Kodak Versamark DP5240 manual
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- Number of pages: 82
- Filetype: PDF
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Index
- Versamark DP5000 Series Printers
- ❯ Versamark DP5000 Series Printers Printing Systems Installation Guide
- Scope
- Important: Availability of the Jetscape products described in this guide is limited. Contact technical support before ordering or planning to purchase any Jetscape product.
- ❯ Text Notations
- Safety Notations
- Note: Information that needs to be brought to the reader’s attention.
- Caution: A situation where a mistake could result in the destruction of data or system-type damage.
- A potential hazard that could result in serious injury or death.
- An imminent hazard that will result in serious injury or death.
- Safety Notations
- ❯ Service and Support
- Contents
- ❯ Figures
- Tables
- Chapter 1. Preparation
- ❯ Safety Precautions
- ❯ Required Tools
- ❯ Printer
- ❯ Removing Packaging
- ❯ Caution: Do not cut into the boxes. Use a box knife or other short-bladed tool and cut where pallet contents do not touch the shrink wrap.
- ❯ Note: A typical printer shipment includes three extra boxes (see “Printer Inventory”). Figure 2.1 shows the pallet with the shrink wrap and smaller boxes removed.
- ❯ Note: Set the accessories box aside for later unpacking.
- ❯ Note: Leave the packaging on the printhead housing at the end of the umbilical.
- ❯ Table 2.1 Printer model shipping numbers
- ❯ Table 2.2 Components, typical printer shipment
- ❯ Moving the Printer
- ❯ Note: Manuals, cables, software and other small items are packed inside the installation kit box. If only a printer and printheads were shipped, these items will be shipped inside a separate box.
- ❯ Caution: The following steps require two persons.
- ❯ Caution: Do not let the printer drop or tip over.
- ❯ Printing System
- ❯ Removing System Packaging
- ❯ Note: Use a forklift or hand truck to move the pallet.
- ❯ Caution: Do not cut into the boxes. Use a box knife or other short-bladed tool and cut where pallet contents do not touch the shrink wrap.
- Figure 2.2 Printing system pallet, shrink wrap removed
- 4. Remove the two wooden ramps from the shipping pallet and set them aside for later use.
- 5. Remove all boxes except the printing system box from the pallet. Set these boxes aside for later unpacking.
- ❯ 6. Cut the bands securing the printing system box lid (see Figure 2.3).
- 7. Remove the box lid.
- 8. Remove and discard the cut bands.
- ❯ 9. Remove the side walls of the box (see Figure 2.4).
- 10. Remove the plastic cover from the printing system.
- 11. Remove the packing material from around the base of the printing system enclosure on the short side of the box next to the two cutouts in the pallet rim for the ramps.
- 12. Remove the screws taped to the ramps.
- 13. Secure the ramps to the pallet with the screws supplied. Use the pre- drilled holes on the pallet frame at each cutout.
- 14. Unlock the printing system enclosure (cabinet) caster locks.
- Figure 2.2 Printing system pallet, shrink wrap removed
- ❯ Caution: The following steps should be done by two persons. If you are alone, exercise additional caution.
- 15. If two persons are available, tilt the cabinet slightly toward either of its long sides, and then pull any packing material under it out. If you are alone, cut away any packing material underneath the cabinet that blocks the casters
- 16. Roll the cabinet down the ramp and onto the floor.
- 17. Stop the cabinet when it is level with all four casters on the floor and lock the casters.
- Hint: It is easier and safer to pull the cabinet down the ramp rather than to push it down. The printer weighs approximately 100 lbs (45 kg), and pulling the cabinet down allows you to guide and slow it as it moves down the ramps.
- 15. If two persons are available, tilt the cabinet slightly toward either of its long sides, and then pull any packing material under it out. If you are alone, cut away any packing material underneath the cabinet that blocks the casters
- ❯ Caution: Do not let the cabinet roll free or tip more than 20 degrees as it moves down the ramps.
- ❯ Note: Leave the protective packaging on the printhead housing. This packaging should not be removed until you perform the printhead installation (see “Printheads”).
- ❯ Table 2.3 Printing system models and shipping numbers
- ❯ Table 2.4 Components, typical printing system shipment
- ❯ System Unpacking
- 1. Move all the boxes to the location where the system is to be installed.
- 2. Place the monitor and computer (system controller PC) boxes by the cabinet. They are unpacked when installed (see Chapter 4, “System Installation”).
- 3. Unpack the PC peripherals box; it contains the following items:
- 4. Set the PC peripherals aside until ready to begin the system installation.
- 5. Unpack the system accessories box. The following contains the system components:
- 6. If options or accessories were included in the shipment, unpack those items (see “Accessories”). Otherwise, continue with the installation procedure (see “Printing System”).
- 1. Move all the boxes to the location where the system is to be installed.
- ❯ Accessories
- ❯ System Unpacking
- ❯ Table 2.5 System shipment contents
- 2. Unpack each accessory box and locate the documentation.
- 3. Refer to installation instructions listed in Table 2.5 for detailed information on each component.
- 4. For software and memory options, see the DP5000 Series software Installation Guide (0114083).
- 5. Continue with the printhead unpacking procedure.
- 2. Unpack each accessory box and locate the documentation.
- ❯ Printheads
- ❯ Table 2.6 Printhead models and shipping numbers
- ❯ DH5120 Printhead
- ❯ Note: The printhead Replacement Instructions (0114252-602) and Packing Instructions (0114253-602) are in the printer or system installation kit.
- ❯ Caution: Cut the tape carefully using a box knife or other short-bladed tool to avoid cutting the printhead capsule inside.
- ❯ Note: Four Phillips screws secure the capsule.
- ❯ Note: This packaging must be used if the printhead is returned.
- ❯ Note: The printhead Replacement Instructions (0114252-602) and Packing Instructions (0114253-602) are in the printer or system installation kit.
- ❯ Caution: Cut the tape carefully using a box knife or other short-bladed tool to avoid cutting the printhead capsule inside.
- ❯ Note: Four Phillips screws secure the capsule.
- ❯ Note: This packaging must be used if the printhead is returned.
- ❯ Note: The printhead Replacement Instructions (0114252-602) and Packing Instructions (0114253-602) are in the printer or system installation kit.
- 4. Note the serial number on the inner box label. This number should match the printhead serial number on the outer box label. Record this number for the installation report.
- 5. Open the inner box.
- 6. Remove the top cushion section and remove the printhead capsule.
- 7. Open the printhead capsule and remove the printhead assembly.
- 4. Note the serial number on the inner box label. This number should match the printhead serial number on the outer box label. Record this number for the installation report.
- ❯ Note: Four Phillips screws secure the capsule.
- ❯ Note: This packaging must be used if the printhead is returned.
- ❯ Table 2.6 Printhead models and shipping numbers
- ❯ Printer Positioning
- ❯ Two persons are required to lift and move the printer. Do not attempt to move or carry the printer alone.
- ❯ Printer Stand Installation
- 1. Position the assembled stand next to the printer shipping pallet.
- 2. Remove the packing material from the pallet to clear the base of the printer (all four bottom edges of the printer enclosure).
- 3. Locate the four holes in the top of the stand that correspond to the printer feet. Orient the stand with its sliding doors at the front of the printer (the operator panel end).
- 1. Position the assembled stand next to the printer shipping pallet.
- ❯ Printer Stand Installation
- ❯ Note: The stand is rectangular and the printer fits only in one orientation.
- ❯ Caution: Do not lift the printer by holding only the umbilical hanger. The hanger will bend or break if it bears the full weight...
- ❯ Note: The screws go up through the stand top into the four feet.
- ❯ Note: The front panel must remain unobstructed to allow access to the ink compartment.
- ❯ Two persons are required to lift and move the printer. Do not attempt to move or carry the printer alone.
- ❯ Fluid Container Installation
- ❯ Internal
- ❯ Note: See the diagram of this procedure on the label inside the fluid compartment door and refer to the instructions shipped with the ink.
- ❯ Note: Retain the cap to put back on the empty bottle when it is removed.
- ❯ Caution: If the bottle collar is left under the support arm, the bottle (bladder) will collapse inside the container and block the bottom of the ink supply tube. This problem produces a spurious ink bottle empty error.
- 5. When you position the container, listen for the click of the quick- disconnect. The click confirms that the ink supply connection has sealed properly.
- 6. Press down on the locking plate until it punctures the bottle seal and locks the container into place.
- 7. Continue with the “Replenisher Bottle” procedure.
- ❯ Replenisher Bottle
- 5. When you position the container, listen for the click of the quick- disconnect. The click confirms that the ink supply connection has sealed properly.
- ❯ Note: Retain the cap to put back on the empty bottle when it is removed.
- ❯ Caution: If the bottle collar is left under the support arm, the bottle (bladder) will collapse inside the container and block the bottom of the replenisher supply tube. Over time, this problem produces high ink concentration.
- 5. When you position the container, listen for the click of the quick- disconnect. The click confirms that the ink supply connection has sealed properly.
- 6. Press down on the locking plate until it punctures the bottle seal and locks the container into place.
- 7. Continue with the “Voltage Selection” or “Printer Connections” procedure.
- External
- 5. When you position the container, listen for the click of the quick- disconnect. The click confirms that the ink supply connection has sealed properly.
- ❯ Note: Replenisher must be supplied from the standard, 1.5 liter internal container (only ink is typically used in sufficient volume to justify an external supply).
- ❯ Note: The standard external supply line (0183648) is 20-ft (6 m) and 1/4-inch (6 mm) diameter. Lines up to 30-ft (9 m) and 3/8-inch (10 mm) diameter can be used.
- ❯ 3. Attach the nozzle to the external supply container.
- 4. Connect the ink supply line to the nozzle.
- 5. Route the line into the fluid compartment and position it so that the line runs out through the notch in the door.
- ❯ 6. Close the door and check the lines for pinching and kinking.
- ❯ Voltage Selection
- ❯ Caution: Do not power up the printer until the correct voltage switch is selected. Applying power at the incorrect voltage will damage the printer.
- 1. Locate the circuit breaker switch and confirm that it is in the offline (O) position (see Figure 3.7).
- 2. Locate the voltage selector switch above the circuit breaker switch.
- ❯ 3. Loosen the two screws securing the safety cover to the switch (see Figure 3.7).
- ❯ 4. Remove the fuse (0178607) (see Figure 3.8).
- ❯ 5. Rotate the safety cover counter-clockwise to clear the rotary switch.
- 6. Select the correct voltage for the input power source at the installation site. Six settings are provided (see Figure 3.9); the factory default setting is 120V. The setting is indicated by the triangle on the rotary switch.
- 7. Replace the fuse.
- ❯ 8. Replace and secure the safety cover.
- 1. Locate the circuit breaker switch and confirm that it is in the offline (O) position (see Figure 3.7).
- ❯ Caution: Do not power up the printer until the correct voltage switch is selected. Applying power at the incorrect voltage will damage the printer.
- ❯ Printer Connections
- Figure 3.10 Connectors, printer back panel
- ❯ Printer Power
- ❯ Note: This switch is on the printer rear panel (see Figure 3.11).
- ❯ Note: The DP5122 does not have the voltage selector switch.
- ❯ Note: The standard printer power cord is CORD-JUMPER ACC UL/CSA <HAR> M/F 10A/250V 8'- 2" (2.5m), part number 0100238-102.
- ❯ Note: CABLE-SERIAL PC: 5120/5240 (0139601) is the standard serial cable.
- ❯ Note: CABLE-PARALLEL, 6 FOOT (0139268) is the standard parallel cable.
- Figure 3.14 Parallel data connection, printer
- ❯ Control I/O
- ❯ Tach and Cue
- 1. Connect one end of the 9-pin CABLE ASSY-TACH/CUE EXT (0139366) to the TACH / CUE connector on the printer back panel (see Figure 3.16).
- 2. Connection to a 200 or 220 system controller requires CABLE, 6240:5120/5240 TACH/CUE. This cable connects the printer to the tach and cue board in the controller.
- 3. Connect the other end of the cable to extension CABLE, 5120/5240 TACH/CUE EXT. 20FT.PKGD (0183205). The extension goes to the tach encoder and cue sensor.
- 1. Connect one end of the 9-pin CABLE ASSY-TACH/CUE EXT (0139366) to the TACH / CUE connector on the printer back panel (see Figure 3.16).
- Figure 3.14 Parallel data connection, printer
- ❯ Note: In a system installation, this cable goes to a T/C port on the system controller PC.
- 4. Check that the tach encoder is installed on the document transport with its friction wheel in contact with a belt or chain that is moving at the same speed as the substrate (paper).
- 5. Check that the cue sensor eye is mounted over reflective tape or in line with the pre-printed cue marks on the web, and located close to and upstream of the printhead.
- 4. Check that the tach encoder is installed on the document transport with its friction wheel in contact with a belt or chain that is moving at the same speed as the substrate (paper).
- ❯ Note: See also the vendor documentation shipped with the tach encoder and cue sensor. Tach and cue wiring is described in “Appendix B, Tach and Cue Wiring.”
- ❯ Table 3.2 Relay contact cable wiring
- ❯ 2. Route the cable with the connector at the printer and the cut ends at the device to be activated (see Figure 3.18).
- 3. Plug the cable into the SORT / STOP connector on the printer back panel (see Figure 3.19).
- ❯ Do not touch the terminals in the cable connector when connecting or disconnecting the cable. The cable terminals are a high-voltage hazard when the cable runs from a label base.
- Figure 3.19 Sort relay cable connection, printer back panel
- 4. Power off the device or I/O box being connected.
- 5. Strip and separate the wires in the cut end of the cable.
- 6. Connect the brown wire to the terminal for contact 1 (hot).
- 7. Connect the blue wire to the terminal for contact 2 (neutral).
- 8. Cap the unused end of the cable.
- Chapter 4. System Installation
- Figure 3.19 Sort relay cable connection, printer back panel
- Figure 3.10 Connectors, printer back panel
- ❯ Enclosure Positioning
- ❯ 1. Check that the umbilical is safely coiled inside the cabinet and that all packing material is clear of the casters. If the umbilical was uncoiled, coil it safely inside the cabinet (see Figure 4.1).
- 2. Unlock the enclosure casters.
- ❯ 3. Roll the cabinet by pushing the front (see Figure 4.2). The enclosure is easier to control if pushed and steered from the front because the front casters swivel, and the rear casters are fixed.
- 4. If possible, position the system enclosure where you have at least 3 feet (1m) of clearance in front and in back.
- ❯ Note: Less clearance makes cabling the system difficult.
- ❯ Controller Positioning
- 1. When the cabinet is properly positioned, check that the casters are locked to ensure that the cabinet does not roll while components are being placed on top of it.
- 2. Check that all boxes were brought from the location where the shipping pallet was unpacked.
- 3. Unpack the controller PC and place the processor chassis on top of the enclosure.
- 4. Unpack the monitor and place it on top of the controller PC (see Figure 4.3).
- ❯ Caution: Take all precautions recommended by the monitor manufacturer to protect the monitor from dust.
- 5. Unpack the keyboard and place it on top of the enclosure. The keyboard skin can be installed, if desired.
- ❯ 6. Unpack the mouse and mouse pad and place them on top of the enclosure.
- 7. Unpack the system accessories box.
- 8. Disconnect the retaining cable attaching the printer rear panel to the enclosure. The retaining cable secures the printer during shipping, but prevents it from being pulled out for service access.
- ❯ 9. Set all the cables aside for later use (see Figure 4.4).
- 5. Unpack the keyboard and place it on top of the enclosure. The keyboard skin can be installed, if desired.
- 1. When the cabinet is properly positioned, check that the casters are locked to ensure that the cabinet does not roll while components are being placed on top of it.
- ❯ System Connections
- ❯ Note: This guide shows a dual-controller PC installation.
- ❯ Cabinet Connections
- ❯ System Power
- 1. Put the power strip line switch in the offline (O) position.
- 2. Plug the female end of the cord into the main receptacle on the enclosure power strip (see Figure 4.5).
- 3. Install the cable-tie strain relief as shown in Figure 4.5.
- ❯ 4. Plug the male end of the power cord into the input power source receptacle.
- 1. Put the power strip line switch in the offline (O) position.
- External Tach and Cue
- ❯ System Power
- Controller Connections
- ❯ Cabinet Connections
- ❯ Note: The tach and cue connection to the PC is described in “Cabinet Connections” because it connects the system enclosure to another printing system component.
- ❯ Note: On older Jetscape controllers, GlidePoint was plugged into COM1.
- ❯ Note: This guide shows a dual-controller PC installation.
- ❯ Installing Software
- ❯ DH5120 Printhead
- ❯ DH5240 Printhead
- ❯ DH5122 Printhead
- ❯ Electronics Tests
- 1. For a printing system, turn on the main power switch (on the power distribution panel). For a printer, check that the line switch on the back panel is in the online (|) position.
- 2. While holding the OPEN EYELID button, press the PRINTER ON button.
- 3. Continue to hold the OPEN EYELID button until all lights on the front panel are illuminated.
- 4. Release the OPEN EYELID button.
- 5. On a printing system, turn on all the components.
- 6. Check for error messages that indicate a POC failure.
- 7. If no errors occur, continue with “Fluidics Tests”. If an error message is generated, note what type of failure occurred and continue with step 8.
- 8. Start diagnostics and run the test on the failed component.
- ❯ Note: See the Service Guide for diagnostics and troubleshooting procedures.
- 1. For a printing system, turn on the main power switch (on the power distribution panel). For a printer, check that the line switch on the back panel is in the online (|) position.
- ❯ Fluidics Tests
- 1. After installing a printhead (see Chapter 5, “Printhead Installation”), turn on the printer with the fluid system bypassed.
- 2. Press and hold the OPEN EYELID button and PRINTER ON until all the operator panel indicators light.
- 3. To fill the ink tank, start diagnostics and select the Service View for the printer.
- ❯ Note: For more information on diagnostics, see CS150 controller online help and Getting Started Guide.
- ❯ Note: Wait approximately 3 minutes for the ink tank to fill. When the fill cycle is complete, state 2 has been reached.
- ❯ Note: Allow the ink to circulate for approximately 5 minutes. When the cycle completes, state 6 has been reached.
- Note: You can also print a test job from the Production screen.
- ❯ Note: See the Operator’s Guide for printing procedures.
- ❯ 11. Check the print quality of the test patterns.
- a. If test patterns do not print, check for tach and cue (see “System Tests”). If print quality is poor, adjust the phase and voltage (see “Printhead Adjustment”).
- b. If the test pattern print quality is acceptable, the system is operational, and the installation is complete. Continue with the installation report.
- a. If test patterns do not print, check for tach and cue (see “System Tests”). If print quality is poor, adjust the phase and voltage (see “Printhead Adjustment”).
- ❯ 11. Check the print quality of the test patterns.
- 1. After installing a printhead (see Chapter 5, “Printhead Installation”), turn on the printer with the fluid system bypassed.
- ❯ System Tests
- 1. Turn on the printer.
- 2. Press PRINTER ON on the operator panel.
- 3. Start diagnostics.
- 4. Select Mode Æ Settings Æ Printer Setup to verify the tach and cue settings.
- 5. Select the Printer Setup tab and check the system configuration parameters.
- ❯ Note: For more information on setup parameters, see CS150 controller online help and Getting Started Guide.
- 6. If required, enter known good parameters (or defaults) and select Apply.
- 7. The maximum values for image Length, substrate Length, cue Distance and cue Delay depend on the maximum image area, which dep...
- 8. If no known good values are available, use the following values as a guideline for test printing:
- 6. If required, enter known good parameters (or defaults) and select Apply.
- ❯ Note: If the printhead is not yet mounted, you can quickly pass a blank piece under the print array to confirm that an image is being printed. If the image appears backwards, run the piece under the print array in the opposite direction.
- 9. On the main Service View screen, select Data Test and A Test Image then Start Test.
- 10. You can also run a test job from the Production screen, or press the [TEST PRINT] button on the printer operator panel.
- 11. To stop printing, press [TEST PRINT] again.
- 12. Check the test patterns.
- 13. If test patterns print, check the print quality. If the print quality is acceptable, the system is operational, and the installation is complete. Continue with the installation report.
- 14. If print quality is not acceptable, adjust the printhead phase and voltage (see “Printhead Adjustment”).If test patterns do ...
- 9. On the main Service View screen, select Data Test and A Test Image then Start Test.
- 1. Turn on the printer.
- ❯ Printhead Adjustment
- ❯ Note: Always print the first test patterns using the factory phase and voltage settings. Adjustments should be made only after print defects are observed in the test patterns.
- ❯ Figure 6.1 Missing spots or bands of print
- 6. Raise the phase setting and check each adjustment by printing test patterns. Stop when a you produce a test pattern with voids or dark defects (see Figure 6.1 ). Note this setting; it is the high end of the phase window.
- 7. Raise the phase setting, and print a test pattern to check the effect of the adjustment. Continue this process until you produce a test pattern with no visible defects. Note this setting; it is the low end of the phase window.
- 8. Determine the middle of the phase window by subtracting the low end value from the high end value.
- 9. If the result is a negative number, subtract it from 56. The resulting value is the size of the phase window.
- 10. Divide the phase window size by 2.
- 11. Add this value to the low-end phase window setting.
- 12. If the resulting value exceeds 55, subtract it from the high-end setting.
- 13. Note the resulting value; it is the mid-range phase setting.
- 14. Select Mode Æ Settings Æ Printer Setup and enter the mid-range value.
- 15. Press Apply to save this setting.
- ❯ Adjusting Voltage
- 1. In Diagnostics, select Mode Æ Settings Æ Printer Setup.
- 2. Enter 165 for the printhead volts parameter.
- 3. If the printer does not operate properly at 165 volts, reduce the volts setting incrementally until you find the highest setting at which the printer operates properly.
- 4. Print a test pattern and examine it for defects.
- 5. Beginning at 165 volts (or the setting determined in step 2), lower the voltage setting by 5 and check print quality.
- 6. Continue lowering the voltage incrementally until you produce a test pattern with dark defects (see Figure 6.2 ). Note this setting; it is the low end of the print window.
- 1. In Diagnostics, select Mode Æ Settings Æ Printer Setup.
- 6. Raise the phase setting and check each adjustment by printing test patterns. Stop when a you produce a test pattern with voids or dark defects (see Figure 6.1 ). Note this setting; it is the high end of the phase window.
- ❯ Figure 6.2 Dark defect, defines low end of print window
- Printer Checklist
- Printhead Checklist
- ❯ Printing System Checklist
- ❯ Electrical Requirements
- ❯ Environmental Requirements
- ❯ Space Requirements
- Tables
- Contents
- Scope
About the Kodak Versamark DP5240
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Frequently Asked Questions
Below, you will find the most frequently asked questions about the Kodak Versamark DP5240.
What is the best way to remove jammed paper from my printer?
It is best to gently pull the paper out of the printer. Turn the printer off, and make sure that the printhead is not hanging over the paper and that no paper remains in the printer.
How come my printer does not accept original cartridges?
Non-genuine cartridges may not be recognised by the printer. In that case you will receive a message that the cartridge is empty. The manual of the purchased cartridge usually contains the solution, if this does not work, it is advisable to contact the seller.
How come my prints are of poor quality?
There can be various reasons for poor print quality. Check if the cartridges or toners are full. If so, inkjet printers often require cleaning the printer, the cartridges have dried out, or the print head is broken. With laser printers, calibrating the laser printer is recommended.
What is the difference between a laser printer and an inkjet printer?
A laser printer prints with a toner and an inkjet printer prints with ink.
How come my inkjet printer has black stripes?
In most cases, the inkjet printer cartridge is broken and the cartridge needs to be replaced.
What does DPI stand for?
DPI stands for Dots Per Inch and is the number of ink droplets (per inch) that end up on the paper when printing.
Is the manual of the Kodak Versamark DP5240 available in English?
Yes, the manual of the Kodak Versamark DP5240 is available in English .
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How to empty the ink tank to change ink