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Polaroid EVEREST 3.2 User Manual
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Polaroid EVEREST 3.2 User Manual

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POLAROID EVEREST 3.2
UV Printer
USER MANUAL
1

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Summary of Contents for Polaroid EVEREST 3.2

  • Page 1 POLAROID EVEREST 3.2 UV Printer USER MANUAL...

  • Page 2: Table Of Contents

    2.3 Consumables..........................2.4 Installation Space........................2.5 External Views, Part Names and Functions................2.6 Starting the printer ........................Chapter 3 - Working System of Polaroid ..................... 3.1 Brief Introduction ........................3.2 The Richo Printhead Assembly....................3.3 Printhead Drive Board ....................... 3.4 Printhead Control Board......................
  • Page 3 5.1 Brief Introduction ......................... 5.2 Starting-up Activities ........................5.3 Printhead Jetting Check ......................5.4 Working on RIP Polaroid Edition Software ................5.5 Shutdown Procedure (the machine will be not operated for more than 4 days) ....5.6 Overnight Shutdown ........................

  • Page 4: Polaroid Digital Printing System

    Disclaimer This is an alpha release of the User's Guide for Polaroid EVEREST 3.2 UV printer. We have made every effort to guarantee the accuracy and integrity of the information in this manual. If you find some errors or omissions, please bring them to our attention so we can check and correct them accordingly.

  • Page 5: Manual Usage Conditions And Limitations

    Printer Introduction The Polaroid EVEREST 3.2 UV printer is a wide format digital printer suitable for small up to medium size business use. It uses a UV curable ink, which is environment friendly. It provides high productivity and is capable to replace traditional silkscreen printing.It use conveyor belt for transfer media.So the...

  • Page 6: General Features

    Table 1 General Features Technical Specification: EVEREST 3.2 Print Model EVEREST 3.2 UV Print Size 3200mm*extension table Printhead 4~9 industrial printhead Daft 40sqm/h 60sqm/h Production 30sqm/h 50sqm/h Quality 22sqm/h 28sqm/h Super 15sqm/h 22sqm/h Resolution Up to 726*1200dpi Print Technology Piezoelectric inkjet, Grayscale Technology...

  • Page 7: About The Manual

    Electricity Request Power 6000W 28A Requirements 200~240 VAC, single-phase, 50/60Hz Warranty One year limited warranty(Please contact your local dealer for details) Table 2 Polaroid EVEREST 3.2 UV Printer Model Coding Code Explanation Polaroid Brand Name EVEREST Product series name 3200...

  • Page 8: Chapter 1 - Safety Operating Instructions

    1.1 Brief Introduction This chapter introduces the important safety information. Please read and understand the safety information carefully before operating the printer. 1.2 Safety Information Polaroid printer uses the following chemical substances • All kinds of printing media • UV Ink •...

  • Page 9: Fireproofing

    Wear UV protection glasses and gloves when operating the machine and avoid § being too closer to UV lights. When doing maintenance task or being close to the flatbed machine, UV lights must • be shut off or close all UV protection doors. 1.2.4 Proper Ventilation and Exhaust System •...

  • Page 10: Exhaust System

    1.4 Exhaust System The printing area should be equipped with sufficient exhaust system. The exhaust should be installed in such a way build up of fumes is minimized. Best location for the exhaust should be at lowest level, this way the fumes build-up is minimized. Solvent fumes are heavier than air, so fumes build-up concentrates on the lower level of the room.

  • Page 11: Consumables

    • Shut off the UV lamp whenever the printer is not in use. • Printing of reflective materials is prohibited、avoid solidifying the nozzle surface. 1.7 Consumables 1. Always use the recommended consumables (printing media, ink, ink filters). Failure to follow this instruction may cause poor printing quality and breakdown.

  • Page 12: Chapter 2 - Basic Operation

    Chapter 2 - Basic Operation 2.1 Getting Started This section provides the necessary information to operate the printer. Familiarize yourself with the basic of the printer before reading Section 2. Contents of this section; • Operating conditions • Consumables • External Views, Part Names and Functions 2.2 Operating Conditions This section describes the operating conditions for the printer.

  • Page 13: Consumables

    • Places exposed to direct sunlight • Places subject to vibration Places with excessive dust Places subject to extreme changes in temperature or humidity • • Places near an air conditioner or a heater • Places where the printer may get wet •...

  • Page 14: External Views, Part Names And Functions

    2.5 External Views, Part Names and Functions Front cover Right front cover, computer display screen Left front cover Belt Media Take up Air bar Main power Front View Back cover Ink bucket Guide roller Feeding Air bar Media Take up Air bar Back View...

  • Page 15: Emergency Stop Button

    2.5.1 Emergency Stop Button The emergency stop button is placed near the four corners edges of the machine. Once it is activated/pressed, electrical power for the printer controls is cut-off. 2.5.2 Start Button The start button is placed on the control panel. This switch will not work if the emergency stop button is not released.

  • Page 16: Uv Power Supply

    Inside of Ink Supply Control Compartment, include pump and filter, All pumps are connected to P3-P12 of USB board. Ink Supply Control Compartment 2.5.5 UV Power Supply The UV power supply provides power to UV lamps and the intensity of light can be adjusted to Low or High.
  • Page 17 2.5.6 Suction While the Media suction pumps provide suction on the plateform to hold the media in place while printing is on progress.The plateform was been divided into 3 areas through three manual valve. Vacuum strength can be adjusted by the control panel.The negative pressure value was show on pressure meter.

  • Page 18: The Control Panel

    Registration Suction control bar switch panel Back roller Front roller switch switch 2.5.8 The Control Panel The operation panel serves as the interface between the machine and the operator. 1 Media Turn on or off material shortage sensing. 2 Light Turn on or off the LED light 3 Servo Power of X and Y axis servo motor.
  • Page 19 2.5.10 PrintHead Carriage Assembly The printhead carriage assembly houses the printheads, secondary ink tanks, printhead control board, raster reader, negative pressure sensor, carriage height adjustment motor and the two UV lamps. Power Switch Media Temperate Printhead Left/Right Ink Tank Solenoid of Control Height Tank...
  • Page 20 2.5.11 Home position of printheads carriage and protection position of all printheads Home position is also called printhead cleaning position where you do ink purging/ priming then wiping the excess ink off the printhead nozzles by your hand. protection position protect the surface of all printhead from dry and solidify. Push flash Printhead tray inside...
  • Page 21 2.5.12 Negative Pressure System The negative pressure system is used to hold the ink and preventing it to drop. The negative pressure can be adjusted thru its regulator. Turn clockwise to increase the vacuum and turn counter clockwise otherwise. Negative Pressure Shut off/on valves are provided at the back of the carriage to keep the negative into the system when the power is shut-off.
  • Page 22 Relay for ink prime Ink prime button Positive pressure pump 2.5.15 Auto Detect Media Thickness System This mechanism will perform media thickness check every time you send an image for printing. A message will pop as shown below, the first window will ask you if you want to adjust the carriage height.

  • Page 23: Starting The Printer

    2.6 Starting the printer Make sure there is no media or materials on top of print flat form specifically along the path of carriage during printing. Plug the machine power cord to the electrical power source outlet. Check and reset all emergency stop buttons. Turn on the circuit breaker, leaving the breaker for the vacuum pump turned off.

  • Page 24: Chapter 3 - Working System Of Polaroid Everest

    Chapter 3 - Working System of Polaroid EVEREST 3.2 3.1 Brief Introduction The Polaroid EVEREST 3.2 large format UV printer is using raster image technology to process photos stored in computer. It is one of the most innovative products, which combines photo digital technology with high precision engine driver.

  • Page 25: Left Side

    Drive Board Left Side Right Side Head Chip Manifold Heater Nozzle Plate Thermistor Ink Jet Parts of the Richo G5 Printhead Printhead Drive Board This board is used as drive board for Printhead which is connected to Control Board thru a data cable and a power cable.

  • Page 26: Printhead Control Board

    Likewise, the printhead heating control is also integrated into the Printhead Control Board. Thus, the printhead temperature can be accessed from the Polaroid print driver graphical user interface or GUI. J36 connects to the DC power source for the printhead driver power and heating current source.

  • Page 27: Usb (Main) Board

    The UV status and the carriage limit sensors are also handled by this PCB. The inputs from the status of the switch on the operational panel or the Polaroid print driver graphical user interface or GUI are being received and processed by this board.

  • Page 28: Single Way Ink Prime Control Board

    The board control single way ink prime of each color thru the electromagnetic value under each secondary ink tank and the Polaroid print driver graphical user interface or GUI (the printer drive software). But the most important function of the board is making the temperature of each electromagnetic value down.

  • Page 29: Carriage And Feeding Servomotors

    Servo Driver 1 (SD1) controls the servomotor for beam assembly, Servo driver 2 (SD2) controls the servomotor for carriage. Servo Servo Driver 2 Driver Signal Driver Signal from USB_IF from USB_IF Board J3, J2 Board J1 To Servomotor To Servomotor Encoder Encoder From AC...
  • Page 30 3.9.2 X-axis Servomotor SD2 controls the SM2 which is responsible in driving the carriage X-axis movement. It is installed at the right end of the beam. Belt Pulley Belt drive Reducer system X-axis servomotor Bearingless motor Magnetic levitation drive system Magnet stator 3.9.3 Z-axis Servomotor (Stepper Motor) Carriage height adjuster stepper motor is responsible in driving the carriage up/down...

  • Page 31: The Automatic Carriage Height Adjustment System

    The system uses move pulse of Z-axis Servomotor to determine the accurate height adjustment from default height settings. All actions of carriage height are operated by the Polaroid print driver graphical user interface or GUI (the printer drive software). Z-axis Servo Motor...

  • Page 32: Ink Protect Tank

    Negative Ink Level Pressure Sensor Printhead System Control Board Secondary Ink Filter Ink Tank (Barrel Type) Last Chance Main Board Filter Pump Ink Barrel Ink Control System 3.12 Ink Protect Tank These tanks serve as the ink overflow protection and the vacuum line system. If overflow happens, the ink will flow into this tank, once the ink reaches the maximum level, the sensor will shut off the printhead control board.

  • Page 33: Negative Pressure System

    3.13 Negative Pressure System Negative pressure system is used to hold the ink from dripping out of the printhead nozzles. Pressure settings vary on every machine. The recommended setting range is from -5.2 to - 5.6Kpa. Too low negative pressure setting will result to ink dripping or printhead cannot jet ink. Too high negative pressure setting will cause ink starving over time and ink overflow in the negative pressure line system.

  • Page 34: Magnetoscale Encoder And Magnetoscale Strip

    The spacer of the upper limit optoelectronic switch The upper limit optoelectronic switch 3.15 Magnetoscale Encoder and magnetoscale Strip The Magnetoscale Strip is a magnetic metal strip marked with dots (magnetoscale Ruler) arranged to form a vertical line, the pitching and number of dots depends on the DPI specification of the strip.The Magneticscale Encoder is responsible for (magnetoscale Reader)

  • Page 35: Chapter 4 - Setting Up The Printer

    This is to describe the proper procedure in unpacking and setting-up the machine. 4.2 Wooden Crate Proper Handling The EVEREST 3.2 UV printer is packed inside a wooden crate. • Check the condition of the crate prior to unloading it out of the container van.
  • Page 36 • Start removing the bolts and nuts from the crate top cover. • Bring down the top cover on the floor and put away from the working area so that you can move around freely and safely during unpacking. • Remove the front cover of the crate by removing all the bolts and nuts around this cover.

  • Page 37: Receiving Report

    Lifting-up the machine using forklift • Open and remove the anti-static cover and air bubble pack from the machine. Machine covered with Anti-static sheet Machine Covered with bubble pack 4.4 Receiving Report In case there are discrepancies noted between the actual parts received and packing list, it should be reported to our nearest representative.

  • Page 38: Pre-Installation Requirement

    4.5 Pre-Installation Requirements • The minimum working area should be 700 cm x 350 cm, this includes the space for the operator to move around the machine conveniently and safely. • Prepare the necessary AC plug on the power cord attached to the machine. Please see the Technical Specification table for the power requirements.

  • Page 39: Software Installation Procedure

    PrintFactory RIP Installation • Turn-on the Power for PC and Monitor. • Insert the CD supplied with the machine with label Polaroid PrintFactory RIP Edition for the necessary installation. • The screen will prompt you with starting InstallShield Wizard…, then Choose Setup language window.
  • Page 40 • The Application Installer Setup will now prepare the InstallShield for the setup process and it will prompt you later to enter your user number and password. The user number and password can be supplied by software vendor. But your PC have to be connected internet.
  • Page 41 After opening the RIP software、 click the help to choose the license information to update it and input the passwords. But if you have to replace the PC, you must stop the license! Then input the passwords again in new PC. Click here to input the Click here to activate password...
  • Page 42 • Right now, we can start the RIP software to set operated language, add printer, create the RIP folder where the images which are finished RIP are stored and add ICC files. Set the language and the units. • Add printer, create the RIP folder where the images which are finished RIP are stored and add ICC files.
  • Page 43 Choose the brand Choose the printer • Import ICC files.
  • Page 44 • Start RIP images, then choose the size, printer and ICC, finally submit it to RIP. Click the icon to add image, the RIP it...
  • Page 45 • Finally submit it to RIP, after finishing RIP to go into the RIP folder, select it to print.
  • Page 46 4.7.2 Polaroid Printer operation software Installation • Insert the CD supplied with the machine with label Polaroid Print-driver CD into the DVD ROM. • Copy the driver software from the CD installer to desktop or any other local folder. The filename should be MORPHO UV.rar or MORPHO UV.zip. So firstly translate it normal file.
  • Page 47 The software is initializing and check the data of the printer. The software finished initializing and checking the data of the printer successfully...
  • Page 48 Setting all parameters in the print option to make the printer work normally! Set original position on Set right data of the left/right UV lamp the pint flat bed by by measuring the distance from the printing color block. first printhead to left/right UV lamp Carriage motion buffer length, calculated from...
  • Page 49 Test kinds of movement and set voltage, temperature, height, etc. to make the printer work safely. Step 1, check the if there are some things on the print flatbed. Step 2, set the safe height of the carriage, then calculate the motion factor, the following figure.
  • Page 50 1.Set the safe height of carriage to test movement and look for home position. 3. Click Apply after setting up 2. When clicked, the carriage moves to the set height. Calculate the X, Y motion factor After setting per time, you have to click apply...
  • Page 51 This is to check the mechanical functionality of the Printer through PC. Using the POLAROID Driver software, move the Printhead Carriage from left to right, § then to home position. Check also if the Y-axis Servo Motor is also working by clicking the appropriate arrow head below.
  • Page 52 4.7.5 Printhead Installation Procedure Unpacking the Printhead Open the package, and then take out the anti-plastic bag. • • Open the anti-static plastic bag and remove the head. • Remove the head cap. The serial number and the voltage of each region of printhead should match Note: The head is pre-loaded with ink analog to prevent drying of the nozzles...
  • Page 53 The ink filters Both front ports for discharge ink Data board Data lines Both back ports for input ink The ink discharge tube • Install the printhead one by one by removing printhead fixation screws from the carriage printhead mounting plate first, position the printhead and replace the two fixation screws accordingly.
  • Page 54 the front fixation screw must be tightened properly The back fixation screw must be before doing Y-align the front fixation screw must be slightly tightened to move with tightened properly before doing Y-align. minimum vertical shake. • Connect the 100pins flexible printhead data cable on each printhead and to the Printhead Control Board.

  • Page 55: Ink And Solvent Preparation

    Perform Ink Prime by activating the toggle switch. Do ink bleeding all printheads at time to remove air bubbles trapped inside the printhead. • Perform auto clean for one printhead thru the Polaroid driver GUI. • Send Test Printhead to see if all printheads prints a shown below. But have to confirm the...

  • Page 56: Printhead Alignment

    3. Start printing. 1. Set the print position 2. Set the print speed The printhead print status of four colors are normal. • Note: Above is an Illustration of Nozzle Test Print, only four colors are shown due to space constraint, Light Magenta, Light Cyan, White and Varnish printheads must print the same result.
  • Page 57 4.9.2 Printheads Mechanical Alignment (Y-Align) • On Polaroid driver GUI, click Maintenance button、then select calibration. • then firstly click. The result should look as shown below. • Choose black Click Vertical calibration to Y-align, including Vertical and Horizontal mechanical •...
  • Page 58 • Below shows how to do Y-alignment of the printheads. Turn the mechanical alignment screw clockwise to pull the printhead forward and counter clockwise to push to calibrate the vertical align. Turn the mechanical alignment screw clockwise to pull the printhead forward and counter clockwise to push to calibrate the vertical align at the...
  • Page 59 4.9.3 Printhead Left Align On the printer tab select from left to right、then click the color offset to print the illustration as shown below. Further below shows how the print out should look like. The Illustration shows the K1 and K2 alignment happened at -5 (in-circled) are is good. Please note that this time C is the reference printhead in aligning all other ptintheads.
  • Page 60 4.9.4 Printhead Right Align • On the printer tab select right to left, then click the color offset to print the illustration as shown below. Further below shows how the print out should look like. The Illustration shows the M1 and M2 alignment happened at 0 (in-circled) are is good. Please note that this time C is the reference printhead in aligning all other printheads.
  • Page 61 4.9.5 Printhead Bi-Dir Align • On the printer tab select Bi-Dir Offset Align option then click send print as shown below. Further below shows how the print out should look like, the Illustration shows the Bi-Dir alignment happen at 4 (in-circled). This time you align the left and right printing directions.
  • Page 62 4.9.6 Printhead Step Align • On the printer tab select Step Size option and choose the pass what you want then send print as shown below. Further below shows how the print out should look like. The Illustration shows Black scenarios. •...

  • Page 63: Printhead Voltage And Temperature Settings

    4.10 Printhead Voltage and Temperature Settings This section will describe the necessity to calibrate the Voltage and Temperature settings for each printhead. • By looking on the Left or Right Align printed samples respectively you can determine what need to be done to get a better print quality. •...
  • Page 64 Sometimes getting the best dot print quality is a painful process so it needs patience. All you can do is play with temperature and voltage settings. The recommended Voltage setting range is controlled by Polaroid operated • software so there’s no chance you set the voltage beyond the recommended range.
  • Page 65 select the Rectification Voltage Do small change of voltage in yellow area, then click Apply Note: The actual reading for both Voltage and Temperature will appear only when click print printhead status or click Flash button to flash about all heads •...

  • Page 66: Chapter 5: Operation Of The Machine

    Chapter 5: Operation of the Machine 5.1 Brief Introduction This chapter introduces the details of the operating instructions of the machine from starting up to shutdown procedure. 5.2 Starting-up Activities It is highly recommended to do housekeeping before starting to operate the machine. Maintaining good housekeeping helps improve the quality of the output as well as the safety of operator.

  • Page 67: Working On Rip Polaroid Edition Software

    Note: Above Illustration show only four colors: black, yellow, magenta and cyan, light magenta and light cyan are excluded due to space constraint, please take note that all printheads must print the same. 5.4 Working on RIP Polaroid Edition Software Basic Elements of the Software. For example 4.7.1 Section.

  • Page 68: Shutdown Procedure (The Machine Will Be Not Operated For More Than 4 Days)

    5.5 Shutdown Procedure (the machine will be not operated for more than 4 days) • Shut-off the UV lamps. • Shut-off the electromagnetic switch of all secondary ink tanks. • Shut-off the power for machine and PC. Disconnect the printhead input line from the Ink Supply line. •...

  • Page 69: Chapter 6 - Service And Maintenance Procedure

    Reconnect the Ink input tubing to the supply line, Do Ink prime by activating the toggle switch. • Click the Auto Clean Mode on the Polaroid driver software to wipe clean the printhead nozzles. • Wipe the printheads with a lint-free cloth to removed excess ink residue near the nozzles.

  • Page 70: Maintenance Of Ink Supply And Vacuum Line System

    Maintenance of Ink Supply and Vacuum Line System • Check the ink supply line system specifically the connectors, plugs and valves for any traces of leakages or broken plastic tubing. • Check and drain any traces of ink or solvent flow from the ink protect tank. If overflow happens, clean the affected line immediately.
  • Page 71 Likewise, when the ink priming pressure becomes weak and the negative pressure will go down below -2.0 reading, the air pump is defective or there might be some leakage somewhere in the vacuum line system or the 4/2 way valve is malfunctioning. Usually, the vacuum pump can attain 20-30KPa pressure when you do ink priming.

  • Page 72: Chapter 7 - Appendices

    Appendix A Material Safety Data Sheet for UV Inks SECTION 1: Chemical Product and Company Identification PRODUCT NAME: VUV-Yellow/Magenta/Cyan /Black/Light Magenta/Light Cyan PART NO: VUV-Y /VUV-M/VUV-C/VUV-K/VUV-LM/VUV-LC SUPPLIER: Polaroid INKS INC. AGENT: Polaroid TECHNOLOGY Inc. SECTION 2: Composition / Information of Ingredients INGREDIENT NAME CAS NO CONTENTS...

  • Page 73: Section 7 Handling And Storing

    SECTION 6 Handling ink spillage PERSONAL SAFETY: Use protective gloves and mask; avoid contact with skin or eyes. SPILL CLEANUP METHODS: Apply toilet paper ENVIRONMENTAL PRECAUTION: Avoid pouring waste ink into tap water drainer and soil. SECTION 7 Handling and Storing USAGE PRECAUTIONS: •...

  • Page 74: Section 11: Toxicological Information

    HYGIENIC WORK HABITS: Wash hands at the end of each work shift, before eating, smoking and using the toilet. Change cloth that becomes wet. Isolate contaminated cloth and wash before reuse. Use appropriate hand lotion to prevent aging and cracking of skin. No eating or drinking while working with this material.
  • Page 75 SECTION 13: Disposal Considerations GENERAL/CLEANING: Refer to Section 7 before handing the product or containers. DISPOSAL METHODS: Disposal must be in accordance with current national and local regulations. Chemical residues generally count as special waste. SECTION 14: Transport Information GENERAL: Not regulated.

  • Page 76: Appendix B Preventive Maintenance Checklist

    Appendix B Preventive Maintenance Checklist Item Daily Weekly Monthly Quarterly Semi-annual Annual Check and shake Ink Supply Level on startup Check for level, Waste Ink Bottle dispose if full or nearly full Ink Filters Change Check and Ink Pumps replace if necessary Check and change if...

  • Page 77: Appendix C Troubleshooting Guide

    Appendix C Troubleshooting Guide Problems Probable Causes Solution 1. Fill-up empty ink barrel • No ink flowing to the tube line of the 2. Replace clogged ink line tubing Printhead Carriage and ink filter • Empty ink supply in the Ink barrel 3.
  • Page 78 • Remove or purge any presence • Presence of ink in the Ink Protect of ink in the Ink Protect Tank • All Ink Pumps are Tank • Replace/Fix Ink Protect Level not working • Defective / Out of Position Ink Sensor by opening the Ink Protect Protect Level Sensor Tank...
  • Page 79 • Aligned the Printhead very well (see Printhead Alignment Procedure) • A particular portion of the • Adjust the tension of the Pinch printer is showing • Feeding of the Pinch Roller is not Roller (see Pinch Roller horizontal banding equal Adjustment Procedure) •...

  • Page 80: Appendix D Glossary

    Appendix D Glossary Adobe Acrobat - Software package created by Adobe for converting any document to an Adobe Portable Document Format (PDF) file. Anyone can open your document across a broad range of hardware and software using the downloadable, free software Adobe Acrobat Reader, and it will look exactly as you intended—with layout, fonts, links, and images intact.
  • Page 81 Contrast: The comparing of light and dark on an image, such as low = gray (light). Crop - To cut off parts of a picture or image. Crop marks - Printed lines showing where to trim a printed sheet. Densitometer - A quality control devise used to measure the density of printing ink. Density - The degree of color or darkness of an image or photograph.
  • Page 82 Encoder - An encoder is a device or transducer that converts linear or rotary motion information into uniformly spaced incremental signals. First In First Out (FIFO) - A form of low-level memory (for example, a shift register. Used in the data path for temporary storage of bitmap data on its way to a printhead.
  • Page 83 Initialization File - A file, usually with the extension .INI, that sets startup variables for an application program. Large Format Printing - refers to large sized prints, typically A1 sized or larger, produced in full color utilizing full color digital ink jet printers. Materials Safety Data Sheet (MSDS) - This is a document which describes the potential safety hazards of a chemical, liquid or solid, and instructs how to handle it safely and how to respond to exposures or spills.
  • Page 84 jetting assembly to force ink, along with air bubbles and debris if present, out the jets through the nozzles. Raster - A line of pixels. Also, the process of rendering an image or page, pixel by pixel, in a sweeping horizontal motion, one line after another.
  • Page 85 Calle 10 No. 206, Col. Granjas San Antonio Del. Iztapalapa, C.P. 09070 info@polaroidlargeformat.com www.polaroidlargeformat.com...