer from your computer.

To open the Toolbox: Open the Start Menu and then click on Toolbox. When the User Interface window opens you will find a

series of Menu Options you can click on at the lower left of the screen. You can check the Printer Status in the upper left part of the screen. NOTE: If you have more than one copy of the M-Series Driver on your computer system; when you launch the Toolbox, you will be presented with a page asking which M-Series Printer you would like the Toolbox to connect to. Select the desired printer from this list.

System Status

This area of the Toolbox show the current status of the system. It also provides details about the hardware (print engine serial number, printhead serial number) and the Firmware version. When things are “normal” all lines will be shown in black. If there is a “warning” or “error”; the effected i t ems wi ll be shown in red.

The “Tilt” indicator will change color; based on the following:

-Black = (0.0 to 0.9 deg) Levels within normal range. Printing allowed.

-Purple = (1.0 – 1.9 deg) Levels slightly out of range warning.

-*Red = (2.0 deg or above) Levels out of range. Stop using the printer and check level.

* Character color may not change to red, with some firmware versions. In this case monitor the actual tilt reading. If it reaches -2.0 (or lower) or 2.0 (or higher); please stop using the printer and recheck the level of the Print Engine.

CAUTION! Operating the printer when the Print Engine is not level can cause operational issues and damage. Do NOT use the Tilt readings to level the Print Engine. See “Leveling the Printer (Print Engine)”.

If you are sure the Print Engine is level, but the Tilt readings are still shown in

purple or red*; contact service support to have them verify level and possibly recalibrate the Tilt sensor.

NOTE: When the electronics are cold; the Tilt readings may not be accurate. Please allow the Print Engine to remain

powered-up for at least 15 minutes before checking/adjusting.

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OPERATING THE PRINTER

Please refer to the “Toolbox System Status Messages” section, for details on the messages that can be displayed in this area.

Ink Level Status

Displays the approximate amount (%) of ink available in each Ink Tank.

NOTE: The Ink Level (%) is an estimated value based on ink that has been ejected (printed) from the printhead. Priming/depriming and manually cleaning the printhead can reduce the accuracy of this calculation.

When the printer has calculated that it has used 250 ml of ink from an Ink Tank; the printer will stop printing, the ink percentage value will be displayed as “0%” and the Toolbox System Status will change to “INK_OUT_X” (X= Tank Color, or Multiple). Examples: INK_OUT_YELLOW, INK_OUT_MULTIPLE (if more than one tank is out)

You may also see the following conditions displayed in place of the Ink Level percentage value: Out = Printer does not see any visible ink in the Ink Tank.

? = No Ink Tank installed or printer doesn’t recognize the Ink Tank. Tip: See “Cleaning Ink Tank Contacts & Prism” section, for possible

remedies for a false “Out” or “?” conditions.

NOTE: When the Ink Level status is displayed as “?”; the Toolbox "Systems Status" will change to

"Cartridge_Missing_X" (X= tank color or multiple).

IMPORTANT! Please be sure to press the “Replace Ink Tanks” button, or power-down the print engine, before installing/removing/exchan ging Ink Tank(s). See the section titled “Replacing The Ink Tanks”. If this rule is not followed the QA Chip on the Tank can be corrupted; rendering the Tank unusable (stranding the remaining ink in the Tank). The Ink Level status of a “corrupted” Tank is commonly displayed as “?” (unrecognized), but it can al so be displayed as “Out” or “0%”.

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User Interface Menu

[A] User Interface Buttons: Let you perform routine maintenance and operating tasks. You can use these buttons to Clear Errors, Cancel a Job, Reset the Job Counter, and Reset the Page

Counter. You can also:

Replace Ink Tanks – Disconnects Printer

communication with Ink Tanks; allowing for the safe removal or install of Ink Tanks. Previously the printer had to be powered-down before Ink Tanks could be safely removed or installed. Press the “Replace Ink Tanks” button bef ore removing/installing Ink Tanks. Press the “Continue” button only after verifying that the Ink Tanks have been properly installed and the Ink Tank Latches are secure. WARNING: If the above procedure is not followed; damage to the Ink Tanks may result, rendering them unusable.

Refresh Ink Levels – Used to update or confirm the ink levels shown at the left side of the screen.

Circulate Ink – May be used to help purge air fro m t he lines and prime the system. Cleaning Buttons: Provide 3 levels of cleaning for the Printhead Cartridge. Use these features to help

recover printhead nozzles that are not firing. Note: The Memjet printhead contains 70,400 no zzl es. Each nozzle is a fraction of the diameter of a human hair. Under normal use; it is not uncommon for a small percentage of nozzles to become clogged. The following buttons work the same way as the three “… Clean Printhead” buttons in the Printer Driver:

• Quick Clean Printhead – Circulates ink, wipes and cleans the Printhead Cartridge.

• Normal Clean Printhead – Runs cleaning and wiping routine twice for better flushing and cleaning.

• Full Clean Printhead – Runs the cleaning routine multiple times for the most thorough flushing and

cleaning of the Printhead.

Tip: If using these cleaning features has no effect or increases the nozzle clogging issue; this may be an indication that the printhead and or “wiper roller” may need to be replaced. Due to the fact that a dirty/worn/damaged “wi per roller” can cause damage to a new printhead; it is recommended that the “wiper roller” be rep l aced whenever the printhead is replaced. Please con t act your service representative to have them perform this procedure. Tip: Do NOT use the above features to try to reduce “scu f f marks” and image smudging/smearing. Using these features will normally aggrav at e t hese issues. “Scuff marks” (black lines/streaks) can occur when the media makes contact with the printhead. Smudging/smearing can occur when the wet image makes contact with the printhead or other areas. The most common head to media contact areas are the h igh points (bows, bends, flaps) on the media and the trailing edge of the media.

Things that may help reduce scuff marks and image smudging/smearing:

- Check to be sure the “Head Media Guide” is properly installed.

See section titled “Installing/Removing the Head Media Guide” for more details.

- Check to be sure the Head Media Guide, printhead surface, lip of cap (capping station) and other

surfaces are clean. Clean using distilled wat er and a lint free cloth.

- Try feeding the media in a different orientation. Rotate piece 90, 180, 270 degrees.

- Try to use media that is flat (not warped, bowed or bent).

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[B] Basic Printer Settings – Lets you adjust automated service and cleaning intervals, adjust the feed mode, manually set the purge bar location and disable “paper jam” detection.

KWS Setting – (Keep Wet Spitting) Incorporates an algorithm to periodically fire all printhead nozzles in order to keep all nozzles wet; thereby reducing nozzle clogging and print quality issues. In general the dots produced on the media by this nozzle firing algorithm are hardly noticeable. However in some cases the dots produced are not acceptable for the application and the user may wish to turn this feature off.

• None = Intrapage spitting is turned off. KWS

dots are not sprayed onto media. WARNING: Selecting “None” will increase the chance for nozzle clogging and print quality issues.

• Light (Default) = Intrapage spitting frequency is set to the "default" level. KWS dots are sprayed

onto media to help reduce nozzle clogging and print quality issues.

• Heavy = Intrapage spitting frequency is increased. An increased number of KWS dots sprayed

onto media to further reduced nozzle clogging and print quality issues.

Mid-Job Servicing – Allows user to adjust the frequency of printhead cleaning (maintenance) during a print job. Based on linear inches of “Media Length”. NOTE: For this feature; “media length” is determined by the Media Height, set by the software/driver, not the actual transport drive distance.

CAUTION: Changing the setting from “Defau lt” may cause print quality issues and red uce p r i nthead life.

• Off (infinity) – Never pauses the job to do head maintenance.

• Level 1 (500m) – Pauses the job to do head maintenance every 500 meters of media length.

• Level 2 (375m) – Pauses the job to do head maintenance every 375 meters of media length.

• Level 3 (250m) – Pauses the job to do head maintenance every 250 meters of media length.

• Level 4 (100m) – Pauses the job to do head maintenance every 100 meters of media length.

• Default (14m) – Pauses the job to do head maintenance every 14 meters of media length.

NOTE: This setting will not affect head maintenance that is performed: before the job is started, at end of job, and or anytime the printer is interrupted (paused, out of paper, paper jam, etc..).

Service interval examples for the “def ault” (14 meters) setting:

8.5" x 11" media (length= 11”= 0.28 meters). Printer stops to clean about every 50 pieces.

Cutsheet Feeding Mode – Permits you to change how the Printer feeds media, depending on the type of job you are running. By default, this value is set to “Safe Feed”.

• Safe Feed – Larger gap between pieces provides slower throughput, but less chance for blanks

(unprinted pieces) to be fed.

• Max_Throughput – Smaller gap between pieces provides higher throughput, but more chance

for blanks (unprinted pieces) to be fed.

NOTE: These two settings can be changed “on the fly” without stopping the job. Example: While running a job in “Max-Throughput” you find that the printer is intermittently feeding blanks. Open the Toolbox, check “Safe Feed” and click “Submit”. The Printer will automatically adjust without having to pause or stop the job.

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SECTION 4 OPERATING THE PRINTER

Purge Bar Position (BoF)* – In operation, the Printhead spits a small amount of ink in the gap between pieces to keep the nozzles refreshed. For irregular-shaped pieces (like a cutout or hole in the media), the sensor may “read” this “irregular shape” as the edge and spray (print a purge bar) on the tip of the media instead of the actual gap. This feature allows you to manually set the purge bar location (bottom of

form), to account for the extra length need ed to reach the actual gap. 1000 = 1 mm. By default this value is normally set to 3000 (3 mm).

* See also “Purge Bar Position” in the “Printer Driver Properties”, “Layout Tab” section. Ignore Exit Sensor. – Disables the detection of a “paper jam” under certain conditions. Allows use of

media that is non-reflective to the Pap er path Exit sensor. When this feature is NOT selected; non-reflective areas, on the underside of th e media, may cause a false “paper jam” condition. The Toolbox will display "Paperpath_Paperjam".

After you select this feature and click on Submit; you will see the "Paperpath Exit" condition, shown in the Toolbox, change to "Exit: Disabled”.

NOTE: Please try cleaning sensors; as outlined in the user's guide; before selecting this f eature. This feature will not solve issues caused by media transport (slipping, hesitating) or a damaged Exit Sensor.

PLEASE BE SURE TO HIT "SUBMIT" AFTER CHANGING THESE SETTINGS

[C] Advanced Buttons. WARNING! These buttons should only be used by an “experienced” user or technician. Improper usage can cause damage to the system.

These buttons control functions that require the machine to be “out of service”, for extended periods of time, while procedures are being performed. To help reduce the chance of an accidental but ton press; an acknowledgement step was also added to the function of these buttons. If one of buttons [C] is pressed; you will be prompted with a message asking if you are sure you want to continue.

Install Service Station – Pulls the Service Station back into place after cleaning, repair or r eplacement.

Eject Service Station – Drives the Service Station out until it is released from the drive gears; so it can be removed for cleaning, repair or replacement. Please refer to the “Operator Maintenance” section for additional details.

Wipe Printhead – Activates the Service Station to wipe the Printhead. Tip: If you open the clamshell before pressing this button; this feature can be used, by an experience user or technician, to inspect the wiper roller . Pl ease be sur e t o keep hands and loose clothing clear of all moving parts. Please be sure to properly (gent l y) op en and close the clamshell.

Release Printhead – Use to remove/install the Printhead Cartridge. Pressing this button will cause the pri nter t o partially deprime the system (evacuate ink from the printhead) and release the Printhead L at ch.

System Deprime – Used to pump most of the ink back into the Ink Tanks; prior to servicing or transporting the Printer.

Shutdown – Powers-down the print-engine. Same as pressing the ON/OFF button on the printer’s control panel. For best system performance, it is recommended to keep the print engine powered-up (ON/OFF light illuminated) at all times. If you need to turn the printer off; please be sure to power-down the printengine, using the “Shutdown” button in the Toolbox or the ON/OFF button on the control panel. Wait until all the control panel buttons go out, before turning off the Main Power Switch.

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OPERATING THE PRINTER

[D] Display Language – Selects the language the Toolbox information will be displayed in. PLEASE BE SURE TO HIT "SUBMIT" AFTER CHANGING THESE SETTINGS

[E] Firmware Download – This feature is used to

update the main firmware in the printer.

SECTION 4

WARNING: This process should only be performed by a qualified support representative. In some cases firmware must be loaded using the “Firmware Migration Tool”. If this process is not performed properly, it can render the printer inoperable.

Diagnostics Menu

From this screen you can see the current status of your Printer. You can also:

Print Sample Page – Prints type and color bands to check print quality.

Print Configuration Page – Shows the current configuration of the Printer including Firmware Version, Network Connection, Printer Serial Number and more.

Print Diagnostic Page – Shows basic Printer information, memory, Network Settings, Event Log, Log History and RAM size.

Print Demo Page – Prints a 4-color sheet. Print Ink Channels – Prints 5 solid blocks/bars of color

(1 block/bar from each Ink Tank CMYKK) to show how well the nozzles are performing, in each color channel of the Printhead.

Print Color Bars Page – Prints a series of 7 color bars to show how well the Printhead is mixing colors and printing.

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SECTION 4 OPERATING THE PRINTER

Ink Usage Menu

NOTICE! The numbers shown in the Ink Usage Menu are provided for estimation purposes only! Accuracy is not guaranteed!

This tool is provided for the purpose of estimating the amount of ink usage for a particular print job. This information can be used to estimate pieces can be printed before each Ink Tank is empty (assuming all Tanks are full). The numbers provided are in nano-liters (nL). Each Ink Tank holds a maximum of 250 ml (250,000,000 nL).

For example: If we use the info from the top row of this chart; each piece/image used an average of 2387 nL (19097/8=2387) of Cyan ink. Therefore the Cyan Ink Tank should be empty after approximately 104,733 pieces (250,000,000/2387= 104,733).

Ink Estimation Mode. – Checking this box lets you predetermine how much ink a given job may use prior to printing. This can be useful for determining per piece costs. The job is sent to the Printer and loads, but does not print. Once the job is loaded, the Ink Usage chart shows the estimated that the job will use.

NOTE: The estimating process will take as long as the job would take to print (i.e., if the job would take 1 hour to print, the estimate will take 1 hour to display.) If a job is incomplete (paused, interrupted), an

apteryx symbol (*) will be shown next to the page count (Pages) number.

When this feature is selected the Toolbox will display: “Ink Estimation Mode”

NOTICE! The printer will not feed or print if the “Ink Estimation Mode” is selected. Please be sure to un-check the “Ink Estimation Mode” when you are ready to print the job.

how many

amount of ink (by color)

Network Configuration Menu

Permits you to view, enter or change settings to connect the Printer to your network via the Ethernet port.

Please refer to the section titled “Connecting the Printer via Network (Ethernet Port)” for detailed instructions.

Note: To set these printer parameters; you must initially install the printer Driver via USB and connect to the printer via USB.

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Service Menus

For authorized personnel only.

Provides access to more advanced Printer contr ol and maintenance menus.

A password is required to open the following features.

• Printer Maint Config

• Printer Control Config

• Scan Sensors

• Commands Help

• Exit Service Menu

SECTION 4

OPERATING THE PRINTER

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SECTION 4 OPERATING THE PRINTER

Printing

Once the printer installation and setup is complete, you are ready to start printing. Please see the section titled “Software Setup Information” for details on how to setup the computer software to print to the printer. If a printhead was recently installed or the printer was left powered OFF for more than a few hours; it is recommend that you perform a “Printhead Cartridge Conditioning” routine, outlined below, before you print a live job.

Printhead Cartridge Conditioning

When a printhead cartridge is installed, it is normal for some residual ink accumulation to occur in certain areas within the print engine. There may also be some color contamination between ink channels and air bubbles trapped in the printhead. These contaminants should be manually cleaned from the components and purged from the printhead. Air bubbles in the printhead will present themselves as unevenly shaped bands of missing color. Color contamination will present itself as mottled, muddy or distorted colors. See “Print Quality Issues” for more details.

After installing a new printhead cartridge, or re-install a used printhead cartrid ge, please use the following routine to condition the cartridge and system.

1. Power-down the printer. After all the control panel lights go out; carefully open the clamshell and

inspect/clean any visible ink from follow i ng areas. Printhead surface. Head Guide (you may need to remove to clean behind guide). Rubber lip of capping station. NOTE: Residual ink will normally be deposited in these areas during the priming process; which occurs after a printhead i s installed. Once you are finished cleaning, carefully close and latch the clamshell.

2. Power-up the printer.

3. Setup and load the printer with at least ten sheets of 8.5 x 11 inkjet suitable paper.

4. Open the “Toolbox” utility.

5. Locate the “Circulate Ink” button. Click on this button.

While the ink is circulating, tap lightly on the ink tubes, located at the operator side of the printer, and on the printhead cartridge. This will help dislodge air bubbles; allowing them to pass through the printhead and out the non-operator side of the printhead. NOTE: It is normal to see air bubble accumulation in the i nk tubes located at the non-operator side of the printer. This is OK. IMPORTANT! To avoid abnormal pressure buildup in the ink system; do NOT press the “Circulate Ink” button more than once every 15 mi nutes (not to exceed more than three times in one hour).

6. Click on the “Diagnostics” select ion (located at left side of screen).

The “Diagnostics” screen will open.

7. Click on “Print Ink Channels” button.

A page representing each individual ink channel (CMYKK) will be printed.

8. Once the “Print Ink Channels” page has finished printing; send it again.

Repeat this process until you are satisfied with the output. You should notice that each time you print another page, the image quality and color will improve. It may take up to ten pages before the output is satisfactory. NOTE: Make sure you allow the printer to completely print each page before you press the "Print Ink Channels” but ton again.

9. Now you are ready to print your job.

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SECTION 5

SOFTWARE SETUP INFORMATION

Section 5 – Software Setup Information

Once the Printer Driver is installed on your computer and the Printhead is primed, you are ready to start printing. Setup your job and send it to the Printer. The Printer will start and print

General Software Setup Info

Note: The following information assumes you have the M Series Driver v13 or higher installed . Do NOT exceed the Min or Max media specification s of the printer:

• Minimum paper size printer can feed: 3" wide x 4.2" long.

• Maximum paper size printer can feed: 9" wide x 14.5" long.

• Maximum print area for the printer: 8.5" wide x 14.5" long.

NOTE: Driver version R13 will accept up to a 30” height, but the Feed Table and Output Stacker are not designed to support media of this length.

To setup the maximum print area:

• For a 9" x 14.5" document, set the paper size to 9" wide x

14.5" long in the Custom Paper. Set top and bottom margins to 0". Set the left-hand margin to 0”. Set righthand margin to 0.5".

• For smaller page sizes (8.5” x 14.5” or smaller), such as

8.5" x 11" (standard letter) or 8.5" x 14.5" (legal size) set the paper size to the exact size and set all margins to zero.

Adobe® Acrobat/Reader Setup Tips

In general, printing a PDF from Adobe Acrobat/Reader is straight-forward and easy. However there are a few limitations and quirks that you should be aware of.

1. Original PDF should be designed for the piece size and orientation you plan to use.

Adobe Acrobat has some nice controls for changing orientation and adjusting the image size to fit the media size you select; but there are limits. For example, if you plan to print an image that covers the entire area of an 8.5 x 11sheet; make sure the original document (PDF) was designed to print an imag e of t his size and in the proper orientation. If the image is designed to print on a smaller piece or in a different orient at ion; adobe can rotate and expand the image, to “fit” the larger piece, but it will normally be distorted and/or may not fill to the edges.

2. Copies are limited to 999.

To print more than 999 copies, duplicate your original PDF to increase the number of pages in the document. For example; If you create ten pages of the same image in the document, the number of pieces you can print in one job are increased to 9,990.

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SECTION 5 Software Setup Information

Setting Up a Job in Microsoft Word® (2007)

Valid when using Microsoft Word® 2007 and the M Series Driver. Before you begin laying-out the document; make sure the “M Series Driver” has been selected as your “default printer” or make sure you have select the “M Series Driver”, for your document, in MS Word.

Letter (8.5” x 11”): The following procedure assumes that the pri nter has been setup to feed 8.5” wide x 11” long media.

1. Click on the “Office Button”

2. Click on the “Page Layout” Tab.

3. Click on “ Size” and select “Letter 8 ½ x 11 in”.

4. Click on “ Margins” and set margins to minimum values or to your desired v al ues.

Tip: If you should get a warning that one or more margins are set outside the printable area of the

page…”; Click on the Fix button.

5. Click on “Orientation: and select “Portrait”.

6. Insert the items (text, graphics, etc..) you want on the document.

7. Click on the “Office Button”

Make sure the “M Series Driver” is showing as your printer name.

8. Click on the “Properties” button.

9. Under the General Tab set the following:

Orientation = Portrait Media Size = Letter 8 ½ x 11 in

10. Click on OK to exit from the “M Series Driver Properties” wind ow.

11. When you are ready to print, Click on OK to send the document(s) to the printer.

8.5” x 5.5” Paper:

The following procedure assumes that the pri nter has been setup to feed 8.5” wide x 5.5” long media.

and then select “New”, to create a new “blank do cument”.

and then select “Print”.

1. Go to File, then Page Setup and select 0"

margins.

2. Select the Paper tab, select Paper

size” then set the paper W paper He

3. The screen at right is an example of a job to be

printed. Once the job is ready for printing, select Print from the File menu and print the job.

For more information about changes that can be made in the Driver please see the “Printer Driver Properties” section.

ight to 5.5". Then click OK.

size “Custom

idth to 8.5" and the

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SECTION 6

CAUTION

KEEP HANDS/FEET AND OTHER BODY PARTS OUT FROM UNDER

OPERATING TH E OU TP U T S T ACKER

SECTION 6 – Operating the Stacker (optional) .

The Automatic High Capacity Output Stacker was designed to work with the MACH 8 printer. With these simple instructions; you should find it very easy to set up and use.

THE RECEIVING TRAY. KEEP HANDS, HAIR AND CLOTHNG CLEAR OF MOVING PARTS

Output Stacker Control Panel Buttons

The UP/STOP and DOWN/STOP buttons, on the Output Stacker, control the Receiving Tray.

UP/STOP: Pressing this button once raises the Receiving Tray.

Pressing this button a second time stops the Tray at its current location.

DOWN/STOP: Pressing this button once lowers the Receiving Tray. Pressing this button a second time stops the Tray at its current location.

Reset: Pressing both buttons (UP and DOWN) simultaneously, for about 6 seconds (butt ons re s po n d by flashing fast), repositions the Receiving Tray to the “ready” position.

NOTE: If the “Stacker Interface Cable” is properly attached and the Output Stacker is ON; the Receiving Tray should automatically move to the “ready” position, before the printer starts to print. If this doesn’t occur; contact your serv i ce representative and ask them to check the Stacker Interface Cable and to verify that the printer model has been properly selected in the Toolbox. Service Menu, Commands Help (set_model, M2 = MACH 8).

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SECTION 5

Press “down button” a second time to stop Tray

OPERATING TH E OU TP U T S T ACKER

Output Stacker Status Light (LED) Indicators

The lights (LED’s), on these two control panel buttons, indicate the status of the Output Stacker.

Output Stacker Status Light Indicator Chart

Stacker Status

Additional Details, Possible Solution or Action

Main power switch is OFF or Stacker is Ready

Stack Height Sensor is BLOCKED (interrupted)

Down button was pressed and Tray is Lowering (moving down)

Receiving Tray at lowest position

Check/Turn ON Main Power switc h. Stacker is “ready” to receive media.

Tray or media stack is interrupting the Stack Height Sensor. Tray cannot be raised higher unless sensor is cleared (media stack reduced or Tray lowered).

Send Print Job or Press RESUME, on printer, if job was PAUSED. Tray should automatically move to the “ready” position. If not; check to be sure the “Stacker Interface Cable” is properly attached.

NOTE: Once stacker is ready to receive media (Tray at “ready” position); if the Stack Height Sensor becomes continuously interrupted by media, for about 6 seconds, the Tray will automatically move down a small amount.

or allow Tray to stop automatically when it reaches the Low Limit Sensor.

Tray reached Low Limit Sensor. Remove media from Tray and press UP button.

Up button was pressed and Tray is Raising (moving up)

Receiving Tray if Full. Job is automatically PAUSED.

The Toolbox will display:

PAUSED

below the “Feeder:” heading.

Pressed “up” button a second time to stop Tray or allow Tray to stop automatically when it reaches Stack Height Sensor.

While in the process of printing, the Tray reached its lower limit (Low Limit Sensor interrupted).

Remove media from the Receiving Tray and then press the RESUME button, on the printer, to continue. NOTE: Tray should automatically raise and then move to the “ready” position, before the printer continues printing. If not; check to be sure the “Stacker Interface Cable” is properly attached.

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CAUTION

KEEP HANDS/FEET AND OTHER BODY PARTS OUT FROM UNDER

Output Stacker Setup

1. Once the Stack er i s powered on, it should automatically

reposition the Receiving Tray to the “ready” position (top of media stack or top of Tray will be located about 1/4” below the stack height sensor). You can press the UP or DOWN buttons to manually reposition the height of the Tray; if necessary. Pressing the same button a second time will stop the Tray at the current positio n. NOTE: The Receiving Tray will automatically reposition, to the “ready” position, whenever the MACH 8 is preparing to print; the Tray will automatically lower (~1/4” at a time) whenever the media continuously interrupts the Stack Height Sensor for about 6 seconds. TIP: Pressing both buttons (Up and Down) simultaneously, for about 6 seconds, can also be used to manually repositions the Receiving Tray to the “ready” position.

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OPERATING TH E OU TP U T S T ACKER

2. Check that the Media Guide Stop is touching the Receiving

Tray [C]. If not, slide the Media Guide down so the Stop

touches the Tray. DO NOT adjust the stop screw.

3. Turn the Backstop Adjusting Knob [D] to unlock the

Backstop. Use one piece of media and/o r the scale on the Control Panel to set the Backstop for the appropriate media length.

4. Adjust the Media Side Guide [E] to fit the media width.

NOTE: Can be adjusted to accommodate 6.5” to 9” wide media.

THE RECEIVING TRAY. KEEP HANDS, HAIR AND CLOTHNG CLEAR OF MOVING PARTS

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SECTION 7 MAINTENANCE

SECTION 7 – Operator Maintenance

This section covers how to perform routine operator maintenance on the printer; including Ink Tank care, Printhead care, clearing paper jams, replacing Ink Tanks, replacing Printhead Cartrid ge, replacing sheet separators. If printer maintenance or service is needed beyond the scope of what is covered in this section; please contact your Dealer/Distributor for support.

Replacing the Ink Tanks

This procedure is almost identical to the p rocedur e for installing new Ink Tanks into a new printer. The only difference are:

- The Toolbox will display an “Ink_Out..” condition; once the ink in a particular Tank is depleted.

- The empty Ink Tank(s) must be removed before installing the new Tank(s).

With these differences in mind; pl ease refer to the section titled “Installing the Ink Tanks”.

Cleaning Ink Tank Contacts & Prism

When reinstalling or replacing Ink Tanks, the Ink Level indicators in the Toolbox may show “?” or “out”, below for one or more Tank positions.

- The “out” condition may be due to a dirty Ink Tank Level Prism.

- The “?” condition may be due to dirty QA Chip contacts. You can clean these areas of the Tank as follows:

1. Open the Printer Toolbox.

2. Click “Replace Ink Tan ks”. O nce the

“Confirm” window opens, it is safe to remove the Ink Tanks. IMPORTANT: Do NOT press “Continue” until after you have replaced the Ink Tank(s) and verified that the Ink Tank Latches are securely closed.

3. Open the Ink Tank Door, rel ease the required Ink Tank Latch(es) [A]

4. Remove the Ink Tank(s) [B] that are displaying the “?” or “out” condition.

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5. Clean the Ink Level Prism [A] and QA Chip

contacts [B] with a clean, dry, lint-free cloth. NOTE: You can dampen the cloth with distilled water to wipe the Prism, but DO NOT get the QA Chip contacts wet.

Tip: A soft pencil eraser can also be used to lightly clean the QA Chip contacts. This can help remove corrosion that is not visible. Wipe the contacts off with a lint-free cloth after cleaning them with an eraser.

6. Re-install the Ink Tanks (labels up) into their appropriate color slots.

7. Close and lock all three Ink Tank Securing

Latches.

IMPORTANT: Make sure both sides of the Latch are engaged at the bottom.

SECTION 7

MAINTENANCE

8. Click on the button labeled “Continue”, in the

Confirm screen of the Toolbox.

9. Watch the Toolbox screen on your computer. You should see all the ink

colors fill-in; if all the Ink Tanks are properly installed and recognized.

Tip: If an Ink Tank color still does not fill-in. Press the “Refresh Ink Level” button. If the problem continues you may need to replace the Tank with a new Tank. Even new Ink Tanks can have dirty/corroded QA Chip contacts. This is not always visible to the eye.

10. Close the Ink Tank Door.

Ink Tank Storage & Shelf Life

Properly stored unopened tanks have a shelf life of up to 1 year. New Ink Tanks should be stored in their original packaging and kept away from extreme hot or cold temperatures. Opened Ink Tanks shou ld remain in the Printer.

Ink Tank Service Life

Ink Tank yield will vary greatly; based on the job being printed. Please see “Ink Usage Menu”, in the section titled “Using the Toolbox Utility”, for details on calculating the approximate Ink Tank yield fo r a particular print job.

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SECTION 7 MAINTENANCE

Ink Tank Disposal

The Ink Tank may be disposed of in a normal manner. Clean up spills with soap and water. Abrasive soap is effective in cleaning ink off your hands.

Cleaning the Printhead Cartridge

The Printhead Cartridge is cleaned automatically; each time the printer is turned ON, before each job, periodically during the print job, and when a User Maintenance Level routine is performed by the operator.

From the M Series Driver:

Clean Printhead Buttons can be found under the Service Tab, in the M Series Driver properties. Each step activates a more thorough cleaning or clearing of the printhead; which also takes additional time to perform. See “Printer Driver Properties”, “Service Tab”, for more details.

From the Toolbox:

Some of the Toolbox features, located in area [C ] , can be used to activate head maintenance routines.

See “Using the Toolbox”, “Advanced Buttons”, for more details.

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SECTION 7

Printhead Nozzle Area

WARNING: Be careful not to damage the

image or media.

MAINTENANCE

Manual Printhead Cleaning:

NOTE: We recommend the use of nitrile powder-free gloves for this pr ocess.

As a last resort, if running the built-in “... Clean Printhead” features don’t help improve print quality; the printhead cartridge can be cleaned manually.

1. Carefully open the clamshell.

2. Clean the printhead nozzles. Dampen a lint-free cloth (i.e.

Cartridge Wipes, PN 2023), with deionized or distilled water. Keep the printhead nozzle area facing down and gently wipe the printhead nozzle area, from end to end, in one direction and in one fluid motion. You can repeat this process a few times, but only wipe in one direction.

NOTE: The use of deionized water (reference ASTM D5127-90 Type E-II Electronic Grade Water) is preferred; however it is acceptable to use distilled water if deionized water is not available. Do NOT cause damage to the printhead cartridge an d possible contamination to the ink system.

use tap water or paper towels to clean the printhead n ozzles. Doing so may

“star rollers” when wiping the printhead. These rollers are designed so they can roll across a wet image, without damaging the image. If the rollers are bent, they will not turn free; causing media feed issues (jamming) and possible damage to the

3. Carefully Close the Clamshell.

CAUTION: To prevent damage, hold onto, then lift and release both latches when closing. If you

force it closed without holding the latches open, you will eventually damage the latches and clamshell switch (door switch).

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SECTION 7

ATTENTION

If you experienced fuzzy print quality or an abrupt failure in a particular area of nozzles on

have them perform this process for you.

WARNING

Never attempt to open the Printhead Latch manually, when in the closed/locked position.

MAINTENANCE

Replacing the Printhead Cartridge

The following procedure describes how to remove the Printhead Cartridge from the printer.

the previous printhead; we recommend that you have the service station inspected/cleaned and the wiper roller replaced, before installing the new printhead. If not; the chance of damage to the new printhead is greatly increased. Service station maintenance and wiper roller replacement should only be performed by a qualified/trained person. Please contact your service representative to obtain training or to

NOTE: We recommend the use of nitrile powder-free gloves for this pr ocess.

1. Plug in the printer. Turn the printer’s Main Power Switch ON; then press the control panel’s

ON/OFF button. Wait about 45 seconds for the print engine to power-up (ON/OFF button will illuminate).

2. Open the Top Cover.

3. Open the Toolbox utility.

4. Click on the button labeled “ R el ease Pr inthead”;

located in the Advanced Buttons area [C] of the User Interface screen. The printer will run a partial deprime routine and then the printhead latch will release so it can be opened.

WARNING! If the printhead latch fails to release do not force the latch open. Severe damage will result. Contact technical support.

5. Open the Printhead Latch fully to disengage the ink couplings from the printhead cartridge.

Severe damage will result. Use the Release Printhead button from the Toolbox Utility.

6. Remove the old printhead as shown below. Tilt the cartridge back and then lift up to remove.

7. To help reduce ink spills; place the printhead into the old protective packaging and discard.

8. Once the old Printhead Cartridge has been removed; please refer to the section titled “Installing

the Printhead Cartridge”; to install the new Printhead Cartridge.

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must not exceed 72 hours .

Printhead Storage & Shelf Life

Properly stored, unopened, Printhead Cartridges have a shelf life of up to 1 year.

Long Term: 14° F to 86° F (-10° C to 30° C)

Storage Temperature Range:

Short Term: -11° F to 140° F (-25° C to 60° C) NOTE: Cumulative storage duration above 86° F (30° C)

SECTION 7

MAINTENANCE

Humidity Range: Atmospheric Pressure Range:

Electrostatic Discharge:

If you find it necessary to remove the printhead from the printer, for a few hours/days, it must be properly protected and sealed; to help reduce damage, nozzle dehydration and clogging.

• Follow the “Replacing the Printhead Cartridge” proced ure to remove the Printhead Cartridge.

• Install the protective cover on the printhead. Be careful to avoid ink spills (drips) and stains

during this process.

• Store Printhead Cartridge in a sealed plastic b ag, along with a cloth that has been dampened with

distilled water.

• Re-install the “Cap Protectors” onto the Ink Revolver Couplings.

• The Printhead should be re-installed as soon as possible. Please see the section titled “Installing

the Printhead Cartridge”. CAUTION: Make sure the cartridges electrical contacts are dry before re-installing printhead.

5% to 95% Relative Humidity, non-condensing 70 kPa to 106 kPa 8 kV air discharges or 4 kV contact discharg es*

*When tested in accordance with IEC 61000-4-2

Printhead Service Life

Manufacturer’s estimated rating: ~125,000 linear inches of continuous printing.

For example; if printing media that is 4.2” in length, at best print quality, with 100% ink coverage (each nozzle firing at 1600 dpi down length of media); the printer is depositing 4.2 liner inches of print per piece. At this rate, you can expect a yield of approximately 30,000 pieces before head replacement may be needed. If printing a typical logo (1” high) you can expect a yield of approximately 125,000 pieces before head replacement may be needed. NOTICE: Individual results will vary. The estimations, provided above, are NOT an expression of Warranty. This information is being provided for informational pur p os es only. The decision on when a printhead is no longer producing acceptable output varies greatly from customer to customer; since this decision is based upon the customer’s expectations (what they consider is or is not acceptable output). Printhead degradation will depend on the make-up of the images printed, the operating environment, servicing, media characteristics (including cleanliness) and other factors. The Printhead has a total of 70,400 nozzles (14,080 per color channel, 5 color channels). Since every print job is different, most do not use the entire width of the Printhead nor do they require t hat every nozzle be fired. Therefore some nozzles do not fire as often as others. The most often used nozzles will degrade more quickly. Noticing the effects of failing nozzles depends partly on the relati ve position of those nozzles to each other.

Printhead Disposal

The Printhead Cartridge may be disposed of in a normal manner. To help avoid ink spills; place the Printhead Cartridge back into its original packaging, before disposal. Clean up spills with soap and water. Abrasive soap is effective in cleaning ink off your hands.

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SECTION 7

Lip of Capping Station

MAINTENANCE

Inspecting & Cleaning the Lip of the Capping Station

The Capping Station (Cap) is part of the Service Station. When the printer is idle, the Service Station automatically caps the printhead to keep the nozzles hydrated. Excess ink can accumulate on the Lip of the Cap. This commonly occurs after a printhead cartridge is installed and the system is primed. During the printhead priming process the system performs multiple purges of ink into the Cap. This can cause excess ink to build on the lip of the Cap. This excess ink will then be transferred to the printhead surface, when the printhead is capped; creating a greater chance for “scuff marks” to occur on the media.

Procedure:

1. Power-down the printer using the ON/OFF button.

2. After the Control Panel Lights have all turn OFF; Open the Top Cover.

3. Carefully release the Latch es and Open the

Clamshell.

4. Using a lint free cloth; carefully wipe the excess ink from the Lip of the Capping Station.

5. Inspect the lip of the cap for signs of wear or damage. If the lip is uneven or cracked, it should be

replaced. Please contact your service sup po r t rep r esentative to have this item replace.

6. Carefully close and latch t he Clamshell.

Important! Make sure to hold the latches open (unlo cked position) until the clamshell is closed.

Then slowly release the latches. If this rule is not followed damage to the latch posts and or door switch may result.

7. Close the Top Cover.

8. Power-On the printer.

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SECTION 7

Wiper Roller

MAINTENANCE

Inspecting the Wiper Roller

The Wiper Roller should be routinely inspected for signs of wear and debris. NOTICE! If you have not been trained or are uncomfortable performing this task, please contact your

service support representative.

Directions:

1. Power ON the printer and power-up the print engine.

2. After the printer has finished performing maintenance,

carefully release the Latches and Open the Clamshell.

3. Open the Toolbox and press the “Wipe Printhead” button.

4. The Wiper Rol ler will be presented

through the opening in the lower section of the print engine. The Service Station will cycle through its normal wiping and capping routine; providing you with the opportunity to inspect the condition of the Wiper Roller. CAUTION: Keep all loose items and hands away from the moving parts within the print engine. Do NOT try to touch or clean the moving components. Injury or damage may result.

5. Inspect th e Wip er R oller for signs of damage/wear (fabric is fuzzy, to r n, uneven) and debris (fibers,

hair, particle accumulation, etc…). Contact your service support representative if you see signs of wear or debris on the roller. The wiper roller may need to be cleaned or replaced. NOTE: A new (unused) Wiper Roller will be white. Once the roller has been used, for a short period of time, it will turn black with ink. This is normal. WARNING: Without training and experience it can be difficult to identify a worn or dirty wiper roller. When in doubt, the Wiper Roller should be replaced. Operating the printer with a worn or dirty wiper roller can cause damage to the p r int head. If the printhead is replaced it is also recommended that the Wiper Roller be replaced at the same time.

6. As soon as you are fi nished inspecting the Wiper Roller; carefully close and latch the Clamshell.

WARNING: If you leave the Clamshell open too long this may cause nozzle dehydration. Important! Make sure to hold the latches open (unlo cked position) until the clamshell is closed.

Then slowly release the latches. If this rule is not followed damage to the latch posts and or door switch may result.

7. Close the Top Cover.

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SECTION 7

Service Station

WARNING

If the Printhead Cartridge is still installed; when you remove the Service Station, the Printhead will

before you begin this process.

Ink Tank

Door

MAINTENANCE

Cleaning/Replacing Service Station Items

The Service Station contains separate areas/d evices that are used to perform the following tasks.

• Cleaning. The Wiper Roller cleans the Printhead nozzles of excess in k and debris.

• Printing/Purging. The Printing Platen acts as a base to support media during printing. It also contains a

purging area; which captures and absorbs ink that is purged, to help keep nozzles clear.

• Capping. The Capping Station seals and protects the printhead nozzles when not in use.

• Evacuating Waste Ink. In addition to the function of supporting the above items; the Service Station

Tray is lined with wicking material that absorbs the waste ink and transfers it out of the Tray and into the “waste ink trough”. This waste ink then flows from the “trough” to the “Waste Ink Tray”, which is located behind the Ink Tank Door.

As the above components become worn/dirty, from use, they can lose their ability to perform as intended. If you experience print quality issues that are not Troubleshootin g Sec t ion under “Print Quality Issues”; it may be time to have the Service Station, or components within the Service Station, cl eaned or replaced.

THESE PROCEDURES SHOULD ONLY BE PERFORMED BY A

QUALIFIED/TRAINED PERSON.

resolved by performing the steps found in the

CAUTION

NOTICE: Due to the technical nature of these procedures; they should only be performed by a qualified

technical support person or someone that has been properly trained on these procedures. Please contact your technical support representative. Please use nitrile powder-free gloves and have plenty of paper towels

remain un-capped. This can cause dehydration of nozzles and printing issues. If you want to reduce the chance for printhead nozzle dehydration; it is highly recommended that you eject the Printhead and follow the procedures described under “Printhead Cartridge Storage and Handling”,

on-hand for these procedures.

Removing the Service Station

1. Open the Top Cover

2. Open the Ink Tank Door (hinged at bottom) to expose

the “Service Station Slot”.

Tip: On older units you will need to remove the Exit Roller Cover by removing the four (4) screws. This is not necessary on newer units.

Slot

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SECTION 7

MAINTENANCE

3. Power-up the printer.

4. Open the Printer Toolbox. In the User

Interface window, press the “Eject Service Station” button.

5. Once the Service Station has ejected; power OFF the printer. Press the ON/OF F button once and

wait about 45 seconds for the print engine to power off (all control panel light’s off). Then turn the Main Power Switch OFF.

6. Slide the Service Station out of the Service Station slot.

CAUTION: Do not pull Station all the way out until you disconnect the Ribbon Cable.

NOTE: It is a good idea to place an absorbent towel

under the Service Station as you remove it to prevent any drips or leaks.

4. Disconnect the Ribbon Cabl e. Slide the Latch open on

the Service Station Circuit Board to release the Ribbon Cable. CAUTION! This latch can be broken if you pull it out too far. Be careful!

5. Remove the Service Station completely from the print

engine and place it on a non-absorbent surface (plastic bag) to protect the surface you are placing it on.

6. If you are replacing or re-installing the Service Station, please see the section titled

“Installing the Service Station”.

7. If you are cleaning or replacin g items in the service station; please see the next section titled

“Cleaning the Service Station”.

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SECTION 7

Wiper Motor Assy

MAINTENANCE

Cleaning the Service Station

Caution: Please be sure that you are using proper cleaning techniques to clean items that come in contact with the printhead. Use only distilled or deionized water and lint free cloths. If you don’t follow this rule, you will introduce contamination into the printhead; which can damage the printhead and ink system.

Wiper Roller Removal and Cleaning or Replacement

Tip: Although the wiper roller can be cleaned; this process is time-consuming. When you factor in labor costs; you may find it more cost-effective to replace the wiper roller instead. We also recommend that th e wiper roller be replaced whenever a n ew printhead is installed.

Removal:

1. Lift up, about one inch, on the Wiper Motor Assembly; to expose the latch

retaining screws [C] (one at each end).

NOTE: Early versions of this assembly did not have retaining screws.

2. Carefully loosen

Tip: To avoid loosing these screws; don’t remove th e screws. You only need to back-out the screws far enough so the latches can be opened.

3. Release the two lat ches that secure the wiper roller.

4. Remove the Wiper Roller from the Wiper Motor Assembly.

Cleaning/Replacement:

1. Using distilled water; immerse for 10 minutes, then remove and pat dry with absorbent lint free

towel. WARNING! Do NOT rub the roller, when cleaning or drying it. This will cause damage to the roller fabric. Do NOT use tap/mineral/spring water to clean the wiper roller; doing so will introduce contaminants into the roller. A contaminated roller will cause damage to the printhead and ink system. Allow the roller to dry completely, before re-installing it.

2. If the Wiper Ro ller shows signs of wear (fabric surface torn, un-even or fuzzy), it should be

replaced. Be sure to remove the plastic cover from the new Wiper Roller before installing it.

Install:

1. Re-install the Wiper Roller into the Wiper Motor Assembly. Make sure the gear on the Wiper Roller

engages the gear in the Wiper Motor Assembly. TIP: If you are planning to clean the Wiper Motor Assembly; don’t re-install the wiper roller until you have completed the Wiper Motor Assembly cleaning process.

2. Carefull y close the latches. Make sure the latches are fully locked and then tighten the latch

retaining screws [C] (don’t over-tighten).

the two small screws retaining the wiper roll er l at ches.

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WARNING

Wiper Motor Assembly Removal and Cleaning

Removal:

1. Disconnect (unplug) the wiper motor cable from the

Service Station Printed Circuit Board [A].

2. Remove the Printed Circuit Board [A] from the

Service Station Tray. Carefully release clip s to remove board.

3. Lift out the Wiper Motor Assembly [B].

4. Remove the Wiper Roller from the Wiper Motor

Assembly [C] [D]. See procedure on previous page.

Cleaning:

1. Pour distilled water into a flat-bottom container to the

depth of about 17mm.

2. Carefull y immerse t he Wiper Motor Assembly, motor

side up, into the water.

SECTION 7

MAINTENANCE

DO NOT IMMERSE MOTOR OR GET

MOTOR WET; TO AVOID DAMAGE.

3. If vents are sh owing, carefully add more water until

they are covered. Allow the Wiper Motor Assembly to soak for 10 minutes.

4. Carefull y remove t he Wiper Motor Assembly. Inspect

the vents and remove any debris with tweezers. P at dry with an absorbent lint-free towel. NOTE: If this assembly shows signs of wear or damage it should be replaced. If the Service Station is more than one year old, depending on monthly volume, it may be worthwhile to replace the entire Service Station instead of replacing comp on ents.

5. Lightly lubricate the Wiper Motor Gears (3) with

synthetic PTFE grease (Super Lube 21030 or equivalent).

Install:

1. Allow the Wiper Motor Assembly to dry.

2. Re-install in r everse order.

NOTE: Make sure the wiper roller is re-installed,

wiper roller latches are fully closed/lock ed and the wiper roller retaining screws are fully tight ened (do not over-tighten). TIP: If you are planning to clean the Service Station Tray; don’t re-install this component until you have completed the Service Station Tray cleaning process.

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SECTION 7 MAINTENANCE

Printing Platen and Capping Station Removal and Cleaning

Removal:

Both of these items simply lift out for removal from the Service Station.

Cleaning:

3. Rinse off i nk using tap water.

Tip: Make sure the valve, located on the bottom of the Capping Station, is clear of debris and working.

4. Pat dry with an absorbent lint-free cloth.

5. After cleaning the Capping Station; wipe the capping lip with a lint free cloth, dampened with

distilled water. This will help insu r e that t he contaminants on the cap are removed, before the cap makes contact with the printhead. NOTE: If either of these items show signs of wear or damage they should be replaced. If the Service Station is more than one year old, depending on monthly volume, it may be worthwhile to replace the entire Service Station instead of replacing components.

Install:

1. Allow the Printing Platen and Capping Station to dry.

2. Reinstall Printing Platen and Capping Station into Service Station Tray.

TIP: If you are planning to clean the Service Station Tray; don’t re-install this component until you have completed the Service Station Tray cleaning process.

Cleaning the Service Station Tray

1. If present; remov e t he Service Station Printed Circuit Board, Wiper Motor Assembly, Printing

Platen and Capping Station from the Tray; as described on the previous pages.

2. Wipe the Tray with a damp, lint-free cloth to remove the major ink buildup. Be careful not to

damage/peel-off the wicking material; from the surface of the Tray.

3. Then rinse the Tray using tap water.

4. Allow the tray to dry.

NOTE: If the Tray shows signs of wear or damage (wicking material torn or coming loose from

surface of tray) the Tray should be replaced. If the Service Station is more than one year old, depending on monthly volume, it may be worthwhile to replace the entire Service Station instead of replacing components.

5. Reinstall the Service Station Printed Circuit Board, Wiper Motor Assembly, Printing Platen and

Capping Station, into the Tray; as described on the previous pages.

Suggestion for High Volume Users:

For printers that are being used at high volumes (over 200,000 pieces per month), we recommend purchasing a second service station to reduce down-time for Service Station Maintenance. The new/clean service station can be swapped with the di r t y one. Then the dirty Service Station can be cleaned according to the above instructions and made ready for the next time Service Station Maintenance is required.

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SECTION 7

Service Station

Tighten

CAUTION!

Make sure the latches for the Wiper Roller are fully latched and secured

Check the latch at each end of

Ink Tank

Door

MAINTENANCE

Installing the Service Station

CAUTION

THIS PROCESS MUST BE PERFORMED BY A QUALIFIED/TRAINED PERSON.

NOTICE: Due to the technical nature of this procedure; it should only be performed by a qualified

technical support person or someone that has been properly trained on this procedure. Please contact your technical support representative. Pl ease u se nitrile powder-free gloves and h ave plenty of paper towels onhand for these procedures.

The Service Station fits in the slot immediately above the Ink Tank slots.

PROCEDURE:

1. Make sure the printer is powered OFF.

If the printer is not engine to power off (all control panel light’s off). Then turn the Main Power Switch OFF.

2. Open the Top Cover.

3. Open the Ink Tank Door (hinged at bottom) to expose the

“Service Station Slot”.

Tip: On older units you will need to remove the Exit Roller Cover by removing the four (4) screws. This is not necessary on newer units.

4. If you are installing a New Service Station; carefully remove the Service Station from its packaging.

NOTE: Loose parts may fall out. Keep wiper roller si de facing up, when removing the packaging.

5. Check to be sure that the wiper roller latches are secure.

powered off, press the ON/OFF button once and wait about 45 seconds for the print

Slot

the wiper roller.

before installing the Service Station. Current versions of this assembly also have latch retaining screws that secure the latches from opening in transit or use. Make sure theses screws have been tighten (do NOT over-tighten).

NOTE: Early versions of this assembly did not have latch retaining screws.

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SECTION 7

Wiper Roller end of

Ribbon Cable

Connected to Service

Closed

Opened

Open

Ribbon

Cable

Service

MAINTENANCE

6. Slide the Cable Securing Latch open on the Service Station Circuit Board; as shown below.

7. Locate the Ribbon Cable (from within the Service Station

Slot). Insert the Ribbon Cable (blue side up) into the space under the Cable Securing Latch [1]. Make sure the ribbon cable is pushed in all the way and is NOT crooked. Then close the Cable Securing Latch [2].

Station Slot

8. Once the Ribbon Cable is properly connected to the Service Station Circuit Board; gently slide the

Service Station, wiper roller end first, into the Service Station Slot until it stops. The Service Station fits into the slot immediately above the Ink Tank slots. NOTE: The Ink Tank Door must be open

to perform this procedure.

Service Station

Station Circuit Board

Page 79

You don’t need to open the Print Engine.

9. Look down through open area, in the Print Engine, to

make sure the Service Station is aligned with the “Bar”; (Service Station Drive Shaft) as shown.

If the Printhead Cartridge is not installed (has been removed), you can look down through the top of the Print-Engine, through the Printhead Cartridge opening.

If the Printhead Cartridge is still installed, you must open the Clamshell to see into this area; as shown.

SECTION 7

MAINTENANCE

IMPORTANT!

The Service Station must perfectly aligned with the “Bar” to prevent misalignment and jamming of the service station.

10. GENTLY push in on the Service Station with one hand, while slowly turning the “Large Gear”

clockwise with the other hand. It should b e easy to turn this gear and the service station should start to drive into the print engine squarely. Once the Service Station moves about ¼ inch past the “Bar” (shown in previous step), stop turning the gear. Do NOT manually drive the Service Station into the print engine beyond this point.

NOTE: The “Large Gear” is located on the non-operator side of Print Engine; as shown below. You don’t

need to open the Print Engine to access this gear.

Shown for clarification purpose only.

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SECTION 7

WARNING

Waste-ink from the Service Station flows through wicking

the printer; causing damage to the system.

Ink Tank

Door

MAINTENANCE

11. Turn the printer’s Main Power Switch ON; then press the control panel’s ON/OFF button.

After printer initialization (~45 seconds) the Print Engine will automatically pull the Service Station the rest of the way in. NOTICE: If the Service Station should get jammed during this process (you hear motor stall noise or gear slipping noise); immediately turn OFF the printer’s Main Power Switch. This is one of the only exceptions for turni n g o ff the pri nt e r us ing the main power switch, before properly powering-down the print engine. Remove the Service station by turning the Large Gear counter-clockwise. Re-check that the Wiper Roller is properly installed and l atched at each end. Then re-install the Service Station starting from step 8 above.

Tip: The “Eject Service Station” button, located in the M Series Toolbox, should be used if the service station needs to be removed in the future.

12. Verify that the wick, located on the bottom of the Service Station, is hanging

into the waste ink trough; as shown (as viewed looking into the Service Station Slot, from the exit end of the printer).

material and out the hole, located on the bottom of the service station. If this wicking material is not directed into the trough; waste-ink will build up on the base of the Service Station Slot. This misdirected waste-ink will eventually find its way onto the Ink Tanks, inside the body of the printer and even under

13. Close the Ink Tank Door.

NOTE: If using an older printer you will need to re-install

the Exit Roller Cover plate, using the 4 screws, before closing the Ink Tank Door. Make sure the cover is installed in the proper orientat ion. TIP: Since the Exit Roller Cover is also an integral part of the frame structure; you may need to push in on the outer frames to get the screw holes in the Exit Roller Cover to align.

14. Close the Top Cover

15. Power the printer on and Test for proper operation.

Still Experiencing Print Quality Issues?

If you still experience print quality issues, after performing all the cleaning processes, outlined in this section, please refer to the “Troubleshooting Guide” for additional help. If you have exhausted all cleaning and troubleshooting options, and you have replaced the Printhead Cartridge and Wiper Roller; then this may indicate that the printer requires technical service. Please contact your support representative to schedule a service call.

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SECTION 7

Waste Ink Tray

MAINTENANCE

Inspecting/Replacing the Waste Ink Tray

The Waste Ink Tray (123-2487) is filled with an absorbent material, used to capture the waste ink that drains from the Service Station.

1. If the printer is on; press the ON/OFF button to power-down the print engine. Wait about 45

seconds until the system shuts down (all control panel lights will go off). Turn off the Main Power Switch and unplug the printer from the power receptacle. WARNING! If this power-down process is not followed; ink color mixing and printhead nozzle clogging may result.

2. Unplug the power cable from the printer.

3. Open the Ink Tank door

4. The Waste Ink Tray is secured to the print engine frame by two tabs.

One tab is located at the left side of the tray and one at the right side. Simultaneously push the two tabs in towards the tray, while pulling the tabs out towards you. The Waste Ink Tray should release from the frame and begin sliding towards you.

5. Slide the Waste Ink Tray out from under the print engine.

6. If the absorbent material is saturated with ink (entire white absorbent pad is now colored); the

Waste Ink Tray (123-2487) should be replaced. WARNING: Do NOT remove the Waste Ink Tray for more than a minute or two. With the tray removed; waste ink will drip onto the base of the printer. This ink will eventually end up in areas that are undesirable; causing damage to the system or other items/properly.

7. When re-installing the Waste Ink Tray, push the tray in evenly and slide it all the way back until it

stops. Make sure the tray securing tabs snap into the print engine frame.

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SECTION 7 MAINTENANCE

Replacing the Sheet Separ a to r s

The sheet separators (43-106-10) insure separatio n of the pieces as they are being fed. If you experience double sheet feeding, and adjusting for Media Thickness (See Feed Setup) does not prevent this, it may be time to replace the separators. Replacing the sheet separators is not difficult; however if you don’t feel confident about doing this yourself; please contact your technical support person.

CAUTION: Be careful that you don’t drop the screws or separators into the printer during this process.

1. Turn OFF and unplug the Printer.

Power down the print engine, using the ON/OFF button. Once the control panel lights turn off it is safe to turn off the Main Power Switch. Then unplug it from the power source.

2. Open the Feed Roller Assembly.

Loosen the two thumbscrews [A] and slide latches back [in direction of arrows]. Then open the Feed Roller Assembly [B].

3. Remove the locking screws on the

Separators [C] and remove the worn Separators. Tip: It may be easier and safer (less chance of dropping screw into printer) if you loosen the screw and remove the screw and separator at the same time.

4. Install a new Separator and reinstall the

mounting screw. Repeat for each Separator.

CAUTION: Don’t over-tighten the screw or you may distort/damage the separator.

5. Close and secure the Feed Roller Assembly.

While holding the Feed Roller Assembly [B] clo sed, slide the latches forward (in opposite direction of arrows) and then secure the thumbscrews [A].

6. Re-connect and Power-On the Printer.

Reconnect the power cord and Turn ON the Main Power Switch. Then press the ON/OFF button on control panel to power-up the Print Engine.

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SECTION 7

MAINTENANCE

Jams in the Printer

When the printer detects a media feed problem, it will stop automatically. Depending on where the media stops; the message “PAPERPATH_PAPERJAM” or “PAPERPATH_FEED_TIMEOUT” will be displayed in the Toolbox. Once the jam has been removed from the sys t em and the print engine is closed; press the PAPER/RESUME button on the control panel or press the Clear Error button in the Toolbox to continue printing.

TIP: If the printer will not “resume” after a “PAPERPATH_PAPERJAM” is detected (Toolbox System Status changes to “ONLINE” and the Mech State changes to “PREP”, but it will not continue printing); this is normally an indication that one or mor e of the med i a sensors is still interrupted. Please be sure to remo ve media from and check/clean the Paperpath sensors and the Feed Sensor.

Some possible causes for jamming are:

1. Feeding more than one piece of media at a time (double-feeding), due to improper Media Thickness

adjustment, worn sheet separators, improper media loading, or media adhesion (media that is stuck together due to static energy or coating).

2. Damaged media, such as dog-eared (turned down corners), curled or bowed media.

3. Media that is not stiff enough may not be usable. Media that meets Postal sti f f ness requirements for

automated feeding is acceptable in th e Digital Color Printer.

4. Media that is too thick for the printer.

5. Media that is too wide for the printer or media that skews as it travels throug h the printer.

6. Media that is too short in length (below 4.2” in length).

7. Media that has colors on the underside; which pass over the Paperpath E xit sensor. Tip: If you are getting a paper jam message, but you ar e not seeing a physical jam. Clean the Paperpath

and Feed sensors. If the issue continues try selecti ng the “Ignore Exit Sensor” feature in the Toolbox.

Removing Jammed Media

The procedure for clearing a jam depends on where the jam occurred. Feed Section:

Open the Feed Roller Assembly. Loosen the two thumbscrews [A] and slide latches back [arrows]. Open the Feed Roller Assembly [B].

Page 84

SECTION 7

CAUTION

LIMITS RAISING THE CLAMSHELL MORE THAN 60°.

CAUTION

Unlatch the Print Engine Clamshell

Raise the Print Engine Clamshell

MAINTENANCE

Forwarding Roller Section: Release the Forwarding Roller Guide Assembly by opening the Latch [C]. Slide the Assembly toward the Control Panel [D]. Carefully lift the Assembly up [E]. Remove jammed media. Reinstall the Assembly.

DO NOT BEND, PINCH OR CUT THE INK LINES LOCATED DIRECTLY IN FRONT OF THE ASSEMBLY.

NOTE: Make sure Assembly is correctly rei nstalled and aligned before starting to print. Assembly should sit flat on transport area surface.

Print Engine Area:

Open the Top Cover. Release and lift the two latches [B] (one on each side of the Print Engine Clamshell) at the same time to raise

the Print Engine Clamshell [C]. Clear the jam, then carefully lower and relatch the Pr int Engine Clamshell. Close the Top Cover.

HOLD ONTO BOTH LATCHES WHEN OPENING AND CLOSING THE PRINT ENGINE CLAMSHELL TO PREVENT DAMAGE.

DO NOT ALLOW THE CLAMSHELL TO DROP OR SLAM CLOSED.

TO PREVENT DAMAGE TO THE INK LINES, A STOP

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SECTION 7

MAINTENANCE

Cleaning the Printer Body

WARNING

THE PRINTER IS A PRECISION MACHINE THAT SHOULD BE CLEANED REGULARLY TO INSURE MANY YEARS OF SERVICE. BEFORE PERFORMING ANY MAINTENANCE, DISCONNECT THE MACHINE FROM ITS POWER SOURCE! DO NOT REMOVE SIDE COVERS! HIGH VOLTAGES PRESENT.

Clean the Printer regularly to remove accumul at ed paper dust and ink. Depending on the types of media that are run, paper dust may accumulate inside the printer and on the transport.

1. If the printer is on; press the ON/OFF button to power-down the print engine. Wait about 45

seconds until the system shuts down (all control panel lights will go off). Turn off the Main Power Switch and unplug the printer from the power receptacle.

2. Unplug the power cable from the printer.

3. Interior: Use a vacuum with a soft brush attachment to help loosen dust particles. Take care not to

damage the PC Boards or electrical wiring .

4. Exterior: Wipe clean with a lint-free cloth using any standard nonabrasive household cleaner that

does not contain plastic harming solvents.

5. Reconnect the power cord and Turn ON the Main Power Switch. Then press the ON/OFF button

on control panel to power-up the Print Engine.

CAUTION

NEVER SPRAY OR POUR CLEANERS DIRECTLY ON OR INTO THE PRINTER. EXCESS LIQUID COULD HARM ELECTRONIC PARTS. DAMPEN A LINT-FREE CLOTH WITH THE CLEANER AND APPLY IT TO THE PARTS TO BE CLEANED.

Cleaning the Feed Rollers and Forwarding Rollers

The rubber feed and forwarding rollers can become gl azed w i th paper lint and ink from the media. They should be regularly cleaned with a mild household cleaner on a damp lint-free cloth. NOTE: Do NOT use solvents to clean the Rubber Rollers.

1. If the printer is on; press the ON/OFF button to power-down the print engine. Wait about 45

seconds until the system shuts down (all control panel lights will go off). Turn off the Main Power Switch and unplug the printer from the power receptacle.

2. Unplug the power cable from the printer.

3. Follow t he pr oc e du re s u nde r “Removing Jammed Media” to open the Feed Roller Assembly and

remove the Forwarding Roller Guide Assembly.

4. Use a vacuum with a soft brush attachment to help loosen and remove dust particles.

5. Dampen a cloth with a mild household cleaner, which does not contain plastic or rubber harming

solvents, and wipe-down the rubber rollers to remove debris. CAUTION: Be careful not to drip any liquids into the sensors or electronics.

6. Reinstall the Forwarding Roller Guide Assembly and close and latch the Feed Roller Assembly.

7. Reconnect the power cord and Turn ON the Main Power Switch. Then press the ON/OFF button

on control panel to power-up the Print Engine.

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SECTION 7

MAINTENANCE

Cleaning the Feed Sensor

The Feed Sensor is located between the F eed Roller Assembly and the Print Engine. It is used to control the delivery of media to the print engine.

TIP: If the Toolbox, Cutsheet Feeding Mode is set to “Safe Feed” and you are getting blanks fed at the end of every job (last piece may stop inside print engine), then the Feed Sensor may not be working properly (dusty/dirty). This can be intermittent. If in doubt; clean the sensor.

NOTICE: If you are uncomfortable performing this task, or this issue is not resolved by cleaning the sensor; please contact your support representative.

1. If the printer is on; press the ON/OFF button to power-down the print engine. Wait about 45

2. Unplug the power cord from the printer.

3. Remove the Forwarding Roller Guide Assembly.

Release the Latch [A]. Slide the assembly toward the control panel [B] (in direction of arrow). Carefully lift the assembly out of the printer.

4. Inspect/Clean the Refl ector [C].

There is a reflector attached to the underside of the Forwarding Roller Guide Assembly. Clean the reflector using a soft damp cloth.

5. Inspect/Clean the F eed Sensor [D].

You can now access the Feed Sensor through the hole in the table-top. Clean the sensor using compressed air and a soft brush, or a soft, dry cotton swab (q-tip).

6. Re-assemble in reverse ord er .

CAUTION: Verify that the Forwarding Roller Guide Assembly is properly installed and latched. Also verify that the ink tubes are not pinched by the fingers on the Forwarding Roller Guide Assembly.

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SECTION 7

CAUTION

LUBRICANTS OR OTHER CHEMICALS.

MAINTENANCE

Cleaning Other Items inside the Print Engine

Areas in the Print Engine can become glazed with a buildup of dust, paper lint and accumulated ink and need to be cleaned regularly.

This section covers the procedures for cleani ng the following items.

Grit Rollers (Media Transport Rollers) Media (Paperpath) Sensors Capping Station Lip Paperpath Surfaces Printing Platen Surface

WARNING

NOTICE: If you are uncomfortable performing these tasks, or this issue is not resolved by cleaning; please contact your support representative.

Procedure:

1. If the printer is on; press the ON/OFF button to power-down the print engine. Wait about 45

seconds until the system shuts down (all control panel lights will go off).

2. Turn off the Main Power Switch and unplug the printer from the power receptacle.

3. Open the Top Cover and then carefully open the Clamshell Assembly.

4. Use a vacuum to pick up any loose debris.

NOTE: Be careful around ink tray and capping station in the Print Engine area as accumulated ink may splash onto other parts of the printer. Take care not to damage the PC Boards or electrical wiring. The use of compressed air is not recommended. I f you direct the air into an area with wet ink; ink will splash onto other parts of the printer, which could affect operation.

USE ONLY DEIONIZED/DISTILLED WATER TO CLEAN PRINT ENGINE COMPONENTS. AVOID CONTAMINATING THE PRINTHEAD W ITH CLEANERS,

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Entry

Exit

Mark

MAINTENANCE

5. Use the procedures, as outlined below, to clean the following items.

Grit Rollers [A]: Clean as needed using a small stiff-bristled brush (toothbrush), lightly moistened with distilled water. Do NOT use anything other than distilled water to clean the Rollers. Pat the roller dry using a lint-free cloth. Do NOT rub with cloth or this may produce lint.

Media (Paperpath) Sensors [B] : Paper lint, dust and ink will

build-up on the Media Sensors. Be sure to clean the Paperpath Entry and Paperpath Exit sensors routinely. Use lightly dampened foam, or lint-free, cotton swab to gently wipe the Sensors. Repeat this process u ntil all ink/debris is removed. Take care not to drip water into the circuit boards. Use a clean, dry swab to dab surfaces dry. Remember to wipe the clear panel, on the Sensor Receiver, which is located in the upper Clamshell Assembl y (above the Paperpath Entry Sensor). Note: The Mark Sensor is not used in the Digital Color Printer.

Capping Station Lip [C]:

Clean as needed with distilled water on a damp, lint-free, cloth. Try to avoid contact with the “wicking material” located in the center o f the Capping Station. Be careful not to splash or drip ink onto other parts of the Printer.

Paperpath Surfaces [D]:

Wipe with distilled water on a damp, lint-free cloth. Pat dry with a lint-free cloth.

6. Reconnect the power cord to the printer and turn the Main Power switch ON.

7. Make sure your hands/clot hes/leaning supplies are clear from the print engine; then Power-up the

print engine using the ON/OFF button. After a short period of time, the Capping Station will drop and the Printing Platen will be presented through the same opening. Carefully clean the Printing Platen as described below.

Printing Platen Surface [E]:

Clean the surface as needed with distilled water on a damp, lint-free, cloth. Try to avoid contact with the “wicking material” located in the center o f the Platen.

8. Carefully close and Latch the “Clamshell”; using two

hands.

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SECTION 7

MAINTENANCE

Cleaning the Ink Revolver Couplings

This process should be performed just before a printhead cartridge i s installed or re-installed; to remove contaminated/dry ink and other debris from the Ink Revolver Couplings. If this step is skipped; the printhead and or ink system could become contaminated resulting in an increase in print quality issues.

1. If Printhead Cartridge is installed; follow the

procedure for releasing and removing the Printhead Cartridge. See section titled “Replacing the Printhead Cartridge”.

2. If the printer is on; press the ON/OFF button to power-

down the print engine. Wait about 45 seconds until the system shuts down (all control panel lights will go off). Turn off the Main Power Switch and unplug the printer from the power receptacle.

3. Lightly moisten a foam swab with distilled water.

4. Insert the swab into one of the ink channel holes and

rotate the swab to clean the chamber.

5. Use a new swab for each of the remaining ink channels, until all 10 openings are clean. (5 on each

side.)

6. Install the Printhead as described in the section titled “Installing the Printhead Cartridge”.

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SECTION 7

Rubber Feed Rollers

CLEAN

Residue and Debris Re moval

CLEAN

WARNING

MAINTENANCE

PRINTER MAINTEN A NCE SCH E D UL E

General, periodic maintenance is needed t o keep the Printer in good working order. Many tasks can be performed by operators with basic supplies, no special tools needed. Other tasks should only be performed by trained service personnel. NOTE: High volume usage may require more frequent maintenance.

COMPONENTS / TASKS

DAILY BI-WEEKLY MONTHLY YEARLY AS NEEDED

MAINTENANCE TYPE

PERFORMED BY OPERATOR

Grit Rollers (Media P ath) INSPECT CLEAN CLEAN Ink Revolver Couplings and

Connections: Inspection/Cleaning

Ink Tank Contacts & Prism (Clean)

Optical Sensors (Media Feed & Paperpath)

Printhead (Manual Wiping) WIPE Printhead, Head Media Guide

& Lip of Capping Station (Manual Wiping)

Sheet Separators INSPECT INSPECT REPLACE Wiper Roller:

Inspection Waste Ink Tray INSPECT INSPECT REPLACE

CLEAN CLEAN CLEAN CLEAN CLEAN

INSPECT INSPECT INSPECT

EVERY

PRINTHEAD

REMOVAL

EVERY INK

TANK INSTALL

AFTER EVERY

PRINTHEAD

INSTALL

Contact Service

to Replace

PERFORMED BY SERVICE TECHNICIAN

Ink Tank Latches/Ink Bay INSPECT Ink Tubing, Couplings,

Components Lubrication (Service Station

Rails, Lift Arm Cams, etc..) Moving Parts/Motors/Gears

Optical Sensors (Service Station Home, Index and Lift)

*Pen Driver PCA Contacts: Cleaning

*Service Station & Components

*Wiper Roller: Replace

Rubber Feed Rollers INSPECT REPLACE

INSPECT

APPLY

INSPECT

& TEST

INSPECT &

TEST

INSPECT &

CLEAN

REPLACE

CLEAN

INSPECT/

CLEAN AFTER

PRINTHEAD

REMOVAL

CLEAN or REPLACE

EVERY

PRINTHEAD

REPLACEMENT

* Customer may be able to perform these tasks with proper training.

ALWAYS POWER DOWN THE PRINTER BEFORE PERFORMING ANY MAINTENANCE; TO AVOID SERIOUS SHOCK OR INJURY.

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MAINTENANCE

Preparing Printer for Transport

Please use this procedure if you ever need to transport the printer to a new location or ship the printer. Please refer to the appropriate sections in t he manual for details on installing/removing items from the printer.

Local relocation

Transporting the printer from one room to another in the same building is considered a local relocation. Local relocation does not normally require that the printer be repackaged before transportation. To move your printer locally:

1. Switch the printer off using the ON/OFF button and wait until all lights turn off.

2. Turn OFF the Main Power Switch. Then disconnect the power cable from the printer and wall

outlet. IMPORTANT! Do NOT switch off the power at the power outlet or remove the power cable until all lights are off. Failure to do so may damage your printer.

3. Disconnect the USB or Ethernet cable from your printer.

4. Carefully relocate the pri nter.

Take care to avoid sharp bumps and strong vibrations during the relocation process. If the printer needs to be lifted; two people are required to lift the printer; keeping it as level as possible during this process. IMPORTANT! The printer should remain semi-level at all times during transportation and storage. Failure to do so may cause the printer to leak ink.

5. Be sure to select an appropriate location; as described in the “Choosing the Location” section

Verify that the Print Engine is level before powering it on

Remote relocation or shipping

Transporting the printer to another building is considered a remote relocation. When transporting your printer to a remote location, your printer will need to be disassembled and repackaged, as set out below: NOTE: This procedure should be performed by a qualified technician. We suggest the use of protective gloves during this process.

1. Plug in the printer. Turn the printer’s Main Power Switch ON; then press the control panel’s

ON/OFF button. Wait about 45 seconds for the print engine to power-up (ON/OFF button will illuminate).

2. Open the Toolbox utility.

3. Deprime system using the “System Deprime” feature located in Toolbox utility.

NOTE: Use the System Deprime feature, NOT

4. Remove the Service Stati o n from the printer, using the “Eject Service Station” feature in the

Toolbox utility. Refer to “Removing the Service Station” section for help with this process.

5. Wrap the Service Statio n in paper towels and place into resealable plastic bag.

6. Power-down the system using the ON/OFF button and wait until all lights are off.

7. Turn OFF the Main Power Switch. Then disconnect the power cable from the printer and wall

outlet. IMPORTANT! Do NOT switch off the power at the power outlet or remove the power cable until all lights are off. Failure to do so may damage your printer.

the Release Printhead feature.

8. Disconnect the USB or Ethernet cable from your printer

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SECTION 7 MAINTENANCE

9. Remove the Printhead Cartridge and install protective covers on printhead.

Be careful to avoid ink spills (drips) and stains during this process. Store Printhead Cartridge in a sealed plastic bag with a damp cloth. CAUTION: Make sure the cartridges electrical contacts are dry before re-installing printhead.

10. Remove all five Ink Tanks. Be careful to avoid spills or stains during this process. Wrap each ink

tank in a clean, lint-free, absorbent material and place them in a sealed plastic bag as a p r ecaution against any spillages during transport.

11. Place paper towels into each Ink Tank slot, making sure the towels make contact wi t h the back of

the slots. This is done to absorb any ink that may leak from “septum needles”. NOTE: Even though the system is deprimed, some i nk will remain in the lower areas of the tubing. In transit, this residual ink may drain out.

12. Inspect the Waste Ink Tray. If it is saturated with ink; the tray should be replaced before the

printer is transported.

13. If re-boxing for transport; remove all accessories from unit before re-boxing.

14. Re-package the printer in the original packaging material, keeping the printer semi-level at all

times.

WARNING! To help avoid damage in transit; the printer should only be shipped in approved factory packaging. See “Unpacking” section for help with re-boxing. Follow the sequence in reverse.

15. Ensure transport labels on the exterior box clearly indicate that the box is to be kept semi-level at

all times. CAUTION! The printer should remain semi-level at all times during transportation and storage. Failure to do so may cause the printer to leak ink. For environmental requirements during storage and shipping, refer to the details found in the “Transport Inspection” section.

16. When re-installing the printer at the new location, please refer to Section 2 (Instilling the Printer)

of this guide. Be sure to select an appropriate location; as described in the “Choosing the Location” section Verify that the Print Engine is level before powering it on

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MAINTENANCE

NOTES

______________________________________________________

Page 94

SECTION 8

WARNING

THERE ARE HIGH VOLTAGES PRESENT BEHIND THE COVERS!

TROUBLESHOOTING

SECTION 8 – Troubleshooting Guide

The following troubleshooting guides are provided to assist you in solving any problems that might occur with the Digital Color Printer. We have tried to make them as complete as possible. The best advice we can offer is to make sure that the system is set up properly, plugged in, and that it has an adequate supply of ink before attempting to troubleshoot any problem.

DO NOT REMOVE THE SIDE COVERS OF THE PRINTER!

Print Quality Issues:

Many things can contribute to print quality issues. Here is a list of things to check:

• To reduce print quality issues, the print engine should remain powered-on. Even in its standby state,

the printer will run routine maintenance cycles to help keep the printhead nozzles hydrated and clean.

• Verify that the media you are printing on is an “inkjet suitable” media. See Paper Types below.

• Verify that the “graphic” you are printing is of a high quality. See Graphic Types below.

• Check to be sure the printer has an adequate supply of ink (30% or more) in all five Ink Tanks.

• Check to be sure all five color tubes, at both sides of the printhead cartridge, have ink filling them.

If not, check for a pinched color tube (finger on Forwarding Roller Guide Assembly may be pinching tube), check related Ink Tank, and or the system may need to be re-primed. Please refer to the Troubleshooting section for information on correcting these issues.

• Try removing air bubbles from printhead and system using the Toolbox utility feature “Circulate Ink”;

while lightly tapping Note: Do not

• Try removing or inserting the “Head Media Guide”.

• Try “Cleaning the Lip of the Printhead Cap”.

• Try “Cleaning/Replacing Service Station Items”.

• If you are still experiencing print quality issues; try “Replacing the Printhead Cartridge”.

Compatible Paper Types: (look for inkjet suitable stocks)

• Inkjet Paper - all types (recommended for best color output).

• Copier Paper

• Card Stock

• Kromekote

• Coated Paper - Gloss finish

• Coated Paper - Satin finish

• Coated Paper - Matte finish

Incompatible Paper Types:

• Color Laser Gloss

• Digital Printer Gloss

• Any Post Print Coated Substrate (aqueous, gravure or UV)

Compatible Graphic Types:

• In general; scalable, vectorized art wi l l produce the best images and color.

Note: Graphic types are not really printer dependent. They are dependent on the software program being used to print the graphic, and what types of graphics that program can handle.

Incompatible Graphic Types:

• Low resolution and web images will not produce quality output and should not be used.

run the Circulate Ink feature more than twice in a row.

on the ink tubes and printhead cartridge.

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SECTION 8

TROUBLESHOOTING

Examples of Print Quality Issues (including possible causes and solutions)

The Memjet printhead cartridge contains 70,400 inkjet nozzles. These nozzles are divided into ten rows; two rows of nozzles for each color channel. Due to the high number of nozzles; it is not uncommon for some nozzles to become contaminated, dehydrated or clogged.

The following examples were produced using a Five Band Color Purge YKCKM. A similar purge pattern can be performed using the “Print Ink Channels” button; located in the Toolbox, Diagnostics Menu.

Air in Printhead Nozzle Area:

Air in the printhead nozzles will show as jagged, irregular shaped lines of missing color. Lines are normally wider than one nozzle.

Possible Solutions:

• Press the “Full Clean Printhead” button, located in the Toolbox, User Interface screen , and lightly

tap on the ink tubes and Printhead Cartridge as the system is circulating ink. This can help dislodge air bubbles within the Printhead and Ink Tubes. Note: It is not a problem if air bubbles accumulate in the ink hoses at the non-operator side of the printhead; since this is the outgoing side.

• Deprime and Reprime the system. Release the Pri nthead, using the “Release Printhead” button.

Remove and re-install the Printhead Cartridge. Then close printhead latch to re-prime the system. Lightly tap on the ink tubes and Printhead Cartridge as the system is priming; to help dislodge air bubbles.

• Contact Service person to have them inspect the system for possible air leaks (damage to i nk tubes

or ink revolver couplings).

• Instead of powering the printer off, when not in use, leave the print engine powered-up; so it can

perform automatic maintenance routines.

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SECTION 8 TROUBLESHOOTING

Clogged/Damaged/Dead Nozzles:

Clogged/damaged/dead/ nozzles will normally show as thin, crisp, vertical lines of missin g co l or. Multiple adjacent nozzles, with same issue, will show as wider, crisp, vertical lines of missing color. Clogged nozzles are normally due to Printhead nozzle dehydration or partial contamination. Damaged nozzles are normally due to improper cleaning or debris on wiper roller causing damage to head. Dead nozzles are normally due to the nozzle reachin g its “end of life” (~50,000,000 ejections).

Possible Solutions:

• Press the “Full Clean Printhead” button, located in the Toolbox, User Interface screen

• Manually clean the printhead nozzles using distilled water and a lint free cloth.

• Set the following Toolbox features to d ef aults to improve/increase head maintenance routines:

KWS Setting (Light) and Mid-Job Servicing (Default).

• Replace the printhead cartridge and wiper ro ller. C ontact Service person to have them

inspect/clean the service station and replace the wiper roller.

• Instead of powering the printer off, when not in use, leave the print engine powered-up; so it can

perform automatic maintenance routines.

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SECTION 8

TROUBLESHOOTING

Color Mixing Issue s:

Color mixing will show as muddy, mottled or distorted (grainy) colors. Color mixing occurs when the ink from one color channel crosses over into another color channel. Since the inkjet nozzle rows are located very close to one another (ten rows of 7,040 nozzles, located within a 0.8 mm space), it is easy for partials or fibers t o create bridges across color channels. These bridges al l ow ink to flow (wick) from one color channel to another; resulting in a “localized” color mixing event; as shown in the examples below.

Color mixing can occur for a number of reasons (here are some common ones)

• Printhead Cartridge just installed. It is common to see some color mixing immediately after the

system is primed with ink.

• Ink wicking due to fibers bridging (crossing) inkjet nozzles. This can also occur if media is left in

contact with the printhead (after a paper misfeed or jam).

• Wiper roller saturation (too much ink on wiper roller). This can occur if the cleaning features

(Quick/Normal/Full Clean Printhead) are run too frequently. The printer needs time between cleanings to desiderate the wiper roller.

• Ink flooding on the nozzle plate; due to printer not being level.

• Ink flooding on the nozzle plate; due to excessive back-pressure in the ink system.

• Wiper Roller is not being cleaned properly by the system. This can also occur if there is a

problem with the squeegee blade in the Wiper Motor Assembly. The squeegee blade and squeegee roller are responsible for removing ink and debris from the wiper roller.

Tip: Muddy, mottled, distorted (grainy) colors can also be caused by the media you are printing onto. Test the printer, using a compatible “inkjet suitable” media, to determine if this could be the cause.

Possible Solutions:

• Remove media from under printhead.

• Wipe printhead using a lint-free cloth, dampened with distilled water.

• Perform a “Printhead Cartri dge Con di tioning” routine.

• Allow the printer to sit, powered on, for 2-3 hours to give it time to clean/desaturate the wiper

roller.

• Make sure printer is on a sturdy/level floor surface and the Print Engine is level.

• Instead of powering the printer off, when not in use, leave the print engine powered-up; so it can

perform automatic maintenance routines. This also allows the pressures in the system to b e routinely equalized.

• Contact Service Support representative to have them inspect/clean the service station. If necessary;

they may need to replace the wiper roller, wiper motor assembly or Service Station.

Page 98

SECTION 8

Direction of transport

TROUBLESHOOTING

Scuff Marks and Smudging Issues:

Scuff Marks occur when the media makes contact wi th an area of the printhead that has ink on it. Smudging occurs when the wet image, on the media, makes contact with something (most commonly the printhead) before it is dry. This issue will also i ncrease the chance for scuff marks.

Scuff Marks:

Here is an example of “scuff marks” that o ccurred when the media made contact with the printhead.

Possible Solutions for Reducing Scuff Marks:

• Make sure the “Head Media Guide” is properly installed.

• Make sure media is as flat as possible.

• Manually wipe the printhead surface, using a lint-free cloth dampened with distilled water to

remove excess ink.

• If possible; rotate the media and image 90, 270 or 180 degrees. Sometimes the direction of feed

and the mechanics of how the media is driven through the printer can have an effect.

• Allow the printer to sit, powered on, for 2-3 hours to give it time to remove excess ink from the

wiper roller; or contact your support representative to have the wiper roller replaced.

• Use a more suitable media (flat and uniform i n thickness).

NOTICE! It is OK to run the “Quick Clean Printhead” routine once, to see if this has any effect on improving this issue. However, if it doesn’t help, you shouldn’t repeat this process or use a higher level cleaning routine. Over-use of the “…Clean Printhead” routines will normall y increase this issue, because the wiper roller will become more saturated with ink with each cleaning routine; if done too frequently. An over-saturated wiper roller will leave more ink behind on the printhead.

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SECTION 8

Direction of transport

TROUBLESHOOTING

Smudging:

Here is an example of “smudging” that o ccurred when an area of this page, with a wet i mage, made contact with the printhead. Note: There are also scuff marks in this example. As mentioned previously; smudging will increase the chance for scuff marks; by deposition ink onto other areas of the printhead.

Possible Solutions to Reduce Smudging:

• Check to be sure the “Head Media Guide” is prop er l y instal led and clean.

• Make sure media is as flat as possible.

• If possible; rotate the media and image 90, 270 or 180 degrees. Sometimes the direction of feed

and the mechanics of how the media is driven through the printer can have an effect.

• Reduce the amount of ink being sprayed onto the media by setting the print quality to “Normal”.

Spraying less ink will improve the drying time.

• Reduce the print speed to provide more drying time. If you are already printing in Normal Print

Quality, you can select (check) the “half sp eed” box; located under the Print Quality selection in the M Series Driver.

• Use a more inkjet suitable media.

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SECTION 8

Fuzzy/Distorted

Good Print

Example

TROUBLESHOOTING

Fuzzy/Distorted Print

Fuzzy/distorted print can occur for a number of reasons; listed/shown below. Problem: Poor original image quality (less than 300 dpi).

Solution: Use high quality images. Problem: Choosing to print image in low resolution from software application.

Solution: Set image to highest resolution possible from software application. Problem: Paper is buckling or bowing during the time of printing.

Solution: Try printing on a thicker piece of media (i.e. 40lb paper ) If problem does not occur on heavier material the media you are feeding may be too flimsy.

Problem: Damaged Printhead nozzle surface; scr at ched from improper manual cleaning, or dirty/damaged wiper roller. Solution: Only use distilled water and a non-abrasive, lint free cloth to manually clean the printhead. Replace the wiper roller at the same time the pr inthead is replaced. Cover the printer, when not in u se, to keep dust/debris (plaster dust) from entering the printer.

Fuzz/Distorted Print Example:

Print Example

Good Print Example:

Rena Mach 8 Operation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual