Dcs_direct_jet_1024uvmvp_users_guide_maintenance_troubleshooting_1.2_030314

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User’s Guide for Maintenance and Troubleshooting DCS_Direct_Jet_1024UVMVP _Users_Guide_Maintenance_Troubleshooting_1.2_030314 Notices The information in this document is subject to change without notice. NO WARRANTY OF ANY KIND IS MADE WITH REGARD TO THIS MATERIAL, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. No liability is assumed for errors contained herein or for incidental damages in connection with the furnishing, performance, or use of this material. This document contains proprietary information which is protected by copyright. All rights are reserved. No part of this document may be photocopied, reproduced, or translated into another language without prior written consent. Trademark Acknowledgements IBM is a registered trademark of International Business Machines Corporation. Windows is a trademark of Microsoft Corporation. All other product and company names mentioned herein are the trademarks of their respective owners. Technical Support If you require technical assistance, contact a technical representative at 860-829-1027 or email [email protected] Technical information and downloads are available on our FTP site: ftp://ftp.directcolorsystems.com/. The FTP site requires a Login and password. You will be prompted to put in a user name and password. (If you are not prompted then double click on a file) Passwords are as follows and are case sensitive: Login: dcs Password: dcsftp Corporate Direct Color Systems® 99 Hammer Mill Rd Rocky Hill, CT 06067 T: 860-829-2244 F: 860-829-2255 Email: [email protected] Web Site: www.directcolorsystems.com EAA Rua do Alto Das Torres, 942 4430-009 Vila Nova De Gaia, Portugal Email: [email protected] DCS_Direct_Jet_1024UVMVP _Users_Guide_Maintenance_Troubleshooting_1.2_030314 Equipment Certificate of Compliance Printing History Edition 1.2 – March 2014 Driver installation instructions updated Printed in the USA © Copyright 2014, Direct Color, LLC. All rights reserved. DCS_Direct_Jet_1024UVMVP _Users_Guide_Maintenance_Troubleshooting_1.2_030314 Go to table of contents Table of Contents Safety and Precautions 6 Getting Started with the Hardware 7 Maintenance and Cleaning 10 Task Overview Daily Maintenance and Cleaning Head Clean Inspect Spit Tray Nozzle Check Empty Ink Waste Bottle Weekly Maintenance and Cleaning Reset Waste Ink Pad Remove Build Up from Spit Tray X- and Y-axis Cleaning and Lubrication Lubricate the Print Engine Shaft Lubricate the UV LED Lamp Track Clean the UV LED Lamp Lubricate Y-axis Rails Clean the Print Head Encoder Strip for the X-axis Clean the Capping Station Wiper Blade Clean Gaskets on Capping Station Monthly or Periodic Maintenance Inspect Intake Fan Filter on UV LED Lamp Change the Intake Fan Filter Replace the Capping Station Draining the Bulk Ink System Flushing the Bulk Ink System Calibration Print Head Height Calibration Check Current Print Head Height Adjusting Print Head Height Level the LED Sensors Check Print Head Height After Leveling LED Sensors Adjusting the LED Sensors for Proper Head Height UV LED Lamp Calibration Check Current LED Lamp Height Adjusting UV LED Lamp Height X-axis and Y-axis Zero Calibration Installing the X,Y Calibration Fixture Printing the X,Y Calibration Test for the First Time Adjusting the Y-axis Zero Point Adjusting the X-axis Zero Point DCS_Direct_Jet_1024UVMVP _Users_Guide_Maintenance_Troubleshooting_1.2_030314 11 12 12 12 12 12 13 13 13 13 14 15 15 16 16 17 17 18 18 18 19 22 23 24 25 25 26 26 27 27 28 28 29 30 30 30 31 32 4 | Page Go to table of contents Thank You Thank you for choosing the Direct Color Systems® Direct Jet 1024UVMVP printer. Your printer is designed to provide you with exceptional output quality on a variety of substrates. The Direct Jet's ability to print to many different materials without the need for surface pre-coating or undercoating represents a sound investment in time and productivity that will put you ahead of your competition. Direct Jet printers have many distinct advantages that will help you produce high quality graphics in record time. • The Direct Jet 1024UVMVP accepts material up to 6" (152 mm) thick. Optional heights fully adjustable to 10" (254mm) or 15" (381mm). • The Direct Jet 1024UVMVP model accepts substrates up to 13" (330 mm) x 24" (610 mm) in size and has a printable area of 10" (254mm) x 24" (610 mm). • Innovative Multisolve™ UV-LED inks print and bond to plastic, wood, stone, etc. Using our adhesion promoter, the inks will bind to many difficult surfaces, such as glass or stainless steel.* • Prints white ink. • Prints clear ink. • A print speed of 1:10 minutes to print an 8" x 10" image bi-directionally at 1440 x 720 dpi / High Speed. • Exceptional print resolution of up to 5760 dpi. • Direct Jet UV printers print from any IBM-PC® or compatible computer running Windows® 7 or 8, 32- and 64-bit versions using Direct Color Systems' exclusive Color Byte RIP (Raster Image Processing) software. * All substrates should be tested for image receptivity, adhesion and durability with final acceptance and suitability determined by the customer. Direct Color Systems® makes no warranty, expressed or implied. DCS_Direct_Jet_1024UVMVP _Users_Guide_Maintenance_Troubleshooting_1.2_030314 5 | Page Go to table of contents Safety and Precautions • • • • • • • • • • • • • Please read these guidelines before operating your Direct Jet printer. Keep all inks, solvents and lubricants out of the reach of children. Use only approved cleaning agents and solvents and then only for the purposes specified in this guide. Use only genuine Multisolve™ UV-LED inks. Keep inks in a cool, dark and dry location. Inks must be used in opaque containers only. This printer produces potentially harmful UV light. Protect eyes and skin from exposure. Avoid physical contact with the printer's table and print head while the printer is in operation. Avoid dropping items or spilling liquids in or on the printer. Keep hair, jewelry or loose clothing away from the moving parts of the printer. Lifting this printer by hand requires a minimum of two people. Do not attempt to repair this machine without prior DCS authorization. Unless specified in this guide, only qualified service personnel should attempt any disassembly, repair or access to internal components. If you need to make mechanical adjustments, turn off your printer and disconnect it from all power and data sources. Safety Glasses and gloves should be used whenever filling or draining ink tanks, or manually cleaning the print head. These symbols will be used throughout this manual as a reminder to use safety glasses and gloves. Wear protective gear whenever there is exposure to the inks, regardless of whether a symbol is displayed. For prolonged exposure, DCS recommends Butyl Black or Ethylene Vinyl Alcohol Copolymer laminated gloves. • The Adhesion Promoter should not be used in an enclosed area without adequate ventilation. RESPIRATORY PROTECTION: If exposure can exceed the PEL/TLV, use only NIOSH/MSHA approved air-purifying or supplied air respirator operated in a positive pressure mode per the NIOSH/OSHA 1981 occupational health guidelines for chemical hazards. DCS_Direct_Jet_1024UVMVP _Users_Guide_Maintenance_Troubleshooting_1.2_030314 6 | Page Go to table of contents Getting Started With the Hardware DCS_Direct_Jet_1024UVMVP _Users_Guide_Maintenance_Troubleshooting_1.2_030314 7 | Page Go to table of contents The 1024UVMVP Below you will find diagrams of the printer and its parts. Be sure to familiarize yourself with all the individual parts and descriptions of the printer as they will be referred to later in this guide. Front View DCS_Direct_Jet_1024UVMVP _Users_Guide_Maintenance_Troubleshooting_1.2_030314 8 | Page Go to table of contents Rear View Bulk Ink System DCS_Direct_Jet_1024UVMVP _Users_Guide_Maintenance_Troubleshooting_1.2_030314 9 | Page Go to table of contents Maintenance and Cleaning DCS_Direct_Jet_1024UVMVP _Users_Guide_Maintenance_Troubleshooting_1.2_030314 10 | P a g e Go to table of contents Task Overview BEGINNING OF THE DAY Power up print engine Perform a head clean as needed Inspect spit tray – clean as needed Achieve a correct nozzle check Clean and lubricate print station X-axis shafts and rails* Page 12 12 12 12 13 END OF THE DAY Achieve a correct nozzle check Power down print engine Empty waste ink bottle Complete Maintenance Log 12 12 12 BEGINNING OF THE WEEK Power up the print engine Reset Waste Ink Pad Counter and power cycle print engine Inspect spit tray – clean/replace as needed Clean and lubricate print station X-axis shafts and rails* Clean the UV lamp Lubricate Y-axis rails Clean print head encoder strip for X-axis Clean the wiper blade Clean gaskets on capping station 12 13 13 13 15 16 16 17 17 END OF THE WEEK Power down print engine Achieve a correct nozzle check 12 12 LONG TERM MAINTENANCE Run a nozzle check once per week (if printer is idle) Inspect intake fan filter on UV lamp and replace as necessary Replace capping station every 84 days 12 18 19 *Heavy users should clean and lubricate print station X-axis shafts and rails on a daily basis. Heavy users are defined on page 13. See the Maintenance Log for a printable checklist. You will be required to present a completed maintenance log for any tech support and warranty requests. Find the printable log at the end of this document. DCS_Direct_Jet_1024UVMVP _Users_Guide_Maintenance_Troubleshooting_1.2_030314 11 | P a g e Daily Maintenance and Cleaning Power Up or Power Down the Print Engine Press . Power up is complete when the LED light turns from amber to solid green. Power down is complete when the LED light turns from solid green to amber. Head Clean Press and hold for 9 seconds to begin a light head clean. Perform an initial charge if needed per the instructions in the Getting Started Guide. Inspect Spit Tray The spit tray should be cleaned of dried ink regularly. Failure to do so will lead to a buildup of ink that could eventually hit the bottom of the head and cause a head strike. Remove the ink by wiping with a dry cloth. Nozzle Check Perform a nozzle check from the Color Byte Rip Queue as outlined in your Getting Started Guide. Do not begin printing before you are satisfied with the nozzle check. Empty the Waste Ink Bottle The ink in the bottle should be emptied at the end of each day (or more often if necessary). Direct Color Systems recommends filling an empty solvent resistant container with cat litter or an oil absorbing product (found in most automotive parts stores). At the end of each day, pour the ink into this can and allow it to harden. Dispose of the mixture in accordance with local and city ordinances. Note The Waste Ink Bottle can be purged without removing the cap and tube by using one of the supplied syringes. Simply insert the needle of the syringe into the breather hole on the Waste Ink Bottle cap to extract the ink. Dispose of the ink as outlined above and in accordance with local and city ordinances DCS_Direct_Jet_1024UVMVP_Users_Guide_Maintenance_Troubleshooting _1.2_030314 12 | P a g e Weekly Maintenance and Cleaning Reset Waste Ink Pad Counter and Power Cycle Print Engine. In the Color Byte Rip 9.1 Queue click on the Device Properties icon. Click on Reset Ink Pad Counter. You must immediately restart the print engine. It cannot be done the following day. Note The waste ink pad counter should be reset at least once per week during normal operations. Failure to do so may result in downtime and the need to contact DCS Technical Support for resolution. Remove Build Up Ink from the Spit Tray Wearing gloves, wipe the inside of the spit tray with a paper towel. Dried ink that is elevated above the edges should be removed as well. It should break off in your gloved hand, but can also be scraped off with a tool if necessary. Dispose of the towel in accordance with local and city ordinances. X- and Y-axis Cleaning and Lubrication Clean and lubricate print station X-axis shafts and rails Due to the additional heat and dryness created by the UV lamp and its fans, it is necessary to clean and lubricate the rails of the printer often. DCS recommends this be done weekly for moderate users. Heavy users (4-8 hours/day, 5-6 days/week) should perform this maintenance daily. Use your discretion and perform this maintenance as needed. Use a 3-in-1 oil on the rails and UV light track. Use the G-71 grease on the print engine shaft only. Locate a spare syringe and filling needle in your printer accessory kit. Fill the syringe with a small amount of G-71 grease. Use a new syringe and filling needle and label it to avoid mixing the lubricants with any other liquid, ink, or flush. The G-71 grease can be applied with a gloved finger. Move the print head carriage into position. Press to raise the print engine several inches above the media table. Press to unlock the print head carriage. When it has stopped moving, manually move it to the center of the shaft. DCS_Direct_Jet_1024UVMVP_Users_Guide_Maintenance_Troubleshooting _1.2_030314 13 | P a g e With a lint-free cloth, polish the print engine shaft clean. Also remove any build up around the bushings. Do not spray WD-40 on or near the printer. Do not let it come into contact with the UV lamp bracket or rails. Use the cloth to clean the entire shaft from one end to the other. Slide the print head carriage back and forth. Check that no grease or debris is left on the shaft. If there is, repeat the cleaning procedure. Lubricating the Print Engine Shaft Locate a spare syringe and filling needle in your printer accessory kit. Fill the syringe with a small amount of G-71 Grease Apply a drop or two of G-71 grease to the areas indicated. Do not over-lubricate. Using a gloved finger, spread the G-71 grease evenly across the areas indicated. Using a gloved finger, apply a small amount of G-71 grease outside and ensure it is applied between the felt bushings and spread as evenly as possible. Failure to lubricate between the bushings could result in increased throughput times. Move the carriage from side to side the full length of the shaft to evenly spread the G-71 grease. DCS_Direct_Jet_1024UVMVP_Users_Guide_Maintenance_Troubleshooting _1.2_030314 14 | P a g e Lubricating the UV LED Lamp Track Locate a spare syringe and filling needle in your printer accessory kit. Fill the syringe with a small amount of 3-in-one oil. Do not use WD-40 on the UV Lamp rails. Clean with a lint free cloth or an IPA wipe when needed. Apply 3-in-one oil to both sides (top and bottom) of the UV track moving the UV light back and forth each time 3-in-one oil is applied to reduce the risk of oil running or dripping on the timing belt. Using a gloved finger, apply a small amount G-71 grease to the underside of the guide rail. Apply in several areas, moving the print engine for access when necessary. Do not grab the UV lamp. It will track with the print head. Move the print head left and right to ensure even distribution of the grease. Cleaning the UV LED Lamp Press to raise the print engine to its maximum height. Press to unlock the print head carriage. When it has stopped moving, manually move it to the center of the shaft. Turn off the printer by the main power switch. Spray a general purpose glass cleaner onto a soft lint-free cloth and wipe the glass covering the UV light. Do not spray cleaner directly onto the lamp. If this does not clean the glass, dried ink will need to be scraped off. Hold the lamp firmly so that it does not move during this process. Use a glass scraper (found in your accessories kit) and gently scrape across the surface until the glass is clear. Wipe the glass again. Visually confirm that the lamp has not moved by checking that it is higher than the print head and that it is parallel to the media table. Also confirm that the reflectors surrounding the glass have not been damaged. Replace if they are bent. DCS_Direct_Jet_1024UVMVP_Users_Guide_Maintenance_Troubleshooting _1.2_030314 15 | P a g e Lubricate Y-axis Rails Using a lint-free cloth, first wipe the Y-axis rails so they are clean of any debris or lubrication. Apply a drop or two of 3-in-one oil to the media table rails as indicated. Press and to move the table back and forth to spread the oil. Oil should be applied to the edges only. Do not apply to the screws. Apply a drop or two. Apply the oil to the rails near the center Using the arrow keys, move the table to the opposite end and again, apply oil to the rails near the center. Move the table back and forth once more to ensure even distribution of the oil. Clean the Print Head Encoder Strip for the X-axis. Both sides of the encoder strip used by the print head should be wiped gently with an IPA wipe (included in the cleaning kit) in order to remove any debris that may have fallen on to it during the lubrication process or from ink residue. DCS_Direct_Jet_1024UVMVP_Users_Guide_Maintenance_Troubleshooting _1.2_030314 16 | P a g e Clean the Capping Station Wiper Blade Clean the wiper in the capping station to avoid streaking in your finished images and/or if drops of ink on the bottom of the print head are not being wiped off after a head clean or initial charge. Press to manually move the print head away from the capping station. Pull back on the tab as shown below and then flip up the wiper. Do not remove the capping station. The picture is for demonstration purposes only. Wiper Tab Wearing gloves, wipe the blade clean with an IPA wipe (provided in your cleaning kit). Inspect the edge of the wiper blade for damage or irregular shaped dried ink that cannot be removed with cleaning. If it cannot be removed, the blade must be replaced. Contact DCS for blade replacement instructions. Note Prior to locking, manually move the Print Head Carriage back to the Capping Station. Failure to do so may result in an error when locked. Return the blade to its original position. Press again. Clean Gaskets on Capping Station Using a cotton swab, clean the edges of the gaskets of any ink. If dried ink exists, use alcohol on the swab. DCS_Direct_Jet_1024UVMVP_Users_Guide_Maintenance_Troubleshooting _1.2_030314 17 | P a g e Monthly or Periodic Maintenance Inspect intake fan filter on UV lamp. Press to unlock the print head carriage. When it has stopped moving, manually move it to the far left of the shaft. Inspect the fan filter. Old Filter New Filter Change the intake fan filter Press to unlock the print head carriage. When it has stopped moving, manually move it to the far left of the shaft. Turn off main power. Remove the four T-10 Torx screws from the filter retainer. Discard the old filter. Clean the retainer and fan guard with a dry cloth if needed. Fan guard Retainer Place the new filter over the fan guard and secure with the retainer and 4 screws. DCS_Direct_Jet_1024UVMVP_Users_Guide_Maintenance_Troubleshooting _1.2_030314 18 | P a g e Replace the Capping Station Replace a Capping Station if: It is more than 90 days old; Some type of physical damage has occurred to the unit; There is an electrical failure of the pump motor; or Nozzle health has worsened Tools Required Long magnetized Philips head screwdriver Needle-nose pliers Press until the print engine is at its maximum height. Press . When the print head carriage has stopped moving, manually move it to the center of the print engine shaft. Then turn the main power switch to the off position. DO NOT PRESS . The Capping Station is mounted to the printer with 5 Philips head screws (4 hold it in place + 1 for the orange ground wire) and a locking bracket. There is also 1 small electrical connector that needs to be disconnected. Remove the hoses from the Y fitting. Remove the 4 Philips head screws. DCS_Direct_Jet_1024UVMVP_Users_Guide_Maintenance_Troubleshooting _1.2_030314 19 | P a g e Remove the locking bracket holding the unit to the side plate. Disconnect the orange ground wire. Disconnect the electrical cable to the motor. Do not leave the gender changer connected to the capping station. Leave it connected to the wire that is attached to the printer. Carefully remove the old capping station. Carefully insert the replacement capping station and slide the black rubber hoses through the 2 holes in the back of the waste ink tray (located under the capping station mounting location). DCS_Direct_Jet_1024UVMVP_Users_Guide_Maintenance_Troubleshooting _1.2_030314 20 | P a g e Do not insert the barb fitting extension into th the e rubber hoses until you have pulled the hoses though the 2 holes in the ink waste tray. Once you have fully inserted the barb fittings into the rubber lines, secure them snugly with the provided zip ties. Connect the orange ground wire. Then insert nsert the locking bracket holding ding the unit to the side plate and insert and secure the 4 Philips head screws to secure the new capping station. Perform an Initial Charge from the Device Properties screen in Color Byte RIP 9.1 to get the ink flowing through the new Capping Station. DCS_Direct_Jet_1024UVMVP_Users_Guide_Maintenance_Troubleshooting _1.2_030314 21 | P a g e Draining the Bulk Ink System Safety Glasses and gloves should be used whenever filling or draining ink tanks, or manually cleaning the print head. For prolonged exposure, DCS recommends Butyl Black or Ethylene Vinyl Alcohol Copolymer laminated gloves. Begin by removing the acrylic back cover from the machine and the tacky mat and media guide from the media table. Press and hold until the media table has reached the right limit and stops. Press and hold until the print engine has reached the upper limit and stops. Then enter the Ink Levels Screen via the Main Menu Screen by pressing . Note Prior to starting the draining process, DCS recommends the media table is covered with a thin material to protect the table against possible leaks or spills. Place an empty bottle, with the cap removed, underneath the ink tank to be drained. Place a paper towel underneath the quick disconnect valve of the ink tank that will be drained. Remove quick disconnect valve from the ink tank by pressing the button firmly until a click is heard. Quickly pull the valve away from tank and hold it upward to avoid any ink that is in the valve from spilling. Wipe clean and place on the paper towel originally placed under valve. Locate a drain valve assembly provided in the accessory kit. Place the open end of the drain tube into the opening of the empty bottle. Press the button on the drain valve assembly until a click is heard. Attach the assembly to the tank. Ink will begin to flow into the empty bottle. Listen for a beep on Ink Levels Screen to indicate tank is now LOW. Note A small amount of ink is still in the tank when the LOW light is on DCS_Direct_Jet_1024UVMVP_Users_Guide_Maintenance_Troubleshooting _1.2_030314 22 | P a g e Before removing the drain valve assembly, ensure ink is no longer flowing or dripping from the open end of the tube. Once ink is no longer flowing or dripping from the open end of the tube, disconnect the drain valve assembly from the tank by firmly pressing the button until a click is heard. Slowly lift the open end of tube from bottle and cover with a paper towel. Wipe entire drain valve assembly clean before storing. Cap bottle. Prior to reconnecting the original quick disconnect valve to tank, confirm button on valve is ready by firmly pressing the button. Release button and then attach quick disconnect valve to tank. Proceed to drain remaining tanks (if needed) following the steps above. Ensure all quick disconnect valves are securely attached to the tanks before proceeding. Open Color Byte RIP 9.1 and go to the Queue Manager by selecting Queue > Manage Queues from the drop down menu. Perform six initial charges per the instructions on 12 page of this guide. Flushing the Bulk Ink System Safety Glasses and gloves should be used whenever filling or draining ink tanks, or manually cleaning the print head. For prolonged exposure, DCS recommends Butyl Black or Ethylene Vinyl Alcohol Copolymer laminated gloves. Begin by removing the acrylic back cover from the machine and the tacky mat and media guide from the media table. Press and hold until the media table has reached the right limit and stops. Press and hold until the print engine has reached the upper limit and stops. Then, enter the Ink Levels Screen via the Main Menu Screen by pressing . Note Prior to starting the flushing process, DCS recommends the media table is covered with a thin material to protect the table against possible leaks or spills. Place a bottle of IR2 Monomer Flush, with the cap removed, underneath the ink tank to be flushed. Place a paper towel underneath the quick disconnect valve of the ink tank that will be flushed. Remove quick disconnect valve from the ink tank by pressing the button firmly until a click is heard. Quickly pull the valve away from tank and place on the paper towel originally placed under valve. Locate a purge valve assembly provided in the accessory kit. Place the open end of the purge tube into the opening of the IR2 Monomer Flush bottle. Press the button on the purge valve assembly until a click is heard. Attach the assembly to the tank. Note When flushing the Clear ink tank, remove all quick disconnect valves. When flushing the White ink tank, remove all quick disconnect valves except the valve assembly linked to the white ink circulation motor (thickest tube). Open Color Byte RIP 9.1 and go to the Queue Manager by selecting Queue > Manage Queues from the drop down menu. Perform six initial charges per the instructions on page 12 of this guide. DCS_Direct_Jet_1024UVMVP_Users_Guide_Maintenance_Troubleshooting _1.2_030314 23 | P a g e Calibration DCS_Direct_Jet_1024UVMVP_Users_Guide_Maintenance_Troubleshooting _1.2_030314 24 | P a g e Print Head Height Calibration Tools Required T-15 Torx driver .050" Hex Head Driver # 1 Philips head screwdriver Head and UV LED Lamp Height Gauge Check Current Print Head Height Press to Power on Print Engine. Press to raise the Print Engine approximately 3 inches (76mm). Press and move media table to left limit. Remove Media Guide and Tacky Mat from Media Table. Confirm both edge guides are down and that the media table is clean of any dust or debris. Press and move media table so the front edge is in line with the acrylic front cover Press Remove front cover lock screws and open front cover Manually move print head carriage to the center of the print engine shaft. The UV LED Lamp will move with the print head carriage. While pressing the watch the Print Head as it lowers to the table Stop the print engine immediately if the print head comes into contact with the table and refer to the “Adjusting Print Head Height” section. If the Print Head stops and does not come into contact with the table, continue. Slide the .155” (3.937mm) head height gauge underneath the print head. It should fit all the way under the head, with very little gap (just enough to slide a piece of paper in between). If the head height appears to be too low or too high refer to the “Adjusting Head Height” section. Check the Print Head height in several places across and down the media table. If there is any significant difference at any of these points, contact DCS Technical Support for adjusting information. Note Prior to locking, manually move the Print Head Carriage back underneath the ink label/stickers. Failure to do so may result in an error when locked. If the Print Head height is acceptable press to lock the print head carriage. DCS_Direct_Jet_1024UVMVP_Users_Guide_Maintenance_Troubleshooting _1.2_030314 25 | P a g e Adjusting Print Head Height The print head height is controlled by the position of the two LED Sensors. The LED sensors must be level and then calibrated to ensure proper print head height. Check that LED Sensors are level Press to Power on Print Engine. Press to raise the Print Engine approximately 3 inches (76mm). Press and move media table to left limit. Remove Media Guide and Tacky Mat from Media Table. Confirm both edge guides are down and that the media table is clean of any dust or debris. Press and move media table so the front edge is in line with the acrylic front cover Place the height gauge on its side at the edge of the table and move the print engine up until the LED sensor (circled in image below) is approximately level with the top of the gauge (see picture below). Media Table Slide the gauge under the sensor. Approach it from an angle so that the neither the gauge nor your hand blocks the sensor and raises the print engine. Do not lower the print engine while the tool is in place. You may damage the sensor. Without moving the table or print engine, place the gauge under the sensor on the opposite side. If the two sensors are level, this process is complete. If the two sensors are not level continue to “Leveling the LED Sensors”. Level the LED Sensors Note Each full turn of the adjustment screw equals .010" (0.25mm) If the Gauge, when on its side, will not fit under Sensor #2 Loosen the locking screws Turn the adjustment screw counter-clockwise Test the Gauge again and repeat adjustments until satisfied Tighten the locking screws. If the gap is too large between the gauge and Sensor #2 Loosen the locking screws Turn the adjustment screw clockwise Test the Gauge again and repeat adjustments until satisfied Tighten the locking screws. DCS_Direct_Jet_1024UVMVP_Users_Guide_Maintenance_Troubleshooting _1.2_030314 26 | P a g e Check Print Head Height After Leveling LED Sensors Press Remove front cover lock screws and open front cover. Manually move print head carriage to the center of the print engine shaft. The UV LED Lamp will move with the print head carriage. While pressing the watch the Print Engine as it lowers to the table Stop the print engine immediately if the print head comes into contact with the table and refer to the “Adjusting Print Head Height” section. If the Print Head stops and does not come into contact with the table, continue. Slide the .155” (3.937mm) head height gauge underneath the print head. It should fit all the way under the head, with very little gap (just enough to slide a piece of paper in between). If the head height appears to be too low or too high refer to the “Adjusting Head Height” section. Adjusting the LED Sensors for Proper Print Head Height Note Each full turn of the adjustment screw equals .010" (0.25mm) To decrease the gap between the Print Head and Gauge (Lower Print Head) Loosen the locking screws for both LED Sensors Turn the adjustment for screw for both sensors the same amount counter-clockwise Test the gauge again and repeat adjustments until satisfied Tighten the locking screws To increase the gap between the Print Head and Gauge (Raise Print Head) Loosen the locking screws for both LED Sensors Turn the adjustment for screw for both sensors the same amount clockwise Test the gauge again and repeat adjustments until satisfied Tighten the locking screws Note Prior to locking, manually move the Print Head Carriage back underneath the ink label/stickers. Failure to do so may result in an error when locked. When the Print Head Height is acceptable, press again to lock the print head carriage. DCS_Direct_Jet_1024UVMVP_Users_Guide_Maintenance_Troubleshooting _1.2_030314 27 | P a g e UV LED Lamp Height Calibration Complete the print head height calibration before adjusting the UV LED Lamp height. Tools Required 3/16" Hex Head Driver 3/32" Hex Head Driver Head and UV LED Lamp Height Gauge Check Current UV LED Lamp Height Press to Power on Print Engine. Press to raise the Print Engine approximately 3 inches (76mm). Press and move media table to left limit. Remove Media Guide and Tacky Mat from Media Table. Confirm both edge guides are down and that the media table is clean of any dust or debris. Press and move media table so the front edge is in line with the acrylic front cover Press Remove front cover lock screws and open front cover Manually move print head carriage to the center of the print engine shaft. The UV LED Lamp will move with the print head carriage. While pressing the watch the UV LED Lamp as it lowers to the table Stop the print engine immediately if the lamp comes into contact with the table and refer to the “Adjusting UV LED Lamp Height” section. If the print engine stops and the UV LED Lamp does not come into contact with the table, continue. Slide the 0.080” (2.032mm) UV LED height gauge underneath the UV LED Lamp. It should fit all the way under the lamp, with very little gap (just enough to slide a piece of paper in between). If the lamp height appears to be too low or too high refer to the “Adjusting UV LED Lamp Height” section. Check UV LED Lamp height in several places across and down the media table. If there is any significant difference at any of these points, contact DCS Technical Support for adjusting information. DCS_Direct_Jet_1024UVMVP_Users_Guide_Maintenance_Troubleshooting _1.2_030314 28 | P a g e Adjusting UV LED Lamp Height While holding the UV LED Lamp, loosen the two bolts securing the UV LED Lamp to the bracket as shown in the image below. Continue to hold the UV LED Lamp above the media table and slide the 0.080” (2.032mm) gauge under the UV LED Lamp. Note Prior to locking, manually move the Print Head Carriage back underneath the ink label/stickers. Failure to do so may result in an error when locked. Slowly lower the UV LED Lamp onto the gauge and tighten the two bolts that secure the UV LED Lamp to the bracket. Press again to lock the print head carriage. DCS_Direct_Jet_1024UVMVP_Users_Guide_Maintenance_Troubleshooting _1.2_030314 29 | P a g e X-Axis and Y-Axis Zero Calibration This procedure is used for adjusting the X and Y "0" point of the printer. Tools Required 1/16" hex head wrench 3/32" hex head wrench Direct Jet X, Y Calibration Fixture Installing the Direct Jet X, Y Calibration Fixture Power on Print Engine . Raise the Print Engine approximately 3 inches (76.2mm). Press to move media table to left limit. Remove Media Guide and Tacky Mat from Media Table. Confirm both edge guides are down and that the media table is clean of any dust or debris. Install the Direct Jet X, Y Calibration Fixture by inserting the two pins into the two pin holes on the media table. Place a piece of clear tape covering the entire area of the indicated Tape Box. Printing the X, Y Calibration Print Test for the First Time Press the and lower the print engine to print height. Open the Color Byte Rip Pro Queue. Go to Tools > Options and set the number of decimal places to three. Select Save and Close. Go to the Calibration MVP Queue Group and Select the X Y Calibration Queue Go to Devices > Print Test Page and select the X Y Calibration Test File The File will import into the Queue, DO NOT change any job settings and Right-Click and print the file. If the cross-hairs align, no further calibration is needed. If the printed cross-hair does not align on the YAxis and/or the X-Axis with the cross-hair on the fixture, continue to adjusting the zero point. Below images represent various scenarios. The Red cross-hair is the cross-hair printed from the machine to the tape. Only Y-Axis Calibration Needed Only X-Axis Calibration Needed DCS_Direct_Jet_1024UVMVP_Users_Guide_Maintenance_Troubleshooting _1.2_030314 X and Y-Axis Calibration Needed 30 | P a g e Adjusting the Y-Axis Zero Point The below image shows two scenarios in which the printed cross-hair does not align with the cross-hair on the fixture. The black cross-hair represents the cross-hair on the fixture and the red cross-hair represents the printed cross-hair. Leading Edge of Media Table Scenario #1 Scenario #2 Scenario #1 Press to raise the elevator to its maximum height. Print Home Sensor and Adjustment Bracket Press to move the media table to the right limit to expose the print home sensor Loosen the locking screws holding the sensor. Turn the adjustment screw counter-clockwise to move the sensor. One full rotation of the adjustment screw equals approximately .025" (6.35mm). Tighten the locking screws. Replace the piece of tape and print the X Y Calibration Test File again. Scenario #2 Press to raise the elevator to its maximum height. Print Home Sensor and Adjustment Bracket Press to move the media table to the right limit to expose the print home sensor Loosen the locking screws holding the sensor. Turn the adjustment screw clockwise to move the sensor. One full rotation of the adjustment screw equals approximately .025" (6.35mm). Tighten the locking screws. Replace the piece of tape and print the X Y Calibration Test File again. DCS_Direct_Jet_1024UVMVP_Users_Guide_Maintenance_Troubleshooting _1.2_030314 31 | P a g e Adjusting the X-Axis Zero Point Refer to the label on the Direct Jet X,Y Calibration Fixture for the factory X-Axis Zero point value. Run this calibration test and record the Final X-Axis Zero point value The below image shows two scenarios in which the printed cross-hair does not align with the cross-hair on the fixture. The black cross-hair represents the cross-hair on the fixture and the red cross-hair represents the printed cross-hair. This calibration will be done within the Color Byte RIP and is not a mechanical adjustment like the YAxis Zero Calibration. Leading Edge of Media Table Scenario #1 Scenario #2 Measure the distance between the cross-hair printed and cross-hair on the fixture. Drag the test file back up from the Reserved window at the bottom of the RIP. Right-Click the FILE and select Open Page Left-Click on the Test File In the bottom right-hand corner of the RIP, under the preview window, adjust the Left Margin value by the measurement taken above. The default Left Margin Value is 3.00” (76.2mm) For Scenario #1 increase the left margin value. For Scenario #2 decrease the left margin value. This will adjust the margin for only this Queue. Repeat printing this file, with a new piece of tape each time, and keep adjusting until a Final Left Margin Value is determined. Note Record this value incase Queues are deleted and/or printer packages are updated. DCS_Direct_Jet_1024UVMVP_Users_Guide_Maintenance_Troubleshooting _1.2_030314 32 | P a g e Enter this Final Left Margin Value as the left margin for all MVP Queues by going to Devices > Manage Media. Select “Add new print media” Select “Create Sheet Media” Name the new media using 1024UVMVP and the Serial# of your machine. Enter the size 13.00in (330.200mm) x 24.000in (609.600mm) and then enter the Final Left Margin Value and select Create. DCS_Direct_Jet_1024UVMVP_Users_Guide_Maintenance_Troubleshooting _1.2_030314 33 | P a g e The new media now has to be selected as the default media for all Queues. Queues cannot have jobs in them when selecting a new default media. In the bottom right hand corner of each queue is the Media selection. Click the drop-down arrow and select the newly created media. Media selection can also be done through the Queue Properties > Media Layout. DCS_Direct_Jet_1024UVMVP_Users_Guide_Maintenance_Troubleshooting _1.2_030314 34 | P a g e