Formax ColorMax 7 Operator's Manual
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Formax ColorMax 7 Operator's Manual

Digital color printer
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ColorMax 7
Digital Color Printer
6/2014
OPERATOR MANUAL
Revision 2

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Summary of Contents for Formax ColorMax 7

  • Page 1 ColorMax 7 Digital Color Printer OPERATOR MANUAL 6/2014 Revision 2...

  • Page 2: Safety Precautions

    In addition, follow any specific occupational safety and health standards for your workplace or area. This manual is intended solely for the use and information of Formax USA, its designated agents, customers, and their employees. The information in this guide was obtained from several different sources that are deemed reliable by all industry standards.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS Table of Contents Section 1 – Getting Acquainted ................... 1 Front View..........................1 Rear View ...........................2 Print Engine Area ........................3 Behind the Ink Tank Door ....................4 Section 2 – Installing the Printer .................. 5 Transport Inspection ......................5 Tools Needed ........................5 Choosing the Location ......................6 Operating Conditions ......................6 Unpacking ..........................7...
  • Page 4 TABLE OF CONTENTS Using the Toolbox Utility....................44 Printing ..........................51 Printhead Cartridge Conditioning ......................51 Section 4 – Software Setup Information ..............53 General Software Setup Info ..................... 53 ® Adobe Acrobat/Reader Setup Tips ................... 54 ® Setting Up a Job in Satori Bulk Mailer ................
  • Page 5 TABLE OF CONTENTS PRINTER MAINTENANCE SCHEDULE .................. 91 Preparing Printer for Transport ..................93 Local relocation ............................ 93 Remote relocation or shipping ......................93 Section 6 – Troubleshooting Guide ................95 Print Quality Issues: ......................95 Examples of Print Quality Issues (including possible causes and solutions)......... 96 The Ink Tank(s) .......................
  • Page 6 TABLE OF CONTENTS NOTES ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________...

  • Page 7: Section 1 - Getting Acquainted

    SECTION 1 GETTING ACQUAINTED Section 1 – Getting Acquainted Front View Control Panel – Provides printer controls. See "Control Panel Functions" section Side Guide Locking Knob – Used to secure the position of the side guide. Rear Media Support Guide – Provides the proper angle to enhance paper feeding and separation.

  • Page 8: Rear View

    SECTION 1 GETTING ACQUAINTED Rear View Main Power Switch, Receptacle and Fuse – Plug in AC power cord here. Switch turns main power ON/OFF. Fuse provides over-current protection. Fuse rating: 2.5A, 250V, slow blow. CAUTION: Make sure power cord is disconnected from printer before checking/replacing fuse. WARNING: Press the ON/OFF Button, located on the control panel, to properly power-down the print engine.

  • Page 9: Print Engine Area

    SECTION 1 GETTING ACQUAINTED Print Engine Area Antistatic Brush Assembly – Contains an antistatic brush that is used to help reduce static energy and remove paper dust from the media. This assembly also contains pressure rollers and fingers that help guide the paper into the print engine. Printhead Latch –...

  • Page 10: Behind The Ink Tank Door

    SECTION 1 GETTING ACQUAINTED Behind the Ink Tank Door Ink Tank Securing Latches – Used to hold the Ink Tanks securely into the slots and against the electrical contacts within the print engine. CAUTION! Before removing/installing Ink Tanks; please be sure to power-down the Print Engine or press the “Replace Ink Tanks”...

  • Page 11: Section 2 - Installing The Printer

    SECTION 2 INSTALLING THE PRINTER Section 2 – Installing the Printer Before using the Digital Color Printer the following must be done:  Transport Inspection. Upon delivery; inspect packaging and report any issues to the Carrier  Gather Tools.  Choose a location for the Printer ...

  • Page 12: Choosing The Location

    SECTION 2 INSTALLING THE PRINTER Choosing the Location The Digital Color Printer should be placed on a sturdy, level, worktable or cabinet; at least 9 inches from any walls. Protect the Digital Color Printer from excessive heat, dust, and moisture – avoid placing it in direct sunlight.

  • Page 13: Unpacking

    SECTION 2 INSTALLING THE PRINTER Unpacking Please refer to the unpacking sequence, shown below. NOTE: Packaging materials may vary slightly from what is shown below. Please save the packaging in a safe place, for possible future use. Two people will be required to safely lift the printer and place it onto a sturdy, level work table. IMPORTANT: WORK TABLE SURFACE MUST BE LEVEL! Level the Table, NOT the Printer! Save the Packaging for possible future use.

  • Page 14: Accessory Box Contents

    [K] Operation CD - contains printer software (driver) and operations manual (in pdf format) Note: Ink Tanks and Printhead Cartridges can be purchased through your local Formax USA Distributor. To locate a Formax USA Distributor, please visit our website: www.Formaxinc.com...

  • Page 15: Removing The Cardboard Shipping Insert And Shipping Tape

    SECTION 2 INSTALLING THE PRINTER Removing the cardboard Shipping Insert and Shipping Tape WARNING! To avoid possible damage to the printer; do NOT plug-in, or power-up, the printer until all shipping materials have been removed; as described below. 1. Open the Top Cover. 2.

  • Page 16: Installing Media Guides

    SECTION 2 INSTALLING THE PRINTER Installing Media Guides The screws needed to attach the side guides to the printer are located under the shipping tape in their respective positions. Begin by installing the Media Registration Side Guide using the two screws [1] provided: Next install the Adjustable Media Side Guide using the two screws [2] provided.
  • Page 17 SECTION 2 INSTALLING THE PRINTER Attach the Rear Media Support Guide using the Knob [3] and washer provided. Remove the knob and washer from the printer. Position the Rear Media Support Guide against the frame of the printer. The two outer holes in the guide fit over the socket head screws;...

  • Page 18: Connecting The Printer

    SECTION 2 INSTALLING THE PRINTER Connecting the Printer Plugging in the Printer  Check to make sure the Main Power Switch [1] is in the OFF position.  Plug the Power Cord into the receptacle [1] at the rear of the Printer. ...

  • Page 19: Connecting To The Computer

    SECTION 2 INSTALLING THE PRINTER Connecting to the Computer The Printer connects to the computer through the USB port [2]. A Network port [3] is also provided; for connecting the printer to a network environment. IMPORTANT: Do NOT connect the printer to the computer, until prompted to do so, during the printer driver installation process.

  • Page 20: Installing The Printer Software (Driver & Toolbox)

    SECTION 2 INSTALLING THE PRINTER Installing the Printer Software (Driver & Toolbox) For the Printer software to operate properly check that the computer system meets the minimum requirements. See section titled “Minimum Computer System Requirements”, on previous page. NOTE: If you are updating the Digital Color Printer (M Series) printer software (printer driver and toolbox utility);...
  • Page 21 SECTION 2 INSTALLING THE PRINTER “Install Printer Software”. The License Agreement window opens. Carefully read the “Software License Agreement”. If you agree to the terms, check “I accept…” then click Next>. After a few moments the “Printer Connections” window opens. Click “Configure to print using USB”.
  • Page 22 SECTION 2 INSTALLING THE PRINTER 11. The “Finished software installation” window opens. Do not select (check) the Print Test Page as the Printer is not set up yet. If desired; you can select (check) the “Set this printer as the default printer” at this time. Then click Next>.

  • Page 23: Connecting The Printer Via Network (Ethernet Port)

    SECTION 2 INSTALLING THE PRINTER Connecting the Printer via Network (Ethernet Port) Valid for M-Series Printers with firmware version 20130820 installed in printer and R12.01 M-Series Driver installed on computer. They should be used as a set. If you haven’t already done so; install the Printer Software (M Series Driver and Toolbox), via USB, by following the instructions in the previous section.
  • Page 24 SECTION 2 INSTALLING THE PRINTER Click on “Diagnostics”. The “Diagnostics” window will open; displaying a lot of information about the printer. This information will include the Network Status and configuration settings. If the “Network Status:” is shown as “disconnected”; click on the refresh button in the browser window.

  • Page 25: Installing The Ink Tanks

    SECTION 2 INSTALLING THE PRINTER Installing the Ink Tanks The Digital Color Printer uses five Ink Tanks (two Black, one Cyan, one Magenta, and one Yellow). The Ink Tank is a delicate, precision device. Handle with extreme care to avoid damage. Ink Tank Anatomy The ink used in this system may be harmful if swallowed.

  • Page 26: Procedure (Installing The Ink Tanks)

    SECTION 2 INSTALLING THE PRINTER Procedure (Installing the Ink Tanks): This procedure assumes that you are installing Ink Tanks into a printer that doesn’t have any Ink Tanks installed. If you are replacing an empty Ink Tank, please refer to the “Replacing the Ink Tanks” section. Install the Ink Tanks as follows: Power the Printer ON.
  • Page 27 SECTION 2 INSTALLING THE PRINTER Insert the new Ink Tanks (label side up) into their appropriate color slots [B]. CAUTION! Be sure each Tank is installed into the proper color slot. If you force the Ink Tank into the wrong slot, you will contaminate the ink system and professional service will be required.

  • Page 28: Installing The Printhead Cartridge

    SECTION 2 INSTALLING THE PRINTER Installing the Printhead Cartridge The Digital Color Printer uses a single Memjet® printhead cartridge. The Printhead Cartridge is a delicate, precision device. Handle with extreme care to avoid damage and issues that could degrade print quality. ATTENTION If you experienced fuzzy print quality or an abrupt failure in a particular area of nozzles on the previous printhead, we recommend that you have the service station...
  • Page 29 SECTION 2 INSTALLING THE PRINTER CAUTION  Use electrostatic discharge (ESD) handling precautions.  Hold the Printhead Cartridge by the handles ONLY.  DO NOT touch the Ink Couplings, nozzle surface or electrical contacts.  DO NOT unpack the Printhead Cartridge until the Printer is ready for installation.

  • Page 30: Procedure (Installing The Printhead Cartridge)

    SECTION 2 INSTALLING THE PRINTER Procedure (Installing the Printhead Cartridge) This procedure assumes that you are installing a Printhead Cartridge into a printer that does NOT have a Printhead Cartridge installed. If your printer already has a Printhead Cartridge installed, and you wish to replace the Printhead Cartridge;...
  • Page 31 SECTION 2 INSTALLING THE PRINTER [A] Carefully remove the Printhead Cartridge from the foil packaging. Tear at notch or cut end with scissors. [B] Remove the protective plastic cover. Hold the Printhead by the handle and unclip the cover from the Printhead. [C] Remove protective strip from the Printhead Electrical Contacts.
  • Page 32 SECTION 2 INSTALLING THE PRINTER Open the Print Engine Clamshell; using with both hands. Using a lint-free cloth soaked with deionized or distilled water, wet the entire Printhead Nozzle area. Be liberal with the amount of water you leave behind on the nozzles (the thin dark line on bottom of printhead cartridge).
  • Page 33 SECTION 2 INSTALLING THE PRINTER If ink doesn’t start filling all tubes during the first 5-seconds of the first ink pump cycle: Using deionized or distilled water; re-wet your lint-free cloth generously. Don’t wait for the pump to stop, open the clamshell and wipe along the Nozzles with the cloth, back and forth twice. Immediately after re-wetting the nozzles, carefully close the clamshell.

  • Page 34: Envelope Printing Attachment Kit

    SECTION 2 INSTALLING THE PRINTER Envelope Printing Attachment Kit The Envelope Printing Attachment Kit (42-900-55) is included with the printer. Kit Includes:  Head Media Guide (1)  Left-hand (large) PPS Spacer (1)  Right-hand (small) PPS Spacer (1) CAUTION: Do NOT use “PPS Spacers” with earlier style Envelope Printing Attachments (Head Media Guides) that did not come with Spacers.
  • Page 35 SECTION 2 INSTALLING THE PRINTER [A] & [B] Start with the Head Media Guide positioned as shown in “A”, on previous page. Note: The “Tab”, on the end of the Guide, fits over the front side of the metal “Support” plate. While lightly pressing up on the Guide;...

  • Page 36: Installing/Removing The Pps Spacers

    SECTION 2 INSTALLING THE PRINTER Installing/Removing the PPS Spacers The PPS Spacers are designed to be used in conjunction with the Head Media Guide. They may come pre- installed in the printer. With the PPS spacers installed and the clamshell closed; the spacers make contact with both ends of the printhead cartridge, which pushes the Platen down a small amount.

  • Page 37: Section 3 - Operating The Printer

    SECTION 3 OPERATING THE PRINTER Section 3 – Operating the Printer Control Panel Functions BUTTON FUNCTION(s) Press to power-up or power-down the print engine. Note: The Main Power Switch must be ON, to power-up the print engine. POWERING-UP: After pressing this button; it takes approximately 45 seconds for the print engine to power-up.

  • Page 38: Printer Status Light Indicators

    SECTION 3 OPERATING THE PRINTER Printer Status Light Indicators Valid with Firmware 20130820 or higher installed. The lights (LED’s), on the three control panel buttons, indicate the status of the printer. Flashing SLOW = 1 time per second Flashing FAST = 3 times per second NOTE: To obtain additional detail about the printer’s condition, please open the Toolbox utility.
  • Page 39 SECTION 3 OPERATING THE PRINTER Printer Status Light Indicator Chart (continued) Printer Status Additional Details, Possible Solution or corresponding Toolbox message Action Press the RESUME button to continue printing. Job can also be resumed by clicking on the “Clear Error” button in the Toolbox. Press the CANCEL button to cancel the job and Printing Paused clear the job from the computer’s print queue.
  • Page 40 SECTION 3 OPERATING THE PRINTER Printer Status Light Indicator Chart (continued) Printer Status Additional Details, Possible Solution or corresponding Toolbox message Action Printer has detected that one of the media (Paperpath) sensors is blocked (interrupted). Carefully remove jam and or clean Paperpath sensors.

  • Page 41: Setting Up The Feed

    SECTION 3 OPERATING THE PRINTER Setting up the Feed The Digital Color Printer is equipped with four sheet separators, two side guides, a rear media support guide and two different sized media support wedges. When properly adjusted these items will separate and guide the media so that only one piece of media is fed into the print engine at a time.
  • Page 42 SECTION 3 OPERATING THE PRINTER Loosen the locking screws, located behind the sheet separators, and raise the separators. Then tighten the locking screws to hold the separators in the up position. Place a single piece of the media, to be run, under the separators.
  • Page 43 SECTION 3 OPERATING THE PRINTER Adjust the position of the Rear Media Support Guide, so that it is centered under the width of your media. This guide slides side to side. Tip: The Rear Media Support will slide, without loosening the knob. Adjust the position of the Media Support Wedge to accommodate the length of your media.

  • Page 44: Printer Driver Properties

    SECTION 3 OPERATING THE PRINTER Printer Driver Properties Valid for M Series Driver version R12.01 or higher. NOTE: The R12.01 Driver was developed for use with printer firmware version 20130820. If you try to use this Driver with older printer firmware versions, some of the Driver properties/features may not work. Driver Compatibility: Windows XP/Vista, Windows 7.
  • Page 45 SECTION 3 OPERATING THE PRINTER  Copies – Lets you choose the number of copies to be printed. NOTE: Driver version R12.01 has a limit of 32,767 copies. However, in some cases, copies are limited by the software program. For example; Adobe Acrobat® limits copies to 999. Reverse Order –...
  • Page 46 SECTION 3 OPERATING THE PRINTER Oversize – Select this box to enable “full bleed” printing (printing off all edges of media). When “oversize” is selected the “custom media size” you define is increased by 0.13” in width and height; without affecting the values shown in the “Custom Media Size” screen. IMPORTANT! In order to take advantage of this feature;...
  • Page 47 SECTION 3 OPERATING THE PRINTER Layout Tab Layout allows you change how/where the document prints without changing the original document.  Resizing Original Size – no changes Custom Resize - lets you resize the original as a % of normal size. The printer will print the document in the size you selected regardless of the size of the paper selected.
  • Page 48 SECTION 3 OPERATING THE PRINTER sensor” sees between pieces; minus at least 5 mm. Setting this value too large may cause blank (unprinted) pieces to be fed, purge bar printing on leading edge of next piece, and or “false” “PAPERPATH_FEED_TIMEOUT” conditions (with media stopping inside the print engine).
  • Page 49 SECTION 3 OPERATING THE PRINTER Import/Export Tab Import/Export is used to preserve any custom Media Sizes and/or Watermarks you may have created/added.  Export – Used to save your custom media sizes and/or watermarks, to a “holding file” (*.ini); before uninstalling/re-installing/updating the M- Series Driver.

  • Page 50: Using The Toolbox Utility

    SECTION 3 OPERATING THE PRINTER Using the Toolbox Utility Valid for M-Series Printers with Firmware version 20130820 installed. Once the Printer Driver is installed you have access to the Printer Toolbox (Embedded Web Server). The Toolbox lets you monitor the job, ink usage, perform diagnostic checks, print reports and run maintenance tasks on the Printer from your computer.
  • Page 51 SECTION 3 OPERATING THE PRINTER Ink Level Status Displays the approximate amount (%) of ink available in each Ink Tank. NOTE: The Ink Level (%) is an estimated value based on ink that has been ejected (printed) from the printhead. Priming/depriming and manually cleaning the printhead can reduce the accuracy of this calculation.
  • Page 52 SECTION 3 OPERATING THE PRINTER User Interface Menu [A] User Interface Buttons: Let you perform routine maintenance and operating tasks. You can use these buttons to Clear Errors, Cancel a Job, Reset the Job Counter, and Reset the Page Counter. You can also: Replace Ink Tanks –...
  • Page 53 SECTION 3 OPERATING THE PRINTER [B] Basic Printer Settings – Lets you adjust automated service and cleaning intervals, adjust the feed mode, manually set the purge bar location and disable “paper jam” detection. KWS Setting – (Keep Wet Spitting) Incorporates an algorithm to periodically fire all printhead nozzles in order to keep all nozzles wet;...
  • Page 54 SECTION 3 OPERATING THE PRINTER Purge Bar Position (BoF)* – In operation, the Printhead spits a small amount of ink in the gap between pieces to keep the nozzles refreshed. For irregular-shaped pieces (like an open envelope flap), the sensor may “read”...
  • Page 55 SECTION 3 OPERATING THE PRINTER illuminated) at all times. If you need to turn the printer off; please be sure to power-down the print- engine, using the “Shutdown” button in the Toolbox or the ON/OFF button on the control panel. Wait until all the control panel buttons go out, before turning off the Main Power Switch.
  • Page 56 SECTION 3 OPERATING THE PRINTER well the nozzles are performing, in each color channel of the Printhead. New: This function can now be accessed by pressing the “Print Ink Channels” button; located on the top, non-operator side, of the Print Engine.

  • Page 57: Printing

    SECTION 3 OPERATING THE PRINTER Service Menus For authorized personnel only. Provides access to more advanced Printer control and maintenance menus. A password is required to open the following features.  Printer Maint Config  Printer Control Config  Scan Sensors ...
  • Page 58 SECTION 3 OPERATING THE PRINTER Locate the “Circulate Ink” button. Click on this button. While the ink is circulating, tap lightly on the ink tubes, located at the operator side of the printer, and on the printhead cartridge. This will help dislodge air bubbles; allowing them to pass through the printhead and out the non-operator side of the printhead.

  • Page 59: Section 4 - Software Setup Information

    SECTION 4 SOFTWARE SETUP INFORMATION Section 4 – Software Setup Information General Software Setup Info Note: The following information assumes you have the M Series Driver version 12.01 or higher installed on computer system and firmware version 20130820 or higher installed on printer. Do NOT exceed the Min or Max media specifications of the printer: ...

  • Page 60: Adobe ® Acrobat/Reader Setup Tips

    SECTION 4 SOFTWARE SETUP INFORMATION ® Adobe Acrobat/Reader Setup Tips In general, printing a PDF from Adobe Acrobat/Reader is straight-forward and easy. However there are a few limitations and quirks that you should be aware of. Original PDF should be designed for the piece size and orientation you plan to use. Adobe Acrobat has some nice controls for changing orientation and adjusting the image size to fit the media size you select;...

  • Page 61: Setting Up A Job In Satori Bulk Mailer

    SECTION 4 SOFTWARE SETUP INFORMATION ® Setting Up a Job in Satori Bulk Mailer Printer Driver Limitation: Satori normally develops printer drivers for use with their software product. However; in the case of the Digital Color Printer; Satori has not developed a driver for this model. Therefore, you will need to use the features within the “M Series Driver”...
  • Page 62 SECTION 4 SOFTWARE SETUP INFORMATION The “Envelope Options” window will open. Double-click on “New Envelope/Letter Layout” An envelope layout window will open. Type a name (example: Digital Color Printer #10 Flap First) into the Layout Name window. Enter these values: Page Width: 8.5 in. Page Height: 4.125 in Click on OK and the envelope layout window will close.
  • Page 63 SECTION 4 SOFTWARE SETUP INFORMATION 14. Add any additional items that you want printed to the “designer” screen. Drag and drop the items onto the layout, wherever you want them to be printed on the envelope. Click on Save. 15. Click on the "Go to Preview Mode" icon , located at the upper left-hand corner of the “designer”...
  • Page 64 SECTION 4 SOFTWARE SETUP INFORMATION 18. From the “M Series Printer Driver Properties” window; Click on the “Custom Sizes” button. The “Custom Media Size” window will open. Set the Width to 8.50 inches and the Height to 4.2 inches. Tip: If you type 4.13 it will default to 4.2. Type a name into the “Media Name”...
  • Page 65 SECTION 4 SOFTWARE SETUP INFORMATION #10 Envelope, Feeding Short Edge First Open Bulk Mailer 5. From the “Home” tab, select (double click) on the “mailing” of your choice. Select the “Print Mail” tab (left side of screen). From the “Print Mail” screen; double-click on the “Print Mail Wizard” which will guide you through the template (layout) setup process.
  • Page 66 SECTION 4 SOFTWARE SETUP INFORMATION 11. The template will be displayed for you to edit (add, remove, position data). Your envelope design (layout) should look similar to the one shown here. 12. Add any additional items that you want printed to the “designer” screen.
  • Page 67 SECTION 4 SOFTWARE SETUP INFORMATION 14. Click on the printer icon , to open the "Mail Print Setup" dialog box. Make sure the “M Series Driver” is selected as your "Printer:". 15. From the “Mail Print Setup” window; Click on the “Advanced Settings”...

  • Page 68: Setting Up A Job In Microsoft Word (2007)

    SECTION 4 SOFTWARE SETUP INFORMATION ® Setting Up a Job in Microsoft Word (2007) ® Valid when using Microsoft Word 2007 and the M Series Driver version R12.01. Before you begin laying-out the document; make sure the “M Series Driver” has been selected as your “default printer”...
  • Page 69 SECTION 4 SOFTWARE SETUP INFORMATION Envelope #10, Feeding Short Side First: ® Valid when using Microsoft Word 2007 and the M Series Driver version R12.01 The following procedure assumes that the printer has been setup to feed # 10 envelopes, short side first. Don’t forget to position the “Media Registration Side Guide”...
  • Page 70 SECTION 4 SOFTWARE SETUP INFORMATION Envelope #10, Feeding Flap First: ® Valid when using Microsoft Word 2007 and the M Series Driver version R9.1. The following procedure assumes that the printer has been setup to feed # 10 envelopes, flap first and that you are using Windows 7.
  • Page 71 SECTION 4 SOFTWARE SETUP INFORMATION Click on OK to close the “M Series Driver Printing Preferences” window. 10. Close the “Devices and Printers” folder. 11. Open MS-Word 2007. 12. Click on the “Office Button” and then select “New”, to create a new “blank document”. 13.

  • Page 72: Section 5 - Operator Maintenance

    SECTION 5 MAINTENANCE Section 5 – Operator Maintenance This section covers how to perform routine operator maintenance on the printer; including Ink Tank care, Printhead care, clearing paper jams, replacing Ink Tanks, replacing Printhead Cartridge, replacing sheet separators. If printer maintenance or service is needed beyond the scope of what is covered in this section; please contact your Dealer/Distributor for support.

  • Page 73: Ink Tank Storage & Shelf Life

    SECTION 5 MAINTENANCE Clean the Ink Level Prism [A] and QA Chip contacts [B] with a clean, dry, lint-free cloth. NOTE: You can dampen the cloth with distilled water to wipe the Prism, but DO NOT get the QA Chip contacts wet. Tip: A soft pencil eraser can also be used to lightly clean the QA Chip contacts.

  • Page 74: Ink Tank Disposal

    SECTION 5 MAINTENANCE Ink Tank Disposal The Ink Tank may be disposed of in a normal manner. Clean up spills with soap and water. Abrasive soap is effective in cleaning ink off your hands. Cleaning the Printhead Cartridge The Printhead Cartridge is cleaned automatically; each time the printer is turned ON, before each job, periodically during the print job, and when a User Maintenance Level routine is performed by the operator.
  • Page 75 SECTION 5 MAINTENANCE Manual Printhead Cleaning: NOTE: We recommend the use of nitrile powder-free gloves for this process. As a last resort, if running the built-in “... Clean Printhead” features don’t help improve print quality; the printhead cartridge can be cleaned manually. Carefully open the clamshell.

  • Page 76: Replacing The Printhead Cartridge

    SECTION 5 MAINTENANCE Replacing the Printhead Cartridge The following procedure describes how to remove the Printhead Cartridge from the printer. ATTENTION If you experienced fuzzy print quality or an abrupt failure in a particular area of nozzles on the previous printhead; we recommend that you have the service station inspected/cleaned and the wiper roller replaced, before installing the new printhead.

  • Page 77: Printhead Storage & Shelf Life

    SECTION 5 MAINTENANCE Printhead Storage & Shelf Life Properly stored, unopened, Printhead Cartridges have a shelf life of up to 1 year. ° Long Term: 14° F to 86° F (-10 C to 30° C Short Term: -11° F to 140° F (-25° C to 60° C) Storage Temperature Range: NOTE: Cumulative storage duration above 86°...

  • Page 78: Inspecting & Cleaning The Lip Of The Capping Station

    SECTION 5 MAINTENANCE Inspecting & Cleaning the Lip of the Capping Station The Capping Station (Cap) is part of the Service Station. When the printer is idle, the Service Station automatically caps the printhead to keep the nozzles hydrated. Excess ink can accumulate on the Lip of the Cap. This commonly occurs after a printhead cartridge is installed and the system is primed.

  • Page 79: Inspecting The Wiper Roller

    SECTION 5 MAINTENANCE Inspecting the Wiper Roller The Wiper Roller should be routinely inspected for signs of wear and debris. NOTICE! If you have not been trained or are uncomfortable performing this task, please contact your service support representative. Directions: Power ON the printer and power-up the print engine.

  • Page 80: Cleaning/Replacing Service Station Items

    SECTION 5 MAINTENANCE Cleaning/Replacing Service Station Items The Service Station contains separate areas/devices that are used to perform the following tasks.  Cleaning. The Wiper Roller cleans the Printhead nozzles of excess ink and debris.  Printing/Purging. The Printing Platen acts as a base to support media during printing. It also contains a purging area;...
  • Page 81 SECTION 5 MAINTENANCE Power-up the printer. Open the Printer Toolbox. In the User Interface window, press the “Eject Service Station” button. Once the Service Station has ejected; power OFF the printer. Press the ON/OFF button once and wait about 45 seconds for the print engine to power off (all control panel light’s off). Then turn the Main Power Switch OFF.

  • Page 82: Cleaning The Service Station

    SECTION 5 MAINTENANCE Cleaning the Service Station Caution: Please be sure that you are using proper cleaning techniques to clean items that come in contact with the printhead. Use only distilled or deionized water and lint free cloths. If you don’t follow this rule, you will introduce contamination into the printhead;...
  • Page 83 SECTION 5 MAINTENANCE Wiper Motor Assembly Removal and Cleaning Removal: Disconnect (unplug) the wiper motor cable from the Service Station Printed Circuit Board [A]. Remove the Printed Circuit Board [A] from the Service Station Tray. Carefully release clips to remove board. Lift out the Wiper Motor Assembly [B].
  • Page 84 SECTION 5 MAINTENANCE Printing Platen and Capping Station Removal and Cleaning Removal: Both of these items simply lift out for removal from the Service Station. Cleaning: Rinse off ink using tap water. Tip: Make sure the valve, located on the bottom of the Capping Station, is clear of debris and working.

  • Page 85: Installing The Service Station

    SECTION 5 MAINTENANCE Installing the Service Station CAUTION THIS PROCESS MUST BE PERFORMED BY A QUALIFIED/TRAINED PERSON. NOTICE: Due to the technical nature of this procedure; it should only be performed by a qualified technical support person or someone that has been properly trained on this procedure. Please contact your technical support representative.
  • Page 86 SECTION 5 MAINTENANCE Slide the Cable Securing Latch open on the Service Station Circuit Board; as shown below. Closed Opened Locate the Ribbon Cable (from within the Service Station Slot). Insert the Ribbon Cable (blue side up) into the space under the Cable Securing Latch [1].
  • Page 87 SECTION 5 MAINTENANCE Look down through open area, in the Print Engine, to make sure the Service Station is aligned with the “Bar”; (Service Station Drive Shaft) as shown. If the Printhead Cartridge is not installed (has been removed), you can look down through the top of the Print-Engine, through the Printhead Cartridge opening.

  • Page 88: Still Experiencing Print Quality Issues

    SECTION 5 MAINTENANCE 11. Turn the printer’s Main Power Switch ON; then press the control panel’s ON/OFF button. After printer initialization (~45 seconds) the Print Engine will automatically pull the Service Station the rest of the way in. NOTICE: If the Service Station should get jammed during this process (you hear motor stall noise or gear slipping noise);...

  • Page 89: Inspecting/Replacing The Waste Ink Tray

    SECTION 5 MAINTENANCE Inspecting/Replacing the Waste Ink Tray The Waste Ink Tray (123-2487) is filled with an absorbent material, used to capture the waste ink that drains from the Service Station. 1. If the printer is on; press the ON/OFF button to power-down the print engine. Wait about 45 seconds until the system shuts down (all control panel lights will go off).

  • Page 90: Replacing The Sheet Separators

    SECTION 5 MAINTENANCE Replacing the Sheet Separators The sheet separators (90-103-09) insure separation of the pieces as they are being fed. If you experience double sheet feeding and cannot adjust the separators to prevent this, replace the separators. Replacing the sheet separators is not difficult; however if you don’t feel confident about doing this yourself;...

  • Page 91: Removing Jammed Media

    SECTION 5 MAINTENANCE Removing Jammed Media Clearing a jam depends on where the jam occurred. From the Feed Section: Remove media stack. Loosen and lift the sheet separators to clear the jam. Then re-adjust the sheet separators as described in this manual.

  • Page 92: Cleaning The Printer Body

    SECTION 5 MAINTENANCE Cleaning the Printer Body WARNING THE PRINTER IS A PRECISION MACHINE THAT SHOULD BE CLEANED REGULARLY TO INSURE MANY YEARS OF SERVICE. BEFORE PERFORMING ANY MAINTENANCE, DISCONNECT THE MACHINE FROM ITS POWER SOURCE! DO NOT REMOVE SIDE COVERS! HIGH VOLTAGES PRESENT. Clean the Printer regularly to remove accumulated paper dust and ink.

  • Page 93: Cleaning The Feed Sensor

    SECTION 5 MAINTENANCE Cleaning the Feed Sensor The Feed Sensor is located between the media hopper and the print engine. It has two functions. - It is used to control the delivery of media to the print engine. - It drives the LCD counter; located on the entrance side of the printer. TIP: If the LCD counter is not incrementing with each piece of media, then the sensor is not working properly (dusty/dirty).

  • Page 94: Cleaning Other Items Inside The Print Engine

    SECTION 5 MAINTENANCE Cleaning Other Items inside the Print Engine Areas in the Print Engine can become glazed with a buildup of dust, paper lint and accumulated ink and need to be cleaned regularly. This section covers the procedures for cleaning the following items. Grit Rollers (Media Transport Rollers) Media (Paperpath) Sensors Capping Station Lip...
  • Page 95 SECTION 5 MAINTENANCE Use the procedures, as outlined below, to clean the following items. Grit Rollers [A]: Entry Mark Clean as needed using a small stiff-bristled brush (toothbrush), lightly moistened with distilled water. Do NOT use anything other than distilled water to clean the Rollers.

  • Page 96: Cleaning The Ink Revolver Couplings

    SECTION 5 MAINTENANCE Cleaning the Ink Revolver Couplings This process should be performed just before a printhead cartridge is installed or re-installed; to remove contaminated/dry ink and other debris from the Ink Revolver Couplings. If this step is skipped; the printhead and or ink system could become contaminated resulting in an increase in print quality issues.

  • Page 97: Printer Maintenance Schedule

    SECTION 5 MAINTENANCE PRINTER MAINTENANCE SCHEDULE General, periodic maintenance is needed to keep the Printer in good working order. Many tasks can be performed by operators with basic supplies, no special tools needed. Other tasks should only be performed by trained service personnel. NOTE: High volume usage may require more frequent maintenance. MAINTENANCE TYPE COMPONENTS / TASKS DAILY...
  • Page 98 SECTION 5 MAINTENANCE NOTES ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________...

  • Page 99: Preparing Printer For Transport

    SECTION 5 MAINTENANCE Preparing Printer for Transport Please use this procedure if you ever need to transport the printer to a new location or ship the printer. Please refer to the appropriate sections in the manual for details on installing/removing items from the printer.
  • Page 100 SECTION 5 MAINTENANCE Remove the Printhead Cartridge and install protective covers on printhead. Be careful to avoid ink spills (drips) and stains during this process. Store Printhead Cartridge in a sealed plastic bag with a damp cloth. CAUTION: Make sure the cartridges electrical contacts are dry before re-installing printhead. 10.

  • Page 101: Section 6 - Troubleshooting Guide

    SECTION 6 TROUBLESHOOTING Section 6 – Troubleshooting Guide The following troubleshooting guides are provided to assist you in solving any problems that might occur with the Digital Color Printer. We have tried to make them as complete as possible. The best advice we can offer is to make sure that the system is set up properly, plugged in, and that it has an adequate supply of ink before attempting to troubleshoot any problem.

  • Page 102: Examples Of Print Quality Issues (Including Possible Causes And Solutions)

    SECTION 6 TROUBLESHOOTING Examples of Print Quality Issues (including possible causes and solutions) The Memjet printhead cartridge contains 70,400 inkjet nozzles. These nozzles are divided into ten rows; two rows of nozzles for each color channel. Due to the high number of nozzles; it is not uncommon for some nozzles to become contaminated, dehydrated or clogged.
  • Page 103 SECTION 6 TROUBLESHOOTING Clogged/Damaged/Dead Nozzles: Clogged/damaged/dead/ nozzles will normally show as thin, crisp, vertical lines of missing color. Multiple adjacent nozzles, with same issue, will show as wider, crisp, vertical lines of missing color. Clogged nozzles are normally due to Printhead nozzle dehydration or partial contamination. Damaged nozzles are normally due to improper cleaning or debris on wiper roller causing damage to head.
  • Page 104 SECTION 6 TROUBLESHOOTING Color Mixing Issues: Color mixing will show as muddy, mottled or distorted (grainy) colors. Color mixing occurs when the ink from one color channel crosses over into another color channel. Since the inkjet nozzle rows are located very close to one another (ten rows of 7,040 nozzles, located within a 0.8 mm space), it is easy for partials or fibers to create bridges across color channels.
  • Page 105 SECTION 6 TROUBLESHOOTING Scuff Marks and Smudging Issues: Scuff Marks occur when the media makes contact with an area of the printhead that has ink on it. Smudging occurs when the wet image, on the media, makes contact with something (most commonly the printhead) before it is dry.
  • Page 106 SECTION 6 TROUBLESHOOTING Smudging: Here is an example of “smudging” that occurred when an area of this page, with a wet image, made contact with the printhead. Note: There are also scuff marks in this example. As mentioned previously; smudging will increase the chance for scuff marks;...
  • Page 107 SECTION 6 TROUBLESHOOTING Fuzzy/Distorted Print Fuzzy/distorted print can occur for a number of reasons; listed/shown below. Problem: Poor original image quality (less than 300 dpi). Solution: Use high quality images. Problem: Choosing to print image in low resolution from software application. Solution: Set image to highest resolution possible from software application.

  • Page 108: The Ink Tank(S)

    SECTION 6 TROUBLESHOOTING The Ink Tank(s) CONDITION PROBLEM SOLUTION One or more of the “septum Installed New Ink Tank and Try removing and re- needles” didn’t fully puncture the shortly after the related Ink installing the Tank. See “Installing The Ink Tanks”. Channel (color) stopped septum seal on the new Ink Tank.

  • Page 109: The Printhead Cartridge

    SECTION 6 TROUBLESHOOTING The Printhead Cartridge The Memjet printhead cartridge contains over 70,000 inkjet nozzles. These nozzles are divided into ten rows; two rows of nozzles for each color channel. Due to the very tiny size of each nozzle and the high number of nozzles;...
  • Page 110 SECTION 6 TROUBLESHOOTING The Printhead Cartridge (continued) CONDITION PROBLEM SOLUTION System will not prime the Printhead nozzles dry (air pulled Wet the Printhead nozzles through nozzles; not allowing using distilled water and a printhead after installing Printhead Cartridge system to create vacuum) wet, lint-free cloth.

  • Page 111: The Printer

    SECTION 6 TROUBLESHOOTING The Printer NOTICE: The printer will not print if any of the five ink tanks are empty or missing. Dots or Lines Printed on Media CONDITION PROBLEM SOLUTION Reduce paper width to 8.5” to avoid exceeding You have exceeded Multiple horizontal black lines are printed down the the maximum print...

  • Page 112: Service Station Problems

    SECTION 6 TROUBLESHOOTING Service Station Problems WARNING! Many of the issues related to Service Station function will require a qualified Service Person, or properly trained person, to diagnose and fix these issues. If you haven’t been properly trained on or don’t feel comfortable performing these procedures;...

  • Page 113: Interface Communication Problems

    SECTION 6 TROUBLESHOOTING Interface Communication Problems CONDITION PROBLEM SOLUTION Wrong USB port selected in “M M Series Driver does not Verify that you are selecting the Series Driver”. respond to printer being appropriate USB port in the connected via USB. driver Ports Tab.

  • Page 114: Feeding Problems

    SECTION 6 TROUBLESHOOTING Feeding Problems CONDITION PROBLEM SOLUTION Intermittent feeding Media Support Wedge not used. The Media Support Wedge adds a slope to the stack and helps feeding. Side Guides set too tight to media. Readjust Side Guides. Dirty Feed Rollers. Clean the Feed Roller with distilled water and a cloth.

  • Page 115: Errors And Warnings

    SECTION 6 TROUBLESHOOTING Errors and Warnings Printer Alert Window Messages Messages sent from the driver and displayed on PC screen in a small popup window. MESSAGE SOLUTION Wait until the message disappears. The printer will start printing your job Cleaning in Progress once the cleaning process has completed.

  • Page 116: Toolbox System Status Messages

    SECTION 6 TROUBLESHOOTING Toolbox System Status Messages Displayed, in red, in the M Series Toolbox utility. Valid for printers with firmware version 20130820 or higher installed. SYSTEM STATUS PROBLEM SOLUTION PAPERPATH_FEED_TIME Out of Paper Load media into printer and press the Media is not reaching PAPER/RESUME button.
  • Page 117 SECTION 6 TROUBLESHOOTING Toolbox System Status Messages (continued) Displayed, in red, in the M Series Toolbox utility. Valid for printers with firmware version 20130820 or higher installed. X = Color. Ink Tank replacement will be necessary X_INK_LOW One or more Ink Tanks soon.
  • Page 118 SECTION 6 TROUBLESHOOTING Toolbox System Status Messages (continued) Displayed, in red, in the M Series Toolbox utility. Valid for printers with firmware version 20130820 or higher installed. SYSTEM STATUS PROBLEM SOLUTION The printer’s electronics TILT_ERROR If just powered on, wait a few minutes; have detected that the error may clear by itself.
  • Page 119 SECTION 6 TROUBLESHOOTING Toolbox System Status Messages (continued) Displayed, in red, in the M Series Toolbox utility. Valid for printers with firmware version 20130820 or higher installed. PRINTHEAD_MISSINGQA Printhead Missing and Install Printhead one or more of the Ink Install Ink Tanks. Tanks are also missing.

  • Page 120: Appendix A - Printer Specifications

    APPENDICES Appendix A – Printer Specifications SPEED (color or mono) Page Printing 8.5” x 11” Up to 3,600 per hour (1600 x 800 dpi @12 ips) No. 10 Envelopes Up to 7,500 per hour (1600 x 800 dpi @ 12 ips) MEDIA SIZE Minimum: 3"...

  • Page 121: Appendix B - Supplies And Optional Hardware

    APPENDICES Appendix B – Supplies and Optional Hardware The following supply items and optional hardware are available from your Formax USA Distributor: Supplies Part # Description Printhead Cartridge M5PRINT-N Cyan Ink Tank (250 ml) M5C250-N Magenta Ink Tank (250 ml)
  • Page 122 To locate a Formax USA Dealer or Branch in your area, please use the following link. www.Formaxinc.com. Service should only be performed by a qualified Formax service person. In addition, you may wish to log onto the Formax USA web site (www.Formaxinc.com), and click on the “support” link. This area contains many useful resources.

  • Page 123: Appendix C - Quick Reference Info

    APPENDICES Appendix C – Quick Reference Info Suggestion: Printout these quick reference sheets and attach to, or near, the printer. Control Panel Light Sequences – Quick Reference Valid with Firmware 20130820 or higher installed. The lights (LED’s), on the three control panel buttons, indicate the status of the printer.

  • Page 124: Driver Properties Printing Adjustments - Quick Reference

    APPENDICES Driver Properties Printing Adjustments - Quick Reference These features are located under the Layout tab of the M-Series Driver (R12.01) Left Adjustment Range: -30 (-3mm) left to 2000 (+200mm) right. Default = 0 - Moves the image area, left or right on the media. Top Adjustment Range: -50 (-5mm) up to 2000 (+200mm) down.
  • Page 125 INDEX IMPORTANT ..............36 Indicators, Control Panel ............ 32 Accessory Box Contents ............8 Ink Revolver Couplings ............3 Adjustable Media Side Guide ..........1, 8 Ink Revolvers ..............90 Adobe Acrobat ..............54 Adobe Reader ..............54 Ink Tank Anatomy .............. 19 Ink Tank Door ..............
  • Page 126 INDEX Preparing Printer for Transport ..........93 Service Life Print Engine .................3 Printhead ................ 71 Service Station..............4, 8 Cleaning .................88 Ink Revolvers ..............90 Cleaning ................. 74 Print Ink Channels ............3 Replacing ............... 74 Printhead Release Button ..........3 Service Station Installation ..........79 Service Station ..............4 Services Tab, Printer Driver ..........

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