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Kodak Versamark, Inc. makes no warranty of any kind with regard to the contents of this document, including, but not limited to, the implied warranties of merchantability and fitness for a particular purpose. Kodak Versamark shall not be liable for any errors or for compensatory, incidental or consequential damages in connection with the furnishing, performance, or use of this document or the examples contained herein.
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Scope This guide describes operating, troubleshooting, and maintenance proce- dures for the 7122 Printer. For information about connecting or discon- necting fluid containers, or changing fluid-related filters, or adding or replacing fluids, see the 7122 Printer Changing Fluid Containers document. The 7122 is a modular, PC-driven, inkjet printer that can operate with compatible controllers as well as with user-designed...
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Text Notations Text Notations This manual uses the following typographical conventions. This style Refers to Text displayed by the software. Ready Anything you type, exactly as it appears, whether referenced in text or at a prompt. Special keys on the keyboard, such as enter, alt, and ENTER spacebar.
Service and Support Service and Support Technical equipment support is available 24 hours a day, 7 days a week. Software and applications support is available 8:00 a.m. to 5:00 p.m. EST/EDT, Monday through Friday. Call for telephone or on-site technical support; to order parts or supplies; to request documentation or product information.
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Chapter 1. Getting Started This chapter provides the following introductory information: • Safety Information • Introduction • Printer Components • Supporting the Printhead • Setting Up the Printhead • Determining Substrate Movement • Locating the Print Array • Positioning Multiple Printheads •...
Chapter 1. Getting Started Safety Information Safety Information Apply all of the following safety guidelines to 7122 operation. • Follow all instructions in the Material Safety Data Sheets shipped with the ink and replenisher. The ink and replenisher used in the 7122 printer are regulated materials in the classifications shown at left.
Chapter 1. Getting Started Introduction Mandatory Action: Consult Operator’s Manual Read all safety information and operator procedures through before performing any action. Mandatory Action: Wear Eye Protection Avoid contact with all fluids, ink and replenisher. Prohibition: No Smoking Never expose the printer, printhead, ink, replenisher or vapor to a heat source or ignition source.
Fluid Compartment Note: Use only fluids approved by Kodak Versamark, Inc. The fluid compartment contains the ink and replenisher tanks. Replenisher maintains the relative concentration of ink to replenisher. A light on the operator panel comes on when a fluid container is low.
Chapter 1. Getting Started Supporting the Printhead Supporting the Printhead The printhead support must hold the printhead steady to protect it from vibration. The support must hold the printhead within 0.250 to 0.375 inch of the substrate (6-10 mm), and support the weight of the printhead and umbilical.
Chapter 1. Getting Started Setting Up the Printhead Setting Up the Printhead Proper printhead setup helps to ensure print quality. Determining Substrate Movement Figure 1.5 illustrates normal and reverse substrate movement. Figure 1.5 Substrate movement (7122 printhead) Front of printhead Rear of printhead Normal substrate movement Reverse substrate movement...
Chapter 1. Getting Started Setting Up the Printhead Positioning Multiple Printheads Position multiple printheads as closely together as possible. The most downstream printhead (the last printhead to print) must finish printing before the next substrate passes under the cue sensor. (See the section “Determining Cue Distance and Cue Delay”...
Chapter 1. Getting Started Determining Cue Distance and Cue Delay Determining Cue Distance and Cue Delay The cue sensor and tach encoder, each mounted on the document transport, are required for proper printing. The information provided by these devices determines when printing occurs.
Chapter 1. Getting Started Determining Cue Distance and Cue Delay Cue Distance Cue distance is the distance from the cue sensor to the print array (Figure 1.10). The minimum cue distance is 1.0 inch (2.54 cm). The maximum cue distance is dependent on the print resolution in the direction of substrate movement and is shown in Table 1.1 on page 1-11.
Chapter 1. Getting Started Document and Image Lengths Document and Image Lengths Two other parameters are required by the printer: document length and image length. These two parameters are illustrated in Figure 1.11. Figure 1.11 Document parameters Image Length Leading Edge Piece Cue Delay...
Chapter 2. Basic Operation This chapter describes basic operating procedures for the printer. Operating procedures include turning the printer on and off, bringing the printer online, and replacing fluids. Idle time guidelines are also described. Safety Information Mandatory Action: Consult Operator’s Manual Read all safety information and operator procedures through before performing any action.
Chapter 2. Basic Operation Operator Panel Functions Panel Buttons The five buttons across the top of the operator panel perform online operations. The lights above each button indicate the status of specific printer conditions. The STANDBY, TEST PRINT, OPEN EYELID (Ready), and PRINTER ON buttons provide more than one function.
Chapter 2. Basic Operation Operating Procedures Panel Lights The eight lights across the bottom of the operator panel indicate specific operating conditions. Table 2.2 describes the lights and the conditions they represent. Table 2.2 Operator panel lights Light Definition Operating Condition ADD REPLENISHER Flashes when replenisher is low.
Chapter 2. Basic Operation Operating Procedures Warning: Irritant Avoid contact with all fluids, ink and replenisher. Warning: Flammable Material Never expose the printer, printhead, ink, replenisher or vapor to a heat source or ignition source. Turning On the Printer To ensure proper communication between the printer and other system components, always turn on components in the following sequence: 1.
Chapter 2. Basic Operation Operating Procedures Turning On the Fluid System When Bypassed To turn on the fluid system when it has been bypassed, press CLEAN PRINTHEAD. The CLEAN PRINTHEAD light flashes during the cleaning cycle and then goes off. The STANDBY light goes out when the clean cycle stops.
Chapter 2. Basic Operation Power Failure Power Failure The printer can withstand a power interruption of up to ½ the operating cycle without affecting operation. During a complete power loss, the eyelid closes to prevent ink spills. Setup parameters are saved. When power is restored, the printer does not automatically power back on.
Chapter 3. Troubleshooting This chapter describes the following troubleshooting procedures: • Printing test patterns • Identifying print defects These procedures apply to the production 7122 printhead with the PAWS line for additional vacuum on the catcher face and anti-wicking channels in the catcher body.
Chapter 3. Troubleshooting Printing Test Patterns Printing Test Patterns Test patterns and test images can be printed by pressing TEST PRINT on the operator panel. A test pattern consists of a pattern of lines designed to verify print quality or to reveal specific print problems. By comparing the print quality of the test patterns you print with the test pattern examples provided in this chapter, you can determine the cause of the printing problem.
Miscellaneous Problems. The procedures described should be performed only by an operator or service technician trained by Kodak Versamark, Inc. Defect groups are not absolute. Different problems can produce similar defects, and more than one print defect can be present at the same time.
Chapter 3. Troubleshooting Identifying Print Defects Buildup and Contamination Dried ink buildup on the following locations is a primary cause of poor print quality: • Eyelid seal • Orifice plate • Printhead bottom cover. Figure 3.2 shows the eyelid seal. The knife-edge seal makes contact with the chamfer on the pan below the catcher.
Chapter 3. Troubleshooting Identifying Print Defects Ragged Print General raggedness is most common problem encountered with 7122 printheads. Raggedness falls into the following three categories: • Slight - caused by dried ink buildup during normal operation • Serious - caused by contamination or lack of cleaning •...
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Chapter 3. Troubleshooting Identifying Print Defects Serious Raggedness Dried ink buildup that is not promptly removed, or contamination deposits on the orifice plate will steadily reduce the print window until it eventually becomes impossible to get good print. Swabbing and print window adjustment should eliminate serious raggedness (see the top pattern in Figure 3.4).
Chapter 3. Troubleshooting Identifying Print Defects Crooked Jets Misaligned jets can be caused by contamination. Figure 3.5 shows a slightly crooked jet, also called a high jet. Cleaning should correct a crooked jet. Figure 3.5 Crooked jets, sample test image and test pattern Crooked jets 3 - 8...
Chapter 3. Troubleshooting Identifying Print Defects Streakers Lines running through the image can be caused by misaligned jets. Cleaning should correct a streaker. A slight amount pickout or dark defect looks the same as a streaker. Figure 3.6 shows a streaker on a test pattern printed at 155 volts and 37 phase counts.
Chapter 3. Troubleshooting Identifying Print Defects Voltage Defects Incorrect charge voltage produces the following defects: • Dark defect • Pickout, or light defect. Change the voltage in 5-volt increments to correct these defects. Dark Defect Charge voltage that is too low causes misdirected drops or extra drops, both called ‘dark defect’.
Chapter 3. Troubleshooting Identifying Print Defects Phase Defect Defects of irregular width running the length of the image indicate incorrect phase setting. Change the phase setting in 5-count increments until the defect disappears. Figure 3.10 shows phase defect on test patterns run at 160 volts and 25 phase counts changing as phase is increased to 35.
Chapter 3. Troubleshooting Identifying Print Defects Elongation An input tach rate that is too slow for the set resolution produces stretched, or elongated characters (see Figure 3.12). Figure 3.12 Elongated and truncated test image, 480 ppi Truncation If cue distance or cue delay is changed without checking the piece size and intra-piece spacing, the image can shift off the piece resulting in truncation (see Figure 3.12).
Chapter 3. Troubleshooting Identifying Print Defects Irregular Gaps Irregular gaps appearing in the test pattern at powerup usually indicate that air is trapped within the printhead. Irregular gaps can also be caused by a concentration of ink. Perform a printhead clean (See Chapter 4). Irregular gaps may also appear when the voltage or phase setting is incorrect;...
This chapter describes the routine and corrective maintenance procedures. These procedures should be performed only by an operator trained by Kodak Versamark, Inc. Routine maintenance must be performed to ensure the printer continues to operate properly. As operator, you perform two types of routine maintenance on the printer: daily and periodic.
Chapter 4. Maintenance Required Tools and Supplies Required Tools and Supplies The following tools are required to perform the maintenance procedures described in this chapter: • Compressed air • Foam swabs • Replenisher in a spray bottle • Wrist grounding strap. Periodic Maintenance Periodic maintenance consists of the following procedures: •...
Replacing the Mist and Fluid Filters The mist filter and the ink or replenisher filters may require changing if system operating pressures rise. Changing these filters is a service procedure. Contact your service technician or technical support at Kodak Versamark, Inc. 4 - 3...
Chapter 4. Maintenance Corrective Maintenance Corrective Maintenance This section describes the corrective maintenance procedures used to correct printing problems identified by the troubleshooting procedures in Chapter 3: • Cleaning the bottom cover • Catchpan installation • Wiping and swabbing. Before starting to clean the printhead, read all the safety information. Warning: Electrostatic Sensitive Devices Avoid generating static electricity.
Chapter 4. Maintenance Corrective Maintenance Cleaning the Bottom Cover This section describes the procedure used to clean the printhead catcher bottom plate. This procedure should always be performed before attempting to swab the printhead. 1. Press STANDBY. 2. Press OPEN EYELID (Ready). 3.
Chapter 4. Maintenance Corrective Maintenance Catch Pan Installation Before starting any maintenance procedure, install CATCH PAN - SERVICE (FRU) - 0192385 (see Figure 4.3) Figure 4.3 Catch pan 0192385 for the 7122 printhead Ground cable Catch pan Fluid drain line Waste tank Warning: Flammable Material Never use a plastic catch pan or an ungrounded catch pan on the 7122...
Chapter 4. Maintenance Corrective Maintenance Figure 4.4 Catch pan installed, 7122 printhead Catch pan ground Wrist strap ground Catcher line connection Standby Pan Installation The 7122 eyelid remains open in standby. If a short or crooked jet occurs, ink can drip from the printhead. To prevent ink from staining the mailbase, transport, or other equipment under the printhead, install the standby pan (see Figure 4.5).
Chapter 4. Maintenance Corrective Maintenance 4. Slide the drip pan (0193687) under the printhead (see Figure 4.6); center it under the print array. Warning: Flammable Vapor Never leave the 7122 unattended while powered up in standby or any other state. Figure 4.6 Standby pan installed under 7122 printhead Standby pan...
Chapter 4. Maintenance Corrective Maintenance 4. Remove the eyelid. 5. Bring the system up and put it in Normal Up State 13 (jets of replenisher). Caution: Do not use the catch pan without its drain line and tank. The pan may overflow.
Chapter 4. Maintenance Corrective Maintenance Incident Recovery If routine cleaning is neglected, ink buildup will eventually coat the knife- edge of the catchpan and create ‘spikes’ on the eyelid. These conditions will cause severe print quality problems. These problems can still be corrected by cleaning, but it may need to be more extensive and thorough than routine cleaning.
Chapter 4. Maintenance Corrective Maintenance Wiping 12. Remove the eyelid and clean its edge thoroughly (see Figure 4.9). 13. Repeat the swabbing procedure (see “Swabbing”). Figure 4.9 Eyelid edge, eyelid removing for cleaning Eyelid edge 14. Replace the eyelid, bring the system up and run more test patterns to check that cleaning eliminated the problem.
Glossary catcher bottom plate The component of the catcher plate that contains a row of electric leads that control drops of ink. When a charge lead is activated, it imparts a charge to the ink drop that causes the ink drop to be attracted to the catcher.
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Glossary downstream In a multiple printer configuration, the last printer to print. Dots per inch, a measure of print resolution. drop interference A printing problem characterized by a ragged line of print or scattered dots, which indicate an interference with the flight of drops.
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Glossary orifice A small hole through which pressurized ink extends in a filament. parameter An item in the system software for which a value can be specified. The component of the printing system that accepts input data from tape or disk, formats the data according to job setup instructions, and sends character-coded image data to the printer.
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Glossary tach 1. A measure of distance, as measured by the tach encoder. 2. A signal emitted by the tach encoder in response to the speed of the substrate. tach encoder A device that detects movement of the substrate and generates tach signals in relationship to substrate speed.