Memjet SFP - User Guide
Memjet SFP - User Guide
Memjet SFP - User Guide
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Copyright statement
2012 OWN-X Kft., This document, attachments, and information contained herein are the
confidential and proprietary property of OWN-X Kft. and their suppliers. As such, this
document, attached files, and information contained herein are subject to all nondisclosure
and proprietary information agreements currently in effect with your organization. Copies of
this document, any portion of this document, or attachments may not be transmitted or
disclosed to any third party without the prior written permission of OWN-X Kft..
2012 OWN-X Kft. All content is the confidential property of, or licensed to, OWN-X Kft.
(Own-X, we, or us) and is protected under Hungarian and Foreign copyright, trademark
and other intellectual property laws.
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Table of Contents
1. Introduction
1.1. Introduction to Memjet print technology
2. Printer Parts and their functions
2.2. Print Engine
2.3. Printhead
2.4. Printhead Cartridge Dock
2.5. Print Mechanism
2.6. Cutter
2.7. Ink Cartridges
2.8. Ink Connection Ports
2.9. Ink Delivery System (IDS)
2.10. Bulkhead Assambly
2.11. Other IDS Components
2.12. Maintenance Module
2.12.1. Wiper Station
2.12.2. Printing Platen
2.12.3. Capping/Spitton Station
2.12.4. Printhead servicing events
2.13. Print Zone
2.14. Onboard Print Engine Controller (OmniPEC) and Main Board
2.15. The Controlling System
2.16. Control Panel (GUI)
2.17. Unwinder/Rewinder
2.17.1. Description of Un/Rewinder
3. Installing the Printer
3.1. Choose a location
3.2. Unpacking and Setup
3.3. Checking the Contents
3.4. Connecting the SpeedStar3000
3.5. Setting up the Printer
3.5.1. Installing the Maintenance Module
3.5.2. Installing the Ink Cartridges
3.5.3. Installing the Printhead
3.5.4. Switch on the Printer
3.5.5. Un/Rewinder setup
3.5.6. Media Handling
3.5.6.1. Print Area
3.5.6.2. Load Media
3.6. Connecting the Printer to a computer
3.6.1. Connecting to a Local Area Network
3.6.2. Direct connection to a personal computer
3.7. Install Printer Driver
3.7.1. Driver specifications
3.8. Label printing, generating print jobs
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1.
Introduction
The purpose of this manual is to describe the operation of the SpeedStar 3000 label printer.
The first section provides and overview of the Memjet print technology to make you
familiar with the terms and basics of this new technology that forms the basis of the
SpeedStar printer series. The following sections walk you through the installation steps,
explain the components of the printer and their roles, and then teach you how to operate
your printer. The manual ends with a maintenance and troubleshooting guide.
1.1. Introduction to MemjetR print technology
Memjet Technology is a revolutionary printing technology developed by Silverbrooks
Research (Sidney, Australia). The core of this technology is a full paper width printhead
capable of printing the entire page width at the same time without head movement. The
result of this setup is a breakthrough 12 inch (305 mm) per second printing speed. The
printhead is manufactured with state-of-the art semiconductor technology; an A4 head
contains 70,400 nozzles delivering 1600 dpi native resolution at full colour. The nozzles are
arranged in 10 rows having 2 rows for each ink channels. The fixed head spans the width of
the label and feeds an entire label at a time similar to a laser printer. This architecture
dramatically improves performance and ink drop placement accuracy during printing, while
decreasing noise and vibration.
Figure 2 The Memjet 8.5 printhead cartidge showing the ink inlet,
outlet ports, various print-related parts and the printhead.
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a)
b)
Figure 3 The Memjet printhead contains 70,400 nozzles in 10 rows (brown stripe in Figure a). An
electron microscope image of a single nozzle (Figure b).
The small size of the nozzles results in very small (1-2 picolitre) paint drops, approximately
14 micron drop diameter on paper, effectively achieving the highest print resolution the
human eye can see.
Printing with this type of precision requires many technical details to be solved including
printhead cooling, using special fast drying inks, feeding paper accurately, controlling the
operation of the unit, etc. A unique property of Memjet printing is the special print
processor that uses a custom hardware print pipeline processing engine to render images at
a very high speed. The level of technical standards are reflected by the fact that Silverbrooks
Research hold 2500 patents related to Memjet Technology along with another 2000
pending.
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Touchscreen
Top cover
Integrated
cutter
Adjustable legs
Ink cartridge
compartment
cover
View Nr.2.
Paperguide
Handle
Service slots
USB Connectors (4x)
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View Nr.3.
Power switch
Power
connector
CAUTION
Do not turn off the printer using the Power switch on the back of the printer. Always turn
it off using the Shut down function within the Liberty software to ensure that the Service
Station is returned to its proper position (Capping). After the touchscreen turns to black,
turn of the printer with the Power button.
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2.1. Printer
The SpeedStar 3000 printer is a state-of-the-art Memjet printer designed for maximum
usability and performance. The major components of the printer are the print engine, the
controller and the control panel.
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2.3. Printhead
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The maintenance module (MM) is a sled that contains stations for wiper, cap/spittoon, and
print zone platen.
To position the correct station into place, a stepper motor moves the sled horizontally, and a
DC motor moves the sled vertically.
The maintenance module:
The maintenance module should be replaced as part of annual maintenance or after printing
one million inches.
NOTE: The maintenance module is not intended to be end-user serviceable, although it is a
service part for technicians.
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Be aware that ink is used by the print engine during printhead maintenance as well as during
printing. All waste ink from the printhead nozzles is contained by the maintenance carousel,
either in the spittoon (holds waste ink generated by priming/cleaning) or in the platen (holds
waste ink generated during printing). Therefore, periodic maintenance will be required to
remove the waste ink.
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2.17. Unwind/Rewind
Unwinder/Rewinder is the official part for Speedstar Printers to handle the different type of
medias. NOTE: It is not replaceable with other companys products.
Picture of an Unwinder/Rewinder
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Speed
determining
arms
Paperguide
roller
Axle
holder
stand
Mandrel
Spindle
Media
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Rewinder/Unwinder
NOTE: 2 sets of ink cartridges and two printheads are part of the spares kit supplied and are
priced separately. We need to clarify that the printer pricing includes on set of cartridges
and one printhead.
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Insert the cable into the printer first. The cable connector should sit in the socket
securely.
Insert the cable into the mains socket.
CAUTION
Do not use an outlet that shares the same circuit with large electrical machines or
appliances
Turning Power On/Off
Powering Up:
1. Press the Main Power Button on the back of the Printer.
Powering Down Printer:
1. Press the Power button within the Liberty software and choose Shut Down Printer.
2. Waint for the printer to stop processing (The screen will turn to black)
3. Press the Main Power Button on the back of the Printer to switch it off.
CAUTION
Whenever powering down the unit NEVER:
1.) Never remove the power cable during the shutdown process
2.) Never switch off the printer with the Main Power Button when Liberty is still running
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The Service Station cleans the Printhead Cartridge of excess ink and debris, keeps the
Printhead hydrated and protected when not in use, captures ink used to keep nozzles clear,
and acts as a base to support media during printing.
CAUTION
Make sure latches on the Wiper Roller are properly closed before installing the
Maintenance Module
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Installation steps:
Unpack the Maintenance Module
Check that each part of the station is complete and functional
Open the printer and the ink tank cover
Open the print engine clamshell
Locate the MM ribbon cable
Connect the ribbon cable to the MM connector at the back of the service station
Insert the station into the print engine
The Service Station fits in the port immediately above the Ink Tank Station.
1. Plug in the white flat flex cable to the motor PCA on the maintenance module.
Slide the Latch open on the Maintenance Station Circuit Board:
Plug the ribbon connector (blue side up) into the space under the Latch than close the Latch:
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3. Slowly turn the gear on the print engine until the maintenance module engages.
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Cyan
Black
Yellow
Magenta
Black
WARNING: The ink 29nt he Ink Tanks may be harmful if swallowed. Keep new and used Tanks out
or reach of children. Discard empty tanks immediately.
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CAUTION
DO NOT touch the printhead cartridge ink couplings, nozzle surface or the
electrical contacts when installing the printhead cartridge. Hold the printhead
cartridge ONLY by the handles.
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 from at all times from dust, fibers, dirt and other contaminants.
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5. Open the end of the printhead package outer box and slide out the foil bag.
Inspect the integrity of the foil vacuum sealing. The foil bag should be formed tightly to the
contours of the printhead cartridge as shown above. If the foil is loose to any degree then
the seal has been compromised.
If a poor seal is suspected, DO NOT USE the printhead cartridge. Report the issue to your
supplier.
6. Carefully rip the foil packaging open at the notch. Use scissors if your foil bag does
not have a notch or you are finding it difficult to tear the bag.
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8. Remove the orange protective plastic cover from the printhead cartridge. Holding the
printhead cartridge by the handle
a. Release the flaps covering the ink ports (1 and 2).
b. Release the clip retaining the cover near the center of the printhead cartridge
(3).
c. Carefully remove the protective cover (4).
9. Remove the protective strip from the electrical contacts. While holding the printhead
cartridge by the handle with one hand, grasp the pull tab with the other hand and,
slowly and carefully, peel back the plastic strip covering the electrical contacts.
Dispose of the removed strip immediately and do not allow the removed strip to
contact the electrical contacts.
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10. Remove the protective strip from the printhead nozzles. While holding the printhead
cartridge by the handle with one hand, grasp the pull tab with the other hand and
slowly and carefully peel back the plastic strip covering the printhead nozzles.
Maintain an angle of no less than 45 with the printhead surface when pulling on the
strip.
Dispose of the removed strip immediately and do not allow the removed strip to
contact the electrical contacts or the printhead nozzles.
11. Raise the printhead latch fully until it is upright so you can insert the printhead into
the printer at an angle.
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12. When the printhead cartridge is fully inserted into the printer rotate it to a vertical
position as shown.
13. Slowly close the printhead latch. The fluidic couplings should advance and seal to the
printhead cartridge.
14. Close the printhead latch. When the printhead latch is closed, the printer will prime,
clean and cap the printhead automatically. This operation will generally take a
minute or two, and will be obvious from sounds emanating from the printer.
NOTE: The Printer may take up to 12 minutes to set itself up during initial startup. This is
normal. The machine will emit a number of chirps, whirrs and other noises as it circulates ink
and runs systems.
CAUTION
Do not remove the Printhead while fluid is primed in the system!
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After the software connected to the Print Engine the printer (Printer status will be Online)
is ready to use.
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Step 2
Install the second guide.
Step 3
Install outer disk.
Step 4
Insert the motorized core holder
into the roll.
Step 5
Install the second outer disk.
Step 6
Turn the knob to fix the roll.
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Step 7
Install the motorized core holder into the guides
IMPORTANT : keep the holder with the connector
on the tower side where there is the power cable.
Step 8
IMPORTANT : put the holder
with the screw hole onto the guide.
WRONG
RIGHT
Step 9
Insert the power cable.
Step 10
Switch on the unit.
Step 11
Install the plates basements together.
Step 12
Pulls up the printer and put on the
basement the first printer feet.
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Step 13
Pull up the printer and put on the basement
align the second printer feet.
Step 14
Install the unwinder on the
basement to the printer and fix with
the two knobs.
Print Area
Print area can be found on the back of the printer where the operator needs to feed the
materials. Any media type must go through the metal paper guide in order to avoid any
movement during printing.
Printing Area is dedicated with the green bar. Left edges of Label (Gap) Sensor and
Blackmark (Tickmark) Sensor is shown with the blue marks. During printing the operator has
to align the actual material to these blue marks otherwise the sensors wont be able to
recognize the media and the printer could run into an error.
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3.5.6.2.
Load Media
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Click on Paper Handling within Liberty on the touchscreen and choose Feed Paper. The
printer will automatically feed the paper to starting position. Choose the right Material Type,
Print Mode, Media Edge Detection and Cut Mode. Printer is now ready to print in Standalone
Mode.
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3.6.
The SpeedStar3000 printer uses an Ethernet connection for printing. There are different
configuration steps to follow depending whether or not you have a local area network at
your location.
NOTE: Although the printer has a USB connector it is not activated as all communication
between the Embedded PC and the Print Engine is working only via Ethernet connection.
This means that this printer cannot be used as a USB printer!
3.6.1. Connecting to a local area network
IP address configuration
If your LAN has a DHCP server that assigns IP addresses dynamically, you can use the
default configuration of the SpeedStar controller. After power up, the controller will
connect to your DHCP server and request the IP address. Later, you can check the
assigned IP address in the Configuration menu under Network Settings.
If you want to assign a fixed IP address to the printer manually, you can do this in the
Embedded PC operating system after closing the Liberty controller.
Connect the printer to your local area network using a standard Ethernet cable.
IP address configuration
First assign an IP address to the printer in the Embedded PC operating system after
closing the Liberty controller. Then, assign an IP address to your personal computer.
NOTE: Make sure the addresses belong to the same segment.
Connect the printer to your local area network using a crossover Ethernet cable.
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3.7.
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Installation begins:
During the setup process, it will detect the SpeedStar printer attached to the network. It has
to be selected by a click when it asked and continue setup:
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Windows may ask for permission to run this setup. Answer with 'Yes' or Unblock.
Setup may ask for 'Run firmware update'. Answer with 'No'.
When its finished you will need to Restart your PC or Laptop to make sure that the
installation process made all necesarry changes!
NOTE: When installing the driver on Windows 7, you can skip the Reboot process by clicking
on Dont reboot. The system will prompt you whether the software was installed properly
or not. Just select Yes.
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7.) Do not forget to create custom sizes when printing. See example here:
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Installation finished.
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Media type and media size are defined by the SpeedStar Series Driver and included during
installation.
Field
Media Type
Media Size
Values
Default
SpeedJet Glossy Label
SpeedJet Matte Label
SpeedJet Standard Label
SpeedJet Vellum
Letter 8 x 11 in
Legal 8 x 14 in
Statement 5 x 8 in
Executive 7 x 10 in
A4 210 x 297 mm
A5 148 x 210 mm
A6 105 x 148 mm
4 x 6 in
5 x 7 in
5 x 8 in
12 IPS
6IPS
Color
Monochrome
Defaults
4 x 10 in
4 x 11 in
4 x 12 in
8 x 10 in
Env. Monarch 3 7/8 x 7 in
Env. Com 10 4 1/8 x 9 in
Env. DL 110 x 220 mm
Hagaki 100 x 148 mm
100 x 150 mm
1 x 1 in
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Layout Tab
Field
Multi-Page (N-Up)
Arrange Pages
My Print Settings
Values
Pages per Sheet: 1,2,4,9,16
Right, then down
Down, then right
Left, then down
Down then left
Defaults
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Media Tab
Field
Position Adjusment
(offset units)
Media Layout
Page Cutting
My Print Settings
Values
Horizontal Offset
Vertical Offset
Inches
Millimeters
Pixels
Inter-Label Gap
Black Mark
Cut Sheet
Continuous
Use Printer Setting
Job Cut (cut at end of job
Sheet per cut (number of pages before
cutting)
Use Printer Settings
Defaults
NOTE: This section of the driver is not recommended to use, as Liberty has most of these
settings under Paper Handling button. Changing values here may cause unanticipated
errors!
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3.8.
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3.9.
command.
This will open up a command window which will be automatically disappeared when the
process finishes.
When you have finished the installation, switch the write protection filter back with the
C:\SpeedStar\EWF\ewf_on.bat
command.
NOTE: If the operator makes changes on C: drive and forgets to turn of EWF all changes will
be lost after rebooting the printer!
3.9.3. Installing .NET 3.5 SP1
The Liberty controller requires the presence of the .NET Framework 3.5 Service Pack 1 on the
embedded PC. Install this first. Open the Internet Explorer, and search for .net 3.5 SP1 or
type the following URL:
http://www.microsoft.com/download/en/details.aspx?id=22
Follow the instructions to install the .NET framework. Note that you dont need to reboot at
the end of the installation. You should reboot only when the entire printer is updated.
NOTE: In order to install .NET on the Embedded PC the printer must have internet access.
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NOTE: Always contact your Reseller to make sure the right step for firmware upgrading.
command.
Once this is complete, restart the entire printer and you are ready to start printing.
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4.
4.1.
The SpeedStar3000 printer has a unique control panel with a large touch-based user
interface. The purpose of using this interface is to provide real-time information and
feedback to the user about the operation and status of the printer in order to give the user
full control of the printer and a frustration free printing experience.
4.2.
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This field displays status strings received from the engine and important printer status
information. The status is a short English description of the current status of the engine.
ONLINE refers to normal operating status, any other status is normally signals a state in
which the engine cannot print
In the middle, you can see the CMYKK ink volume display chart shows the actual amount of
ink in each tank in relative percent values.
On the left, you can see the current time and date as well as the state of the printer. The
green Printer OK message signals that the printer is operating without problems.
On the right, the status of the LAN Ethernet as well as the print engine connection is
displayed. Inactive connections are shown in red colour. If the Engine status is Down and
displayed in red, a print engine connection problem occurred. In this state, printing is not
possible.
The middle part of the touch screen is used for displaying important configuration, and
printing status information. It is also used for displaying windows of the menu system.
The Operation mode message includes Roll-to-Cut and Roll-to-Roll mode (See the roll-toroll section for explanation of its behaviour) feedback, the actual printing mode (label,
continuous or tickmark material) and cutting (cut at end of job, cut after N label, no cut) as
well to help operators identify how the printer is configured
Paper status is the feedback from the Print Engines paper sensors that show the actual
status of the paper. (Present or not present)
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The bottom of the screen gives access to various menus. On the right, a large red virtual
Power On/Off is shown. Use this button to switch off the printer! Under this button the two
values are the version of Liberty and the version of the firmware.
The versioning scheme used in Liberty uses the major.minor.build numbering scheme. The first number major
refers to the main version. This number is currently 1 and will only change if a substantial, typically
compatibility breaking change occurs in Liberty . The second number minor shows the improvement of the
product represented by the major version by increasing numbers with each release. The change in this number
typically means added functionality that improves the product but do not represent significant change in the
architecture. The third number build refers to the internal development identification of the changes as
development progresses. In the future you may receive updates that only change in the third number. This is
normal, as build number changes typically signal correction of minor internal errors, commonly called as
software bugs. When referring to a particular version, we normally use the first two numbers, major.minor,
and assume the highest available build number.
The state of the Print Engine is also shown here. This is mainly for error reporting purposes.
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4.3.
The paper handling menu contains functions for controlling the print configuration of the
printer and performing paper-related operations.
Use the manual Feed Paper button to paper feed the paper into the printer.
Use the Unfeed Paper button to remove paper from the printer. You only need this
function when you want to change non/empty rolls or had a paper jam and need to clear the
paper path.
Pressing the Cut Paper button performs a manual cut operation. Under normal conditions,
the printer cuts the paper automatically, hence you rarely need to perform cut manually.
NOTE: The print configuration depends on the combination of the print mode, material type
and the cut mode.
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Automatic by choosing this option you rely on the printer sensors to handle the material
Supervised with this option the operator is able to set the liner-label distance (the distance
between the liner edge and the label edge in millimetre) of the current material. This case
liner edge is detected and the liner-label distance is added to it resulting the final left offset
of the print job.
NOTE: This option is a material dependent setting and should be updated each time a
material is different liner-label distance is used. The liner edge detection is usually more
stable and in this case the whole detection might be more stable. This mode can be also
used for other non-die-cut materials where a left offset adjustment is needed.
Turn off this choose will turn of the left offset sensor and let the operator to set it
manually. Remember this value is in millimetre.
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Roll-to-Cut
The printjob starts as normal, there is no possibility to attach the media to the rewinder.
Roll-to-Roll
When a roll-to-roll print job starts, it will push blank material through the printer in length
long enough to attach the material to the rewinder. After pushing the paper
forward, it will stop for 30 seconds to wait for the operator to attach the paper to
the rewind, and then it will continue by starting to print the job.
The SpeedStar printer supports roll-to-roll printing usually for entire roll-long print jobs.
Since the printer needs to remove the paper for maintenance operations, it cannot
finish a job and leave the paper within the printer. If you want to print shorter jobs
but want the labels to be rewound on a core, you can do that with the roll-to-roll
end of job cut configuration.
NOTE: Roll-to-roll and roll-to-cut modes can cut after the job, but the paper load
mechanisms are different.
4.3.4. Cut Mode
In the Cut Mode section set how you want the printer to cut media. The default operation
is cut at the end of each job. It is also possible to cut after every N th label. This option
enables you to create e.g. individually cut labels.
There is an option for No Cut but this option is only available when you set printing mode
to Roll-to-Roll.
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4.3.5. Adjustments
NOTE: The values here are counted in micron which means 1000 micron = 1 millimetre.
In order to use this option you also need to activate it within the driver during printing.
This function stich the individual labels to each other leaving no gap or margins.
Stich Mode usually used when printing on continuous material.
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4.4.
Label library
The SpeedStar printer allows the operator to store pre-set labels in the printer for future
retrieval and printing. The labels are displayed as small preview images. You can page
through the labels and select the one you would like to print. After selection, pressing the
Print button will be change to active and starts the print process.
Deleting pre-set labels is not possible from here. You can see a more detailed description in
the print job generating section.
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4.5.
The role of the maintenance menu is to give access to functions that relate to maintaining
your printer and the quality of printing. Statisctisc and some calibration functions are also
available here.
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The print engine monitors the state of the ink delivery system and ensures it is always fully
primed. On inserting a new printhead, however, in some cases the built-in priming algorithm
sometimes leaves the system incompletely primed (ie. The ink lines show extensive trapped
air). In such cases, performing a manual prime operation helps bringing the system into
normal operational state. Make sure that operators always start with the lightest priming
level and only move to a higher level if the lower level did not cure the problem after one or
two attempts.
These buttons are added to provide the user/technician to eject the service station for
removal and then send home the station after inspection or replacement. T
NOTE: The print engine has to be opened to eject the service station!
The controller attempts to discover error states and guide the user in order to recover from
these. In cases when this is not sufficient or the controller failed to detect the engine error
and react to it, pressing this button may help clearing engine error states (eg. after paper
jam).
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4.5.5. Statistics
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The network setting dialog is only informal, to read the LAN connection setting. Changing IP
address is not possible from here.
Changing the Printhead is an automatic process. It consists of removing the ink from the
head, removing the old head, inserting the new one, then filling the system with ink again.
The operator just has to follow the steps an wait till the process finishes.
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The printer has built-in tilt sensor which should be calibrated once the printer is properly
installed. It should also be recalibrated if the unit is moved.
4.6.
When you start a print operation, either from a PC or from the label library, the touch screen
display changes to displaying the printing status. Information is compiled under the heading
Current Job. While the data is being processed, the job status is showing Preparing. Once
printing starts, the job status will change to Printing and you will see the total number of
labels to be printed as well as a running count of the already printed and remaining labels.
The controller also gives an estimated value for the remaining print time for the job.
In case you want to cancel a print job, press the STOP Printing button which will
immediately stop the current printjob and cut the material.
In case you want to momentarily pause printing, press the Pause Printing button. Printing
will be suspended and the button changes its status to Continue. If you press the continue
button, the print is continued from the position it has been stopped at previously.
The pause interval is unlimited but less than 60 second is recommended.
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4.7.
The SpeedStar controller has been redesigned to be fault-tolerant. If for some reason
the print engine reboots during operation, the controller will not stop. It will detect
the problem and display a dialog stating the problem with the print engine. If the
engine restarts, the controller will automatically detect it and reconnect to it.
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4.8.
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4.9.
Known Issues
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5. Maintenance Guide
5.1.
Maintenance Overview
To ensure reliable operation and high print quality while using the product, the regular
inspection and maintenance steps are required to be performed. These include mechanical
subsystems checks, occasional cleanings, consumables changing and print head cleaning.
Cleaning
The most essential maintenance operation is automatic cleaning the print head and
preventing it from dehydration. The print engine performs various maintenance operations
before and after print jobs and in the background. Normally manual print head cleaning is
not required.
Regular checks
At regular intervals (say at the beginning of a shift or day) inspect that the maintenance
station is in cap position, the cutter is not obstructed, the paper path is clean (there are no
paper clippings present), sensors are not covered. Check that wires are not loose, there is no
ink leaking.
If the operator detects print quality problems, check the troubleshooting part for steps to
perform in order to solve the issues.
Consumable change
The main consumables in the printer are the ink and the print head. The most frequent user
intervention during the life time of the printer is the ink cartridge and print head change.
When the printer is running out of a particular ink, the Liberty controller will display a
message on the screen specifying which tank is out of ink. Remove the empty tank and insert
a new one and the printer will operate again as before.
NOTE: The printer is working only with all cartridges installed!
If the operator need to change a print head due to unrecoverable printing defects, open the
Maintenance menu and select Replace Printhead command. This starts a wizard that will
guide you through the print head change procedure. Follow the steps and wait until the
wizard finishes its operation.
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5.2.
Standard Maintenance
General and periodic maintenance procedures are needed to keep the Print Engine in good
condition. In anticipation of industrial applications, an extensive list of service parts are
available for the printer. Please contact you Reseller for futher details.
High volume usage and specific use cases/configurations may require more frequent
maintenance.
NOTE: Repair and replacement tasks, are referred to qualified technicians! For some
maintenance tasks it is better to remove the engine from the printer!
Use the table below to determine which maintenance task (inspection, cleaning, lubrication,
or replacement, etc.) to perform at a given time period or usage interval.
The following tasks are to be performed by the operator only with very basic supplies, no
special tools are needed.
General Maintenance
Tasks
Interval
Daily
Bi-weekly
Monthly
Anually
As Needed
Wipe
Every PH
Removal
Every PH
Removal
Clean
Clean
Clean
Clean
Clean
Clean
Clean
Clean
Inspect
Inspect
Clean
Inspect
Inspect
Inspect
Inspect
Inspect
Clean
Inspect
Inspect
Inspect
Clean
Test
Replace
Clean
Inspect
Inspect
In order to avoid personal injury, always use appropriate personal protection when
performing maintenance tasks
Clothing protection
Powder-free nitrile gloves
Lint-free cloth wipes It is critical that the wipes used be soft to avoid scratching the
prtinhead, and lint-free to avoid contaminating the printhead.
De-ionized (DI)/Distilled water (electronics grade) Use only deionized or distilled
water for cleaning the unit. Take care to avoid contaminating the printhead with
cleaners, lubricants, or other chemicals.
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WARNING! Always power down the Print Engine before investigating any cable
connections! The printer runs off a 24-volt DC supply. Although this is considered low
voltage, the current is sufficient enough to cause injuries.
5.2.1. Daily Maintenance Tasks
Aerosol and debris removal
Ink may transfer from printer components into media path. Remove excess ink and debris
daily to ensure optimal printing.
NOTE: If the operator finds paper debris on a starwheel, check to see whether or not it is
aligned with the edge of the media. If so, you may need to adjust the paper guide and
margin so that the starwheel no longer rubs the edge of the paper.
1. Perform this procedure with the printer powered on, so the platen is raised.
2. Pinch the clamshell latches to release, as shown on the pictures. Open the clamshell
and allow the upper portion to rest on the hard stops.
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Grit
Rollers
Platen
Housing
Page 72
Starwheels
Pinch Rollers
Aerosol
6. Fold the cloth between wipes to ensure a clean, uncontaminated surface is used each
time.
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7. Use a vacuum cleaner if necessary to remove debris inside and outside surfaces of
the clamshell.
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Page 75
3. Place the damp swab on each sensor and twist back and forth to clean the surface.
Use a new, moist swab on each sensor.
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NOTE: The wiper is automatically in the up position when the clamshell is open.
2. Go to Liberty and click on Eject Sevice Station button.
3. Inspect the wiper to ensure that it is spins freely with no excessive noise
4. Check the surface of the microfiber roller (MFR) for any irregularities (bumps, divots,
etc.) or delamination (peeling of the wiper surface at the seam). Iff irregularities are
seen, escalate to a technician for replacement.
5. Use tweezers to remove any large clumps of debris.
5.2.3. Monthly Maintenance Tastks
Aerosol and debris removal; Paper path optical sensor cleaning; Wiper inspection see at
bi-weekly maintenance tasks.
Waste ink absorber inpection
Waste ink absorber must be inspected every month. The waste ink absorber was designed to
last the life of the printer under normal printing conditions.
1. Release the waste ink tray latches at the front of the unit and slide the tray out.
Waste Ink Tray Latches
2. Even the absorber is completely darkened with waste ink, with no white showing, it
may still be able to hold additional ink due to evaporation. The capacity of the waste
ink absorber is 1.6L. Visually inspect the waste ink absorber and tray to see if there is
ink leaking out of the tray. If yes, replace the absorber with a new one.
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3. Slide the waste ink tray back into the frame until it clicks.
Ink Tubing Inspection
The following ink tubing and connections, visible to the operator, must be inspected every
month:
Peristaltic
Pump
Page 78
Pump Motor
Buffer Box
2. Use a finger to gently pry both fluicid coupling covers off in order to inspect the ink
tube connections underneath.
3. Visually inspect each tubing connection point for leaks. If leaks are found, escalate to
a technician for troubleshooting.
4. Follow the exposed length of each tube and visually inspect each ink tube for kinks or
pinches in the tubing. Undo the irregularity to allow ink to flow freely. Escalate to a
technician if leaks result.
5. Re-install the fluidic coupling covers.
6. Re-install any housing removed to access this area.
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Lift Motor
Motor Encoder
(under cover)
1. Inspect the lift motor gear for general wear (worn teeth, debris, etc.). Remove any
debris found. If excessive wear is observed, escalate to a technician for repair.
2. Use a lint-free wipe, damped with DI water, to very gently clean exposed encoders.Gently
rotate the encoder after each wipe to ensure cleaning of the entire surface.
NOTE: On some printer there is a cover on the lift motor encoder that protects it from aerosol and
debris. No cleaninig is required on these units.
Page 80
Grit
Rollers
Page 81
1. Inspect the print rollers for ink residue and debris. If none is found, proceed to the
next PM task. If residue is seen, perform the following steps to remove it.
Aerosol and debris removal; Paper path optical sensor cleaning; Wiper cleaning; Waste ink
absorber inspection; Ink tubing inspection; Lift motor gear inspection; Paper path grit roller
inspection see at monthly maintenance tasks.
Moving Parts Motor Test
1. Activate the media path, cutter, pump, pinch valves, and maintenance module and
listen for any noises not present when the printer was new.
2. Inspect the motion of the media path and the maintenance module to ensure the
motion looks smooth and free.
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Page 83
3. Prepare a large absorbent towel to catch any ink which might leak from the
maintenance module or the wick to the waste ink reservoir. Make sure to fold the
towel over 2 or 3 times so that it can absorb lots of ink. Be prepared to cover the
bottom of the maintenance module with the towel as you pull it out.
4. Manually rotate the maintenance module positioning gear until the module
disengages from the drive gear and gently pull the module forward until you can
disconnect it from the translation motor.
Positioning
Gear
5. Disconnect the ribbon cable connector for the wiper motor to free the MM.
Page 84
6. Use a lint-free cloth, moistened with DI water, to gently remove any ink residue or
debris from the Maintenance Module. Once the lint-free cloth is soiled, use a new
cloth.
7. Inspect both wicks (printing platen and cap) for warping, plugged up sections, or to
see if it is falling out. If fouled, escalate to a technician for replacement with new
wick(s).
8. Inspect the cap for ink contamination and cracking or permanent deformation of the
cap. If permanently damaged, escalate to a technician for replacement.
Page 85
10. Remove the paper dust from underneath the maintenance module, during the
annual cleaning. Use a vacuum cleaner for the interior of the unit, if necesarry.
Wiper cleaning
Wiper cleaning usually means that the oparator has to change the microfiber roller as it
comes to the end of its lifetime. The operator can easily recognize this stage. First of all the
shape of the roller turns from rounded to ellipse. Secondly this chage within the shape will
cause significant noises during maintenance.
NOTE: Lifetime of the wiper roller depends on the usage, but should be change at least twice
a year.
1. Disconnect the wiper motor connector PCB from the mounting clip.
Page 86
2. Disconnect the wiper PCB from the ribbon cable, as shown int he figure below.
3. Route the ribbon cable through th housing to free the wiper, as show non the next
pictures.
4. Flip up the retention tab at each end of the wiper assembly to free the microfiber
roller.
Retention
tab
Page 87
5. Remove the MFR to access the transfer roller (TR) that is installed below the MFR in
the wiper module assembly.
6. Visually inspect the transfer roller (TR) for unusual ink accumulation. The transfer
roller is stainless steel. Ink may accumulate in scratches on the roller. Wash the roller
with damp lint-free cloth if necesarry.
7. Re-assemble the wiper module.
8. In Liberty, navigate to OneTouch Maintenance and press Home Service Station
button to re-install the MM into the print engine.
Page 88
2. Carefully slide all five ink tanks, one at a time, out of the unit.
5. Re-fasten each ink tank latch to ensure it moves properly and engages fully. If not,
escalate to a technician for replacement.
Page 89
WARNING! To avoid personal injury, power off the printer before performing this task!
1. Fold a damp lint-free cloth and insert it into the groove beneath the cutter
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Page 91
5. Fold the cloth and clean the nozzle plate again to remove remaining debris.
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Page 93
Latch popped up
6. Tilt the printhead cartridge towards the rear of the unit until it clicks.
Page 94
8. Gently wipe the printhead from one end to the other, with a lint-free cloth
moistened with DI water, and then cap the printhead to keep it moist while
performing other tasks.
Page 95
NOTE: Each time the printhead is removed, clean the PPCA contacts and fluidic couplings!
9. Locate the PPCA contacts.
PPCA Contacts
10. Use a new, lint-free cloth dampened with DI water to gently wipe up-and-down to
clean the PPCA contacts.
CAUTION
Use only a very gentle up-and-down motion (never side-to-side) because the contact pins
are very easy to bend which can damage the printhead and the printhead circuit board!
Page 96
Fluidic Couplings
Page 97
13. Place the foam swab in one of the ink channels on the fluidic coupling and rotate to
clean.
14. Use a new, moist foam swab and repeat the process for each ink channel on both
fluidic couplings until all 10 openings are cleaned.
Page 98
16. Wipe from one end to the other with the damp lint-free cloth.
17. Align the PH cartridge with the pin on the PPCA board and slide it into the print
engine.
PH Alignment
Pin
Page 99
Alignment Pin
PH Groove
18. Tilt the top of the printhead cartridge toward the back of the printer, about 20.
19. Gently seat the back of the printhead cartridge into the print engine.
20. When the back of the printhead is firmly seated, gently rotate the printhead cartridge
into position against the stops on the printhead connector board until it clicks into
place.
CAUTION
If the printhead will not rotate into position, do not force it!
21. Slowly close the printhead latch. The fluidic couplings will advance and seal to the
printhead cartridge.
22. Close the printhead latch. When the printhead latch is closed, the printer will prime,
clean and cap the printhead automatically. This operation will generally take a
minute or two, and will be apparent from sounds emanating from the print engine.
23. When the system is primed, print a test printjob from Liberty to make sure the
cleaning process was right and the printhead is working properly.
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2. Use a gloved hand to pull the waste ink absorber out of the waste ink tray and
dispose of it according to local regulations.
3. Align a new waste ink absorber with the shape of the waste ink tray and push into
place until evenly seated and flush with the tray top edge.
4. Slide the waste ink tray back into the frame until it clicks.
Page 101
6.Troubleshooting
6.1. Maintenance Module (aka Service Station) Troubleshooting
The following table lists some possible problems related to the maintenance module, with
possible causes and solutions.
Problem
Motor stalls
Color Mixing
Unable to remove
maintenance module from
the print engine
Possible Causes
Jammed gear train
from broken post or
improperly seated
gears
Squeegee (doctor
blade) wedged, not
seated properly
Debris build-up on
blade and rollers,
increasing friction
Bad motor
Wiper roller
(microfiber
roller(MFR)) is
saturated
Squeegee (doctor
blade) wedged, not
seated properly, or is
bowed
Latches on the
maintenance module
were not completely
closed when the MM
was inserted and
they are now hooked
on the bottom of the
paper path
Solution
1. Check through each
of the possible
causes.
2. If possible, correct
the situation. For
example, re-seat the
gears and squeegee,
clean off debris from
blade and rollers.
3. Re-test.
4. If motor is still
stalled, contact
Customer Service
1. If wiper roller is
saturated, replace it.
2. If squeegee is not
seated properly, reseat it.
3. If squeegee is bowed,
contact Customer
Service
Contact Customer Service or
your Application Engineer
Page 102
Problem
Air and air bubbles causing
bloacked nozzles
Debris on printhead
Ink mixing
Problem Causes
Solution
Appear as missing groups of Cured by recirculation,
adjacent drops but the shape priming or cycles of
is often rounded or irregular depriming
and repriming. Often the
bubbles will go away with
time
Shows up as regularly
Cured by automatic servicing
missing
or manual wiping
or misdirected nozzles, or as
ink color mixing
Appears as mixed or muddy Cured by automated serving
colors. Can be caused by ink or manual wiping
flooding, air in the
printhead,
or a dirty printhead
Results in no print or crisp
Cured by reseating the
blocks of missing drops
printhead or replacing the
usually conforming to the
printhead
printhead die boundaries
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Problem Causes
Mech_error determines
various errors
Solution
First go to OneTouch
Maintenance and push Clear
Error button. If this not helps
contact Customer Support
Make sure that the printer is on
a levelled surface. Then go to
OneTouch Maintenance and
push Tilt Calibration button to
reset the tilt sensors.
Restart Liberty.
Reconfigure the Internal LAN
settings.
Page 104
7. Printer Specifications
Printer Technology
Drop on Demand Thermal Inkjet printing
Printable width is 215.9 mm (8.5 inch)
70,400 nozzles (14,080 per color)
Five channels: Cyan, Magenta, Yellow, Black (2x)
Print Speed
300mm/s at 1,600 x 1,600 dpi black
300mm/s at 1,600 x 800 dpi color
150mm/s at 1,600 x 1,600 dpi black and color
12 inches/s (21,6 km/day)
Print Quality
Black and color: 1,600 dpi native resolution
Operating Systems
Microsoft Windows XP and Windows 7
Media Formats
Roll Media, Fan Fold Media
8.75wide perforated, 500 6 fan-fold
Media Handling
Gap sensing
Black mark sensing
Continuous roll handling
Media Dimensions
Max media width: 215,9mm (8,5 inch)
Minimum media width: 50mm (2 inch)
Minimum media length: 91.5mm (3.6 inch)
Media thickness: 0.13 to 0.33mm (.007-0.13 inch)
Interface
USB 2.0 (4x)
Ethernet 10/100T
Power Interface
20 AMPS @ 24VDC
(Maximum current power supply load)
Page 105
Ink Cartridges
Dye based inks, colors: CMYKK
Non-refillable ink cartridges
Cartridge size: 250ml
Cutter
Integrated cutter
Operation data
Power supply
Power consumption
Operating temperature
Humidity
Dimensions
Width
Height
Depth
Weight
61 cm
40 cm
40.5 cm
40 kg
The table below shows the print performance of the printer expressed in printing length and
label count for given print time intervals. This information is for getting a feel of the volume
the printer can print for planning purposes.
Printing
time
1 sec
30 sec
1 min
10 min
30 min
1 hours
8 hours
24 hours
5x8 hours
24/7
operation
week
Time to
print a 150
m roll (min.)
6
12
Printed lenght
(inch)
(inch)
6
12
Number of 150 m
rolls
6
180
360
3,600
10,800
21,600
172,800
518,400
864,000
3,628,800
12
360
720
7,2
21,600
43,200
345,600
1,036,800
1,728,000
7,257,600
0.2
4.6
9.1
91.4
274.3
549
4,389
13,167
21,946
92,172
0
0
0.1
0.6
1.8
4
29
88
146
614
16.4
8.2
0.3
9.1
18.3
182.9
548.6
1,097
8,778
26,335
43,891
184,343
1.5
45
90
900
2,700
5,400
43,200
129,600
216,000
907,200
3
90
180
1,800
5,400
10,800
86,400
259,200
432,000
1,814,400
0
0
0.1
1.2
3.7
7
59
176
293
1,229
Page 106