Vutek UltraVU 5300 Manual

UltraVu x300Digital Printing System (32-head version) Owner’s Manual July 1999 UltraVu x300 Digital Printing System (32-head version) Owner’s Manual D7012-A July 1999 (c) 1999 VUTEk, Inc. VUTEk, Inc. Corporate Offices 189 Waukewan Street Meredith, New Hampshire 03253 Voice (603) 279-4635 Fax (603) 279-6191 All rights reserved. No part of this document may be reproduced, copied, adapted, or transmitted in any form or by any means without express written permission from VUTEk, Inc. VUTEk, Inc. makes no representations or warranties with respect to the contents of this manual. Further, VUTEk reserves the right to revise or change this publication without obligation to notify any person of such changes. VUTEk, UltraWorks, and UltraVu are trademarks of VUTEk, Inc. Windows 95/98/NT are registered trademarks of Microsoft Corporation. Adobe, Acrobat, Illustrator, PhotoShop, PageMaker, PostScript are registered trademarks of Adobe Systems Incorporated. Pantone is a registered trademark of Pantone, Inc. Apple Color Sync System, AppleTalk, and Macintosh are registered trademarks of Apple Computer, Inc. Kodak is a registered trademark of Kodak Corporation. IBM is a registered Trademark of International Business Machines, Inc. JAZ is a registered trademark of Iomega Corporation. Harlequin and ScriptWorks are trademarks of Harlequin, Inc. PosterWorks is a trademark ofS.H. Pierce & Company. Flightcheck is a trademark of Markzware, Inc. Sony is a registered trademark of Sony Corporation. QuarkXPress is a registered trademark of Quark, Inc. Intel and Pentium are registered trademarks of Intel Corporation. Tektronix is a registered trademark of Tektronix, Inc. Table of Contents •••••• List of Figures xv Preface xxi A bout This M anual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxi C onventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxii Chapter 1 Introduction 1-1 W elcom e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 P urpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 P rinter C om ponent Location . . . . . . . . . . . . . . . . . . . . . . 1-3 C ontrols and Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 P rinter S tatus LC D . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 P rinter Function B uttons . . . . . . . . . . . . . . . . . . . . . . 1-9 Online Button . . . . . . . . . . . . . . . . . . . . . . . . 1-9 Test Button . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10 Test 1. . . . . . . . . . . . . . . . . . . . . . . 1-10 Test 2. . . . . . . . . . . . . . . . . . . . . . . 1-10 Test 3. . . . . . . . . . . . . . . . . . . . . . . 1-10 Test 4. . . . . . . . . . . . . . . . . . . . . . . 1-10 Test 5. . . . . . . . . . . . . . . . . . . . . . . 1-10 Test 6. . . . . . . . . . . . . . . . . . . . . . . 1-10 Test 7. . . . . . . . . . . . . . . . . . . . . . . 1-10 Advance Button. . . . . . . . . . . . . . . . . . . . . . . 1-11 Table of C ontents iii Error Button . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11 Takeup Button . . . . . . . . . . . . . . . . . . . . . . . . 1-11 Bail Button . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11 Reset Button . . . . . . . . . . . . . . . . . . . . . . . . . 1-11 On/Off Switch. . . . . . . . . . . . . . . . . . . . . . . . . 1-12 Printer Function Selector Switch . . . . . . . . . . 1-12 Empty Pack Setting . . . . . . . . . . . . 1-13 Solvent Purge Setting . . . . . . . . . . 1-13 Solvent Flush Setting . . . . . . . . . . . 1-13 Ink Prime Setting . . . . . . . . . . . . . . 1-13 Ink Purge Setting . . . . . . . . . . . . . . 1-13 Fire Jets Setting . . . . . . . . . . . . . . . 1-13 Ready Setting. . . . . . . . . . . . . . . . . 1-14 P laten/P reheater and S ubstrate D ryer C ontrols . . . . 1-14 O perator R equirem ents . . . . . . . . . . . . . . . . . . . . . . . . . 1-15 Chapter 2 Overview 2-1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Jet P ack U nits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 The P iezo P rinciple . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Jet P ack D escription . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 C arriage C om ponents . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Jet P ack B oards . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 C ooling Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 E dge D etector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 S olenoid Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Ink and S olvent S ystem s . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Ink and S olvent C ontrol . . . . . . . . . . . . . . . . . . . . . . 2-4 S olenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 iv Table of C ontents A ir, S olvent and W aste Lines . . . . . . . . . . . . . . . . . . . 2-8 P rinter S elector S w itch Logic . . . . . . . . . . . . . . . . . . . 2-8 P rim ary Ink R eservoir . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Ink P um ps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 S olvent R eservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 A ir P ressure R egulators A nd S olenoids . . . . . . . . . . 2-10 P urger P late (C apper) . . . . . . . . . . . . . . . . . . . . . . . . 2-11 M otors, Servos and Encoders . . . . . . . . . . . . . . . . . . . . 2-12 M otors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 S ervo C ontrollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 X Servo Controller . . . . . . . . . . . . . . . . . . . . . 2-14 Y Servo Controller . . . . . . . . . . . . . . . . . . . . . 2-14 M otor E ncoders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 X Servo Linear Encoder . . . . . . . . . . . . . . . . 2-15 Y Servo Rotary Encoder . . . . . . . . . . . . . . . . 2-15 P laten/P reheater and S ubstrate D ryer C ontrols . . . . . . . 2-16 Chapter 3 Operation 3-1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 S tarting and S hutting D ow n . . . . . . . . . . . . . . . . . . . . . . 3-2 S tarting the P rinter . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 S hutting O ff the P rinter . . . . . . . . . . . . . . . . . . . . . . . 3-2 R ecovering from an E m ergency S top . . . . . . . . . . . . 3-2 W orking w ith M edia, Ink and P rinter S etup . . . . . . . . . . 3-3 Loading M aterial . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 W orking w ith M ultiple R olls . . . . . . . . . . . . . . . . . . . . 3-5 U sing the M esh O ption . . . . . . . . . . . . . . . . . . . . . . . 3-6 A djusting the E ncoder W heel . . . . . . . . . . . . . . . . . . 3-11 Table of C ontents v . . . . . .M aintaining Ink Viscosity . . . . . . . . . . . . . . . 3-25 U nderstanding U ltraV u’s C apabilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24 U sing U ltraV u Softw are . . . . . . . . . . . . . . . . . . . . . . . 3-19 O perating the H eater C ontrols . . . . . 3-19 C ontrolling the P laten V acuum Level . . . . . . . . . . . 3-15 U nderstanding the P rinter C ontrols . . . . . . . . . . . 3-25 vi Table of C ontents . . . . . 3-22 U nderstanding P rint S peeds . . . . . . 3-24 U nderstanding P rint M odes . . . . . . . . . . . . 3-17 Test 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23 High Speed . 3-18 Test 5. . . . . . . . . . 3-23 Standard Speed. . . . . . . 3-13 P rim ing the Jet P acks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 Test 7. . . . 3-18 Test 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24 Ultra Mode . . . . . . . . . . . . . . . . 3-22 PostScript File Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19 U nderstanding File Form ats . . . . . . . . 3-22 VUTEk CT File Format . . . . . . 3-24 Lo Res Mode . . . . . . . . . . . . . . . . . . . . . 3-12 P reparing the Jet P acks for P rinting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 Test 2. . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 R ecovering from P lugged Jets . . . . . . . 3-17 U sing the Internal Test Patterns . . . . . . . . . . . . 3-12 Before Printing Occurs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 After Printing Concludes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24 Enhanced Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 Test 4 . . . . . . . . . . . . . . . . . . . . . 3-18 Test 6. . . . . . . . . . . . 3-46 Help Menu . . . . . . . . . 3-35 Print Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35 Duplications . . . . . . 3-47 Help Topics . . . . . . . . . . . . . 3-28 S tarting the U ltraV u C ontrol P rogram . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25 Workstations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29 U nderstanding the U ltraV u M enu Structure . 3-49 P rint G ap . . . . . . . 3-38 Print . . . . . . . . . . . . . . . . . . . . . . . 3-37 Output Resolution . . . . . . . 3-47 About UltraVu . . . . . . 3-33 Print Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48 Get Printer Stats . 3-25 U pgrading U ltraVu x300 S oftw are . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31 File Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30 Button Bar . . 3-48 Get Printer Rev . . . . . . . 3-39 LookUp Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40 Setup Menu. . . . . . . . . . . . . 3-38 Select Area . . . . . . . . . . . . . . . . . . . . . . 3-43 Default Path . . 3-45 Update Firmware . . .Data File Types . 3-27 Form atting R em ovable D isk C artridges . . . . . . . . . . . . . . . . 3-39 View Menu . . . . . . . . . . . . . . . . 3-45 Enter Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29 UltraVu Menu Structure. . 3-42 Printer Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26 U pgrading U ltraVu x300 Firm w are . . . . . . . . . . . . . . . . . . . 3-49 Table of C ontents vii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48 Im proving P rint Q uality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34 File Info . . . . . . . . . 4-2 U ltraV u 5300 D igital P rinting System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Ventilation . . . . . . 4-5 R elaxing and A ligning the R ail . . . . . . . . . . . . . . . . . . . . . 4-7 Installing the B anner K it O ption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51 Chapter 4 Installation 4-1 P urpose . . . . . . . . . . . . . . . . . . . . . . . 4-1 U ltraV u 3300 D igital P rinting System . . . . . . . . . . . . . . . . . . 4-5 Leveling the P rinter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Installation P rocedures . . . . . . . . . . . . . . . . . . 4-4 A ir R equirem ents . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 S pace R equirem ents and D im ensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 P ow er R equirem ents . . 4-8 Installing the M esh K it O ption . . . . . . . . . . . . . . 4-9 Chapter 5 Maintenance 5-1 M aintaining the P rinter . . . . 3-49 P laten/P reheater and V acuum S ettings . . . . . . . 4-1 S ite P reparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Installing the P ow er C onditioning System . . . . . . 3-49 S ubstrate D ryer Settings . . . . . . . . . . . . . . . . . . . 3-50 Takeup Tension S ettings . . . . . . . . . . . . . . . . . . . . . . . 3-51 Trial R uns . . 3-51 Low er R esolution R IP Files . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 viii Table of C ontents . . . . . . . . . . . . . . . . . . . . . . . . . . .S tep Setting . . . . . . . . . 3-50 Jet O utage . . . . . . . . . . . . . . . . . . 4-3 Environm ent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 C leaning the P rim ary Ink Tank Filters . . 5-1 Daily . . . 5-14 A djustm ent P rocedures . . . . . . . . . . . . . . . . . . . 5-2 Every Six Months . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 Older Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13 C leaning the D C P ow er S upply Fans . . . . . . . . . . . . . . . . . . . . 5-4 Installing the Jet P acks . . 5-14 A djusting the C arriage D rive B elt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13 C hecking C arriage Belt Tension . . . . . . . . . . . . . . . . . . . . . . . 5-1 Every Eight (8) Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 R eplacing the Ink and A ir Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 C hanging G earbox O il . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12 C leaning the C arriage C ooling Fan . . . . . . . 5-2 Yearly . . . 5-7 Lubricating the C arriage R ail . . . . . . . . . . . . . . . . . . . . . . . . . .S chedule D etails . . . . . 5-14 V erifying the Jet P late A lignm ent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 C aring for the Jet P ack . . . . 5-2 M aintenance Procedures . . . . . . . . . . . . . . . . . 5-10 Newer Models . . . . . . . . . . . 5-3 C leaning the U ltraV u x300 . . . . . . . . . . . . . . . . . . . 5-12 C leaning the S econdary Ink Tanks . . . . . . . . . . . . . . . . 5-3 R em oving the Jet P acks . . . . . . . 5-1 After Printing Each Segment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17 Table of C ontents ix . . 5-1 Weekly . . . . 5-2 Monthly . . . . . . . . . . . . . . . . . . . . . . . 5-12 C leaning the Ink Level S ensors . . . 5-5 C hanging the C olor O rder of the Jet P acks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22 A djusting the Jet Pack Tem perature . . . . . . . . . . . 6-1 Invalid Date with Last Checked . . . . . . . . . . . 6-3 Y Servo Echo Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 U ltraV U Softw are E rror M essages . . . . . . . . . . . . . . . . . . . . . . . . 6-5 Linear Encoder Alarm . . .A ligning the Jet Plate . . . . . . . . . . . . . . . . . . . . . . . 6-3 X Servo Echo Error . 6-4 Error Receiving Y. . . . . . . . . 6-4 Y Runaway Detected . . . . . . . . . 6-5 Rename Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 X Servo Echo Time-out . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20 A djusting the E ncoder W heel . . . . . . . . . . . . . 6-2 Print Error # 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18 S etting the P rint G ap . . . . . . . . . . 6-1 LC D D isplay E rror M essages . . . . . . . . . . . . . . . . . . . . 6-3 Y Servo Echo Time-out . . . . . . . . 5-19 A djusting the E dge D etector . . . 6-3 Y Servo Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 E rror M essages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21 V erifying Platen Alignm ent . . . . . . . . . . . 6-4 Y-Position TIme-out . . . . . . . . . . . . . . . . . . . . . . . . 6-5 Error Jogging Y . 6-3 Error Jogging X . . . 5-25 Chapter 6 Troubleshooting 6-1 O verview . . . . . . . . . 5-23 M aintenance C hart . . 6-5 x Table of C ontents . . . . . . . . . . . . . 6-2 X Servo Error . . . . . . . . . . . . . . . . 6-25 Table of C ontents xi . . . . . . . . . . . . . . . . . . . . . . . 6-15 Bios for 2A59CM2G (200 MHz) Processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 No Paper Detected . . . . . . . 6-14 P rinter C ontroller O verview . . . . . . . . . . . . . . . . . . . 6-14 P rinter C ontroller C PU Bios V alues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 P rinter D iagnostic M ode . . . . . . . . 6-5 E Stop Error . . . . . . . 6-6 Color Overflow . . . . . 6-15 Bios for 2A591M2D (233 MHz) Processor . . . . . . . . . . . . . . . . 6-8 Color Pack Error . . . . . . . . . . . . . . . . . 6-6 Shift Register Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 Too Many Rolls . . 6-13 P rinter C ontroller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 E ntering the D iagnostic M ode . . . . . 6-24 R S 422 Interface B oard: A A 70021 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21 C ontroller Board: AA 70012 . . .Erase Error . . . . . . . 6-8 Capper Stuck Down or Capper Stuck Up . 6-7 Waste Can Full . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19 P rinter C ontroller C PU M odule: P 7028-A . . . . . . . . . . . . 6-9 C orrective P rocedures . . . . . . . . . . 6-17 Printer Controller Layout . . 6-23 P ixel B oard: A A 70176 . . . . 6-8 Roll Detector Error . . . . . . . . . . . . . . . 6-7 Color Supply Low . . . . . . . . . . . . . . . . . . 6-6 Umbilical Error. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13 R ecovering from R O M D isk Failure . 6-6 Start Print Time-out Error . . 6-7 Check Color Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 Solvent Supply Low. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43 P ow er D istribution Panel Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31 Bios for 2A69KN09 (400 MHz) Processor . 6-28 U ltraW orks R IP Station O verview . 6-40 C arriage B ackplane B oard: A A 70184 . . . . . . . . . . . . . 6-31 W orkstation C ontroller Layout . . . . . . . . . . 6-38 P rint H ead C ontrol . . . . . . . . . . . . . . . . . . . . . . . . . 6-42 P ow er D istribution System . . . . . . . . . . 6-46 P ow er S upply D istribution B ox: AA 70028 . . .R O M D IS K B oard: P 7029-A . . . . . . . . . 6-41 C arriage B ackplane C onnections: A A70184 . . . . . . . . . . . . . . . . . . . . . . . 6-45 P ow er D istribution C ontactor P anel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 xii Table of C ontents . . . . . . . . 6-39 Jet P ack M odule: A A 70185-32 . . . . . . . 6-37 P C I Interface B oard: A A 70175 / A A 70203 . . . . . 6-39 Jet D river B oard: A A 70181 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30 W orkstation and R IP S tation B ios V alues . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34 U ltraV u W orkstation C P U M odule . . . . . . 6-43 P ow er B oard: A A70233 . . . . . . . . . . . . . . . . . . 6-47 Chapter 7 RIP Station 7-1 U ltraW orks . . . . . . . . . . . 7-1 R IP Station Features . . . . . . . . . . . . . . . 7-1 A dditional D ocum entation . 6-27 W orkstation C ontroller . . . 6-36 U ltraW orks R IP Station C P U M odule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28 W orkstation C ontroller O verview . . . . . . . . . . . . . 7-2 P rinter O perating M odes . . . . . . . . . . . . . . . . . . . . . . 7-1 O verview . . . . . . . . . . . . . 6-26 V G A M onitor Interface: P 7127-A . . . . . . . . . . . . . . . . . . 7-17 C alibrating C olors . . . . 7-5 W orking w ith the U ltraW orks D ongle . . . . . . 7-11 W orking w ith R TL Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19 UltraVu Page Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 U nderstanding U ltraW orks . . . . 7-3 Postscript / Vector Mode . 7-10 Worst Case Scenario . . . . . . 7-17 Default Page Setup . . . . . . . . . 7-5 Installing U ltraW orks . 7-20 Preview Page Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14 Destination Disk Selection . . . . . . . . . . . . . . . 7-14 Destination Disk Selection . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20 U sing IC C P rofiles . . . . . . 7-16 B acking U p (R estoring) R IP S ettings . . . . . . . . . . . . . . . . 7-18 PhotoShop Linear Page Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22 E ncountering R IP Problem s . . . . . . 7-23 Table of C ontents xiii . . . . . . . . . . . . . . . . 7-4 Installation . . . . . . . . . . . . . 7-22 W orking w ith the S W O P IC C P age S etup . . . . . . . . . . . . . . . . . . . . . . . . . .CT File Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .RTL File . . . . . . . . . . . . . . . . . 7-10 C ustom izing the P age Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9 D eterm ining R IP S peed . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Workspace File 7-15 S electing O ptions . . . . 7-20 ICC SWOP Mode . . . . . . . . . . 7-9 G etting S tarted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10 D eterm ining Input File S ize . 7-20 G enerating C ustom er C alibration C urves . . . . . . . . . . . . . . . . 7-17 PhotoShop Color Correction . . . 7-10 Best Case Scenario . . . . . . . . . . 7-7 U ltraW orks O peration . . . . . 7-23 Postscript Errors . . . . . . . . . . . . . . . . . . . 8-1 P rinting G uidelines . . . . . . . . . . . . 8-3 PhotoShop Separation Setup . . . . . . 8-1 C reating A File in A dobe P hotoShop . . . . . . . . . . . . . . . . . . . . . 7-24 Font Errors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Disk Full Errors . . . . . . . . . . . . . . . . . . . 8-6 Chapter 9 Specifications 9-1 U ltraV u 5300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 Appendix A xiv Table of C ontents Ventilation Hood Design A-1 Glossary G-1 Index I-1 . . . 8-3 C reating a File in Q uarkX P ress . 8-2 PhotoShop Printing Inks Setup . . . . . . . 7-24 Chapter 8 Prepress 8-1 Q uick S tart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 C reating a File in PosterW orks . . . . . . . 8-1 O verview . . . . . . . 9-1 U ltraV u 3300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Figure 2-4 Ink and Solvent Carriage Components . 3-3 Figure 3-2 Substrate Feed Path . . . . . . . . .List of Figures •••••• Chapter 1 Introduction Figure 1-1 x300 Digital Printing System . . . . . . . . . . . . . . . . . . . . . 2-6 Figure 2-5 Ink Control Diagram . . . . 2-9 Figure 2-7 Purger Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Figure 3-3 Media Hub Diagram . . . . . . . . . . . . . . . . . 2-2 Figure 2-3 Ink and Solvent Carriage Components . . . . . . . . . . . . . . . . Solvent and Air Supply Layout . . . . . . . . . . 1-9 Figure 1-5 Function Selector Switch . . . . . . . 1-4 Figure 1-3 Control Panel Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Figure 2-6 Ink. . . . . . . . . . . . . . . . . . 1-8 Figure 1-4 Function Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 Chapter 3 Operation Figure 3-1 Control Panel . . . . . . . . . . 2-11 Figure 2-8 Takeup Roller Drive System Diagram . . . . 1-14 Chapter 2 Overview Figure 2-1 Piezo Jet Fill and Fire Waveform . . . . . . . . . . . . . . . . . . . 1-12 Figure 1-6 Platen/Preheater and Substrate Dryer Controls. . . . . . . . 2-12 Figure 2-9 Servo Controller Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Figure 3-4 Blotter Material Enclosure . . . . . . 1-3 Figure 1-2 x300 Digital Printing System . . . . . . . . . 2-1 Figure 2-2 Piezo Jet Operation . . . . . . . . . . . . . . . . . . . 3-7 List of Figures xv . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36 Figure 3-21 Borders Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38 Figure 3-25 Select Printing Areas Screen . . . 3-45 . . . 3-11 Figure 3-10 Printer Selector Switch . . . . . . . . . . . . . . . . . 3-43 Figure 3-32 Mesh Kit Settings Screen . . . . . . . . . . . . . . . . 3-42 Figure 3-31 Set Printer Parameters Screen . . . . . . . . . . . . . . . . . 3-9 Figure 3-8 Set Printer Parameters Screen . 3-29 Figure 3-15 UltraVu Menu Structure .xvi List of Figures Figure 3-5 Mesh Paper Holder Locations . . . . . . . . . . . . . . . 3-20 Figure 3-14 UltraVu Printer Control Program Menu Screen . . . . . . . . . . . . . . . . . 3-37 Figure 3-23 Duplications Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Figure 3-11 Jet Function Selector Switch . 3-44 Figure 3-33 Defaults Path Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36 Figure 3-22 Units Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38 Figure 3-26 Print Parameters Selected Screen . 3-39 Figure 3-28 Select Luts for this Job Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35 Figure 3-19 Print Mode Screen . . . . . . . . . . . . . . . . 3-14 Figure 3-12 Control Panel . 3-34 Figure 3-18 File Information Screen . . . . . . . . 3-8 Figure 3-6 Mesh Fabric Guide Placement View . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30 Figure 3-16 File Menu with File Open Screen . . . . . . 3-37 Figure 3-24 Output Resolutions Screen . . . . . . . . . . 3-40 Figure 3-29 Edit Luts Screen . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Figure 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33 Figure 3-17 Print Pull-Down Menu. . . . . 3-17 Figure 3-13 Heater Controls . . . . . 3-35 Figure 3-20 Media Layout Screen .7 Tension Scale Setup for Tension Setting . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Figure 3-9 Remote Adjustable Encoder Wheel Shaft . . . . . 3-41 Figure 3-30 Setup Pull-Down Menu. . . 3-39 Figure 3-27 View Pull Down Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18 Figure 5-7 Print Gap Adjustment . . . . . . . . . . . . . . . . 5-16 Figure 5-5 Jet Plate Alignment Test Pattern . . . . . . . . . . . . . . . . . . 4-6 Figure 4-4 Access Panel . . . . 5-19 Figure 5-8 Encoder Wheel Adjustment Layout . . . 3-48 Figure 3-38 Printer Firmware Revision Level Screen . . . . . . . . . 3-48 Chapter 4 Installation Figure 4-1 UltraVu 3300 Digital Printing System . . . . 4-7 Chapter 5 Maintenance Figure 5-1 Redirect and Takeup Motor Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47 Figure 3-37 About UltraVu by VUTEk Screen . . . . . . . . . . . . 5-15 Figure 5-4 Carriage Belt Adjustment Layout . . . . . . . 5-11 Figure 5-3 Carriage Belt Layout. . . . . . . . . . . . . . . . . . . . . . . 5-23 Figure 5-10 Temperature Probe Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Figure 4-3 Rail Relaxation and Alignment .Figure 3-34 Update Firmware Screen . . . . . 5-17 Figure 5-6 Jet Plate Alignment Screw Location. . . . . . . . . 5-8 Figure 5-2 In-line Ink Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25 Chapter 6 Troubleshooting Figure 6-1 Printer Controller Block Diagram . . 5-24 Figure 5-11 Potentiometer Location on Jet Driver Board . . . . . . . . . . . . 3-46 Figure 3-36 Help Pull-Down Menu. . . . . . . . . . . . . . . . . 6-19 List of Figures xvii . . 6-14 Figure 6-2 Printer Controller Backplane . . . . . . . . . . . 3-45 Figure 3-35 Password Entry Screen . . . . . . 4-2 Figure 4-2 UltraVu 5300 Digital Printing System . . . . 5-21 Figure 5-9 Platen Alignment Fixture Layout . . . . . . . . . . . . . . . . . 7-4 Figure 7-2 UltraWorks Screen . . . . . . . . . 7-5 Figure 7-3 UltraWorks – Configure RIP Screen. . . . . . . . . . . . . . .CPU Module (200 MHz). . . . . . . . . . 6-26 Figure 6-10 Printer Controller – VGA Monitor Interface. . . . . . . . . . 6-24 Figure 6-8 Printer Controller – RS422 Interface . . . . . . . . . . . . . . 7-6 . . . . . . . . . . . . . . . . . 6-45 Figure 6-24 Power Distribution Contactor Panel . . . . . . . . 6-39 Figure 5-18 Jet Driver Board . . . . . . . 6-37 Figure 6-16 PCI Interface Board . . . . 6-47 Figure 6-26 Distribution Box . . . . . . . . . 6-29 Figure 6-12 Workstation Controller Backplane . . 6-35 Figure 6-14 UltraWorks Workstation CPU Module (400 MHz) 6-36 Figure 6-15 UltraWorks RIP Station CPU Module (400 MHz) . . . . . . . . . . . 6-48 Chapter 7 xviii List of Figures RIP Station Figure 7-1 Pixel to Cell Processing Representation . . . . . . . . . . . . . . 6-43 Figure 6-22 Power Supply Distribution Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20 Figure 6-4 Printer Controller – CPU Module (233 MHz) . . . . . 6-40 Figure 6-19 Carriage Backplane . . . . . . . . . . . . . . . . . . . . 6-23 Figure 6-7 Printer Controller – Pixel Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42 Figure 6-21 Power Supply Distribution Connectors. . . . 6-27 Figure 6-11 Printer Workstation Block Diagram . . . . . . . . . . . . . . . . . . 6-44 Figure 6-23 Power Breaker Panel . . . . . . . . . .Figure 6-3 Printer Controller Board Configuration . . . 6-22 Figure 6-6 Printer Controller – Controller Interface . . . . . . . . . 6-21 Figure 6-5 Printer Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25 Figure 6-9 Printer Controller – ROMDisk. . . 6-34 Figure 6-13 Workstation Controller Board Configuration. . 6-46 Figure 6-25 DC Power Supply Distribution Box. . . . . . . . . 6-41 Figure 6-20 Carriage Backplane Connectors . . . . . . . . 6-38 Figure 6-17 Jet Pack Driver . . 7-11 Figure 7-10 New Page Setup Screen . . . . . 8-8 List of Figures xix .Print File Screen . .Separation Setup Screen . . . . . . . . 7-12 Figure 7-11 Page Layout Screen. . . . . . . . . . . . . . . . . . .Configure RIP Extras Screen . 7-8 Figure 7-8 UltraWorks . . . . . 7-14 Figure 7-13 UltraWorks . . . . . . 7-21 Figure 7-20 Edit Color Setup Screen. 7-6 Figure 7-5 Multimedia Properties Screen . . . . . . . . . 8-2 Figure 8-2 PhotoShop . . . . . . . . . . . . . . . 8-7 Figure 8-8 PosterWorks . . .Figure 7-4 UltraWorks . .Layout Options Screen . . . . . 8-4 Figure 8-5 QuarkXPress . . . . . . . . . . . . . . . . . 8-3 Figure 8-4 PhotoShop . . . . .Printing Inks Setup Screen . . . . . . . .Trim Area Setup Screen . . . . . . . .Printing Inks Setup Screen . . .PostScript Text Over Image. . . . . . . . . . 8-8 Figure 8-10 PosterWorks – Showing Cropped Image . . . . . . . . . . . . 7-23 Chapter 8 Prepress Figure 8-1 PhotoShop – Showing TIFF Image . . . . . . . . 7-7 Figure 7-6 Add Unlisted or Updated Driver . . . . .Configure RIP Options Screen . . . 7-9 Figure 7-9 UltraWorks . . . . . . . . 7-16 Figure 7-16 PhotoShop . . . . . 8-6 Figure 8-7 PosterWorks . . . . . . . . . .Page Setup Manager Screen . . . . . . . . . . 7-15 Figure 7-15 Page Setup Options Screen. . . . . . . 8-5 Figure 8-6 PosterWorks . . . . . . . . . . . . . . . 7-18 Figure 7-18 Calibration Manager Screen. . . . . . . . 7-20 Figure 7-19 Edit Uncalibrated Target for UltraVu Screen . . . . . . . . . . . . .Configure RIP Screen . . . . . . . . . . . . . .Page Layout Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8 Figure 7-7 UltraWorks .Separation Setup Screen . . . 8-3 Figure 8-3 PhotoShop . . . . . . . 8-7 Figure 8-9 PosterWorks . . . . . . . . . 7-18 Figure 7-17 PhotoShop . . . . . . . . .Placed Image Screen . . . 7-15 Figure 7-14 Select Folder Screen . . . 7-13 Figure 7-12 RTL Printer Configuration Screen . . .Image Size Screen . . . . Figure 8-11 xx List of Figures PosterWorks . . . . . . . . 8-9 . . . . . . . . . .Print Screen . plea se d o n ot h esita te to con tact o ur P rod uct S u pp ort S taff at (60 3) 279 -463 5. Preface xxi . T his w ill help to red uce do w n tim e an d im prov e print q uality.Preface •••••• About This M anual T his m an ual sh ow s yo u h ow to install. op erate. T here are a lso chap ters on u sing th e U ltraW o rk s S oftw a re and perform ing p rep re ss w ork. A s a result you w ill be m ore efficien t w ith o perating an d m ain tainin g yo ur U ltraVu x 30 0 S ystem . T h e m anu al is organize d as fo llo w s: 1 Introduction 2 Overview 3 Operation 4 Installation 5 Maintenance 6 Troubleshooting 7 RIP Station (UltraWorks) 8 Prepress 9 Specifications P lease take th e tim e to fam iliarize yo urself w ith each section . o r an y other V U T E k serv ice o r p ro du ct. m a intain an d trou ble sh oo t th e U ltraVu x 30 0 D igital P rinting S y stem (3 2-hea d versio n). If yo u hav e any q uestion s ab ou t th is m a nual. o r d ata. softw are. W A R N IN G : A lerts yo u to so m eth in g th a t h as th e p oten tia l to cau se ph ysica l h arm to yo u o r o th ers a rou n d you . xxii P reface . C a u tion : A lerts yo u to so m ethin g th at h as the p otential to cau se da m a ge to h ardw a re.Conventions T his m an ual u ses the fo llow ing inform ationa l con ven tio ns : N o te: A special techn iq ue or inform ation tha t m ay h elp yo u perfo rm a ta sk o r u nd erstan d a p rocess. W e strive to ensu re th at yo u are sa tisfied w ith th e q uality and in nov ativen ess o f th e x 30 0 D igital P rinting S y stem . W e ho pe y ou en jo y yo ur n ew system an d w elcom e an y com m ents an d sug gestion s you m ay hav e abou t ou r prod ucts. It also show s y ou the location o f m ajor com p one nts of th e sy stem and d escribes th e con trols an d in dica tors need ed to op erate the U ltraVu x 300 . O ur h igh ly sk illed em ployees and o ur prom ise to use o nly qu ality co m p on ents ensures th at yo u are receivin g th e very be st. Introduction 1-1 . T h is chap ter intro duc es y ou to th e m ain featu res and op tio ns of the p rinte r. com p ute r-gen era ted g rap hics o n ro lled m edia. T h e chap ter c loses w ith a list of op era tor req uirem en ts. Purpose T he U ltraVu x3 00 D ig ita l P rin tin g S ystem (32 h ead v ersion) has been design ed to p ro du ce w id e-fo rm at.Chapter 1 Introduction •••••• Welcom e C o ngratu latio ns! You hav e pu rch ased the fin est su per-w id e fo rm at. ink jet prin tin g sy stem in th e w o rld! W e at V U T E k tak e prid e in ou r p rinters. L o w R e s (resolution ) M o de • O p tio nal m esh and fabric sub strate p rinting k its • M u ltiple roll capa bilities 1-2 C hapter 1 . 40 0 M H z. 25 6 M B R A M O n e 14 G B (o r larg er) H ard D rives (ID E ) Io m ega JA Z D rive 17 ” S V G A M on ito r C D R O M D rive U ltraVu softw a re (P rin ter In terface S oftw are) U ltraW orks (H arleq uin R IP ) so ftw are and W o rk S tation O n lin e do cum en tation lib rary H arlequin D o ng le (R IP S tation ) A d ditio nal features o f th e U ltraVu x30 0 D igital P rintin g S y stem in clu de: • • • • 30 0 dp i prin t capab ility H igh resolution P iezo-elec tric prin t head s S olv ent b ased Ink s T hree prin t m o des: E n han ced M ode .U ltra M ode .1 00B aseT E therne t C ard P entium C P U .Features T he follow in g are all op tio ns in clu ded in bo th the U ltraW orks R IP S tation an d U ltraVu P rinte r C o ntroller: • • • • • • • • • • • • M icro soft N T O p era tin g S ystem N etw o rk read y . Pumps. F ig ures 1 -1 and 1 -2 sho w the lo catio n of its m ain fe atures. S u bstra te F ee d R o lle r Substrate Dryer Printer Controller Workstation Controller Redirect Roller Pneumatic Pinch Rollers Power Distribution Panel Control Panel Servo Controllers Platen Source Rollers (x2) Carriage and Print Head Ink Supply Tanks. Solenoids Figure 1-1 x300 Digital Printing System Introduction 1-3 .Printer Com ponent Location In o rd er to beco m e acq uainte d w ith y ou r U ltraVu x3 00 D igital P rinting S ystem w e en cou rag e yo u to read the fo llow ing descriptio n of the prin ter ’s com p one nts. Regulators. Controller / Power Supply Control Panel Circuit Breakers and Power Distribution Panel Figure 1-2 x300 Digital Printing System 1-4 C hapter 1 . End Takeup and Redirect Rollers Tension Drive Assemblies Vacuum Pump Motor Carriage Drive Motor/Gear Box Servo Controllers Power Distribution Panel Platen Stepper Motor (Substrate Feed Roller Motor) Left of Center. Left Side. Lower Front Primary Ink Tanks Ink Pumps Air Pressure Regulator Air Solenoids Introduction 1-5 . Front Material Advance Encoder Rear Pneumatic Pinch Rollers .Each pinch roller actuator has an On/Off Switch. Up is Off.Printer Component Location Location Component Left and Right Side. Top Emergency Stop Buttons Right Side. Air.2 jets/board Jet Pack Arrays .2 jets/board Filters (Ink. Left (Carriage Assy) Jet Driver Board Carriage Backplane Board Jet Pack Boards (16) . and Solvent) Directional Solenoids Secondary Ink Tanks Edge Detector Linear Encoder Sensor Carriage Height Adjuster Heating Elements Carriage Cooling Fan 1-6 C hapter 1 . Lower Rear Component Printer Controller CPU UltraVu Workstation CPU DC Power Supply DC Fuse Panel Left End UltraVu Workstation Monitor UltraVu Workstation Keyboard UltraVu Workstation Peripheral Devices Front.Printer Component Location (Continued) Location Left Side. Reset. Ink Prime. Power On/Off Print Head Function Selector Switch: Empty Pack. Cyan. Used in conjunction with the Print Head Function Selector Switch to select specific jet pack functions. Upper Front Component Control Panel Platen/Preheater and Substrate Dryer Controls Printer Status LCD Print Head Capper Mesh Kit Takeup Spool Function Buttons: Online. Advance. Tope Center Takeup Rollers Center Bottom Substrate Source Rollers (x2) Introduction 1-7 . Solvent Purge. Magenta. Black. Ink Purge. Error. Behind Carriage Substrate Feed Roller Platen Bail Actuators Substrate Platen/Preheater Rear. Solvent Flush. Top Center Redirect Roller Substrate Dryer Middle. Takeup.Printer Component Location (Continued) Location Left Side. Front. and Ready Color Function Buttons: Yellow. Fire Jets. Bail. Test. T he m ain fu nctio ns of the C o ntro l P an el’s b utton s and co ntro ls are ex plained in th e follo w ing p arag rap hs.Controls and Indicators F igu re 1 -3 sh ow s the con trol p anel of the U ltraVu x3 00 . Figure 1-3 Control Panel Layout 1-8 C hapter 1 . o nline status. W h ile the prin ter is o ffline . W hen th e butto n is illu m inated the p rinter is onlin e. y ou can m ov e m edia fo rw ard and b ack w ard.Printer Status LCD T he P rinter S tatus L C D is lo cate d in the cen ter o f th e C on trol P an el. C om m on fu nction s include: re ady m od e. N o te: A b utton tha t is illu m in ated is O N u nless o th erw ise no ted below. Figure 1-4 Function Buttons Online Button T he O nline b utton tog gles onlin e and o fflin e operation . Printer Function Buttons R efer to F igu re 1-4 for the locatio n o f the printer fu nction b utton s on th e C o ntrol P an el. S electing O F F L IN E w ill su spen d all op era tio ns in p ro gress. It is used to displa y th e statu s o f th e printer. Introduction 1-9 . and error m essag es. test m od e. 1-10 C hapter 1 . starting an d en ding w ith fo ur solid b ars. Test 1 T his test fires all jets w ith no sp acin g at 10 0% density. Test 6 T his te st p rints all jets on an individual b asis. T he do ts sho uld be vertically align ed. step s the m aterial a nd p rints an oth er set o f ho rizon tal lin es. Test 4 T he S tep A d justm e nt Te st prints a series of ho rizontal lines. It p rints a te st pattern con sisting o f a yellow horiz ontal line directly ab ov e a b lack horiz ontal line. Test 2 T he B i-D irectio nal A lign m en t Te st prin ts a test p attern of a lin e of do ts spaced apart ho rizon tally. T his v alu e can b e adjuste d th ro ug h th e U ltraVu S etu p to w ith in 0. the test is u sed to set th e B i-D irectio nal S ettings in the P rinter S etu p S cree n.00 01”.Test Button T he Test B utton initia tes the p rinting o f o ne of seven inte rn al test patterns. T he ho rizon tal line seg m e nts sho uld app ear to be on e lin e (lin ed up ho rizon tally). Test 7 N o te: T h e Test B utton ca n also be u sed to reset th e aud ib le alarm du ring norm al o pera tio n. T h e values can b e adjusted th ro ugh the U ltraVu S etu p to w ithin 0. Test 3 T his test prin ts a so lid 40 0% fo ur color b lack p attern in th e specific m o de prev iou sly p rinte d. E ach color is p rinte d in divid ually. th en step s the m aterial and rep eats the pattern. T h e test is m od e specific.00 01 ”. C olors a re sp aced ap art so in div id ual jet ou tp uts can b e view ed . It prod uces solid co lo rs in the specific print m o de p rev iou sly u sed fo r prin tin g. Test 5 T he Jet P late A lig nm ent Test is used to che ck th e Je t P late’s align m en t. T h is test is m o de sp ecific. T he seven test patterns are describ ed below : T his test fires all 38 4 je ts fo r ea ch co lor. T h e horizo ntal distan ce is a dju stab le th ro ug h th e S te p S ize P aram e ter on the U ltraVu S etu p S creen. A list of errors can be fo un d in C h apte r 6. Takeup Button T he Tak eup B utton activates the Tak eup a nd R e direct R ollers. A n op en co nd ition ind icates th at the pn eum atic P in ch R ollers are n ot activated and are retracted fro m th e S u bstrate F eed R oller. T his bu tto n m ust b e a ctiv ate d before go ing o nlin e to prin t. re verse the m edia. an d step throu gh the in ternal tests. Error Button T he E rro r B u tto n w ill flash to in dicate a prin ter e rror c ond ition . Reset Button T he R eset B utton resets the P rinte r C o ntroller and initiates a b oo t sequ ence. To clea r th e e rror cond ition . Introduction 1-11 . b ut n ot the erro r con ditio n. Trou blesho oting .Advance Button T he A dva nce B u tto n perform s th re e fun ction s: adv ance th e m edia . Bail Button T he B ail B u tto n op ens an d clo se s the pn eum atic P inch R ollers that are used to hold th e m ate rial on th e S u bstrate F eed R o lle r. dep ress and hold do w n the Tak eup B utton w hile dep ressing the A d van ce B u tto n to rew ind the sub stra te. T he seco nd fun ction o f th e A dv ance B utton is to re w in d th e substrate. Its third fun ction is to adv ance throug h th e seven test fu nctio ns describ ed in the Test B utto n section ab ov e. O n ce active. D ep ressin g th e Test B u tton w ill reset the aud ib le alarm . T h e B a il m ust be activated or th e p rinter w ill n ot g o on lin e. d epress and re lease th is bu tto n. It doe s n ot reset th e U ltra Vu W o rk station . To p erform the rew ind fun ction an d activate the rollers the Tak eup B u tto n m ust be d epressed. Its p rim a ry fu nctio n is to ad van ce th e su bstrate m ed ia. D ep re ssing an d ho ld ing the E rro r B u tton w ill d isp lay the app ro priate erro r m essage on the L C D . Figure 1-5 Function Selector Switch D u ring a pau se in p rinting . prim e and test th e ink jets p rio r to prin tin g. F a ilu re to co rrectly shu t do w n W in do w s N T m ay resu lt in files beco m ing corru pted on the ha rd d rive. Tak eup and B ail B u ttons o n the C ontro l P anel m o m en tarily flash. C a u tion : B efore sw itchin g th e O n /O ff Sw itch off. th e C arriage w ill m o ve in to the m ain ten ance p osition . D u ring these functio ns. N o te: T he R eset. A dva nce a nd the C o lor Selection B u ttons d o no t illum in ate w hen the system is initia lly turn ed on . the W ind ow s N T O p erating System runn in g th e w orksta tion m ust b e sh ut d ow n . 1-12 C hapter 1 . E a ch C olor B u tto n contro ls th e eigh t Jet P a cks fo r that colo r. W he n any o f th ese fu nctio ns are selected . W hen in itially tu rn ed O N . th e o perato r can use th ese fun ction s to clear up ink jet prob lem s. N o te: D epressing a nd h olding d ow n o ne o f the four co lor b utton s con trols colo r selectio n. O nline. the Test. T he H e ater C on trol b rie fly disp lay s the m axim u m allo w ab le tem p erature.On/Off Switch T he O n/O ff S w itch p ow ers th e U ltra Vu x 30 0 prin ter on o r off. o nly one co lo r b utton m ay b e dep ressed a t a tim e. Printer Function Selector Switch T he P rinter F un ctio n S elector S w itch (see F ig ure 1-5) p ro vides fu nctio ns fo r op eratin g the in k con trols allow in g th e o perato r to p urg e. th e P rint H ead w ill m ov e to the m ain tena nce po sition (w ith the cap per retracted). It is reco m m en ded that this fun ction be con tinued to be used u ntil only a so lid co lo r (n o air) exits the W aste R eturn L in e. U se th e IN K P R IM E settin g to rem o ve th e air bu bb les before using th e IN K P U R G E S e tting to restore the jets.T his fun ctio n is use d to rem ov e ink o r solven t by pressurizing th e S eco nd ary Ink Tank s an d Jet P ac ks. A ir bu bb les a re usually present in the Jet P ack w h en a nu m ber of th e jets m isfire. W hen usin g the F IR E JE T S settin g. and to clear clo gg ing in th e jet orifices. A ir b ub bles are usu ally present in th e Jet P ac k w h en a nu m b er o f th e jets m isfire. To test fire th e je ts a sh eet of pa per is usually placed on th e P rint H e ad an d th e C olor B utton is b riefly dep resse d. th e ink o r solven t is flush ed in to th e W aste C o ntainer. It is u sed to u nclog a Jet P ack o r to pu rge the system be fo re rem o vin g a S eco nd ary Ink Ta nk or Je t P a ck. Fire Jets Setting W A R N IN G : D o n ot u se th is fu n ction w ith o u t th e Jet P a cks bein g covered as an in k spill a n d p oten tia l eye h azard w ill occu r. T he in k th at is pu m ped th ro ug h the Jet P ack s is p um p ed to the W aste C o ntain er. a ssist in re m o ving air bu bb les from th e sy stem . It is reco m m en ded that this fu nctio n be used b efore prim in g w ith in k. T he IN K P R IM E settin g is useful in rem o vin g air bu bb les from in side th e Jet P ack. T his fun ction is u sed for b ulk prim in g th e Jet P ac ks and sho uld not b e used for lon g periods of tim e. T he S olven t P urge S etting is in ten ded for clean in g and u nclog gin g th e Jet P a cks. T he S olv ent F lush S etting is u sed to c lean th e Jet P ac ks an d initially w et th e surfaces in sid e th e Jet P ac ks before prim in g w ith in k. T h e printed pattern o n th e p aper w ill ind ica te w hich jets a re w ork ing an d w hich a re n ot. T his p ro ced ure also rem ov es air from th e Je t P ac ks and sh ou ld b e p erfo rm ed u ntil no air b ub bles are seen w ith in the W aste R e turn L in e (ap prox im ately five to ten so len oid clicks). T h e Ink P u rge S ettin g is used to p rim e th e Jet P ack s. It is also used to in itially w et the surfaces inside th e Je t P a ck before prim in g w ith ink . Em pty Pack Setting T h is fu nction se nds cleaning solven t th ro ug h a Jet P ack to clear ink from the Jet H ead s. Introduction 1-13 . Ink Prim e Setting T his fun ction is used to fo rce ink to the su rface of th e Jet P ack . Solvent Flush Setting T h is fu nction fills the selected Jet P a cks w ith in k a nd fo rc es an y o verflow into the W aste L in e assu rin g th at the Jet P acks are filled w ith ink. Solvent Purge Setting T his fun ction is u sed to sen d cleaning solven t th ro ug h the Jet P ack and into the W aste C on tain er. W he n active. Ink Purge Setting T his fun ctio n fires the Jet P acks as th oug h yo u w ere prin tin g a solid co lo r. (↑). B elo w th e L C D s are tw o rotary H eater S elec tor S w itches.Ready Setting T his fun ctio n pu ts th e printer in the R eady M od e a nd m ove s the P rint H ead to a p ositio n un der the P urg er P late A ssem bly. the O n lin e B utton can b e a ctiv ate d. O n ce R E A D Y is sele cted an d th e C arriage is po sition ed un der th e P urger P late A ssem bly. W h en th e printer O n/O ff S w itch is O N . T h e up per num b er represents the cu rrent tem peratu re o f th e heater an d the lo w er num b er represents the op erator selectable target tem peratu re . lab eled O F F /L E FT a nd O N LY /B O T H . W h en th e H eater S ele cto r S w itch is O F F. O p era tio n. Platen/Preheater and Substrate Dryer Controls T he U ltraVu x3 00 D igital P rin tin g S y stem s are eq uip ped w ith tw o sets of H eater C o ntro ls fo r prehe atin g th e substrate and d ry in g th e ink (see F igu re 1 -6 ). the H ea ter C on tro l L C D w ill briefly d isp lay the m axim u m allow able tem peratu re. Figure 1-6 Platen/Preheater and Substrate Dryer Controls T he H eate r C o ntro l L C D displa ys tw o n um bers w h en sw itched on . B elow the nu m bers o n th e L C D are fo ur b utton s: S et. T h e O nline B u tto n m ust be illu m ina ted to start prin tin g. (↓) a n d (←). W ith th ese c ontro ls yo u can select w he ther to use th e w h ole heater o r just the le ft side o f th e heater. 1-14 C hapter 1 . To o perate an y of the se co ntro ls you shou ld refer to C hap ter 3. th e d isp lay w ill sh ow the am bient te m p erature of the hea ters. C o lor aptitu de an d the ory. Tech nical bac kgrou nd inv olvin g ele ctronics and m ech anics. C ap able o f p hon e-assisted p ro blem resolution and repair. C o m m u nicatio ns link w ith V U T E k P rod uct S u ppo rt D ep artm e nt. W ind ow s N T and P C exp erien ce. P rep ress and P o stscript kno w ledg e. Introduction 1-15 . F luen t in the E n glish lan gu age.Operator Requirem ents T he follow in g req uirem en ts and respo nsibilities are recom m en ded for op erators of the U ltraVu x3 00 D ig ital P rin tin g S ystem : • • • • • • • • R esp onsible for P rin ter ’s o peration an d m ain ten ance . 1-16 C hapter 1 . Yo u sh ou ld refer to F ig ure 2-1 fo r th e fill an d fire electric al w av efo rm used to d rive th e jets. H ere are the m ajor co m pon ents th at are d iscu sse d: • • • • • • Jet P acks U n it C arriage C o m po nen ts In k an d S o lv ent S ystem In k an d A ir S upp ly S y stem M o tors. You sho uld rou tin ely ch eck the m to ensu re th at you g et the best prin tin g resu lts from y ou r U ltraVu x3 00 . The Piezo Principle T he U ltraVu x 30 0 D igital P rintin g S yste m u ses P iezo d riven jets th at are based o n a “fill and fire” co ncep t.Chapter 2 Overview •••••• Introduction T his ch apter d escribes th e m ajor c om po nen ts and su bsystem s that com p rise the U ltraVu x3 00 D ig ital P rin tin g S yste m . T he section b egins w ith a discussio n o f th e p iezo princ iple. the con cept of the in k jet techn olog y used in th e U ltraVu x 30 0 P rinter. E ach o f th e com p onents d iscussed here is critical to the successfu l op eratio n o f y our prin ter. Figure 2-1 Piezo Jet Fill and Fire Waveform Overview 2-1 . S ervo s an d E nco ders P late n/P reheater an d S ub stra te D ryer Jet Pack Units T his section describe s som e o f the m ajor characteristic s of th e Jet P ack un its. 1 m s). T h e re su lt is the rapid exp ulsion o f a drop o f ink to w a rd s the sub stra te m aterial. the P iez o shorte ns its len gth slig htly. draw ing add ition al in k in to it from an ex ternal ink reservo ir. W hen v oltag e is app lied. so tha t the cu rv ed up per su rface o f th e liq uid (m en iscus) at th e jet orifice rem ain s intact. pu lling the diaph rag m . redu cin g th e volum e of the ink ch am ber rap idly. T he exp ansion o f th e ink ch am ber o ccu rs slow ly (0.W ith th is techn ology o ne e nd of th e p iezo dev ice is an cho re d in a fixed po sition an d has a v oltage sou rce ap plied to it (see F igu re 2 -2 ). T h e o th er end is c onn ected to a d iaph ragm and is fre e to m ov e. Figure 2-2 Piezo Jet Operation 2-2 C hapter 2 . W h en a v oltag e transitio n (+ 65 V to 0 V ) o ccurs. the P iezo retu rn s to its orig inal len gth . T he in k reserv oir is com m on to all jets w ith in the Jet P ack. T his actio n causes a cha m b er co ntaining the in k to exp and . 35m m ) apart. an d w h ite for desired tem peratu re . T here are tw o Jet P ack A rrays per Jet P a ck B o ard A ssem blies.0 64m m ). E ach Jet P ack A rray h as o ne in pu t and o ne in pu t/o utp ut lin e.05 3” (1 . th e JP B a nd a rra y assem blies m ust b e rep laced as a set.0 02 5” (0. T he flexib le ribbo n c able th at is attached to th e array p lug s in to a tap ere d head er o n the jet pack b oard an d is held in p lace w ith a ta pered A n ti-B ac kou t C lip.Jet Pack Description A n ind ividu al Jet P ack co nsists o f tw o array s of 4 8 in -line jets. In all there are 3 2 Jet P ack A rrays per carriage (16 JP B ’s). L ines 2 to 49 are th e 4 8 in divid ual jet sig nal lines. Jet Pack Boards F or a full descrip tio n of the jet pack bo ard s y ou sh ould refer to the previou s sectio n. i. T he JP B assem blies are sh ipp ed an d h and led a s a dua l jet pack set. g reen fo r co oling . O n th ese flexible rib bo n cables lin es 1 and 5 0 are g ro un d con nectio ns. T his fun ction h elp s m aintain co nsistent ink viscosity as w e ll as electron ic a nd m echan ical p erform ance s w ithin the O verview 2-3 . T herefo re. T he elec trical co nne ctio n to each jet array is via a flexible ribb on ca ble orig ina tin g on the JP B . N o te: S epa rate a rrays can no t be rep la ced in the field .e. A n in div id ual P ie zo crystal d rives each jet. E ach o f th e o rifices is 0. T he inpu t line is used to sup ply ink to th e jets w hen p rinting occu rs. a n E d g e D etec to r. and 2) to rem ove ink w hen p rim ing and flu shin g occ urs. a therm ostatically con trolled C o o lin g F a n . Cooling Fan T he P rint H ead’s tem peratu re is k ept co nstant b y a C oo lin g F an m oun ted on the side o f th e C arriage A ssem b ly. and S olen o id P la te. Carriage Com ponents T he carriage u nit con sists of the Jet P ack B oards. T he in put/o utp ut line serves a d ual p urpose: 1 ) to su pp ly in k to th e jets. It h as the ab ility to m ain tain the C a rriag e A ssem bly’s in ternal tem peratu re to w ithin ±1°F of 84 °F. red for h eating . A n ind icator (L ed # 9) on th e JP B ind icates the state of the H ea ter/C o oler. T h e orifice diam e ter is 0 . T hese assem blies sh ou ld b e stored in sea led con tainers or in p la stic ba gs. T h e filter on the extern al b oxe r fa n m u st be clean to allo w fo r prop er airflow. Solenoid Plate F or inform atio n on the S oleno id P late. M aintenan ce. Edge Detector T he E dg e D etecto r is a light em itter/sensor lo cated o n th e side o f th e carriage assem bly. for m aterial lo ading in fo rm ation a nd C h apter 5 . th ereb y. To a ccess these co m p on ents. Yo u sh ou ld refer to C h apter 5. B etw een the C arriag e a nd th e In k S up ply P late is a series o f tube s an d m anifo lds u sed to de liv er the ink to the P rin t H e ads. P lease refe r to C hap ter 3 . refer to “S o len oids” in the ne xt section . N o te: To m in im ize th is effect you sh ou ld verify th e m ateria l ha s b een properly align ed prior to p rintin g. fo r th e C o oler ’s m aintenan ce sched ule an d m ain ten ance p ro cedu res. M a intenan ce. for th e E d ge D etector S ensitiv ity A djustm en t details. O peration s. T he su pp ly sy stem fo r each color h as fiv e con trol soleno id s. To p rint e d g e to e d g e (o r p an els) the E d g e D etecto r m ust b e activated.prin t head . T h e Ink L ev el S ensors are com p rise d of tw o therm isto rs th at ch ang e their resistivity w h en 2-4 C hapter 2 . You sh ou ld refe r to C hap ter 3 . T he E dg e D etecto r can be tu rn ed off d urin g p rinting throu gh U ltraVu’s P aram eter S etup S creen . O peration . th e stain less steel c ove r on the carriage m ust b e rem ov ed (fo ur thu m b screw s fasten th e cov er). un der P rin t O p tio ns M en u fo r m ore detail. W h en off. the E dg e D etecto r w ill n ot d etect an edg e durin g prin ting. Ink and Solvent System s Ink and Solvent Control R efer to F igu re 2 -3 (old er system s) and F ig ure 2-4 (n ew er system s) for a dia gram o f th e ink and so lve nt co ntrol c om po nen ts on the C arriage P late . T h e P rin ter C on troller u ses the senso r to d ete rm in e th e start and sto p ed ges of the m ed ia du ring th e in itial pass. an in-lin e filter and a secon dary in k reservo ir and in k lev el sensors. ensurin g th e im age w ill m aintain an even m arg in th ro ug ho ut th e im age . im m erse d in the in k. older version Figure 2-3 Ink and Solvent Carriage Components O verview 2-5 . R efer to ch apter 5. a llo w ing the prin ter c ontro l system to m onito r th ese c ond ition s. T h e follo w in g section deta ils th e fu nction s o f th e in div id ual co m po nents o f the In k an d S o lv ent C ontro l S yste m . N o te: T he In k L evel Sen sors can b eco m e covered w ith dry in k resultin g in the senso r m alfun ction ing . M a in ten ance. fo r in form ation on the m a in tena nce o f th e low -level in k sensors. newer version Figure 2-4 Ink and Solvent Carriage Components 2-6 C hapter 2 . w h ich creates a p ositiv e pressure fo r prim ing o r pu rgin g. W hen energ ized . allow ing the ink to be draw n in to th e jets w hile printin g and the can to be refille d w itho ut p re ssu rizin g. W h en ene rg ized . solv ent. it a llo w s solven t to flow into th e Jet P ack s. W hen energ ized . air. S olen oid #4 is a n orm ally closed unit. it op ens th e W aste L in e fo r pu rgin g in to the W aste C o ntain er. E a ch is used to g ate in k. it opens the Ink S u pply L in es fro m the S econ dary Ink R ese rv oir to the app ro priate jet p acks. W hen d e-energ ized . S olen oid #3 is a three-w ay u nit. Figure 2-5 Ink Control Diagram S olen oid # 1 is a no rm ally clo se d u nit. it allow s th e ink th at is circulating in th e u m bilical to pa ss in to the S econ dary Ink R eservo ir. S olen oid #2 is a three-w ay u nit. W hen ene rg ized . it a llo w s pressurized air to flo w in to th e secon dary reserv oir. an d w aste throu gh the in k and so lv ent sy stem . O verview 2-7 . W h en de-en ergiz ed. it vents th e S econ dary Ink R e se rv oir to the atm o sp here th ro ug h a disk filter.Solenoids T here are fiv e so len oids on the C arriage (see F igu re 2-5). M ainte nan ce. Air. T h e In-L in e F ilters w hich h ave an 8 µm m esh are p lace d in lin e w ith the air. You shou ld refer to C hap ter 3. sho uld be replaced m on thly. O peration . solv ent and w aste lines are c om m on to all co lo rs. is th e lo gic tab le.S olen oid #5 is a th re e-w ay un it. W he n de-energ ized it allow s ink o r solven t to en ter th e W aste O u t L in e. sho w in g th e relationsh ip b etw een th e five soleno ids d escribed ab ov e and the P rinter F un ction S elec tor S w itch on the C o ntro l P anel. Solvent and Waste Lines T he air. F o r m ore inform ation o n re plac ing these filters. in k and S o lv ent F eed L ines. T h e air a nd so lven t filters sho uld be re plac ed on a n ann ual b asis. T he in k filters. W h en en ergiz ed it allo w s ink to flow to th e Jet P ac k. Printer Selector Sw itch Logic Tab le A . fo r a desc rip tion on using th e P rin ter F u nctio n S e lector S w itch . yo u sho uld refer to C h apter 5. isolated b y th eir respectiv e soleno ids. In k an d S olven t S y stem S ole noid F un ction s. T h is w ill o nly w ork if th e printer is in the o ff-line po sition . Table A Ink and Solvent System Solenoid Functions Switch Setting Fire jet Ink purge Ink prime Solvent flush Solvent purge Empty pack 2-8 C hapter 2 Sol #1 active active active inactive inactive inactive Sol # 2 vent air in air in vent vent air in Sol #3 ink ink ink solvent solvent ink Sol #4 closed closed open open open open Sol #5 ink in ink in waste out waste out waste out waste out . T his sw itch selects w h ich jet func tio n w ill o ccur w h en an in divid ual colo r bu tto n is de presse d. lo cated in th e ink lin es. N o te: T he S econ da ry Ink R eservo irs ho ld a pproxim a tely 2 0 cc of ink un der no rm a l opera ting co nd ition s. O verview 2-9 . Ink Pum ps F our pu m p s m o un ted o n th e Ink S u pp ly P late circulate th e ink (F ig ure 2-6). throug h th e um bilic al and fed b ack to the p rim ary tan k via the ink circu lation lin e. fo ur ink sup ply tanks and on e w aste tan k located on th e ink sup ply p late (see F ig ure 2-6). E ach pum p is d riven by its o w n direct d rive.Prim ary Ink Reservoir T he P rim ary Ink R eservoirs co nsist o f five 5 -liter po lyethy len e tank s. W hen ink is n ot d em and ed fro m the system . T h is is a no n-term inal erro r. N o te: O n som e old er system s th is m a y be a bru sh m o to r a nd g earb ox assem bly. ind icatin g to th e o perator w hen the ta nk n eeds to b e em ptied. T his circu lating m o tion p ro vid es visco sity con trol. Figure 2-6 Ink. Solvent and Air Supply Layout T he P rim ary In k Tank s are eq uip ped w ith level senso rs to detect an “in k ou t” co nd ition . brushless D C m otor. th is loo p is un brok en an d ink flow s th ro ug h it contin uou sly. T h e ink is p um pe d to the carriage by con tin uo usly cyclin g in k pu m p s. T he w aste holding tank also con tains an in ternal se nsor fo r detecting a full con ditio n. allo w in g the p rint fu nction to b e resu m e d after refilling w ith in k. T h is reg ulato r is used for setting th e bail p ressu re an d is no rm ally set at 1 5 to 30 psi. T he A ir P ressu re R egu lato r for this sy stem is loca ted d irectly ab o v e the so lven t tan k o n the Ink S u p p ly P late a n d is set to betw een 2 and 3 psi. A ll th e so len oid s m o un ted o n th e ink su pp ly p late can be m anu ally op era ted w ith an elec trical o verride co ntrol. C a u tion : D o n ot ad just this regu lator h ig her than 5 psi. A P ressu re R elief Valve lim its th is to 5 p si m axim u m . T he S olvent Tank R egu lator also prov id es air p ressure fo r th e p u rg e fu n ctio n a t the sam e p ressure lev el. To activate the soleno id. N ext to th e M ain R eg ula tor is the P in ch R o ller R eg ulato r. T his w ill energ ize th e so len oid and allo w airflo w w h en th e printer is o n. T he S olven t Tan k h as a lev el senso r bu ilt in. T h e P urg er P late w h ich reg ulates the air pressure to the P urge r P late C ontro l S ole noid sho uld be set to approx im ately 4 0 psi.Solvent Reservoir T he S o lven t Tank su pp lies the U ltraVu In k S olven t use d for the clean ing and p u rg in g the jets (see F ig ure 2 -5 ). 2-10 C hapter 2 . Air Pressure Regulators And Solenoids T he M ain P ressure R egu lator is lo cated in the u ppe r righ t co rn er o f th e In k S u pp ly P late (see F igu re 2-5) an d is set to 5 0 p si. T he rem aining reg ulato r is the P u rger P late R egu lato r. b ut w ill v ary dep end in g on the m aterial bein g prin ted . press the sm all b lu e b utton on the lo w er half of the so leno id assem b ly. W hen a p rint fun ctio n or a m a intenan ce fu nction is in itiated .Purger Plate (Capper) T he P u rger P la te is an air a ctua ted cov er for th e Jet P acks (see F igu re 27). A p prox im ately ten seco nd s after the C arriage A ssem b ly parks at ho m e. Adjust Flow Cover Blotter Paper Figure 2-7 Purger Plate O verview 2-11 . T he air pressure used b y th e P u rger P la te is con trolled b y a reg ulator lo cated on th e In k S up ply P late. N o te: T he a bso rb ent p ap er on th e P urger P late m u st be rep la ced w h en it b ecom es satu rated w ith in k. W h en th e p rinte r is n ot in use or is offlin e. Its pu rp ose is to p re ven t the ink fro m d ry in g as w ell as lim iting the exp osu re of th e ink to co ntam inates. To red uce th e spe ed at w hich th e P urg er P late low ers adjust the scre w in sligh tly on th e R estrictor Valve located on the A ctua tor (air cy lin der) m ou nted ab ove the P urger P late (see F igu re 2 -7 ). the P u rg er P late w ill au tom atically lift o ff th e Jet P ack s before th e C a rriag e m o ves from h om e. th e P u rger P la te w ill low e r its co ver onto th e Jet P a cks. the C arriag e A ssem bly w ill park in its “h om e” po sition . T he regu lator shou ld be set at 4 0 p si of air pressure. T his sam e ty pe of brushless servo m o to r driv es the S ub strate F eed R o ller. T he Y S ervo D rive C o ntro lle r m anag es the S ubstrate F eed R oller S ervo m otor. T he X S ervo D rive C o ntro ller m anag es th e C arria ge D riv e S ervo M otor. y ou w ill need to refe r to C hap ter 3 .Motors. too th ed. C arriage D riv e B elt. E ach m o tor gearbo x assem bly drive s o ne ro ller th ro ug h a series o f flex c oup lings an d a m agn etic h yste risis c lutch. T h e D rive R o ller uses a zero bac klash harm o nic drive u nit fo r precision o peration . F o r add ition al inform atio n o n se tting th e Ten sion param eter. O peration . T he to rq ue o f th e clutch is ch ang ed by v aryin g th e Tension p ara m eter un der th e U ltraVu S etup m enu . Figure 2-8 Takeup Roller Drive System Diagram 2-12 C hapter 2 . T h e M ain D rive P ulley is link ed d irectly to a 90-de gree w orm style ge arb ox and is d riven by the brush less serv o m otor. Servos and Encoders Motors T he P rint H ead C a rriag e A ssem bly is con nected to the M a in D riv e P ulley by a rein forced. T he Tak eup a nd R ed irect R o llers are d riven b y A C m otors co nn ected to a 90 -d egree w o rm gear red ucer (see F ig ure 2-8). they are co nfig ured an d prog ram m ed d iffe ren tly throu gh the u se o f in div id ual P erson ality C o ntrol M od ules that are fo un d on the M ain S erv o C o ntroller B oard. B o th servo s co m m u nicate w ith the P rinte r C o ntroller ’s C P U throu gh R S 42 2 cab les. F ig ure 2-9 sho w s th e layo ut for the S ervo C ontro llers. A lthou gh the S ervo C o ntro lle rs are iden tical un its. Figure 2-9 Servo Controller Layout O verview 2-13 .Servo Controllers T he prin ter uses tw o serv o con trollers: an X S ervo C ontro ller for carriage m otion and p ositio nin g. an d a Y S erv o C o ntro ller fo r th e S ubstrate F eed R oller m o tion an d po sition ing . O n e useful featu re o f th e S ervo C on trollers is th e n on -v olatile fault code m em ory w h ich sto res th e error co des fo r all m otion an d p osition in g failu res th e printer h as incu rred sin ce it w as shipped. sy stem p ow er w ill b e cut o ff. 2-14 C hapter 2 . T he inco m ing po w e r to the S ervo C o ntroller is 2 30 VA C . T h is m o d u le is id entical to th e X S ervo w ith th e excep tion o f th e P erson ality M o du le th at gives it the fu nctio nality n eed ed to p ro vide th e su bstrate m aterial fe ed fu nctio n. (T he E m ergen cy S to p bu tton is a 2 4-Volt high sid e sw itch that sen ds a sign al to th e prin ter C P U and con tactor sim ultaneo usly. T he S ervo C o ntro lle r is con nected to the C P U u sin g an R S 42 2 cab le. and the E m erge ncy S to p B u tto ns. O ther con nection s to th e Y S erv o C o ntroller includ e the E m ergen cy S top B utton s. P ow er p asses th ro ugh a S ch affn er F ilter. and the m ain co ntacto r before fe edin g th e serv o con troller. th e circuit breaker. T his cable has a D -typ e co nn ecto r at th e con troller end and a m ilitary ty pe con nector at th e m otor end . In the case of a se rv o fau lt or the E m ergency S to p B u tto n being p ush ed. T he E m ergen cy S to p B u tto n is a 2 4-Volt high side sw itch that send s a sign al to the prin ter C P U and contacto r sim u lta neo usly. T h e po sition ing feed back is via a 15 -co nd uctor R S 23 2-style cab le from th e interna l M oto r E n cod er to th e S erv o C ontro lle r. Y Servo Controller T he func tio n of the Y S ervo C on troller is to con trol an d m on ito r th e serv o m o to r tha t d rive s the S u b strate F ee d R oller. O ne po le of th e E m erg ency S to p B u tton also breaks th e sup ply to th e M ain C on tactor.) A red lig ht o n th e c ontro ller w ill ind icate a loss of signa l from an en cod er. T he S ervo C o ntro lle r is con nected to th e m otor via fou r p ow er lead s. T his cable has a D -typ e co nn ecto r at th e con troller end and a m ilitary typ e co nn ecto r at the m oto r en d. sy stem po w er w ill be cu t off. T he S erv o C o ntro ller con nects to th e C P U via a R S 4 22 ca ble. O ther con nectio ns to the X S ervo C o ntro ller in clu de th e left and rig ht lim it sw itche s. In th e ca se o f a servo fault or the E m ergen cy S top B utton bein g pu shed . T h e inc om in g po w er to th e S ervo C on troller is a dire ct 23 0 VA C c onn ection . T he S ervo C ontro ller is co nne cted to th e m o tor th ro ugh fo ur p ow er leads. P ow e r p asses th ro ugh the S cha ffne r F ilter. a c irc uit break er a nd a M ain C o ntacto r b efore fe edin g th e S e rv o C on troller. T he p ositio ning fee dba ck is via a 1 5con du cto r R S 23 2-style cable from th e intern al M o tor E nco der to th e S erv o C ontro lle r.X Servo Controller T he func tio n of the X S ervo C on troller is to con trol an d m on ito r th e serv om o tor driving the C arriag e. see C hap ter 3. th e Su bstra te F eed R oller w ill rotate out of con tro l a t a very high sp eed un til an error con ditio n is detected. T he step size for the en cod er is prog ra m m ab le th ro ug h th e U ltraVu P rog ra m . X Servo Linear Encoder T he X S ervo u ses a linea r enc ode r to ch eck p rint h ead po sition a nd com p ares it to th e internal en cod er o n th e C arriag e D riv e M otor. Tw o extern al enc ode rs. T he en cod er feeds th e positio ning d ata direc tly to th e Y S erv o C o ntroller. T h is strip. verify eac h serv o’s p ositio n. Y Servo Rotary Encoder T his o ptical enco der m easures th e step d istance o f the su bstrate m ed ia.Motor Encoders B o th the S u bstrate F eed R oller D riv e M o to r a nd C arriage D rive M otor hav e built in ro tary en cod ers. c ontain s m ag netic m ark ers th at are sp aced o n a vernier scale. T he L in ear E n coder uses a m agn etic strip that ru ns th e full len gth of the prin ter. givin g th e m a gnetic strip a resolution of 5 µm . C on ta m inatio n of the m ag netic strip ca n resu lt in ina ccu ra te o r m issed reading s. D o n ot expo se it to an y kind o f m a gn etic m ateria l or use ab rasive o r corro sive clea ners o r it w ill b e destroyed. If the fe ed ro lle r adv ances th e m aterial and the enco der do esn’t de tect m o tio n. C a u tion : If the enco der is no t in con tact w ith the m aterial and is allow ed to ro ta te. a step erro r w ill o ccur. o ne o n th e C arriage R a il an d the o th er on the S ub strate F eed R o ller. N o te: T he sensor and its ca ble are m an ufa ctu red as on e un it. w hich is m oun ted on th e b ack of th e insid e C arriag e R ail. N o te: A ny co nta m ina tio n of th e E n cod er W heel can in du ce slipp ag e a nd m a y cau se ina ccura te step read ing s. an y lo ss o f re ading (thro ugh w heel slip pag e or step erro r) from th e m aterial w ill prod uce a step error. O verview 2-15 . T h e P icku p S e nsor se nds a sig nal b ack to th e E n cod er M odu le th at is lo cate d in the m id dle o f th e printer ’s um bilical troug h. To ad ju st the step size. C a u tion : T h e m ag netic strip is very sensitive to m ag netic fields. T h e en cod er prov id es p osition al fe edback inform ation th ro ug h the co ntro l bo ard to th e C P U . A M ag netic P ick up S en so r that sen ses the m agn etic m arks is m ou nte d on the P rint H ead C a rriag e. req uiring th at the com plete assem bly b e rep laced if the cab le is d am a ged or the senso r fails. O pe ration . B ecau se th is enc oder feeds d irectly bac k to the Y S erv o C o ntro lle r. th e su bstrate c om es in co ntac t w ith th e heated platen im m ediately before an d du ring the p rinting process. T he S ub strate D ry er (he ater) ap plies he at to th e freshly prin ted substrate to sp eed th e d ry ing p ro cess. w a rm in g th e m aterial b efore ink is ap plied . A s th e p rinted im a ge m o ves ac ro ss th e surfac e o f th e S u bstrate D ry er. an d to allow a g reater rang e o f sub stra tes to be u se d. S o m e su bstrates w ill o nly w o rk e ffic iently w hen heated. 2-16 C hapter 2 . T he he aters o n th e U ltra Vu x30 0 prin ters w ork b y con du ctio n. T h e P late n/P reheater w arm s the sub strate m aterial b efo re the ink is ap plied . heat is ap plied to d ry the in k before bein g ro lled on to the Tak eup R oller. In th e case of th e P laten /P reh eate r.Platen/Preheater and Substrate Dryer Controls T he U ltraVu x3 00 D igital P rin tin g S y stem s are eq uip ped w ith tw o sets of heaters for p reh eating the sub strate an d dryin g th e in k. T he P late n/P reheater and S u bstrate D ryer P lates are heated inte rn ally and th e heat con duc ts to th e m a terial as it p asses ove r th e p lates. T he S ub strate D ry er is slightly cu rved and lo cated o n top of the printer. Top ics cov ere d in clud e: Starting and Shutting Down • S tartin g th e P rin ter • S hutting O ff th e P rin ter • R eco verin g from an E m ergency S to p Working with Media. Ink. and Printer Setup • L oad in g M aterial • W orking w ith M ultip le R o lls • U sing the M esh O ption • A d ju stin g th e E n cod er W heel • M ainta ining Ink Viscosity • P rep sring the Jet P ackss • P rim ing the Jet P acks • R eco verin g fro P lu gg ed Jets Understanding Printer Controls • U sing the In ternal Test P attern s • C o ntrollin g th e P laten Vacuu m L ev el • O p era tin g th e H eater C o ntro ls • U n derstan ding th e F ile F orm ats • U n derstan ding th e P rin t S peed s • U n derstan ding th e P rin t M o des Using UltraVu Software • U n derstan ding U ltraVu’s C apab ilitie s • U p grading the x3 00 S o ftw are O peration 3-1 .Chapter 3 Operation •••••• Introduction T his ch apter d escribes ho w to u se the U ltraVu x 300 P rin ter and the U ltraVu C on trol P rog ram . 3-2 C hapter 3 . p ress the C ontro l P an el’s P o w er S w itch to O F F. C a u tion : F ailure to w ait the specified tim e period w ill cau se a n overloa d current to da m a ge th e S ervo C o ntro ller C o nta cto r. press the C o ntrol P an el’s P ow er S w itch to O N . Recovering from an Em ergency Stop If for an y reaso n an E m erg ency S to p B utton is dep ressed . yo u m u st w ait a m inim u m o f 6 0 secon ds before restartin g th e p rinter. E n su re th at b o th E m erg en cy S to p B u tto n s are fu lly o u t. B e sure to sh ut do w n the N T O perating S y stem .• • • • U p grading the x3 00 F irm w are F orm a tting R e m o vab le D isk C artrid ges S tartin g th e U ltra Vu P rog ram U n derstan ding th e U ltraVu M enu S tru ctu re Improving Print Quality • P rint G ap • S tep S ettin gs • P late n/P reheater an d Vacu um S ettings • S ubstrate D ryer S ettings • Tak eup Tension S ettin gs • Jet O u tag e • Tria l R un s • L ow er R e so lu tio n R IP F iles Starting and Shutting Down Starting the Printer To start the prin ter. Shutting Off the Printer To shut off th e p rinter. O peration 3-3 . then up and behind the Carriage Rail. Ink and Printer Setup Loading M aterial To load m aterial you sh ould refer to F igure 3-1 an d F igu re 3-2 and p erform th ese step s: 1 2 Depress the Takeup Button to turn off the Takeup Rollers. Figure 3-1 Control Panel 3 Place the substrate material on the Substrate Source Rollers and position the material to ensure contact with the Rotary Encoder. If additional tension is needed (on material under five meters in width). feed the material around the Substrate Source Roller before feeding up behind the Carriage Rail.Working with Media. Depress the Bail Button to release the Pinch Rollers. Spool the substrate off the Feed Roller. . Pull all loose material to the front of the printer until all the slack is taken up. Pull out enough substrate so that its end reaches the floor in front of the printer. Ensure that there are no wrinkles where the substrate leaves the Source Rollers and on the Substrate Feed Roller. 7 When properly aligned. This is done by visually aligning the left edge of the loose material to the substrate coming off the Feed Roll. check for alignment. Fold excess substrate over and place on the shelf under the Feed Drive Roller. Pull an additional 10" (25cm) of material so a fold can be made. 6 While viewing the front of the printer with the substrate hanging down. With the Bail open pull the substrate over the Redirect Bar and feed over the Drive Roller. feed the substrate over the Drive Roller and under the Platen/Preheater. 5 From the rear of the printer.Figure 3-2 Substrate Feed Path (side view) 3-4 C hapter 3 4 Go to the rear of the printer. close the Pinch Rollers by depressing the Bail Button. Tape at corners of material and work inward towards center. B y fa nfo ld ing the m a terial m ultip le ro lls are less lik ely to c reate stepp ing errors or un equ al leng th se gm ents caused by fee din g the su bstrates a t different ra tes. ca re m ust b e taken to avo id u neq ual im age len gths. engaging the Tapeup Rollers once the center of the substrate is secure will help keep tension on the material while the taping is finished. On wide material. If the sub stra te ro lls are n ew a n d are o f e q u a l len gth and th ick ness. d iffere nt d iam eter rolls can cau se differences in the m aterial feed rate . S ince all ro lls use th e sam e S u bstrate S ource R o lle rs. depress the Takeup Button to engage the Takeup Roller.8 Feed the substrate material up and over the Redirect Roller and over the Substrate Dryer Plates until it reaches the Takeup Roller. p rintin g c an p ro ce ed n o rm ally. If the rolls are u nequ al diam eters. From the rear of the printer verify alignment by ensuring that the loose end aligns with the substrate that is wrapped around the Feed Roller. 10 Ensure that the material is wrinkle-free and advance material until the substrate is wrapped once around the Rear Takeup Roller. A n other m etho d w ou ld b e to un ro ll and fan -fold th e m aterial un der th e m achine to m inim ize resistance fro m m u ltiple su bstrate rolls. Working with Multiple Rolls W h en prin ting o n m ore than one su bstrate roll. When securely attached. O peration 3-5 . be st results are ach iev ed by u sin g an extern al m ateria l crad le (b ehind the prin ter). on e ro ll can resist m o vem ent of the other causing m ate rial feed p ro b lem s. W hen m ultiple rolls share the sam e S ource R o lle rs. 9 Attach the substrate material to the Takeup Roller by applying tape. If the su bstrate “w alk s” a nd the space b etw een tw o adjacen t rolls beco m e s less th an 4” (1 0. e dge de tector erro rs can re su lt. O th erw ise.A n im porta nt p oin t to rem em ber abo ut w orkin g w ith m u ltiple rolls is th at th ere m ust b e app ro xim ately 4 ” (1 0.2 cm ) o f spac e b etw een adjacen t ro lls.2 cm ).T h e M esh K it is desig ned to place b lo tte r m aterial o ver the P laten to ab sorb the in k th at is no t abso rb ed by the m ate rial. M e dia H ub s ca n be u se d to m ainta in this d istan ce by p re ven tin g th e su bstrate rolls from m ov ing late rally (see F igu re 3-3). Figure 3-3 Media Hub Diagram Using the M esh Option To en sure the v ery best prin ting results w h en w o rk in g w ith m esh m aterials. y o u w ill n eed to u se th e V U T E K M esh K it O p tio n . in k w ill co llec t on the P late n and tran sfe r to the ba ck of the m esh. 3-6 C hapter 3 . Repeat for all Mesh Hinge sections. and pull down the length of the Platen (see Figure 3-4). N o te: A lw a ys low er th e C arria ge b efo re locking dow n th e M esh H in ges. Slide the material in from the enclosure. To use the M esh B lotter p erform th ese step s: 1 Lower the Carriage to the lowest position by loosening the Carriage Thumb Screws securing the Carriage to the plate. If the in k beg in s to ru n. Figure 3-4 Blotter Material Enclosure 4 Place a core on the Takeup Spool and tape the blotter material to the core (wound clockwise). Turn the Height Adjustment Knob to lower the Carriage position. set the p re-hea t tem p era ture to 12 0°F (6 6 °C ). 3 Place a roll of blotter material into the Dispenser and feed the blotter material through the Mesh Fabric Guide then between the Platen and the Mesh Hinge. O peration 3-7 . F o r be st resu lts use m esh w ith a larg e "scrim " su rface area and sm all ho le area. an d th e D ryer tem peratu re to 15 0 °F (4 9 °C ).W h en p rinting in th e sing le strike m od e. E nsu re the C arria ge w ill clea r the M esh H ing es b efo re po w erin g up the printer. the n raise the p reh eat te m p era ture. 2 Lower the Mesh Hinges and rotate the Mesh Print Cam Levers downward to hold them into place. N o te: V U T E K reco m m ends th at the D oub le Strike M o de no t be used w ith m esh m a teria l. Turn the Carriage Height Adjustment Knob to lower the Carriage. E n sure the ca rriag e w ill clea r the M esh H ing es befo re pow erin g up the printer. These are magnetized strips used to prevent the blotter material from sagging and coming in contact with the Print Heads. 8 3-8 C hapter 3 Lower the Mesh Hinges and rotate the Mesh Print Cam Levers downward to hold them into place. N ote: A lw ays lo w er the C a rriag e before locking d ow n the M esh H in ges. Repeat for all Mesh Hinge sections. . 6 Move the Encoder Wheel Assembly down to a position of about ¼” down from a straight line formed when a straight edge is placed from the Mesh Hinge (lowered) to the front Redirect Roller. End View Front View Mesh Paper Holder Figure 3-5 Mesh Paper Holder Locations 7 Lower the Carriage to the lowest position by loosening the Carriage Thumb Screws securing the Carriage to the plate.5 Install two of the Mesh Paper Holders to the underside of the right hand Upper Cabinet Cover (see Figure 3-5). Figure 3. 11 Once the blotter material is installed into the Mesh Hinges on the Platen. Slide the material in from the enclosure. attach the Tension Measuring Scale (P/N P7734-A) to the end of the blotter material as shown in Figure 3-7. O peration 3-9 . 13 With the Vacuum Pump running. Figure 3-6 Mesh Fabric Guide Placement View 10 Place a core on the Takeup Spool and tape the blotter material to the core. apply pressure to the Scale until it shows 5 lbs. This will ensure that the material will move easily enough to prevent the Takeup Motor from prematurely failing. and pull down the length of the Platen (see Figure 3-6).9 Place a roll of blotter material into the Dispenser and feed the blotter material through the Mesh Fabric Guide then between the Platen and the Mesh Hinge. Adjust the Vacuum Adjustment Knob (located on the right hand end panel) until the material pulls through the guides at 5 lbs.7Tension Scale Setup for Tension Setting 12 Enable the Vacuum Always On option in UltraVu’s Printer Setup Screen. N o te: E n sure that the C a rriag e is not ra ised too h igh . 16 Check the blotter material and adjust the speed through the Set Print Parameters Screen (see Figure 3-8) as necessary to prevent the ink from dripping. Enable the Mesh Kit Setting and enter a rate of speed for the Mesh Winder Motor. 17 After printing on mesh.14 Enable the Vacuum in the UltraVu Program by selecting the Vacuum On when Printing option in the Set Printer Parameters Screen (see Figure 3-8). you should always clean the Platen to remove any ink over spray.4 mm) below the mesh material. so tha t it w ill co m e in co ntact w ith the M esh H in ges. 3-10 C hapter 3 .060" (3 . This check should be performed after every large print job or whenever new mesh is loaded. Figure 3-8 Set Printer Parameters Screen 15 Adjust Carriage Height to 0. Avoid using m ore than 250% total ink. A djust the M esh W inder Takeup Speed to keep the blotter m aterial from becom ing saturated and dripping ink onto the im age. The use of heat m ay increase the printing length. U se a higher preheat tem perature for large im ages Adjusting the Encoder W heel To ac com m od ate th e use of a w id er va rie ty o f sub stra te m aterials the E nco der W h eel on the U ltraVu X 30 0 p rinte rs is d esig ned to b e ad justed. Ink w ill w ick around to the back of the m esh and w ill cause sm earing. To adju st th e E ncod er W h eel tension . refer to F igu re 3-9 an d follow th ese steps: 1 Turn the Remote Adjustment Knob located on the left side of the frame clockwise to increase pressure (CCW to decrease pressure). Figure 3-9 Remote Adjustable Encoder Wheel Shaft (top view) O peration 3-11 . T his ad ju stm ent allo w s the o perato r to vary th e pressu re the en cod er places on th e different su bstrate m aterials in o rd er to m inim ize slip pag e on flex ib le or slip pery m aterials. Avoid double-striking on m esh. 2 Experiment with this setting to determine what works best for the materials you may use. The absolute m axim um length of an im age that can be printed on m esh depends on the im age and the m esh.Tips for w orking w ith m esh • • • • • C lean the print head often w hen printing on m esh. A djusting the E nco der W h eel in this m ann er im p ro ves prin t qu ality on fab rics and m esh m aterials as w ell. any v iscosity reading is ab ov e 70 seco nd s. C a u tion : N ew in k in bo ttles sho uld be stirred. In k m easured d irectly from th e bottle m ay resu lt in a h ig her re adin g. th e C arria ge w ill pa rk itself u nd er the P urger P late. Figure 3-10 Printer Selector Switch 3-12 C hapter 3 . T h e c orrect o perating rang e for V U T E k in ks is 5 5-65 seco nd s at a tem p erature of 6 5-75 °F (18 -2 4 °C ) usin g a V U T E k Viscosity C u p. no t sha ken . N o te: If th e prin ter is po w ered up w ith the P rin ter F un ction S elector Sw itch is in the R E A D Y po sition .Maintaining Ink Viscosity F or b est prin tin g results ink v isco sity n eeds to be prop erly m ain tained . D o n ot th in th e in k. Preparing the Jet Packs for Printing B efore an y p rinting op eratio n o ccurs yo u w ill n eed to p roperly care for th e jet pa cks. after prop er circu latio n. Viscosity sh ou ld b e ch ecked often . If. M easurem ents sh ou ld be ta ken from th e m ain ink ta nks on ly after the ink h as b een circulating for at le ast o ne ho ur. p rio r to u se in the U ltra Vu x30 0. This will cause the Purger Plate to lift off the jets assembly and the Carriage to move left and park in the head maintenance position. Before Printing Occurs To p rep are the jet p ack s perform th ese step s: 1 2 Power up the printer. Select the INK PURGE setting on the Printer Function Selector Switch (see Figure 3-10). T h e P urger P late w ill then low er itself onto the Jet P a cks after a 10 -seco nd d ela y. no tify V U T E k’s P rod uct S up po rt S taff. 2 Coat the jEt Packs with solvent and cover with polyethylene wrap to minimize drying of the ink and to protect the Jet Packs from contamination. wiping the ink from the Jet Packs one final time.3 With the Carriage in the maintenance position. After a ten second delay the Purger Plate will lower to seal the Jet Packs. you n eed to p erform th e follow in g steps: 1 Move the Printer Function Selector Switch to the INK PURGE position (see Figure 3-10). 5 Move the Printer Function Selector Switch to the INK PURGE position. remove and discard the polyethylene wrap covering the Jet Packs (applied to keep the ink from drying on the Jet Packs during idle times). This positions the Jet Packs under the Purger Plate. press the Color Buttons. the UltraVu x300 printer is ready to be put online. P la cing th e C a rriag e un der th e P urger P late (co vered w ith po lyethylene w rap ) ca n result in excess in k run nin g out o f the C arria ge. 6 Move the Printer Function Selector Switch to the FIRE JETS position. Briefly depress the Color Buttons. After Printing Concludes W h en th e prin tin g op era tio n is finished y ou n eed to care for the P rint H ead. 3 Press the Color Buttons to push ink out of the jets to mix with the solvent and coat the Jet Packs to prevent drying. move the Printer Function Selector Switch to the READY position. 4 Turn the Printer Function Selector Switch to the READY position. and wipe clean those jets as they become wet. O peration 3-13 . Place a sheet of white paper over the jet packs and quickly depress each Color Button to verify that the jets are firing correctly. To prep are th e jet pack s for w hen the p rin ter is n ot b eing used . T h is proced ure is don e to p rev ent the in k fro m drying in th e jets. 4 Using only an approved wiper cloth (VUTEk part # P7240-A). When satisfied with the performance of the jet packs. Once the Carriage has moved under the Purger Plate. N o te: T h e printer h as a Weep F unctio n. one color at a time. T h e jets w ill w eep w h en und er the P u rg er P la te. Prim ing the Jet Packs If any w ork has been do ne on the Ink S up ply S y stem or if a Jet P a ck has air b ub bles in it. Depress each Color Button for approximately 30 seconds or until no air bubbles can be seen in the Waste Line. v erify th at all o f the jE t P ack s are securely in place w ith th e o-ring s seated an d screw s tig htened d ow n. Hold the color button down until the solvent that flows into the waste line is bubble free (this should take about 30 seconds). kink or restrict the waste tube for that color and solvent flush again. Depress the appropriate button for each color to refill the upper reservoirs. it w ill be nece ssa ry to p rim e th e in k system to re fill the re se rv oirs and Jet P ack to regain all o f th e in k jets. Depress the appropriate button for each color to fill the Jet Pack with solvent. This will force more solvent through the jets rather than down the Waste Line. Stop the purge function when the ink tube to the Ink/Solvent Solenoid for each color becomes full. Wipe the jets while performing this step. . This function will prevent air from being pushed into the Jet Packs when they are filled with ink. Figure 3-11 Jet Function Selector Switch 5 3-14 C hapter 3 Fill the jet packs with ink by selecting INK PRIME function on the Printer Function Selector Switch. Do not use this function to fill the Jet Packs at this time. If re pair w o rk h as been do ne. Select INK PURGE on the Printer Function Selector Switch to refill the upper reservoir. To prim e th e Jet P ack s refer to F igu re 3-11 an d p erform the follow in g step s: 1 2 Power on the printer. 4 If solvent does not appear to come out of all of the jets. 3 Select SOLVENT FLUSH on the Printer Function Selector Switch. w hen used in th e E n ha nced and U ltra M od e. 7 To test the jets. This will purge any remaining air from the jet packs. W h en this p ro b lem s o ccurs it m ay be n ecessary to a pply a sm all a m o un t of solven t to the su rface of th e jets an d th en co ver th em w ith po ly eth yle ne w rap for a perio d o f o ne to 1 6 ho urs. Wipe the jets while performing this step. 3 Retest the jets. Momentarily depress the appropriate Color Button to fire the Jet Packs. one-second bursts) and wipe excess ink from the Print Heads. Repeat this step until all jets are firing. place an ordinary sheet of paper on top of the Print Heads. N o te: T he p rinter w ill run w ith u p to 1 5 to 20 jets m issing (no t con secutive). you can do th e follow ing: 1 2 Use the INK PRIME function for ten seconds. 8 If any jets are missing. Recovering from Plugged Jets S om etim e s the in k jets can b e com e p lu g g e d . select the INK PURGE. Use the INK PURGE function (one or two. Repeat as necessary. select FIRE JETS on the Printer Function Selector Switch. A s a q u ick recovery for p lu gged jets. O peration 3-15 . Simultaneously depress the appropriate Color Button for five seconds and wipe the ink as it is being emitted. With the Print Head at the maintenance station.6 Select INK PURGE on the Printer Function Selector Switch and depress the appropriate button for about five seconds for each color. The Jet Packs should fire and leave eight lines of ink dots for each color on the paper. T h is sh ou ld o nly be do ne w h en the prin ter is idle for a perio d of tim e. w ith ou t a no ticeab le drop in prin t qu ality. the m eniscus can break and the jet w ill lose its prim e. D ried ink inside the jet orifice can cause a spiral effect. A n air bubble in a Jet P ack w ill cause the jets to lose its prim e. cleanroom cloths for cleaning. A ny kind of m echanical dam age done to the surface of the jets w ill cause problem s.Potential hazards with jet packs • • • • • • • 3-16 C hapter 3 The Jet P ack Array (orifice plate) is assem bled w ith glue. giving the appearance of a zigzag line. C over w ith polyethylene w rap and leave for at least one hour (overnight. . if possible) to dissolve the blockage. VU TE k recom m ends that U ltraVu ink be used on all U ltraVu x300 D igital P rinting S ystem s. D irt on the exterior of the jet can cause the droplets to scatter or fire in the w rong direction. Flushing. If a bubble occurs. purging and w iping can clear this problem . W ith norm al usage. fill the jet pack w ith solvent and place one or tw o w ipes on top of the heads and soak w ith solvent. C hange these filters every m onth to avoid clogging. To correct this problem . You can purchase these w ipes from V U TE k or the vendor (or see V S B 102). M aintenance. if the ink viscosity is out of specification. for the m aintenance schedule and replacem ent procedures. Therefore. R efer to C hapter 5. Ink viscosity is im portant. only use soft lint-free. Ink other than V U TE k U ltraVu ink m ay soften this glue. the ink w ill start to clog the 8 m m blue filters after about six w eeks. prim e and purge the w hole Jet P ack. When the desired test number is shown. Figure 3-12 Control Panel O peration 3-17 .Understanding the Printer Controls Using the Internal Test Patterns T he U ltraVu x 300 D ig ital P rinting S ystem contain s sev en in ternal test fun ctio ns that can b e used to fo r test p rint qua lity. 2 Press the Advance Button while printing the test pattern to change the test number. To step to the next test pattern. refer to F igu re 3-12 an d p erform on e of th e follow in g p rocedu res: M eth od # 1: 1 Depress and release the Test Button on the Control Panel to initiate a test pattern. release the Test Button to initiate the test pattern selected. N o te: T h e Test B utton resets th e ala rm du ring norm al o pera tio n. depress the Advance Button while holding in the Test Button. T he Test B u tton w ill run o ne of sev en test p rint patterns (the prin ter fu nction selecto r sw itch do es no t hav e to be in th e R E A D Y po sition to prin t the test patterns). 3 Depress the Test Button to terminate the test. M eth od # 2: 1 2 Select and hold in the Test Button and the test number will display. To activate the Test F un ctions. 3 Depress the Test Button to terminate the test. 0 1” or less or u ntil th e dots lin e u p vertically) usin g U ltraVu’s S etting s M enu . th en step s the m aterial and rep eats the pattern in th e o pp osite directio n. Test 3 Test 3 is a b i-direction al align m ent test. th en th e B idirectio nal A lign m en t P aram e ter m u st be ad ju sted . black pattern. 3-18 C hapter 3 . T he lines sho uld be align ed v ertically. T h e ho rizon tal distan ce is con trolled throu gh th e step size param eter o n the U ltraVu S etup S cree n.T he seven test p attern s are describ ed below : Test 1 Test 1 fires all 3 84 jets in all colors. P ro duc es so lid m ulti-color p attern s. Test 5 Test 5 is a step adjustm en t test. th e p rin ter m u st be printing . the colors w ill be m ag enta and bla ck. Test 2 Test 2 fires all jets w ith n o spacing at 1 00 % d ensity. step s th e m aterial and p rints ano th er set. It p rin ts a test p attern o f a line of do ts sp aced apart ho rizon tally. N o te: F or p rinters th at are con fig ured to p rint m a gen ta first. It prin ts a yellow horizo ntal line directly ab ov e a h orizo ntal black line. Yo u can c han ge th is param eter (b y 0. It prin ts a series of h orizo ntal line s. T he ho riz ontal line segm en ts sh ou ld app ear to b e o ne lin e (lin ed up ho rizon tally). 4 00 % fou r-color. Test 4 Test 4 prin ts a solid. C o lo rs are sp aced ap art to v iew in div id ual jet ou tp uts. Test 6 Test 6 is a jet plate align m e nt te st.T he test is useful for exercising the je ts and ch ecking for jet d ro p ou t.000 1”. T h e p aram e ter v alu e m u st be set for b oth S tand ard and H ig h S peed N o te: To initia te a m od e ch an ge. If th e d ots d o no t app ear d irectly ov er on e ano th er. T he va lue can be adjusted to w ithin 0 . W hen sw itched off. Test 7 Test 7 c heck s each Jet P ack for prin t q uality an d p rint con sisten cy. In add ition to th e Vacuu m A djuste r. O n w id er m aterials. W hen th e p rinter O n/O ff sw itch is turned on. M ore air restriction (C W ) w ill increases the v acuu m level. th e others are (↑). a Vacuu m D ive rter Valv e on the righ t pan el of th e prin ter is a vailable to fin ely ad just v acu um leve l. M aintenan ce. If rea lign m en t is req uired. w hile less air restrictio n (C C W ) w ill decrease th e va cuu m lev el. ro tate the Vacu um A d juster (loc ated o n th e righ t end o f th e P laten /P reh eate r A ssem bly). T his test p rints a series of c olo red ban d fo r each Je t P a ck. N o te: T he m axim u m a llow a ble tem pera tu re for the P reheater and D ryer ha s b een set a t th e factory as fo llo w s: P re-hea ter D ryer 120 º F 200 º F 49º C 93º C B elow the n um be rs on th e L C D a re fou r b utton s. P ro per align m ent occu rs w he n the y ellow and black lines ju st to uch eac h other (see F igu re 5 -5 ). O ne is m a rk ed S et. N o te: T his align m en t is perform ed a t the fa ctory an d realign m ent shou ld no t be necessary. th e v acuu m lev el m u st b e d ecre ased to m inim ize ad hesio n to th e surfac es o f th e P laten /P reheater an d S ubstrate D ryer. A ll jets are fired . To chan ge the vacu um lev el.D u ring the test o nly th e rig ht-m ost b lack and the left-m ost y ellow jet pack s w ill discharg e in k. sid e-b y-side. Controlling the Platen Vacuum Level T he P laten’s v acuu m leve l is adjustab le o n th e U ltra Vu x30 0 prin ters. T he up per num b er d isplays th e curren t tem p erature of the he ater a nd the lo w er n um b er sho w s th e target tem p erature. Operating the Heater Controls W h en o n the H eate r C o n trol L C D d isplay s tw o n u m b ers: an u p p er nu m b er an d a lo w er num b er. refer to C h apter 5. (↓) and (←) arro w s. for th e Jet P la te A lignm ent P rocedure. such as 1 2’ to 1 6’ (4 m to 5 m ). flank ed b y 10 0% of that colo r. O peration 3-19 . th e d isp lay w ill sh ow the am b ient tem p erature of the he aters (prov id ed th e printer is p ow e red o n). th e H eater C o ntro l L C D w ill briefly d isp lay the m axim u m allo w ab le tem p erature. The highlighted number will change up or down. The highlighted number will move one position to the left (i. 0095 if the ↑ is depressed). 2 To select a different number position. The target temperature can be adjusted to any value required for the print media being used (i. depress the (←) button.e. 0085). All numbers will flash with the selected number position highlighted (i. 0085) allowing for modification. Figure 3-13 Heater Controls 3-20 C hapter 3 . 3 Push either the (↑) or (↓) button. refer to F igure 3-13 and follow th e p roced u re b elow : 1 To set the operating temperature.e.e.To ad ju st th e tem p eratu re for the app rop riate h eater. depress the Set Button on the desired Heater Control LCD. respectively. allowing modification to the tens position. T his in turn offsets the am o unt of do t gain in this area of the p rint. d ot g ain is d ecreased. T his can result in so m e a reas in a p rint hav in g lo w er ink d ensitie s than o the r areas. th en co nta ct V U T E k’s P ro du ct S upp ort S taff. the h eads te nd to gain heat from the P late n P reheater and this inc reases the likeliho od of ink drying in the jets a nd clog gin g th em . A d ditio nally w ith the P laten P re heater tem p era ture set high . to 1 20 ƒF (49 ƒC ). It w as no t inte nded to b e used as an ink d ry er.Platen PreHeater Temperature and Image Control V U T E k has set the P late n P reh eater ’s u pp er te m p erature lim it. V U T E k reco m m en ds th at yo u prin t w ith as lo w a P late n P reh eater tem peratu re as p ossib le. m esh o r other w ov en m aterials y ou m ay need to increase the tem peratu res. To help red uce th e lik eliho od o f jet drop ou t. S etting the P laten P reh eater ’s tem perature too h ig h ten ds to w arp the P late n and c ause it to arc d ow nw ard tow ard s the P rint H ead s. If after p erform ing tests o n a m aterial y ou find th at you n eed to in crea se the te m p era ture abo ve 1 20 ƒF (49 ƒC ) y ou sh ou ld b e aw are th at th ere are trade-offs in do in g so. C lo th w ick s ink into the fib ers in crea sing d ot g ain . O peration 3-21 . T h is red uces th e ink den sity o n th e im age. If you intend to p rint o n cloth. S om e custom ers are usin g th e P laten P rehe ater to w a rm the m aterial. w h ich w ill red uce im a ge qu ality. this in tu rn increases th e ink den sity. th e tem p erature am plifies the in con siste ncie s across th e len gth of the P laten P reh eater. If this is n ot en ou gh. A lso. y ou sh ou ld p rin t w ith Jet B ars en abled. b elo w 12 0ƒF (4 9ƒC ). If yo u need to in crease the P laten P re heater ’s up per tem peratu re lim it abo ve 12 0 ƒF (49 ƒC ). th en th e Je ts can be cleared by p urg ing them . w h ich helps to crea te a m ore un iform p rinted im ag e. w h ich can qu ick ly dry the ink an d red uce dot g ain . w ith th e h ig her tem peratu re settin gs. T he P laten P reh eater w as orig ina lly design ed and installe d to w arm th e m ed ia to a c onstant tem peratu re. W ith the m ate ria l clo se r to the p rin t head s. A gain th is can result in in k den sity shifts across th e im age. on 3 2 head printers. T his chan ges th e distance s b etw een th e P rin t H ea ds and the m aterial ty pic ally in th e m idd le o f the p rinte r. T h is m axim u m tem pera ture is set a t th e factory as a sa fety p reca ution . A lw ays shut the hea ters off w hen the p rinter is not p rin tin g fo r a n extend ed period.12 0 °F (O ff . T IF F o r B M P ) in that it con tains no h alf ton e frequ ency.4 Push the Set Button.g.75 dpi / 37.5 dp i. the adjusted temperature setting will be saved. W hile un der-sam pled T IF F 3-22 C hapter 3 . The lower number will now stop flashing. VUTEk CT Format Highlights 18. N o te: D ifferent sub strate m a teria ls req uire different tem p erature setting s. C a u tion : T h e D ryer C on tro l selecta ble tem p erature (low er n um ber o n th e d isp lay) can no t be ad ju sted a bo ve a set lim it o f 20 0º F (93º C ) for th e D ryer an d 12 0 °F (4 9 °C ) for th e P reh eater. We recom m en d th at yo u exp erim ent to fin d th e best settin gs. VUTEk CT File Format T he con tinuo us to ne (C T ) im age form at is sim ilar to bit m a pped im age fo rm ats (e.5 dpi CT input (similar to airbrush printer files Easy and fast to process Small file size Fonts applied in PhotoShop Color correction at prepress or printer PostScript File Format T he P ostS crip t file fo rm at is th e stand ard typ e used o n the U ltraVu x3 00 . Typical tem p eratures ran ge from 130 °F .49 °C ) for th e P la ten/P reh eater.75 d pi. Too h igh a tem pera ture setting o n either of the hea ters m a y cau se the sub strate to dra g on the h eater p lates. cod e or v ecto r inform atio n. and the heaters will operate respectively. P ostS crip t is a p rint d escription lan gua ge th at w ill allow vector text to be en larg ed to any size w ith ou t lo ss o f d etail. T h e C T fo rm at tend to kee ps file size sm all. Im ag es in T IF F form at are ra sterized into a fin e do t pattern fo r p rinting .18 0 °F (5 5 °C 82 °C ) for th e Su bstra te D ryer a nd fro m O ff . T his d rag w ill affect the qu ality o f th e p rinted im ag e. or 37. Understanding File Form ats T he U ltraVu x3 00 ca n process bo th C T an d P ostS crip t (v ecto r) file fo rm ats. T h is fo rm at w ill prin t at 18 . Start at roo m tem pera tu re an d ad ju st the tem p eratu re u pw a rd in 10 ° in crem ents. bu t its p rints m ay app ear to be g rainy. UltraVu Linearization SWOP .UltraVu Linearization ICC Profile for SWOP and UltraVu Modification of ICC profiles Understanding Print Speeds T he U ltraVu x3 00 D ig ita l P rin tin g S ystem h as tw o p rint sp eeds. O peration 3-23 . m inim izin g th e need for P rin t H ea d m aintenan ce du ring p rinting . S tand ard and H ig h S peed . Standard Speed S tand ard S peed o perate s th e Jet P acks in a co nservativ e m o de. 100.im ag es w ill loo k grain y (as in C T m od e). Japanese. Arabic. R efer to In tern al Test P a ttern s sectio n discussed ea rlier in th is cha pter fo r details on p erform in g th e a lignm ent. 75. Vutek PostScript Format Highlights Resolutions: 50. th e B i-D irection al A lign m en t w ill need to b e reset (both Stan da rd a nd H igh Speed M od es). N o te: P rint speeds are cu rren tly ch an ging d ue to im p rovem en ts in softw a re an d firm w a re. 150. 300 pixels per inch (ppi) 300 dpi text or selected resolution Accepts Type 1 and True Type fonts (PostScript Level II) Type 0 fonts (Chinese.A s a resu lt. N o te: W h en ch ang in g th e “ S peed ” . ov er-sam ple d T IF F form at im ag es create la rg e file sizes a nd do n’t n ecessarily en han ce the qu ality of the fin al ou tpu t im ag e. etc…) Color correction during process or with UltraWorks RIP Preset plug and play calibration PhotShop CMYK separation tables PhotoShop . prin t qu ality an d detail w ill be im p ro ved . A u ser can prin t a d ense billb oard w itho ut sig nifica nt jet d ro p o ut an d w itho ut th e n eed to in terru pt the prin tin g proc ess to pu rg e or w ip e the Jet P acks. P lea se ca ll V U T E k fo r cu rren t specification s. this m od e pu ts d ow n h alf the am o un t o f in k o n the im ag e as d oes the other m od es. M o re sa teliting o f e dge artifacts m ay occu r at th is speed . Lo Res Mode T he L o R e s M o de is the draft or “b illbo ard” m od e. E nh anced and L o R es. T h is m ode is ideal for gene ral p rinting that w ill be view ed from any d ista nce. W ith practice the L o R es M ode ca n prod uce ou tstan ding results. g iv ing the h ig hest qu ality im ag es. A draw back to L o R e s p rinting is that saturated colo rs are no t as v ib ran t as w ith th e U ltra or E nh ance d m od es. Ultra Mode U ltra M od e is the m ost p rec ise fo rm of printin g. care m u st b e taken to ensu re a qua lity p rint. hig h qu ality im ag es fo r view ing u p clo se. U ltra. In stead o f p rinting 300 dp i ho rizon tally. th e printer o utputs at 15 0 dp i.High Speed H igh S peed o perates th e Jet P acks in a less co nservativ e m od e that m ay re quire p urging an d w iping d urin g the p rinting p ro cess to regain lo st jets. In practice. so th is m od e m ay be very u se fu l w h en high throug hp uts are req uired . W h en prin ting at no rm al b illbo ard d ensitie s. T h is m o de is recom m en ded for printin g sm a ll. In g eneral th e U ltraVu x 30 0 ink s hav e a ery stro ng co lo r in ten sity. To u se the m od e prope rly the u ser m ust p rep re ss th e im age to in crea se qu arter an d m id tones. N o te: T he C T fo rm a t m a y not p ro du ce hig h qu ality p rints in L o R es M od e beca use th e h alf to ne cell structure is o ptim ized fo r the other m o des of p rin tin g. Understanding Print Modes T he U ltraVu x3 00 D ig ita l P rin tin g S ystem h as the cap abilities of prin tin g in three op era tio nal m o des. O nce th e ope rator un derstan ds th e m eth od of prin tin g it m ay m ake sen se to use L o R es for billb oard p rin ting . 3-24 C hapter 3 . Enhanced Mode T he E nh anced M o de is design ed to b e the regu lar print m o de used fo r day to day printin g. T his m o de prin ts every other do t in the ho rizon tal directio n. Ve rtical resolution rem ain s u nch ang ed. p lease re fer to C hap ter 7 . for d etails on h ow to prepa re an d loa d im age s into the U ltraVu x3 00 D ig ital P rin tin g S yste m . T he exce ption b ein g th at on ly o ne licensed D on gle is provided . refe r to the prev iou s sec tio n fo r d etails. B o th w o rk station s are prov id ed w ith a 1 00B ase-T ne tw o rk card so tha t the U ltraVu W o rk station ca n b e c able d d irectly to an existin g W ind ow s N T O peration 3-25 . Workstations T he U ltraVu x3 00 D ig ita l P rin tin g S ystem inclu des an U ltraVu W orkstatio n for op eratio n o f the printer and to provide file m anagem ent task s. F o r d etaile d in fo rm ation o n th e prin t speed s an d m od es. R IP S tation . T his W o rk station is config ured as a W ind ow s N T w orkstatio n. T his R IP S tatio n is co nfigu red id entical to th e U ltraVu W o rk station w ith bo th hav in g the U ltraW orks R IP so ftw are residen t o n the hard driv e. T he system is co nfig ured to a llo w file h and lin g to take p lace du ring prin tin g an d to p ro vid e a netw ork co nn ection for p eer to peer file han dling . E n h an ced an d L o R es.RT L (sp ecific ty pe) F or ad ditio nal in fo rm ation o n file form ats. Data File Types T he U ltraVu softw are su ppo rts the follow in g data file typ es: • S cite x C T (S C T w ind ow s v ersion) • . T h is w ill allow the o perato r to o rgan ize im ag es and p ro cess files w h ile p rinting to allow alm ost co ntinu ou s p rinting to oc cur. T h ese file fo rm ats can b e p rin ted in tw o sp eed s. A lso availab le is an o ption al secon d W orkstation for R IP processing. S tan d ard an d H ig h S p eed . U ltra.Using UltraVu Software Understanding UltraVu’s Capabilities T he U ltraVu P rinte r C o ntrol P rog ram w ill p ro cess b oth C T and P o stscrip t file fo rm ats. E ach sp eed can b e co n fig u red in th re e d ifferen t p rin t m o d es. From the Windows Desktop screen. Type A:\Setup then click OK. To in stall the u p grade. N o te: A lterna tively. A ty pica l so ftw are an d firm w are up grade (see nex t section fo r firm w are up grade p ro cedu re) fo r th e U ltra Vu x 30 0 prin ter con sists of tw o 3 . . Select Next for the remaining selection options. T he U ltra Works R IP is loca ted o n th e ha rd d rive on the U ltra Works R IP S tatio n.E P S • P ostscript (P S) form ats. T he P o sterWo rks so ftw are is su pp lied sepa rately an d can resid e on the U ltraVu (printer) Wo rkstation or on the U ltraWorks R IP Station . N o te: T h e U ltraVu x300 D ig ital P rin ting S ystem s a re provided w ith U ltraWorks raster im ag e pro cessor (R IP ) a nd P o sterWo rks im a ge prepa ration so ftw are. D ou ble-click o n “ Setu p” . click the “ M y C om pter” a nd “ 3-1/2 F lo ppy (A :)” ico ns. T his w ill m ake th e prin ter in opera ble.N etw o rk o r the U ltraW orks R IP S tatio n as a p eer to peer netw o rk partn er. ho w ev er.5” flop pies labeled “U ltraVu and F irm w are U pgrad e”. W h en it b ecom es nece ssa ry to up grade th e prog ram th en U ltraVu w ill h ave to b e re installe d. T he U ltraWorks So ftw are su ppo rts th e follow ing da ta file typ es: • . • T IF F Upgrading UltraVu x300 Software U ltraVu com es in stalled on the W o rk S tation h ard d rive. A lso in clu ded o n th e h ard drive are detailed do cum entation an d techn ica l b ulletins for the U ltraWorks R IP an d U ltra Vu So ftw are. follow th e step s ou tlin ed b elow : 1 2 3 Install Disk #1 of 2 into the floppy drive. recom m end or supp ort th at either of th ese sy stem s be setu p as an N T S erv er. select Start and Run. C a u tion : D o no t con vert th e U ltra Vu Workstation to a W ind ow s N T F ile server.V U T E k d oes no t. 4 3-26 C hapter 3 Select Next at the selection option and click Yes. P eriod ically V U T E k prov id e u pg rad es to th e U ltraVu softw a re. If th e pro per files are presen t. You may also find this file in the directory: “C:\Program Files\Vutek\UltraVu” on a new installation of the software. restart UltraVu. N o te: If th is proced ure fails.D u rin g a reinstallation of the softw a re. o r d uring a n up grad e. Upgrading UltraVu x300 Firm ware To up grad e th e firm w are. and select Finish. Verify the software and firmware revisions are the same. T h is is also ava ila ble a t w w w. The update procedure cannot proceed unless the printer is online. 7 After the printer has restarted. The printer is now ready to proceed with the upgrade. the “Update Completed” message will be displayed. The UltraVu Workstation will perform an automatic reboot. insert disk #2 of 2 and select OK. 5 Press the Advance Button on the printer Control Panel (press Error to cancel). remove disk #2 of 2. This will display the UltraVu Software and Firmware Revision Levels. Please follow the procedures below to upgrade the firmware. The upgrade will proceed automatically. After the system has rebooted. The message Writing Data will be displayed on the Printer Status LCD. place the printer online and start the UltraVu Software.vu teksu pp ort. Place the printer online. you m u st h ave th e flop py set lab eled “U ltraVu an d F irm w are U p grad e” or cop y of th e “E m ergen cy R ecovery D isk #2”. 1 2 Insert disk #2 of 2 into the floppy drive. 6 To activate the new firmware. reboot the Printer Controller by depressing the Reset Button on the Printer’s Control Panel. so m e files used b y the existin g w ill still be p resent. Select Help and then About UltraVu. When done. O peration 3-27 . u se the “ E m ergen cy R ecovery D isk #2 ” provided w ith the up gra de. the message “Update Requested” will appear. N o te: N ot a ll p rinters w ill req uire D isk # 2. Double click on the file labeled VX300. 6 When the setup is finished. th e second disk m ay no t be need ed. F ollow th e in stru ctions b elow to perform th e in stallation p rocedu re.5 At the installation prompt. 4 On the Printer Status LCD Readout. This procedure will read from the floppy drive and display all files on Disk #2 of 2.co m . 3 Start the UltraVu Software. Select Setup and then Update Firmware. F:\) 2 If a JAZ Cartridge is being formatted. This creates the necessary partition information on the selected removable cartridge. 7 Right click on the removable disk letter inside the diagonal lined box. Right click on the removable disk letter inside the diagonal lined box. 3-28 C hapter 3 . go to File System and select either FAT (File Allocation Table) or NTFS (NT File System) disk formats. Select Programs. This is the letter that was assigned in the first step above. If a MO Cartridge is being formatted. 13 Close all currently opened windows. the format process is complete. To form at a disk you w ill need to p erform th ese steps: 1 Select My Computer under Windows and note the removable disk(s) letter(s). select Start and click OK when the warning box appears. click Yes to confirm. insert the cartridge into the drive. 3 From the desktop menu select Start in the lower left corner. and then click OK. If a JAZ Cartridge is being formatted. Right click on the removable disk letter located inside the diagonal lined box. 10 Select the Format option. 12 If a MO Cartridge is being formatted. N o te: If a C a rtrid ge w a s p reviou sly fo rm atted . N o te: If this ca rtrid ge w ill be used w ith a p rep ress system . Record the letter(s) here for future reference: ____________ (For example. turn the cartridge over and repeat the above procedure to format the other side. insert the unformatted cartridge into the drive with the side to be formatted facing up. 8 9 Select Commit changes now. 6 Select Create. The format process will begin. 4 5 Click OK to the warnings and Yes to confirm. In the format menu box. then Administrative Tools (Common) and then Disk Administrator. This selects the disk to be formatted. Click OK.Form atting Rem ovable Disk Cartridges T he follow in g proced ure describ es h ow to form at a rem ov able disk cartridg e. it w ill no t be necessary to create a new p artition in the follow ing p ro cedu re. 11 Under the Format Options. th e o pera tor m u st use th e FAT (F ile A llocation Ta ble) fo rm a t. Starting the UltraVu Control Program To start th e U ltraVu p rinter con trol softw are, do uble click o n the U ltraVu pro gram ico n on the W in dow s N T D esk top . Understanding the UltraVu M enu Structure T his section d escribes each of the fu nction s p erform ed by th e p ull-do w n m enu s and the B utton B ar ic ons d isp layed on th e m ain U ltraVu S cre en. R efer to F igure 3-14 for the U ltraVu S o ftw are m a in m enu layo ut. F igu re 3-15 sh ow s the m enu stru ctu re. Figure 3-14 UltraVu Printer Control Program Menu Screen O peration 3-29 UltraVu Menu Structure File Open O pens file for printing Recent File Shows last four files printed Exit Exits UltraVu Software File Info Displays selected file inform ation size in bytes, resolution, etc. Print O ptions l Print Print M odes Print M odes, Print Speeds, Segment Spacing, and Edge Detect Settings Media Layout M edia width, m argin settings, multiple roll setup Borders Sets borders on printed image for top, bottom , left, and right, border color select Unit Selects inches or m etric display values within UltraVu Duplications Duplicates selected im age both vertically and horizontally. O utput Resolution Specifies output resolution for RTL and CT files Select Area Im age and printer statistics. Prints specific area of im age. Print Selected Area Print selected area or complete im age S 1/8 Displays selected image 1/8 norm al size S 1/4 Displays selected image 1/2 norm al size 1/2 Displays selected image 1/2 norm al size Norm al Displays selected image norm al8 normal size (default) 2X Displays selected image 2 tim es size View 4X Displays selected image 4 tim es norm al size Display Bitm ap If set on (default) when im age is opened, will display selected im age. View size is defined by above View size selection Edit Luts/G roups Used with CT files. M odifies LookUp Tables for CM YK values. Manage Groups M anages the Luts/G roups Printer Settings Bi-Directional Adjustm ent, Take-up Tension Setting, Printer Vacuum Setting, M edia Step Size, Maxim um M edia Accuracy Setting, Save and Read Default Functions, Mesh Kit Settings Default Path Set up the default path for Im age files, Dither Pattern, LUT files, Job files Update Firm ware Using 3.5" floppy update printer firm ware. Also displays current firmware revision level Enter Password Password activates UltraVu Software Lookup Setup Help Help Topics Lists Help Topics About UltraVu Displays UltraVu and Firmware revision levels, free disk space, and physical mem ory size (RAM ) Get Printer Rev Displays Firm ware Revision level G et Media Stats Displays the print m edia settings Figure 3-15 UltraVu Menu Structure 3-30 C hapter 3 Button Bar B elow the com m an d m enu is a bu tton b ar co ntaining sev en sho rtcut com m an d bu tto ns. T h e ico ns rep re se nt th e fo llo w ing co m m a nds (from left to rig ht): O pen , P rin t, A b ou t, H elp, A u to -D ry, M edia A d van ce and U se S elec ted A rea . S om e of the se fun ctions m ay also be acce ssed usin g th e p ull-do w n m en us. B elow is a d escriptio n of the fun ctio ns for the seven sh ortcu t com m an d to ol b utton s. O p en - T h e O pe n bu tto n func tio ns th e sam e as th e F ile - O pen m e nu co m m an d. P rin t - T he P rint p erform s the sam e fu nction as the P rint S elec ted A rea co m m an d. A bo ut - T h e A bo ut bu tton fun ctio ns th e sam e as the H elp – A bou t U ltraVu com m an d. T his fu nction w ill prov id e revisio n lev els of the firm w are and softw are, as w ell as d isk an d m em ory param ete rs. H elp – T h e H elp b utto n fu nction s the sam e as the H elp m enu . A uto-D ry - T h is fu nction is n ot su pp orted o n th e pu ll-do w n m en u. W h en sele cted , th e A u to-D ry fu nctio n w ill au tom atically ad van ce the su bstrate m aterial un til th e end of th e prin ted im age is on th e S ubstrate D ryer. T he m aterial w ill ad van ce at th e sam e m aterial feed rate th at th e im age is p rinted at. M edia A dva nce - T his functio n is n ot sup po rted by a pu ll do w n m en u co m m an d. S electing this b utton w ill ad van ce the su bstrate m aterial app ro xim a tely 2.5” (6.35 cm ). T h e A d van ce butto n on the prin ter C o ntrol P an el also initia tes this fun ction . O peration 3-31 U se Selected A rea – T his bu tton is u sed in con ju nction w ith the P rint S elected A rea com m and . It allo w s th e ope rator to selec t a portion o f an im age to p rint u sing the P rint S elected A rea com m and . M esh M od e – T his b utton calls up a second ary w ind ow for se lecting M esh S etu p P aram eters. Wa lk-up – T h is bu tto n w a kes up the system . A uto Sh utd ow n – T his b utton a uto m atic ally sh uts do w n the system . 3-32 C hapter 3 File Menu To acce ss th e F ile M enu , select F ile o n the m enu b ar. R efer to F igu re 31 6 for the F ile M en u w ith F ile O p en S cree n . T h e c o m m an d struc tu re fo r th e F ile m enu is as follow s: File E xit Open O pens a specific file for printing Recent File Show s last four files opened Exits U ltraVu S oftw are Figure 3-16 File Menu with File Open Screen O peration 3-33 Figure 3-17 Print Pull-Down Menu T he co m m an d structure is as follow s: P rint File Info D isplays selected file inform ation (e. R efer to F igure 3-17 for th e P rin t P u ll-D ow n M en u. Selects specific area of im age Print Selected P rint S elected Area of im age or Area com plete im age . U nits of m easurem ent O ptions . Borders. and E dge D etect settings M edia Layout M edia w idth. Print S peeds. m ultiple roll setup Borders Unit 3-34 C hapter 3 Sets borders on printed im age for top. Print M odes Print M odes. bottom .g size in bytes. se lect P rint on the m enu bar. M edia Layout. left and right. m argin settings. resolution) Print O ptions D isplays P rint M ode.Print Menu To a ccess the P rint M en u. S egm ent Spacing. border color select S elects Inches or m etric display values w ithin U ltraVu Duplications D uplicate selected im age both vertically and horizontally O utput Resolution Specifies output resolution for RTL files Select A rea Im age and printer statistics. Figure 3-18 File Information Screen T he P rint M ode s S creen (see F igure 3-19 ) co ntrols S tand ard o r H igh speed print sp eeds an d a cho ice of L o R es. Figure 3-19 Print Mode Screen O peration 3-35 . the D o ub le S trike O ption B ox en ables the p rin ter to p rint B a ckligh t display s. F ile in fo rm atio n display ed inclu des Im a ge S ize (in pixels) and D im en sio ns (h eig ht an d w idth ). W hen ch eck ed. B o rd ers or U n its. E n han ced . or U ltra p rint. File Info Print O ptions allo w s yo u to ch oo se from P rin t M o des. E dg e D ete ctio n can b e selected or deselected . M edia L a you t.disp lay s p ara m eters o f th e se lected file. E d ge O v erlap can be set as w ell as the ve rtical sp acin g betw een se gm ents. R eso lutio n and Im age S ize in by tes (see F ig ure 3-18 )l. specify w id th an d co lor fo r ap plication to a print. Figure 3-21 Borders Screen 3-36 C hapter 3 . T h is screen also en ables the use o f righ t m arg in s to h elp con trol edg e o verlap . an d oth er sim ilar con ditio ns.T he M ed ia L ay ou t S creen (see F igu re 3 -2 0) e nab les op erator to selec t th e a m o un t of left m argin a nd m ed ia w idth fo r each roll of m edia load ed on th e p rinter. Figure 3-20 Media Layout Screen T he B o rd ers S creen (see F igu re 3-21 ) allow s the user to select a bo rd er. T he E dg e D etecto r (loc ated o n th e C arria ge A ssem bly) autom atically detects each su bstrate’s w idth w he n the p rinter is first p ut o nline . fo rce d p anel en din gs. Figure 3-22 Units Screen allow s for th e d up lic atio n of selected im ag es b oth vertically and horiz ontally. en ablin g th e u ser to prin t m ultip le im ag es o n th e su bstrate. Duplications Figure 3-23 Duplications Screen O peration 3-37 .T he U n its S creen (se e F ig ure 3-22 ) allow s for selection o f U S or M etric dim e nsio ns to b e used d uring printin g of the sele cted im age. R e fer to F ig ure 3 -2 3 for d etails on this screen. T he area ou tlined by th e m ou se bo x w ill b e p rinted.Output Resolution specifies output reso lution for RT L files o nly (see F igu re 3-2 4) . T h e u ser c an set th e U se M o used A rea S ettin g (see F ig ure 3 -2 5) after a section of an im ag e has b een outlined w ith the cursor. h old dow n the m ou se b utton and d ra g th e box aro un d th e section of th e im ag e that is d esired. Figure 3-25 Select Printing Areas Screen 3-38 C hapter 3 . To o utlin e an area of im age . Figure 3-24 Output Resolutions Screen Select Area allow s the u ser to sp ecify w hat area of an im ag e is to be prin ted . select th e View fro m the U ltraVu M en u B ar. Figure 3-27 View Pull Down Menu O peration 3-39 . Figure 3-26 Print Parameters Selected Screen View Menu To ac cess the View M enu (see F igu re 3 -2 7).Print disp lay s th e p rint pa ram eters fo r th e selected im a ge and in itiate s im ag e p rinting . It is im po rtant to check these p aram eters before prin tin g (see F ig ure 3-26 ). T he pu rp ose o f th is fu nction is to prov id e a m etho d fo r m aking m in or c han ges to ex isting C T files o n th e U ltra Vu D ig ital P rinting S ystem . W ith this op tio n th e u ser can lo ad th e C T file an d app ly m ino r co lo r adjustm en ts before prin tin g.T he View com m and stru ctu re is as fo llow s: View S 1/8 D isplays selected im age 1/8 size S 1/4 D isplays selected im age 1/4 size 1/2 D isplays selected im age 1/2 size Norm al D isplays selected im age norm al size (default) 2x D isplays selected im age tw o tim es norm al size 4x D isplays selected im age four tim es norm al size DISP LAY B ITM A P If set w hen file is opened. D isplay size is defined by above View size selection . T h is com m and chan ges th e L U T (L o ok U p Tab le) files fo r C T files on ly. R efer to F ig ure 3 -2 8 fo r the E dit L uts/G rou ps S creen lay ou t.D efault is O N LookUp Menu T he L oo kU p M en u sup po rts the E dit L uts/G rou ps a nd th e M an age G rou p fu nction s. Figure 3-28 Select Luts for this Job Screen 3-40 C hapter 3 . w ill display selected im age. Figure 3-29 Edit Luts Screen To ad ju st and save C T M od e L ooku p s: 1 2 3 4 5 Select LookUp 6 7 Select OK when finished. such as lightening the lo w er part of a curve w h ile d arken ing the u pp er en d to ad d or rem ov e con trast (n ote the S ig m a C urve in F ig ure 3-29 ). Use the current Lut Group.T he E dit L uts F un ction ca n app ly eith er a S igm a or G am m a C urve . Select Edit Luts/Groups Select Edit Luts Select the color requiring adjustment Select Sigma or Gamma for the curve shape or Straighten Button for straight line Luts. T he M an age G ro up F u nction is u sed to m an age the L uts/G rou ps. O peration 3-41 . select Save Group on the Edit Luts/Groups Screen if the settings must be retained for future use. 8 Select OK when finished and save the default Lut path. If a Lut has been renamed. or straig hte n an existing cu rv e. T h e G am m a c urve lightens or darken s an im ag e. T h e S igm a C u rv e w ill allow c orrectio ns in m ultip le d ire ctio ns. allo w in g the user to app ly a co rrection in o ne d irection o nly. file default path and the u pd ate firm w are fun ction (see F igu re 3-30 ). A lso displays current Firm w are revision level installed Enter Passw ord U ltraVU H ardw are K ey (dongle) passw ord. Takeup Tension. P roper passw ord m ust be entered to activate dongle. M edia Step S ize. M axim um M edia Accuracy setting. and therefore U ltraVu softw are. . Printer Vacuum S ettings.5” floppy. M esh K it E nabled setting. D ither P attern and Job Files Update Firm w are U pdate printer firm w are using 3.Setup Menu T he S etu p m enu allo w s th e u ser to access printer settin gs. R ead and Save default settings function Default P ath Specify default path for Im age and LU T Files. Figure 3-30 Setup Pull-Down Menu T he co m m an d structure is as follow s: Setup 3-42 C hapter 3 Printer Settings Bi-D irectional A djustm ent. T his va lue typically in cre m e nts (or decrem en ts) in 0. the step size is too great and has to b e d ecreased. If a lig ht or a w h ite line ap pears.000 1” (0 .002 5 m m ). O n a ll th e tim e or O ff a ll th e tim e. T he ad justm e nt is m ade b y changing the percen tag e of tensio n needed in 5 % increm ents.Printer Settings T h is op tio n op ens th e S et P rin ter P aram eters S creen (see F ig ure 3-31 ) w h ich a llo w s th e u ser to set th e P rin ter Vac uum S etting s to O n w hile prin tin g.0 25 m m ) step s d epending o n th e alig nm en t on th e im ag e. O peration 3-43 . T he op era tor can also read curren t defau lt prin ter setting s. Figure 3-31 Set Printer Parameters Screen T he M ed ia S tep S ize S etting is u se d to calib rate the p recise adv ance m e nt of th e m ed ia. T he o perato r sho uld start at th e default value and adju st th e step size b ased up on the ab ove criteria. m od ify or sa ve setting s a s the current d efau lt.00 01 ” (0. T he Takeu p Ten sio n S etting allow s the u ser to spec ify th e R ed ire ct an d Tak eup R o ller ten sion settin gs fo r different sub strate typ es an d w idth s. A dark lin e at th e top of a ban d o f print m ay in dica te that th e o verlap is too great an d the ste p size sh ou ld b e increased by 0 . a b acking m aterial m ust b e c ycle d beh in d th e im age to a bsorb all excess in k passing throug h th e im age . M ax im um M edia S ize S ettin g is used w hen m axim u m im age qu ality is desired . O n ce th is align m ent is se t. W he n enab led . T his w ill prev ent dripp in g or spilla ge o f ex cess ink on to the m esh . T h is se tting w ill inc rease p rint tim e in m ost cases. the S po ol Tak eup S p eed S ettin g w ill de term ine th e speed a t w h ich th e back in g w ill be cy cled . T his is acco m p lish ed by allow ing the Y S ervo (S ub strate F ee d R oller) to settle ou t to w ithin 0 . M esh K it E n abled S etting (see F igu re 3 -3 2) enab les m otion o f th e S poo l Tak eup F u nction to con tinu ously cycle the ink ab sorben t back in g m aterial.T he B i-D irection al A d ju stm ent S ettin g allow s y ou to adjust th e B idirectio nal A lig nm en t (the vertical alig nm ent o f row s o f do ts). N o te: A lw ays record you r d efa ult setting s b efore cha ng ing any pa ram eters on this screen. it sh ould n ot requ ire adjustm en t. allow in g the o perato r to w o rk w ith variety of back ing m aterials. Figure 3-32 Mesh Kit Settings Screen 3-44 C hapter 3 . T his sh ould be set for both high an d stan dard sp eeds. T h is adjustm en t is m ade using Test P attern 3 to adjust to the p ro per align m en t.001 ” (0 . T he sp eed ca n be adjusted from 0 (o ff) to 1 00 (fast). W hen u sing the M esh K it.0 25 m m ) o f accu racy before th e X S e rv o (C arriag e) m o tio n is in itiated . Figure 3-33 Defaults Path Screen T his o ptio n o p e n s the U pd ate F irm w are S creen (see F igu re 3-34 ) w hich allo w s the user to v iew th e cu rrent revision nu m ber fo r the resid ent firm w are . T h e U p date F un ctio n for th e firm w are is also in clu ded o n th is screen . L u ts. D ither P a ttern and job file directory paths fo r q uick access to file s. Update Firm w are Figure 3-34 Update Firmware Screen O peration 3-45 .Default Path T his o ption o pen s the D efau lt P ath s S creen (see F igu re 3 33 ). T his allow s the u se r to set up d efau lt im a ge. followed with the Password Code. The UltraVu Program should now be activated. You can procu re a p assw ord fro m V U T E k b y callin g th e P ro duct S u pp ort S taff at (60 3) 279 -4 63 5. N o te: To p erfo rm the steps a bo ve yo u w ill need U ltra Vu Versio n 2 . Enter Password A t the tim e o f shipm ent all 32 h ead U ltraVu prin ters w ere eq uipped w ith hardw are k eys. kn ow n as D o ngles. Two numbers are required. Only the exact numbers provided by VUTEk will work. If incorrect numbers are input. Figure 3-35Password Entry Screen To in stall a D on gle p assw ord : 1 Select the Setup menu and click Enter Password. D on gle s are used to con trol the prin ter's use. your Key which you should already have and the actual Password assigned by VUTEk.0 4 o r ab ove. W h en a m essage ap pears o n th e w orkstation m on itor screen that a p assw ord is requ ired. otherw ise. 3-46 C hapter 3 .T h is optio n op ens th e P assw ord E ntry S creen (see F igu re 3-35 ) w hich allo w s the user to en ter tw o n um b ers to a ctiv ate th e U ltraVu S o ftw are. T h e D o ngle K ey req uires a p assw o rd to be in stalled at sp ecific tim es d uring the y ear. A Password Window will appear (see Figure 3-35). 3 Click Ok. you m u st sup ply one. 2 Enter the Key first. the window will close after three attempts. Help Menu T he H elp P ull-D o w n M enu (see F igu re 3 -3 6) p ro vides access to the H elp To pics. O peration 3-47 . A b ou t U ltraVu. an d G et M edia S tats S cree ns. G et P rinter R ev. T h e H elp com m and stru ctu re is as fo llow s: Help Help Topics About U ltraVu Get P rinter R ev G et M edia Stats Figure 3-36 Help Pull-Down Menu Help Topics T his o ption is n ot av ailable a t th is tim e. Get Printer Rev Figure 3-38 Printer Firmware Revision Level Screen Get Printer Stats 3-48 C hapter 3 T h is op tio n displays th e P rint M ete r Valu e in M 2 . . It d isplays th e S o ftw are B uild an d F irm w are R ev isio n. T he M em ory S ize an d D isk S pace F re e P aram eters are also display ed o n th is sc reen .About UltraVu T his op tio n op ens the A b ou t U ltraVu by V U T E k S cre en (see F ig ure 3-37 ). Figure 3-37 About UltraVu by VUTEk Screen T h is o ption o pen s th e P rin ter F irm w are R evision L ev el S cree n (see F ig ure 3 -38) and d isp lays th e curre nt V U T E k F irm w are R ev isio n. th e S tep S ettin g shou ld b e set betw een 1. T h is allow s the m ost d ot ga in an d un iform ity in th e so lid fill areas. • To increase im a ge p rint q uality. Step Setting G en erally. seam s.0 . R e fer to C hap ter 5 .2. if th e “ perfec t alig nm en t” value is 1 . M ain ten ance.25 ”.5 m m – 5 m m ).1. • 16 fo ot (5 m eter) w id e vinyl’s m ay req uire larger prin t g aps o f 0 . fo r the p ro cedu re to a dju st th e prin t g ap.22 ” . etc. E nsu re th e test p attern is “ perfec tly ” alig ned since this ad justm e nt is critical to prin t size.5 m m ). L arg er p rint gap s result in “ fu zzier” lin es du e to in k drop let satellites hitting the m edia la ter than th e m ain d roplet. B elow are so m e su gg estions for gap sizes: • R eco m m en ded p rint gap for 8’ (2. T his p ro vides fo r im ag e ov erlap allow in g th e prin tin g to be “m ore fo rgiv in g” in the solid fill area s. Print G ap T he P rint H ead m ust b e adjusted fo r m inim um print gap (w itho ut h ittin g th e m ed ia) fo r im p ro ving p rint q uality.Im proving Print Quality T his sectio n discu sses so m e o f the fa ctors tha t can affect prin t qu ality and offe rs sug gestion s for im prov ing print q uality.2 41 ".1 0" . du e to w rin kles.2 42 ". Platen/Preheater and Vacuum Settings In gen eral. • If th e ink run s o r d rips. F o ur-co lo r blacks sho uld no t excee d 75 % (50 % preferred) fo r eac h of C M Y K colors.06 " . Vinyl sub stra te m aterial w ill differ in re ceptivity to th e ink . ru n P rin ter Te st 5 . y ou sh ould either in crease the P late n/P reheater tem peratu re or ru n th e im age throug h prep ress process w ith less in k.2 0" (2 . • To verify th at this setting is accu rate. try prin tin g at 1 . F ollo w th e gu ide lin es belo w to inc rease im ag e qu ality from th e printer.1 0" (1 . Test 5 p rints a ho rizon tal lin e pattern fo r alig nm ent of the step func tio n.5 m ) w id e o r less m ate rial is 0. try red ucing the step size by on e unit. O peration 3-49 . F or ex am ple.5 m m . b ut the jet p acks m ay need to b e w ip ed m ore frequ ently to m aintain p rint q uality.0 . sta rt w ith the P laten/P reh eater at ro om tem p erature. T h e jet pack arrays w ill a ccum ulate m ore ink o n th eir face p lates than w ith sm a ller prin t gap s. T his gen erally doe s n ot cau se jet ou tag e prob lem s. red ucing frictio n betw een the m aterial and heater surfaces. 3-50 C hapter 3 . • Turn ing the v acuu m o ff w ill have a dram atic im pact on prin t qu ality w h en prin ting o n 16 ft.3 " p itch in E nh anced M od e). Ty pical te nsio n percen tag e values sho uld ran ge betw een 5 5-75 % (60 % is reco m m en ded ). B y m inim izin g th e drying tem peratu re . H ow ever. vinyl m aterial w ill adhere to the S ub strate D ryer. to o hig h a tem pe rature o n th e P la ten /P reh eate r can cau se the viny l to adh ere to th e P laten /P reh eater resultin g in w hite lin es. • H o w m uch P laten /P reh eate r hea t is req uired ? N orm ally 10 0°F (3 8°C ) w ill su ffice fo r m ost m aterials. F o r fabrics requ irin g a higher setting . T his w ill h elp re duc e the prob lem s of step erro rs cau sed by o ver heatin g the v in yl. Vinyl in co nta ct w ith th e P la ten/P reh eater w ill ha ve a different dot gain in the no nco ntacted area. V U T E k reco m m en ds startin g at roo m tem peratu re an d gradu ally in crea se the tem p era ture in 1 0°F steps un til an op tim u m perform an ce is ach iev ed . m ay th e vin yl to adh ere to the P laten an d S u bstrate D ry er P lates. U sually. lo w erin g th e tension results in few er step errors (w h ite line s). U sua lly. Tensio n setting s also w o rk in c onjun ction w ith the h eat an d v acuu m setting s. the ad hesio n o f the v iny l to th e P late n and S ubstrate D ryer is re duced. (5 m ) w id e vin yl. i. Takeup Tension Settings Tak eup an d R ed irect R o ller Ten sio n P aram eters can b e set th ro ugh the U ltraVu S o ftw are un der S etup .e. S etting the ten sion as lo w as p ossib le. high tensio n settin gs w ith h igh h eat an d vacuu m w ill increase adh esio n of the v iny l to the P laten an d S u bstrate H eaters.• If w h ite line s ap pear du rin g de nser ink co verag e (at 0 . N o te: If the m edia do t g ain is no t h igh eno ug h. V U T E k re com m end s that y ou ad van ce th e m aterial w ith the A dvan ce B u tto n im m ediately before beg in nin g a new im age p rint cy cle. H igh vacuum . A t these te m p era tures. Substrate Dryer Settings T he S u bstrate D ry er heaters sho uld b e set fo r th e m in im um tem peratu re need ed to adeq uately d ry the im ag e. A d hesio n is stron gest if the viny l has rem ain ed static and in co ntac t w ith a ho t S ubstrate D ryer fo r som e tim e .P rin ter. the result w ill a lso b e w h ite lines on the im a ge. a tem pe rature ran ge of 13 0°F -1 80 °F (55 °C – 82°C ) is recom m end ed.1 20 °F (49 °C ) m ay be re quire d. in con jun ction w ith high P laten/P reheater tem peratures. th en th is m ay in dic ate th at th e P laten /P re heater tem p erature m a y need to be d ecreased. (5 5-65% ) w ill decrease m edia tensio n. H ig her ten sion s m ay be necessary for very lo ng job s o r on h eav y vinyl. • T he P rint H eads are com in g in c ontact w ith the sub strate. C o lors w ill still m atch w he n scaled a nd p rinted on the sam e vin yl.8 m ) sam ple can b e used fo r m o st trial ru ns. • H igh P laten tem p eratures are ca usin g th e ink to dry o n un der u sed jets. for sm all or closeu p w ork. • D u st. O peration 3-51 .6 m x 1. O bv io usly.Jet Outage L iste d below are som e of the facto rs th at cau se jet ou tag e. • D irty m edia is ca usin g du st to acc um ulate on the Jet P ack s. W ith so m e app lications. N o te: H ig h in k viscosity do es n ot jet w ell an d w ill cau se blo cka ges. print the file . Low er Resolution RIP Files You m ay n eed to rip files using low er resolu tions. F or exam p le. • L arge prin t ga ps are accu m ula tin g exc ess ink o n th e Jet P ac ks. 50 d pi w ill loo k better than 30 0 dp i. O n ce the im a ge has be en ripp ed. ex cep t at a re duc ed size. h ig her reso lutio ns are n eeded . Trial Runs Try u sing a scaled d ow n version of the billboard y ou p lan to prin t. P ro cess the file throu gh U ltraW o rk s as y ou n orm ally w o uld . e xcess in k or c ontact w ith the m edia is causing the Jet P ack surfac es to beco m e dirty. a 2' x 6' (0 . 3-52 C hapter 3 . A ll asp ects such a s sub con tracto r sched uling sh ou ld b e don e before the sy stem 's arriv al. T h e initial in stallation an d testing of the U ltraVu x3 00 D igital P rin tin g S ystem w ill b e con ducted b y an autho rized V U T E k representative to en sure tha t the eq uipm ent is fu nctio nin g to sp ecifica tio n. w h ich the custom er sh ould review. N o te: If th e equ ipm ent is to be m oved after the insta lla tion. T he facility th at w ill hou se the printer sho uld be “U ltraVu x3 00 R eady ”. Site Preparation In order to ensu re a tim ely an d succ essful installatio n yo u sho uld th orou ghly rev iew yo ur V U T E k Site P rep aratio n G uide and th is ch apter prio r to th e arrival o f the system .Chapter 4 Installation •••••• Purpose T his ch apter p ro vid es im po rtant installation inform ation. T he in fo rm atio n presented in this ch apter is in ten ded to serve as a plann ing aid fo r the installation of th e system o r if th e system is m ove d to a d iffe ren t lo cation. V U T E k stro ng ly recom m en ds tha t you con tact our P ro du ct Service Sta ff b efo re m a kin g th e m ove. Space Requirem ents and Dim ensions T his section d eta ils th e reco m m en ded sp ace req uirem en ts and the actu al prin ter d im en sion s o f th e U ltraVu x30 0 prin ters. E ach sub con tracto r m ust com p lete the req uired w o rk before the sy stem in stall date. Installation 4-1 . 1 5 m ) W eig ht 40 00 lbs (1 . preferab ly located in front o f the prin ter.5 m ).35 m ) D ep th 45 inch es (1 .6 m ) L eng th 25 0 in ches (6.5 m ). In ad d itio n y o u sh o u ld allo w sp ace fo r th e rem o v al an d d ry in g o f im ag es. T his w ill req uire an un ob structed area o f 60 ’ x 28 ’ (18 m x 8.8 M etric Tons) Figure 4-1 UltraVu 3300 Digital Printing System 4-2 C hapter 4 .UltraVu 3300 Digital Printing System T he U ltraVu 3 300 has floo r sp ace re quirem en ts of 10 ’ x 2 8’ (3 m x 8 . T he U ltraVu 33 00 h as these d im ensions (see F igu re 4-1): H eigh t 62 inch es (1 . 5 M etric Tons) Figure 4-2 UltraVu 5300 Digital Printing System Installation 4-3 . T his w ill req uire an u no bstructed area of 60’ x 35 ’ (18 m x 11 m ). preferab ly located in front o f the prin ter. In ad ditio n yo u sho uld allow sp ace fo r th e rem o val an d drying o f im ag es.6 m ) L eng th 33 6 in ches (8.1 5 m ) W eig ht 55 00 lbs (2 . T he U ltraVu 33 00 h as these d im ensions (see F igu re 4-2): H eigh t 62 inch es (1 .UltraVu 5300 Digital Printing System T he U ltraVu 53 00 h as floor space requ irem ents o f 10 ’ x 3 5’ (3 m x 11 m ).55 m ) D ep th 45 inch es (1 . it is reco m m ended th at a P ow er C o nd ition ing S ystem (P C S ) w ith a cap acity of 10 kW (or 1 2 kVA ) be in sta lled . T h e blo w er w ill n eed to b e capa ble o f extra ctin g 60 0 cfm at 1 . T he n eutral g ray colors an d dayligh t lightin g w ill aid op erators a nd clien ts in ju dg ing color ac curacy. T he A C po w er circuit m ust b e w ired w ith an in dep end ent circ uit breaker and circuit groun d (com pu ter grade) that is isolated from oth er equ ip m e nt. N o te: In areas w ith u nsta ble p ow er so urces.9 in ches of W a ter (H W G ). b ut d oes re com m end a v entilatio n ho od d esign (see A ppendix A ). V U T E k recom m en ds a 2 kVA P C S be in stalled . To p ro tect the system s com puters a nd electron ics. P o w e r sho uld not be suscep tib le to voltag e fluctu ation s. W A R N IN G : C u stom ers are requ ired to su pply a blow er an d ven tilatio n h oo d. w h ile the U ltraVu 53 00 requ ires 50 A m p s to op erate. It is also im po rtant that the roo m ha ve neu tral gray co lo rs and is equ ipp ed w ith pu re w hite (d ayligh t) lig hting . a fu m e extraction sy stem sho uld be used to re m o ve solven t vap ors that occu r du ring the drying process. T he p rinte r sho uld not be in stalled ne ar viny l seam w eld in g equ ip m en t or any o th er sou rc es o f stron g R adio F req uen cy In terferen ce (R F I). 50 /60 H z. th e blow er m u st b e equ ip ped w ith a Totally E n clo sed F an C oo led (T E F C ) m oto r a n d an alu m in u m im peller. Pow er Requirem ents T he U ltraVu x3 00 p rinters can ac cept a 2 00 . To install a P C S you sh ou ld refer to In sta lling the P C S (P o w er C o nditio ning S ystem ) fo un d la ter in this ch apter. V U T E k do es n ot su pp ly a ven tilation sy stem . electrical co nn ection. T h e U ltraVu 33 00 has a curren t requ irem e nt o f 40 A m ps to p ro perly o perate. 4-4 C hapter 4 . T he ro om sho uld b e clean . d ust-free. and m a intain a sta ble tem peratu re betw een 68°F and 85°F (2 0°C an d 29 °C ).0 00 w atts. S ing le P hase . the U ltraVu x300 prin ters ha ve w ired to h ave a n in terna l po w er con ditio ning system in stalled . T he to tal p ow er co nsum p tio n is 10 .Environm ent T he U ltraVu x3 00 printers o perate b est in a co ntro lled env ironm en t.2 50 VA C . S in ce so lven t fu m es are p oten tially flam m ab le. T he floo r shou ld b e easy to clea n and sh ou ld n ot ge nerate du st or static electricity. E ach printer is ship ped w ith a 10 ’ (3 m ) 8/3 Ty pe S O p ow er cable (w ith no term inatio n). Ventilation To en sure tha t the roo m is safely v entilated . 3 m m ) m a le fitting . B ec ause o f this. 2 Adjust the front and rear legs appropriately until both bubbles indicate a level condition. such as. th e B ann er K it. between the Substrate Drive Roller and the Takeup Roller. it is critical that the prin ter be lev eled fro m fron t to b ack. Leveling the Printer T he U ltraVu x3 00 D ig ital P rin tin g S yste m requ ires a level location fo r in stallation. Installation Procedures T his d escribes som e im po rtant installation p ro ced ures sh ould th e p rinter ever b e m ov ed. T he air co nn ectio n is a ¼ ” (6 . Top ics co vered in clud e leveling the p rinter and relaxing and alig ning the ra il. L ev eling w ill elim inate an y tw ist in th e carria ge rails and m aterial ro lle rs that m ay oc cur from an un even floo r.0 50 ”. It a lso prov id es instru ctio ns fo r installing o ption al equ ip m en t. Relaxing and Aligning the Rail N o rm al sh ipm en t of the p rinte r w ill cau se the rails to m ov e o ut o f align m en t a s m uch as. The adjustable legs require a 7/8” (22 mm) wrench to adjust. To level th e p rin ter d o th e follow in g: 1 Locate the two precision bubble levels that are built into the printer.Air Requirem ents A ll U ltraVu x 30 0 D igital P rin tin g S y stem s req uire an air sup ply w ith a m inim um of 5 0 psi (3. th e P o w er C on ditio nin g S yste m . and the M e sh K it.52 kg/cm ) at 2 cfm (0 . O n ce th e p rinter is m ov ed in to p lace. These levels are mounted on each end of the x300 frame.0 56 cm /m ) th at is oil and w ater fre e. Installation 4-5 . the ra ils m u st b e re laxe d an d a lig ned at the tim e of th e in itial installatio n or w h enev er th e prin ter h as been m o ved to ano th er lo cation . T his occu rs w hen eve r the printer is p laced on or rem ov ed fro m a sh ipp in g p allet. you w ill n eed to p erform these step s: 1 Position the Carriage in the center of the printer where the left and right rails join together. Do not loosen the center four bolts (#1 through #4).labeled #1 through #4 (see Figure 4-3). Tighten the bolt closest to the bolt #5. push the rail towards the Drive Roller until the upright piece is against the Drive Roller on the left end. . . Tools Required “T” Handle Allen Wrench 3/16” Rail Alignment Fixture – T50915 To relax an d align th e rails. loosen all of the remaining bolts holding the rail in place.The Carriage should cover four Rail Mounting Bolts . Repeat for the right end of the printer and tighten bolt #6.To p erform this task a special set of to ols is require d. Do not use excessive force to push the rail and Rail Alignment Fixture against the Drive Roller. 3 Holding the Rail Alignment Fixture firmly down on the rail. Figure 4-3 Rail Relaxation and Alignment 4-6 C hapter 4 2 Starting at one end and working towards the center. These are the bolts that join the two rails together. and switch off the Main Breaker. Installing the Pow er Conditioning System T he U ltraVu x3 00 printers are config ured to allo w for th e in stallation of a P o w er C on ditio ning S ystem (P C S ) un it to con ditio n th e pow er. Retighten bolts #1 through #4. d o th e follow in g: 1 Locate the main Ac Distribution Panel at the left rear of the printer. below the Takeup Roller. 2 Remove the Access Panel (see Figure 4-4). 5 With the Rail Alignment Fixture. The panel is located to the right of the Ac Distribution Panel. There are two screws on the left side of the panel that must be removed from the outside and two screws located on the right side of the panel that can only be removed from inside the cabinet. To in stall the P C S. A 2 kVA P C S u nit is reco m m en ded .4 Loosen the bolts #1 through #4 and repeat Step 3 using the Rail Alignment Fixture. You can access the inside screws by opening the access doors (front side of printer) in front of the X and Y Servo Controllers. w h ich are n ot protected by th is system . left) Installation 4-7 . AC Distribution Access Panel Figure 4-4 Access Panel (rear. do not use excessive force to push rail and Rail Alignment Fixture against the Drive Roller. The screws will be on the inside edge of the panel. retighten all the remaining bolts starting from the center and working towards the each end. T h e con nection fo r th e P C S is m ade after p o w er is d istrib ute d to the h ea ters an d m o tor c irc u its. Again. then 68” lengths will need to be cut. If the connections on the PCS are not compatible. The PCS can be mounted on the cabinet bottom. 40” wide. If the printer has the wide top heater (32 head production models). If the printer has the standard top heater (32 head field upgrades). The material must be cut into pieces of either of two lengths.3 Once the panel has been removed. 3 Move the taped end of the material to the top heater and hold in place with the adhesive side up. sticky side up. the UltraVu 5300 requires four pieces of material at the pre-determined length. PTFE Paper. depending on the type of heater installed on the printer. The material comes in a 24’ roll. 4 Lay the material out and line up the edges and seal to the tape. 40”or 68”. there will be a male/female twistlock plug held to the side of the distribution box. 6 Repeat the procedure for the other banner strips. . Installing the Banner Kit Option T he B an ner F a bric K it (A A 7 02 11) includes the fo llow ing : Quantity Part Num ber Description 1 P7630-A G lass Fabric. 5 When the material is attached correctly. 24’ R oll 1 P7699-A Tape. It is important to ensure that the ends are square to each other. contact your electrician to have the plug and receptacle changed. Cut off any excess tape. then 40” lengths will be required. Have another person loop the untaped end of the material around the heater under the frame and match up with the other end of the material. The plug is a HBL4570C (Hubbell) and the receptacle is a HBL4579C (Hubbell). 2 To install the material on the printer. p roceed as follow s: 4-8 C hapter 4 1 Cut the banner material (P7630-A) to the required length. unroll a strip of tape (P7699-A) at least 40” long and place it on a table. lay down another strip of tape to cover the joint. It is critical that the material be cut perfectly square. three pieces of material at the pre-determined length are required. Polyester Silicon To in stall the k it. In the case of the UltraVu 3300 printer. Take one of the pieces of the pre-cut banner material (cut end) and press it to the tape so that ½ of the width of the tape is covered by the banner material. Disconnect this plug to install the PCS unit. R evised: In sta lla tion and O p erating Instruction s.co m Installation 4-9 . T his d ocu m e nt can b e o btain ed from V U T E k’s W eb page: w w w.Installing the M esh Kit O ption To install th e M esh K it O ption . yo u ne ed to o btain V U T E k S up po rt B u lletin (V S B 71 -3 ). U ltra Vu x3 00 M esh K it .v ute ksup po rt. 4-10 C hapter 4 Chapter 5 M aintenance •••••• Maintaining the Printer T his c hap ter con tain s m a intenan ce proc edu res an d a sch edu le de tailin g ho w o fte n to perfo rm th em . Yo u m ust m a intain the U ltraVu x 30 0 p rinter on a regu lar basis to keep it ru nn in g at th e hig hest p erform ance level. Schedule Details B elow is d etailed inform a tio n for p erform in g different levels o f m ain tena nce as ou tlined in th e M ain ten ance S ched ule fo und a t the en d of the ch apter. V U T E k reco m m ends th at th e sched ule b e cop ied an d placed w here it can b e seen, i.e. o n th e printer o r nea r th e ope rator ’s station . After Printing Each Segment • C le an the surfa ce o f th e Jet P ack A rrays w ith U ltra Vu H ead C leaning F luid (ink so lv ent). • R eco ver any lost je ts before startin g th e nex t se gm ent. Every Eight (8) Hours • T he carriage rails o n th e U ltraVu x 30 0 prin ter m u st be lu bricated every eigh t ho urs w ith petroleum base d oil (e.g. 3 in 1 oil). C au tion : D o no t use synthetic oil. Syn thetic oil w ill da m a ge th e carriage b earin gs. Daily • C h eck filter an d w a ter trap on inco m ing A ir S u pp ly S y stem s. E m pty w h en ne cessary. • C h eck th e In k O v erflo w A b sorber loc ated o n th e back side o f th e C arriage. N o te: T his is a leng th of felt rop e lyin g in a sm all tray th at stretch es the fu ll w idth o f th e C a rriag e. T h e felt is used to a bsorb an y run off of ink or solvent from the rear of the C a rriag e. T h is felt rop e sh ou ld b e checked an d rep la ced as necessary. M aintenance 5-1 • C h eck th e blo tter m aterial on th e P rin t H e ad P urger P late. If it is satu rated w ith ink , replace m a terial w ith a fresh piece. • C h eck th e blo tter m aterial on th e P rin t H e ad P urger P late. If it is satu rated w ith ink , replace m a terial w ith a fresh piece. • C h eck th e W aste Tan k and e m p ty w hen necessary. • C le an bo th the substrate feed and P in ch R o lle rs as w ell a s th e ro tary enco der w h eel w ith U ltraVu H ead C leaning F luid . C au tion : B e sure tha t th e prin ter is po w ered off w hen m an ua lly tu rnin g th e R o ta ry E n cod er W heel. N ote: U sing so lven ts other th an U ltra V U H ead C lean in g F luid (or P M A ceta te) ca n lea ve a residu e on th e ro llers th at w ill a ffect printing . Weekly • R ep lace o r clea n the foam filter o n th e o utside o f th e fan o n th e C arriage’s C oo lin g F an.. E n sure the fan blades are clean b efore re plac ing Monthly • R em ov e and c lean the Ink L ev el S ensors,. • C h ang e the blue in line in k filters fo r the C M Y K Ink F eed L ines. • R em ov e and c lean the S econ dary Ink C a ns. • C le an th e E d g e D etecto r len s w ith a clean lin t free c lo th o r w ip e. C au tion : D o no t clea n w ith solvent o r clea ner. • C h eck th e C arria ge D riv e B elt Tension. • R em ov e du st from the D C P ow e r S upp lies (i.e. P rin ter C on troller an d U ltraVu W orksta tio n) Every Six Months • T he Tak eup /R edirect D rive G earb ox o il sh ou ld be ch ang ed. • R em ov e du st from P o w er S upp ly an d S erv o C o ntro llers w ith com p ressed air. Yearly • C h ang e the tw o blue filters o n the C arriag e fo r th e so lv ent an d A ir F eed L in es. • C le an th e P rim ary Tan k F ilters. 5-2 C hapter 5 Maintenance Procedures Cleaning the UltraVu x300 W ith the ex ception of the je t pack su rfaces, the U ltraVu x 300 D ig ital P rinting S ystem m ay b e clean ed w ith gene ral c lean ing cloths and clea nin g com p ou nds. W h en cleaning the Jet P ack A rray surfa ces, a clea n ro om style lin t-free clea nin g clo th o r w ipe m ust b e used . N o te: O n ly a clea n roo m style lint-free clea nin g cloth o r w ip e th at m eets V U T E k sp ecifica tio ns m ay be used to w ipe the in k an d solvent fro m the Jet P a ck su rfa ces. U sing o th er types o f clea nin g cloth s o r w ipes w ill da m a ge th e Jet P ack su rfaces a nd vo id the w arra nty o n th e Jet P acks. You m ay p urcha se the spec ial lint-fre e c lean ing c loth fro m V U T E k o r directly from the m anu fa ctu rer that produ ces th is produ ct to V U T E k specification s. Lint-Free C leaning C loth Fisher Scientific 711 Forest Avenue P ittsburgh, PA U S A 15219-4785 VU TE k P art # P 7240-A Vendor P art # - 33330 Tel: 973/467-6400 Fax: 973/379-7638 Tel: 800/766-7000 U S A only Caring for the Jet Pack T he surface of the jet pack a rrays m ust b e k ept w et w ith eith er ink o r U ltraVu H ead C lean in g F luid. F ailu re to use U ltraVu H ead C lean in g F luid w ill resu lt in dam ag e to the jet pac ks. If the prin ter is no t g oing to be u se d, lig htly coa t the Jet P ack s w ith th e flu id an d th en co ver the surfac es w ith po lyethy len e w rap to p rev ent dryin g. N o te: P o lyethylene w ra p ha s b een th e on ly plastic clin g w ra p fou nd to w ithstand the ink solvents. If th e prin ter is goin g to b e id le for an extend ed p eriod of tim e (Tw o d ays or m ore), you w ill n eed to d o the follow in g: 1 2 Coat the surface with UltraVu Head Cleaning Fluid. Place polyethylene wrap over the Jet Pack surface to retard drying. M aintenance 5-3 If it is necessary to rem ove th e Jet P ack s, you w ill need to do th e follow in g: 1 Flush the Jet Packs with solvent and lightly coat the heads with UltraVu Head Cleaning Fluid. 2 Store Jet Packs in an air tight plastic bag. N o te: F a ilu re to store the Jet P a cks correctly w ill result in clog ged jets an d w ill perm an ently da m a ge th e Jet P ack A rrays. A ny Jet P a ck B oards returned to V U T E k for servicing m ust be p rep ared in this m ann er or th ey w ill be rejected. Rem oving the Jet Packs To rem ove th e Jet P ack s, d o th e follow in g: 5-4 C hapter 5 1 Empty the jEt Packs of ink. Use EMPTY PACK for each color in sequence until no ink flows from the jets. 2 Flush the Jet Packs with solvent. Use SOLVENT FLUSH for each color in sequence for approximately 30 seconds. 3 4 Alternate a SOLVENT PURGE with a SOLVENT FLUSH. 5 Empty the Jet Packs of solvent. Use EMPTY PACK for each color in sequence until no solvent flows from the waste orifices. 6 7 Power down the printer. 8 Remove the two screws holding each Jet Pack Assembly to the Alignment Plate and pry up to remove the board from the backplane. When removing the Jet Packs, start at the left side and place each in the order they were removed on a cleanroom-type, lint-free cloth. Each purge and flush should be five seconds. You will need to do this step five times or until purged solvent exiting the jets appears clear. This ensures that no ink is left in the pack to dry the orifices. Remove the Cooling Fan from the left side of the Carriage to allow access to the inside of the Carriage. 04 or ab ove) w ill need to b e ch anged . M aintenance 5-5 . You should feel the board's edge connector and seat it into its mating connector. Use the UltraVu’s Printer Function Selector Switch and the Yellow and Magenta Color Buttons for this operation. Reach into the carriage through the Cooling Fan opening to guide the Jet Pack Board into position. Swap the sensor wires from the Yellow and Magenta Tanks. 2 Select EMPTY PACK and press the Yellow and Magenta Buttons until Jet Packs show bubbles 3 Select the Solvent Flush Function and press the Yellow and Magenta Buttons until the output lines from the Carriage Back Plate appear clear. 2 If all jet packs will be installed. 4 Tighten the screws. 4 Select SOLVENT PURGE and press the Yellow and Magenta Buttons until the solvent from the Jet Packs is clear. begin with the right most Jet Pack Assembly. T h is can b est b e p erform ed by follow in g th e steps b elow : 1 Before shutting the system down. Lightly tighten the screws. proceeding from front to back. do th e follow ing: 1 Ensure o-rings are installed into the recessed holes located on the Alignment Plate. 5 6 7 Shut down the workstation. Power down the printer.Installing the Jet Packs To in stall the Jet P acks. 3 Install Bezel Screws to hold unit in place. Inside of the Ink Supply Plate. It is important that all screws holding the Jet Pack are evenly torqued before tightening them. Changing the Color Order of the Jet Packs To red u ce b i-d irection al effects in som e im ages th e ord er of th e Yellow and M agen ta Jet P ack (U ltraVu x300 F irm w are 2. the Yellow and Magenta Secondary Ink Tanks and jet packs must be emptied. the sensor wires from the Yellow and Magenta Tanks must be swapped (connect yellow up to where magenta was connected and magenta up to the original yellow connection). Disconnect the Luer fitting in the Yellow and Magenta Supply Lines and reconnect with yellow to magenta and magenta to yellow. 5-6 C hapter 5 . 12 Enter the Printer Diagnostic Mode. 15 Select EMPTY PACK and press the Yellow and Magenta Buttons until Jet Packs show bubbles 16 Select SOLVENT FLUSH and flush the Yellow and Magenta Jet Packs with solvent. 17 Select INK PRIME and prime until the output returning from the Carriage Back Plate is the correct color. This will take about ten seconds.8 On the Carriage Plate swap the ink lines from the Magenta and Yellow Ink Tanks. Locate where the Ink Supply Lines come into the Carriage from the umbilical supply lines. This will take about ten seconds. remove the colored cap on the Yellow and Magenta Control Buttons. 14 Select INK PURGE and press the Yellow and Magenta Buttons until you see the proper colors feeding through the ink lines into the ink tank. Swap the caps and snap them back on. 18 Perform the Ink Purge Function until the ink color coming out of the Jet Packs is correct. 9 Using a small flat blade screwdriver. Troubleshooting. This will take about ten seconds. 19 Load some material and print a test image. for details. 11 Ensure there are no leaks. 10 Power up the printer. 13 Enter Function code 11 and select the color order. You will need to refer to the Printer Diagnostics Mode in Chapter 6. W h en ch ang ing o il V U T E k reco m m en ds tha t you order o ne th e the follow in g kits: Parts Required Parts Description AA70239 Gearbox Oil Change AA70239-F Gearbox Oil Change w/ Fittings (only needed first time) The kit includes: P2006-A Tubing P7680-A Oil. P7688-A Bottle. 1Quart P7687-A Dispenser Bottle w/ Dispenser Cap. 4 Remove the Right End Top Cover. remove the 3/8” nut. Remove the right rear access panel. On the Workstation side of the frame upright (behind the end of the heater and rollers) remove the six 5/32” Allen Cap Screws. Also inside. This is done by removing two 5/32” Allen Cap Screws at the top (and two additional screws in the middle on some models) and loosening three 5/32” Allen Cap Screws at the bottom. remove the four 5/32” Allen Cap Screws at the bottom edge of the panel behind the Feed Roller Drive Motor. remove the two hoses from the valve (inside of the panel). 500 ml P2040-A Teflon Tape. If the Vacuum Adjuster is installed. On the bottom left corner (still inside). 1 Roll P7672-A Oil Relief Fitting (2) P7673-A Oil Adapter Fitting (2) -F Kit Only -F Kit Only To chan ge oil you w ill n eed to follow these steps: 1 2 Shut down the printer and turn off power at the Circuit Breaker Panel. From inside the cabinet. The Upper Panel is secured by two 5/32” Allen Cap Screws under the black hole plugs at the top. remove the three 5/32” Allen Cap Screws holding the Top Cover to the frame. Remove the two Flat Head Phillips Screws located on the frame under the front Redirect Roller. If the printer is equipped with a fan mounted on the End Panel. 4 oz. 3 Remove the Right Upper End Panel. Mobil SHC 634.Changing G earbox Oil T he o il in the Ta keup and R ed irect G earb ox es sho uld be ch ang ed ev ery six m on th s. disconnect the wires. M aintenance 5-7 . 11 Remove the Front Fill Plug and the lower right Bottom Drain Plug and drain the used oil into the bottle. Install the Adapter Fitting (Vent Plug) into the rear hole and tighten with a 5/8” Wrench.5 6 Disconnect the Air Supply Line. Be sure to wrap the Adapter Fitting threads with Teflon tape before installing. With the help of another person. 10 Place a funnel under the Redirect Motor Roller and place the 500 ml Bottle (P7688-A) under a funnel to collect the waste oil. remove the upper back plug on the Redirect Motor. disreg ard Step 9. Screw the Oil Relief Fitting (P7672-A) into the Oil Adapter Fitting (P7673-A) and tighten with a 7/16” Wrench. N o te: If ven t fittings a re used . Figure 5-1 Redirect and Takeup Motor Drawing 9 Using a 1/4” Allen Wrench. 7 Drape a scrap piece of vinyl over the rails under the Redirect Motor (front). You will need a 9/16" (or 5/16" Allen) Wrench. 8 Remove the upper right hand bolt from the motor mount to gain access to the upper back plug on the gearbox (see Figure 5-1). 5-8 C hapter 5 . Remove cover and place in a secure area to prevent damage. lift up the back edge of the Top Cover and move the cover forward to access the slot over the power cord. remove the tubing and allow oil to completely drain. When the oil has stopped draining.12 Reinstall the Bottom Drain Plug once the oil has stopped draining. Use a 1/4” Allen Wrench and tighten. Wrap the Adapter Fitting threads with Teflon tape before re-installing. Be sure to wrap the plug’s threads are wrapped with Teflon tape before installing. Cut off the tip of the Dispenser Bottle. 14 Connect one end of the tubing (P2006-A) to the stem of the Dispenser Bottle. 16 Move to the rear Takeup Motor and drape a scrap piece of vinyl over the top of the Power Distribution Panel. Tighten with a 5/8” Wrench. When oil starts to run out of the fill hole. M aintenance 5-9 . 20 Remove the bottom Drain Plug with a 5/16" Allen Wrench and drain the waste oil into a pan. 18 Remove the lower left hand bolt from the Motor Mount to gain access to the Bottom Drain Plug. Clean up any left over oil that may stay on the mounting frame and wipe area clean. 15 Replace the upper right hand bolt into the Motor Mount. Install the Adapter Fitting into the upper right Fill Plug. You should refer to Figure 5-1 for placement. 21 Connect the Tubing (P2006-A) to the end of the Dispenser Bottle. This is directly under the Takeup Motor gearbox. This will cause the oil to drain onto the mounting frame and drip down both sides. 13 Fill the dispenser bottle with the oil (P7680-A) provided. The Drain Plug is at the bottom on the motor side of the Gearbox. Fill the dispenser bottle with the oil (P7680-A) provided. When oil starts to run out of the fill hole. Screw the Oil Relief Fitting (P7672-A) into the Adapter Fitting (P7673-A) and tighten with a 7/16” Wrench. leaving the stem small enough to fit into the tubing supplied (P2006-A) with the kit. Clean up any left over oil that may stay on the mounting frame and wipe area clean. Wrap the Fill Plug threads with Teflon tape and reinstall the Fill Plug. 19 Use a 1/4” Allen Wrench and remove the upper right Fill Plug. Use a 1/4” Allen Wrench and remove the front Fill Plug. Place the end of the tubing into the front fill hole on the Gearbox and fill. N o te: If ven t fittings a re used . wrap the Drain Plug threads with Teflon tape and re-install. Place the other end of the tubing into the front fill hole on the Gearbox and fill Gearbox with oil. remove the tubing and let it drain until it stops (this will insure the oil level is up to the drain hole and no higher). Wrap the Fill Plug threads with Teflon tape and reinstall. disreg ard Step 19 . 17 Place the funnel and the oil collection bottle under the mounting frame of the Takeup Motor. Ensure that the funnel is wide enough to catch the oil that will drip from both sides of the mounting frame. Use a 9/16 Wrench or a 5/16” Allen Wrench and tighten. and then return the printer nnline. apply a thin film of oil to each rail using the oiled cloth or wipe. It w ill dam ag e the ca rriag e slid ers. close the Bail. take the printer offline. Wipe any excess oil from the rails and the Linear Encoder Strip (under rear rail) before returning the printer to operation. at idle (with the rollers turning freely) or during operation and then change the Gearbox oil again (only the first time that the oil is changed). The Carriage will move to the right and return to the home position. Older Models O n old er m o dels the p rinte r used a filter arra ngem en t (P 705 9-A B lue Inline F ilter) tha t con sisted o f a 90 ° elb ow fittin g (g ra y pla stic o -ring fitting s) to c onn ect into the ink lines. Too m u ch o il m ay drip on to the sub strate a nd d am ag e a prin t. 2 After applying the oil to the rails. Lubricating the Carriage Rail T he carriage rails o n th e U ltraVu x3 00 p rinter m ust be lub ricated e very eig ht h ou rs w ith a pe tro leu m b ased o il (e. Replacing the Ink and Air Filter To replace th e C arriage P late F ilte rs fo r the A ir an d S olv ent L ines. 25 Dispose of waste oil responsibly. Be sure that oil is distributed evenly over all surfaces of the Carriage Rails over the full length. T hese fittin gs req uired the com p ressio n of the In ner R ing (dark gray) to release the filter stem fro m th e fitting.g . 3 Using a cloth. wipe the rings at the Carriage both ends of the Carriage rail. To oil th e C arriage S lid e R ails. 5-10 C hapter 5 . 24 Replace the Rear Top Panel and End Panels in the reverse order of Steps 1-6.22 Install the lower left hand bolt that was removed in Step 18. open the Bail. yo u m ust first tu rn th e M ain A ir R egu lator to z ero and ble ed o ff all pressure from th e S o lv ent Tank S ystem . 3 in 1 oil). C a u tion : Avoid a pplyin g o il d irectly on th e rails. C a u tion : D o n ot u se syn thetic o il. 10-19. p erform th ese steps: 1 Apply a small amount of oil to a lint free cloth or wipe. 23 Turn on the power and run the motors for one hour. Repeat Steps 7-8. With the Carriage in the home position. 3 4 Put filter in place and snap Quick Disconnect Fittings back on. 5 Release the tubing clamps (P7744-A) on both ends of the tubing that is connected to the Ink Filter Stem. Newer Models O n n ew e r m od els the p rinter uses a filter arran gem en t th at con sists of tw ist lo ck rem ova ble fittin gs to co nn ect in to the in k lines (see F ig ure 5 -2 ). Compress the Inner Ring (dark gray) on the Quick Disconnect Elbow Fittings and snap off. 4 Remove the filter from the Carriage by sliding it out of its tie wrap holder securing it to the Secondary Ink Tank.To rep lace th ese filters. Slip the piece of the tubing over the Ink Filter Stem and slide on two clamps. Figure 5-2 In-line Ink Filter To chan ge th e filter. Slip the clamps off of the hose and save for reuse. you w ill n eed to perform th e follow ing step s: 1 2 3 Shut down workstation and power down the printer. d o the follow in g: 1 2 Place a cloth under the filter to collect any spilled ink. M aintenance 5-11 . Pull the twist lock fitting (P5379A) from the end of the hose. 6 Cut 1½” (3. Place the filter in a container to collect the ink that may spill. Reapply pressure to the system. Place a cloth under the filter to be removed to collect any spilled ink. 7 Install the Twist Lock Fitting (P5379-A) into the end of the tubing and compress the clamps (P7744-A) until they are secure on the Filter Stem and the twist lock fitting. Rotate the Twist Lock Fittings (P5379-A) to release the Filter Assembly from the ink line.8 cm) of ink tubing (P7743-A) for each end of the filter (P7059-A). VUTEk recommends that a spare set of ink level sensors be available to install while one set is being cleaned. To rem ove an d clean th e In k L evel S en sor. 3 Soak the ends of the sensors in UltraVu Head Cleaning Fluid (or PM Acetate). . A plugg ed filter slow s in k pu m p ra tes or can cause th e d eco uplin g of the m agn etic drive b etw een th e pu m p and m otor. T he end s of th e senso rs co llect sm all drop lets of in k that m a y d ry and bu ild up to create a sm all ba ll o f drie d in k. 9 Turn on the printer. d o th e follow in g: 1 2 Remove the hoses from the top of the Secondary Ink Tank. 4 Replace the cover o-ring and reinstall the cover onto the Secondary Ink Container. T his w ill affec t th e se nsor ’s ability to d etect low and h ig h ink con ditio ns. T h is filter c an be clean ed in solven t a nd re used o r re plac ed. Remove the screws holding the cover to the Secondary Ink tank and lift the cover off. Cleaning the Ink Level Sensors T he in k lev el sen so rs are loc ated in th e top o f the S econ dary Ink C o ntainers and m ust b e rem o ved and cleaned on a m on thly basis. T h e filter co nsists of a m esh b ag (rec tan gular) th at is pressed o nto th e en d of th e ink p ick up tu be. Ensure the direction arrow on the filter is pointing towards the Secondary Ink Tank. Disconnect the hose and remove the tank. Cleaning the Secondary Ink Tanks To clean the S econd ary Ink Tan ks.8 Reinstall the new filter into the Filter Holder and connect the ink plumbing at the twist lock fittings. Cleaning the Prim ary Ink Tank Filters T he P rim ary Ink Tank F ilte rs req uire cleaning o r ch ang ing o n a yea rly basis. 10 Ensure there are no leaks and that the Secondary Ink Reservoir is receiving ink flow. Clean off with a lint free cloth. do th e follow in g: 1 2 5-12 C hapter 5 Remove the cover as outlined above. e. this proce dure sho uld be perform ed at least o nce a m on th . Reinstall the snap-on Filter Holder onto the Fan Guard. Clean or replace the Filter. vacuum or wash and dry. you n eed to perform th ese steps: 1 2 3 4 5 6 7 Power down the printer. the P ow er S up plies w ill coo l eno ug h to autom atically turn th em selv es on. Cleaning the Carriage Cooling Fan T he C o oling F an on th e C arriage has a foam filte r re quiring w eekly m ain tena nce. T his cy cle of shu t w ill co ntinu e u ntil som e m ajor co m p on ent is dam ag ed. A fter a few sec ond s. Clean the Fan Blades and Fan Guard with a vaucuum cleaner. To clean th e C arriage C oolin g F an . Cleaning the DC Power Supply Fans O v er tim e. 4 5 Reinstall the tank and reconnect the hoses Reinstall the cover as outlined above. M aintenance 5-13 .3 Clean the inside and outside of tank with UltraVu Head Cleaning Fluid. Reinstall the filter. A s a m in im um . Remove the Filter. Ensure the Fan can move freely. rem ov e any du st from in side the P ow er S up ply (see F ig ure # 1). A s they get ho t th ey sh ut them selv es off ag ain . d ust c ollects in sid e the D C P ow e r S up plies fo und on the an d causing them to o verhea t W hen the P ow er S up plies gets too h ot. Remove the snap-on plastic from the Filter Holder. i. U sing an A ir G un w ith a m axim u m pressure of 50 psi. T his filter is u sed to redu ce du st bu ild u p on the F an B lades and C arria ge com p onents. th ey w ill turn off an d shu td ow n the W o rk station a nd th e P rin ter C on troller. If the Carriage Drive Belt is tight. then the D rive B elt is lo ose an d n eeds to be tigh ten ed. but do not remove. .2 m) and 5’ (1. place a mark on the Carriage Drive Belt at the 4’ (1. If th e C arria ge D rive B elt to uch es the D rive B elt G uide w ithin th e first 4’ (1 . turn the adjustment bolts ¼ turn CCW. the two bolts that hold the Carriage Drive Belt Bearing to the frame. If th e C arriage D rive B elt d oes no t tou ch th e D rive B elt G uide w ithin the 4 ’ – 5’ (1. Loosen. 3 If you need to adjust the belt.5 m) distance. If the Carriage Drive Belt is loose.2 – 1.2 m ).Checking Carriage Belt Tension To check the C arriage D rive B elt Ten sion you w ill n eed to p erform th ese steps: 1 Position the Carriage Plate in the center of the printer (see Figure 53). you sh ou ld p erform th e follow ing step s: 5-14 C hapter 5 1 2 Position the Carriage Plate in the center of the printer. N o te: B etw een 0 ’ a nd 4 ’ (1 . the D rive B elt is to o tigh t an d m u st be lo osen ed. These two bolts are located in the Carriage Drive Belt Bearing adjustment slots. The Carriage Drive Belt should be touching the Drive Belt Guide between the 4’ and 5’ marks. follow the procedure described below.2 m ) distan ce.5 m ) ran ge. but loose enough to allow the block to be adjusted. turn the adjustment bolts ¼ turn clockwise. Adjustm ent Procedures Adjusting the Carriage Drive Belt To ad just th e C arriage D rive B elt. The two bolts should be tight enough to stop the bearing from rocking up and down. 2 Measuring from the left side of the Carriage Plate Drive Belt Mounting Bracket. 3 4 Loosen the locking nuts that hold the adjustment bolts in place. the C a rriag e D rive B elt sho uld not tou ch th e D rive B elt G u id e. N o te: T h e fa cto ry ha s an align m en t fixtu re a vailab le for this p ro cedu re. the Carriage Drive Belt Bearing must be aligned to the Carriage Rails. Figure 5-3 Carriage Belt Layout 6 If the Carriage Drive Belt touches the guide within the first 4’ (1.2 m) marks. If the Carriage Drive Belt does not touch the Drive Belt Guide within the 4 . Between 0 and 4 ft (0 .2 – 1. The alignment process will center the Carriage Drive Belt on the pulley. C o nta ct V U T E k P ro du ct Su pp ort fo r m ore inform ation .5 The Carriage Drive Belt should be touching the Drive Belt Guide between the two marks placed on it. the Carriage Drive Belt should not be touching the Drive Belt Guide (see Figure 5-3).2 m). M aintenance 5-15 .5 m) area. then the Drive Belt is loose and needs to be tightened.5 ft (1. the Drive Belt is too tight and must be loosened. 7 After the correct tension has been set.1. 8 Place a straight edge against the outside edge of the rail and measure the distance from the Carriage Drive Belt Bearing (location A) to the straight edge (see Figure 5-4). The distance at location A must be the same as location B. No adjustment is required to the Carriage Drive Belt at the right end of the printer. Figure 5-4 Carriage Belt Adjustment Layout 5-16 C hapter 5 . adjust accordingly. If the distances are not the same. Then measure the distance from the Carriage Drive Belt Bearing (location B) to the straight edge. 9 Tighten the two bolts in the adjustment slot and the locking nut on the adjustment bolt. depress the Test Button to terminate the test. you sh ou ld perform th ese step s: 1 Take the printer offline. To verify th e Jet P late align m en t. 3 Advance the material so that the Test #6 pattern is visible above the Redirect Roller. You may need a magnifying glass or eye piece to correctly determine line orientation. 4 Compare the printed test pattern with the diagram on Figure 5-5 and adjust the Jet Pack Plate accordingly. use the Advance Button to move to Test 6. C o rrect align m ent is ob tain ed b y using Test #6 and adjusting the jet pac k plate so tha t the ye llo w line is tou ching an d abo ve the b lack line.Verifying the Jet Plate Alignm ent T his p ro cedu re is p erform ed du ring the m anu fa cturin g process an d re adju stm en t in m o st in stan ces shou ld not be n ecessary.. Release the Test Button to activate the test. 2 Allow the printer to complete one pass. R efer to F ig ure 5-5 (v iew ed fro m ab ov e the redirec t ro ller) for th e co rrect yello w to b lack lin e o rientation . While holding down the Test Button. Then. Figure 5-5 Jet Plate Alignment Test Pattern M aintenance 5-17 . if yo u fe el that th e Jet P ack P late is ou t of adjustm en t. H ow ever. p lease fo llo w the below procedure. except those number 1. . and 7. 9 Perform Test #6 again to verify a correct alignment. and #5. 7 Repeat Test #6 (refer to the first 4 steps above). 8 After the alignment process has been completed. Lightly tighten screws #1. 6 Move the right end of the Jet Pack Plate toward the printer. 4. The screws are numbered 1. and #7. 4 Move the left end of the Jet Pack Plate away from the printer. (Screw #7 will act as a pivot point). #3. on the left end. you sh ould d o the follow in g: 1 Remove the two Material Deflector Plates at both ends of the Jet Pack Plate. 3. 3. 5. 8. and four unnumbered screws (see Figure 5-6) Figure 5-6 Jet Plate Alignment Screw Location 2 3 Loosen all screws. 5-18 C hapter 5 5 If the black line is above or overlaps the yellow line. T he ho le diam eter is slig htly la rger th an the screw size. 7. Tighten screws #1. N o te: T he m ovem en t of the Jet P ack P late is lim ited by th e difference betw een the ho le d iam eter an d th e screw size. tighten all twelve screws in an alternating pattern. (Screw #3 will act as a pivot point). If the yellow line is below or overlaps the black line. #5. 5. T he sm a llest m o vem en t w ill affect the align m en t process. loosen all screws except #7. You may have to perform the alignment procedure a few times to correctly align the Jet Pack Plate. loosen all screws except #3. on the right end. The removal of the right-side material deflector plates will expose the Jet Pack Mounting Plate Screws on the right end.Aligning the Jet Plate To align th e Jet P ack s. 060" by lowering the Carriage Height Adjuster Knob until . Figure 5-7 Print Gap Adjustment M aintenance 5-19 . 2 Turn the Carriage Height Adjuster Knob to either increase or decrease the print gap.Setting the Print G ap T he U ltraVu x 30 0 p rinter has been de sign ed w ith a p rint gap that can be adjuste d to acco m m o date varyin g sub strate th ick nesses. N o te: If a M esh K it is in stalled . The print gap is typically set to 0. This is done by placing a sheet of paper on the heads and move the Carriage under the Platen. To set th e p rin t gap . 6 Tighten the four thumbscrews. you should p erform these step s: 1 Loosen the four thumb screws securing the Carriage to the Carriage Plate (see Figure 5-7). Raise the Carriage until the paper can no longer be moved between the Platen and the Print Heads. Tighten Lock Down Knob. th e P rin t H ea d m u st b e low ered to clea r th e M esh K it ra ils b efore pla cin g th e prin ter on lin e. 3 Zero the Print Head Gap Dial Indicator.060" is indicated on the Dial Indicator.5 mm). The minimal print gap for the UltraVu x300 printers is 0. T h e C arriage H eigh t A d ju ster K no b is lo cated on the left sid e o f th e C arriage.10 “(2. 5 Set the gap to 0. T h e p rint h ead m ove s u p and d ow n on A djuster P osts to allo w for p rint g ap adjustm en ts.060” (1.5 mm). 4 Loosen the Lock Down Knob on the Dial Indicator and set dial to zero. 6 Exit the Diagnostic Function Mode and return to normal printer operation. just off scale). 3 Reduce the reading with the Sensitivity Screw so that at its highest point it is just below “1” (i. This function allows the Carriage to be moved using the yellow and black Control Panel Buttons. 10) when the detector is over the substrate. move the Carriage to the right until the detector is on the Redirect Bar.e. 2 With no material loaded. O n th e side o f th e detecto r th ere is a row o f L E D ’s labeled 0 th ro ug h 10 . the O u tp ut L E D . Adjust the Sensitivity Screw until it just reads “1”. below “1”). and an op ening for the S ensitiv ity A djustm en t S crew. you w ill n eed to p erform th e step s b elow : 5-20 C hapter 5 1 Enter the Diagnostic Function Key code #9. . To adju st th e sen sor level. Now move the carriage to the right and find the position that gives the highest reading along the length of the Redirect Bar.e. T he E d ge D e tecto r is attach ed to the rig ht rear sid e of the C arriage (see F igu re 5-7). 4 Move the Carriage back and forth across the Redirect Bar to check if it is always off scale (i.e. repeat to ensure that full scale is achieved (i.Adjusting the Edge Detector T he E dg e D etector m ay n eed to be readjusted for so m e m esh and v in yl m aterials. 5 When the material is loaded. 3 Use the Adjustment Knob to increase or decrease the Encoder Wheel tension as needed (see Figure 5-8). th e tension o n th e e ncod er w heel m ay need to be increased (see F igu re 5-8). The encoder wheel should extend down ¼” (6 mm) below the edge of the straight edge.Adjusting the Encoder W heel T he E n cod er W heel can b e adju sted to acc om m oda te a w ider variety of sub stra tes. To com pen sate for m aterials hav in g slick surfac es. Figure 5-8 Encoder Wheel Adjustment Layout (right view) To ad ju st th e ten sion of th e E n cod er W h eel. T h is adjustm en t allow s the op era tor to v ary the E n code r W h eel p ressure on the sub strate m ate ria l to increase prin t qua lity fo r fa bric and m esh . an d to co m pen sate for su bstrate slipp age cau sed by sm ooth m aterials. This should represent the starting adjustment for the encoder (see Figure 5-8). 2 Measure the distance from the straight edge to the wheel as it presses into the material. you w ill n eed to p erform th ese step s: 1 Place a straight edge against the Platen and the Redirect Roller (see Figure 5-8). M aintenance 5-21 . 7 Rotate the indicators to a 45 degree angle so that they are easier to see as well as provide clearance to the Feed Roller to prevent contact. T he P laten P reh eate r w a s o rigin ally design ed and installed to w arm the m edia to a con stant tem peratu re . Verify that the Revolution Indicator on the Dial Indicators are on the same revolution. . You can dete rm in e if an y w a rp ing has occu rred w ith the V U T E k P laten A lign m ent Tool (T 5 001 9). A fter perfo rm in g a serie s of tests on m aterial y ou m ay fin d yo u need to in crease the tem p eratu re abo ve 12 0°F (4 9°C ). W e reco m m e n d that y o u p rint w ith a s lo w a P laten prehe at tem peratu re as po ssible. attach the fixture to the edge of the Carriage using the same holes that the Material Deflector was attached to. to 1 20 °F (49 °C ). Be sure to leave the Carriage to the normal print gap distance of 0.060” (1. w h ich help s to create a m ore unifo rm prin ted im ag e. S ettin g the P late n P reh eater ’s tem peratu re too h igh tend s to w a rp the P laten and cause it to arc do w n w ard to w ards th e P rin t H ea ds. To verify th e P laten ’s align m en t. T h is chan ges th e distanc es b etw een th e prin t head s an d th e m a terial typ ically in the m idd le of th e p rinter. 9 Replace the top plate on to the Platen Alignment Fixture and set the Dial Indicators to zero. Remove the Edge Detector. o n 32 h ead p rinters. H ow ever. This is done by removing the two Phillips head screws holding it in place. yo u sho uld b e aw are of trade-off in volved .5mm). To do this remove the three screws securing it to the Carriage. Power down the printer. you n eed to p erform th e follow in g step s: 5-22 C hapter 5 1 2 3 Shut down workstation. 4 Remove the right hand Material Deflector from the top of the Carriage. It w as n ot inten ded to be used as a n ink d ry er. 6 Remove the Dial Indicators from the box and install into the two bottom holes in the bottom plate. 5 Remove the top plate from the Platen Alignment Fixture (see Figure 5-9). Tighten the Allen set screws at the base. This will ensure that your reading is not off by one revolution or more.Verifying Platen Alignm ent V U T E k has set the P late n P re-H eater ’s up per tem pe rature lim it. 8 Using the three screws provided with the fixture. 10 While holding down the Dial Indicator Shafts. you need to contact VUTEk’s Product Support for further direction. you w ill n eed to d o th e follow in g: 1 Enter the Diagnostic Menu by connecting the video monitor and keyboard up to the Printer Controller or by switching to B on those printers equipped with the A/B Switch Boxes. Depress the Escape Button to enter the Diagnostics Menu. Select Key Code #5 to display the head temperature reading. 12 Remove the Platen Alignment Fixture from the carriage and replace the Material Deflector and the Edge Detector. 11 Take several data readings along the length of the Platen. Plot a graph of these readings. Figure 5-9 Platen Alignment Fixture Layout 13 Place the three screws provided with the platen alignment fixture and return. o r th e jE t D riv er B oard is re pla ced. Adjusting the Jet Pack Tem perature T his p ro cedu re w ill e xplain h ow to v erify an d calibrate the Jet P ack Tem pe rature S en sor. To ad ju st th e Jet P ack tem p eratu re. T his p ro cedu re m u st be fo llow ed w h enev er a tem p erature sh ift is susp ected . M aintenance 5-23 . If significant deviations are noted. remove the plate and move the Carriage under the Platen. insuring the Carriage Cooling Fan is not running or the heater is not on. 5-24 C hapter 5 . 5 Locate the Adjustment Potentiometer on the Jet Driver Board (see Figure 5-11). if the temperature probe measures 90°F and the temperature reading on the monitor is 84°F.2 3 Attach a temperature meter or probe as shown in Figure 5-10. For example. Figure 5-10Temperature Probe Placement 4 Locate the Adjustment Screw and turn the screw slowly until a change occurs on the screen (CCW lowers the temperature). green = cooling). th e sam pling ra te is slo w. N o te: B e p atient. Adjust the Potentiometer until the reading on the monitor equals the reading from the temperature probe. Ensure that the Heating/Cooling LED is OFF (red = heating. It w ill ta ke ten second s o r m o re fo r tem p erature ch an ges to sh ow o n th e m on ito r. then you must adjust the Potentiometer on the Jet Driver Board until the monitor reading equals 90°F. The potentiometer is located on the front right corner behind the LED labeled Heating/Cooling. Maintenance Chart V U T E k re com m end s that a schedule be fo llow ed to insure m ain tenance tak es p lac e at ind icated in tervals red ucing d ow n tim e an d m a xim izin g prin t qu ality. C op y th e M ain ten ance S che dule (sh ow n below ) and p ost it o n or near you r p rinter.Figure 5-11 Potentiometer Location on Jet Driver Board 6 After making an adjustment. allow the Carriage temperature to stabilize for 10 to 15 minutes before re-checking the calibration. M aintenance 5-25 . Remove dust from DC Power Supply. Yearly Replace solvent and air filters on the Carriage. Replace as necessary.UltraVu x300 Maintenance Schedule Frequency Procedure After printing each segm ent Clean the surface of the Jet Packs with solvent. M onthly Replace iNk Supply Line Filters for CMYK on Carriage Plate. Clean Cooling Fan Filter. Feed Roller rubber coating should not be smooth. Check the felt rope behind the Carriage Plate. D aily Check the water trap and filter on the incoming Air Supply System to the printer. Clean or replace the Primary Ink Tank Filters. slightly tacky is preferable. W eekly Clean Purge Plate Pad. Check tension of the cArriage Drive Belt. Clean sEcondary Ink Tank Sensors and Secondary Ink Tanks. Replace Purger Plate Pad. Clean both Feed and Pinch Rollers with Head Cleaning Fluid. Every 6 m onths Change the oil in the Takeup and Redirect Drive Gearboxes. 5-26 C hapter 5 . Clean Carriage Fan Filter. Every 8 hours Oil the rails. A t so m e p oint d uring the life o f prin ter yo u m a y hav e questio ns or enco un ter ope ration . N o te: If yo u enco un ter an error th at p ersists or a prob lem yo u do not un dersta nd . it w ill o nly w o rk on a d ate later th an th e date it w as last run . It is easy to correct m ost o f th e p ro blem s an d co nsequ ently n ot d elay o peration for very lo ng . In add ition to th e tro ub lesho otin g charts fo un d th ro ug hou t th e chap ter. If U ltraVu is ru n w ith an inc orrect date. sim p ly co rrect the Troubleshooting 6-1 . T h is do es n ot p ose a prob lem on a system w h ich h as been set to a date prior to the actu al d ate. the softw are w ill resp ond w ith th e m essag e “In valid D ate w ith L a st C h ecked ” and d isab led the syste m . Yo u m a y w an t to refer to the m w hen trou blesh oo ting. co nta ct V U T E k’s P rod uct S up port G ro up for assistance.exe” P rog ra m w ill check th e S ystem D a te ea ch tim e it is ru n.co m Error M essages UltraVU Software Error M essages Invalid Date with Last Checked T he “U ltraVu .Chapter 6 Troubleshooting •••••• Overview T his ch apter p ro vid es so m e h in ts fo r trou blesho oting error m essag es th at th e p rinter can d isp lay an d prob lem s yo u m ay exp erienc e w ith th e prin ter. w e h ave prov id ed a nu m b er o f ele ctrical a nd m ech anic al draw ing s o f critical system co m pon ents. It w rites this d ate into th e S ec urity D o ngle. q uality. Tel: (60 3) 279 -4 63 5 F ax: (6 03 ) 27 9-61 91 E m a il: vutek@ vu teksu pp ort. If the U ltraVu P rog ram enco un ters a date th at is earlier tha n the date w ritten in the D on gle. o r com m un icatio n prob lem s. View in g the m essag e sequ ence on the m o nitor w ill defin e this error furth er. T h ere fo re. Solution fu rther. the D o ngle w ill disab le the m ach in e un til a passw ord is entere d. N o rm ally. the S ystem D ate reverts to an earlie r date. If the system d ate is acciden tally set sufficie ntly forw ard of the actual d ate . N o te: If th e prin ter sto ps w itho ut a m essage o n th e P rinter L C D o r the m o nitor. P ress R eset butto n o n the prin ter co nso le. T h erefo re. th e security tim e-ou t on the D o ng le m ay exp ire. X S ervo re late d (C arriage m o vem en t) or Y S erv o related (substrate ad van cem ent). sim ply setting the system tim e to the actu al tim e w ill no t corre ct th e p ro blem . see exp lan atio n of X and Y S erv o errors below. p lease refer to “ L in ear E nco der A la rm ” sectio n below. LCD Error M essages C ertain errors app earing on th e P rinte r L C D m ay be o verw ritten by th e last detected erro r. in the ev ent o f a B IO S failure. 6-2 C hapter 6 View ing the m essage s o n the m o nitor w ill defin e this error . it is im p ortan t to v erify the d ate at th e tim e o f po w er-u p. T he u ser w ill b e prom pted to enter a p assw o rd to e nab le it. D o no t a ttem pt to set the S ystem D ate ahead of the actual da te for a ny reaso n. D oin g so can disa ble the m a chine un til a rep la cem en t D o ng le is in stalled . To determ ine the co rrect reason for the error c ond ition . the reb y g iv ing a false in dic atio n of th e true erro r. Print Error # 1 Cause C arriage m o vem en t error.date to reflect th e actu al da te. som e erro r m essag es are sent on ly to the m o nitor. Solution X Servo Error Cause N o rm ally th is is th e sec ond m e ssag e to o ccur after o ne of the below X S ervo errors occu r. Yo u w ill n eed to acqu ire the co rrect D on gle passw ord from V U T E k. C a u tion : It is im p orta nt th at the system date be correct. If yo u hav e n ot receiv ed th e p assw ord fo r th e date th e syste m is set to . it is recom m end ed th at a m o nitor be con nected to the P rinter C o ntroller or the A -B S w itch set to p ositio n B . N o t all erro r m essage s are sent to th e P rin ter L C D . P lease call V U T E k P ro duct S u pp ort if an exce ssive nu m ber o f “P rint E rror # 1“m essages occu r. M essages sen t to th e P rinter L C D are also sen t to the m on ito r. T his m essag e m ay app ear at po w er u p and w ill in dic ate that the C on troller and X S erv o are perform ing a S yn c ope ration . P rinter C on troller o r cab le fro m the R S 42 2 In terface B oard to the X S erv o. R S 422 In terfac e B oard. or there is a prob lem w ith th e X S erv o C o ntroller. R eplace as necessary. a “Y S ervo E cho Tim e-ou t” m essage o ccurs. P o ssib le prob lem s w ith th e R S 422 In terface B oard: the cab le from R S 4 22 In terface to th e X S e rv o C o ntro lle r is no t co rrectly seated. Y Servo Echo Time-out Cause E ach co m m an d sent to the Y S ervo is ech oed b ack to the P rinter C o ntroller. th e m essa ge “X S ervo E ch o E rror” occu rs. P o ssib le prob lem w ith th e X S erv o. Solution Error Jogging X Cause T his m essage ap pears on the m onito r on ly an d no t on the P rinter L C D D isplay. P o ssib le lo ss of po w er to th e Y S erv o. R eset prin ter. If th is do es n ot o ccur w ithin a specified tim e . If th is doe s n ot o ccur w ithin a sp ecifie d tim e. If the prin ter fun ction s n orm ally after com p letion o f the po w er up seq uen ce. S e rv o com m an d s a re sen t fro m the co n tro lle r to the X S erv o. If the com m and ech oed b ack is n ot th e sam e as th e c om m and sent. R eset prin ter. an “X S ervo E cho Tim e-ou t” m essage o ccurs. If th e co m m an d is n ot un derstoo d b y the servo . Solution Y Servo Error Cause N o rm ally the seco nd m essa ge to occu r after on e o f the below Y S erv o erro rs occu r. Solution View ing the m essage s o n th e m o nitor w ill defin e this error fu rther. this m essag e and th e c om m and sen t to the servo is then sen t to the m on ito r. P o ssib le lo ss of po w er to th e X S erv o. P lea se ca ll V U T E k P ro du ct S upp ort Solution Troubleshooting 6-3 . P lea se ca ll V U T E k P ro du ct S upp ort Solution X Servo Echo Error Cause E ach co m m an d sent to the X S ervo is ech oed b ack to the P rinter C o ntroller. this m essage sho uld be igno re d. M alfu nction o f the Y S erv o.X Servo Echo Time-out Cause E ach c o m m an d se n t to the X S e rv o is e ch o e d b a ck to th e p rin ter con troller. M alfu nction o f the X S erv o. T he error is a failure o f th e S ub strate F ee d R oller to m ov e to the m a terial th e sp ecified step v alu e. it m ust be in con stan t con tact w ith the E nco der W h eel. Solution N o te: A ll ro llers sho uld be cleaned w ith P M A ceta te da ily. P o ssib le prob lem w ith th e Y S erv o. B o th th e E nco der w he el and S u bstrate F eed R oller m ust m o ve th e sam e distanc e.Y Servo Echo Error Cause E ach co m m an d sent to the Y S ervo is ech oed b ack to the P rinter C o ntroller. Takeu p R oller ten sio n m ay ne ed to be increased or decreased. th is error m essage is displa yed . then th e m essage “Y S ervo E c ho E rror” occurs. A prob lem w ith the m ov em e nt o f th e S u bstrate F eed R oller. Solution Y Runaway Detected Cause T he in ternal Y S e rv o E nco der and the S ubstrate E nco der m onito r m aterial m o vem en t ov er th e P laten /P reheater an d E nco der W h eel. the enco der w he el w ou ld n ot m ove the sam e distance as th e feed ro ller. M aterial m ay a lso be slipp in g on the S ou rce F eed R o ller c ausin g th e roller to creep . T his m essag e m ay be ov erw ritten on the P rinter L C D w ith a Y S e rv o E rror. E nsu re F eed R o ller is clean. If the com m and ech oed b ack is n ot th e sam e as th e c om m and sent. T h is m essage m ay app ear at po w er u p and w ill in dic ate that the C on troller and Y S erv o are perform ing a S yn c ope ration . P rinter C o ntroller or cab le fro m the R S 4 22 In terface to th e Y S ervo . If the prin ter fun ction s n orm ally after com p letion o f the po w er up seq uen ce. W h en th e m a terial ad van ces. Va cuu m m ay also be ho ld ing m a terial ag ain st the P late n/P reheater. this m essage sho uld be ig no red . H e nce. T h is can include the m aterial slip pin g on the F eed R oller. If th ere is a 0 . M ate rial sags m ay be cau sed by the take-up ten sion b eing lo w or th e m aterial m ay be stick ing to th e S ub strate D ryer A ssem bly. m ay exist. View in g th e m essag es o n th e m o nito r w ill defin e this error furth er. 6-4 C hapter 6 . R efer to th e Y R u naw ay D etecte d S o lu tio n S ection for m o re d etail. T his m essage m ay b e ov erw ritten w ith “Y S ervo E rror” on the P rin ter L C D . M aterial m ay be sticking to th e low er P la ten/P reh eater or the u ppe r S ubstrate D ry er H eater.060 ” (1 . in crea sing friction. not allow in g the m edia to m o ve the specified distan ce. R epla ce as nece ssa ry.5 m m ) d iffe ren ce in m ov em e nt betw een the E n cod er W heel an d S ub strate F eed R o lle r. Solution Y-Position TIme-out Cause A p pears on m on itor as “W aitin g fo r Y p ositio n tim e -o ut”. R S 422 In terfac e. S erv o co m m an ds are sen t from th e con troller to the Y S ervo . P o ssib le prob lem s w ith R S 4 22 In terfac e B oard: th e cable from R S 42 2 In terface to th e Y S erv o C o ntro ller is no t correc tly se ated . Solution Rename Error Cause T his m essage w ill only occur in th e p rocess of u pg rad in g th e F irm w are. It w ill ap pear on the P rinter L C D an d a “R en am e E rror # ” w ill ap pear on the m on ito r. please chec k tha t th e L E D In dicato r o n th e L inea r E nc ode rC o ntro lle r is activ e. Error Jogging Y Cause T his m essage ap pears on the m onito r on ly an d no t on the P rinter L C D . T he E rase E rror # w ill b e an M S -D O S error nu m b er. T h e L inea r E nc oder C o ntroller is loca ted in th e ce nter of the m ach ine b elo w th e U m bilica l Trou gh . If th e p rinter sto ps fo r no app aren t reason . It w ill app ear on the P rin ter L C D an d an “E rase E rror #” on th e m o nitor. Troubleshooting 6-5 . or th ere is a prob lem w ith the Y S ervo C o ntro lle r. Solution P lease call V U T E k P rod uct S u ppo rt fo r fu rther in stru ction s. enc ode r cab le or C on troller B o ard . E nco der S trip. Tu rn in g th e w hee l on the enc oder sho uld provide feedb ack data to th is E scape M enu F un ction . th e m essage “E rro r R ece iving Y ” w ill be d isplayed . T his m essage w ill only ap pear if the prin ter c ontro ller is placed in th e E scape M enu o f th e D iagno stic M od e an d Te st F u nction #18 is activated. Erase Error Cause T his m essage w ill only occur in th e p rocess of u pg rad in g th e F irm w are. this m essag e and the com m an d sent to th e Y S ervo is se nt to the m o nitor. Solution Linear Encoder Alarm Cause M essag e m ay (or in so m e case s m ay n ot) app ear o n th e P rin ter L C D and th e m o nitor. If no feed back is detected .Error Receiving Y Cause T his m essage app ears on th e m o nitor o nly an d no t o n th e L C D . Solution P o ssib le prob lem w ith en cod er. or cable fo r da m ag e. T his ind icates a p roblem w ith th e L in ear E nc ode r. In sp ect the L in ear E n cod er. T h e R en am e E rro r # w ill be an M S -D O S erro r nu m ber. R e-adjust th e distance fro m the L in ear E n cod er to the M ag netic E nco der S trip. If th e com m and is n ot u nd erstood by th e serv o. bo th errors w ill app ear. S ee “S hift R eg ister E rror” below.Solution P lease call V U T E k P rod uct S u ppo rt fo r fu rther in stru ction s. A ctivation o f th e E -S to p S w itch w ill also cre ate X and Y S e rv o E rrors. Solution Shift Register Error Cause C he ck ed a t p o w er-u p o n ly. E v en m om en tary activa tio n w ill create this erro r. P ossib le cable prob lem in th e um bilical. E ch o E rrors. Solution Start Print Time-out Error Cause X S ervo p ro ble m . Solution Umbilical Error Cause C hecked at pow er-u p on ly. Tim e-ou t E rrors and p ossib ly o th er ty pes of errors. C hecks lo gic o n C on troller B oard. R eplace Jet D riv er B o ard or C ontro ller B o ard . If a m on ito r is con nected to th e P rin ter C on tro ller. R esea t all cab les an d verify con nectio ns. R eset the E -S top S w itch (pu ll o ut) an d press th e E rror B utto n to reset the erro r. a S hift R e gister E rro r w ill o ccur. If this te st fails. Solution 6-6 C hapter 6 . R eseat the bo ard s a nd th e con nectors. a sho rt circu it. E Stop Error Cause A ctiv atio n of the E -S top S w itch. A n E S to p E rror m a y also b e caused from a loss of the 24 V S upp ly. Jet D riv er B o ard and the U m b ilical C able fro m the C o ntro ller B oa rd C o nnector J10 to th e Jet D river B oard C onn ector J2 11. C h eck C o nnector J10 at th e Jet D riv er B o ard . m otors o r cou pling s. C he ck th e X S e rv o to assu re green lig ht is illu m inated. C ab le con nectio ns in th e ce nter of the U m bilical Trou gh . C arriage m ove m en t or L in ear E n cod er p ro ble m . R ep lace C o ntro ller B oa rd . T his erro r w ill a lso create an “U m bilical E rro r” w h ich w ill ov erw rite the “S hift R eg iste r E rror” o n the P rinter L C D . o r L in ea r E nco d er S y stem . P ossib le problem s w ith the C arriage D riv e S y stem . C arriage d id n ot m o ve to start of m edia w ithin th e sp ecified tim e pe riod. or P ow e r S upp ly m alfu nction . L im it S w itch ac tiv ated . C he ck con nectors a t left end of Jet D river B oa rd . T he C o n tro ller B oa rd p erfo rm s a test on the S hift R eg isters. T h is w ill re m o ve in k fro m th e S e con dary In k C o ntainer. R em ov e and clean S econ dary Ink C o ntainer. Solution No Paper Detected Cause T he E dg e D etecto r did no t detect m ate rial. C lean in k senso rs in seco nd ary ink can. A d d add ition al S olven t to th e prim ary con tainer. the Ink an d S olv ent P urg e B u ttons are dep re sse d for an ex ten ded p eriod. Solution E m pty th e W aste C an. F or the last con ditio n. S lo w ly rem ove the lid from th e con tain er as it is p re ssu rized u p to 5 p si. R eplace rou nd filte rs o n soleno id s. p rin ting sho uld co ntinu e. D ep ress th e E m p ty P ack B utton fo r fo ur secon ds. Yo u m ay perform th is fun ctio n w h ile the prin ter is printin g. O b serv e the row o f L E D s o n th e E d ge D etector. Solution Waste Can Full Cause T he W aste C a n is fu ll. this allo w s the S eco nd ary In k C o nta ine r to b rea th (th ere sho uld be no ink in th is filter). adjustm en t m ay be n ecessary.Color Overflow Cause T he S econ dary Ink C ontain er is filled to capacity. filter m ay b e restricting flow of ink . B e sure to po ur slo w ly in o rder to av oid disturbing the Ink L ev el S ensor F loat. T his m ay occu r if th e ink se nsors are no t functio ning co rrectly. Solution Troubleshooting 6-7 . You m a y perform this fu nction w h ile the prin ter is prin ting. R ep lace ink filters. replace if th e p ro blem occu rs again. It sh ou ld m o v e fro m z ero to 1 0 w he n m aterial is b elo w th e E d g e D etecto r. Solution Check Color Filter Cause In k usag e is hig her tha n th e ink p um p can rep len ish. in stall a set of In k L ine R estric to rs after th e b lu e filte rs. If the prin ter is plac ed on lin e. R em ove and clean restrictor betw een Ink F ilte r and S eco nd ary In k C o ntainer. Color Supply Low Cause T he P rim a ry Ink C on tain er is low o n in k. D ep end in g on the m aterial used. or th e ink is flow ing too rap id ly in to the can . Solution Solvent Supply Low Cause T he S olvent P rim ary C o nta iner is lo w on S o lven t. C lean th e Ink L ev el S en sors. A d d add ition al in k to the specified co lo r. P lace the p rinter o nline . p rinting sho uld con tin u e . A ra pid lo w erin g of the P urg er P late o nto th e Je t P ac ks w ill rem o ve the prim e from th e Je t P a ck A rra y O rifices.46 kg/cm ). Verify that the E dge D etector is fu nctio nin g correctly.Too Many Rolls Cause T he E d ge D etecto r d eterm in ed there w ere m ore th an fo ur ro lls of m aterial o n th e printer. o r th e E d ge D etector is m alfu nctio nin g.1 kg /cm ) to 35 psi (2. C heck P urg er P late air reg ulator pressure loca ted b y th e P rim ary In k C o ntaine rs. F ollow p roced ure for re cov ery o f lo st jets to re fill Jet P ack s. S ee C h apter 5 . E m pty the Jet P ack s for the sp ecific color. C he ck sw itch at to p of P u rger P late. M aintenan ce. If you hav e m o re th an fou r rolls o f m ateria l on the prin ter. M inim um distance b etw een ro lls is 4 ” (10 cm ). P ressure setting sh ou ld be 3 0 psi (2. re m o ve th e ad ditio nal rolls o f m aterial. Solution 6-8 C hapter 6 . for setting u p th e E dg e D ete ctor. Solution Color Pack Error Cause O n e o r m ore of the sp ecified c olo r Jet P ack B oards is no t correctly plu gg ed in to the slo t. Solution Roll Detector Error Cause T he E dg e D etecto r determ ined there w ere m ore left edg es o f m aterial d etec ted than rig ht ed ges of m a terial o r m ore right edge s o f m aterial d etec ted than left e dge s o f m aterial. T he E d ge D etector m a y be m alfu nctio nin g o r m ultip le rolls of m aterial m ay b e to o clo se to on e ano ther. A dju st so th at P urger P late slo w ly lo w ers o nto th e jet p ack A ssem b ly. the to p con nector for the blue w ire and m id dle con nector for the w h ite w ire. Solution Capper Stuck Down or Capper Stuck Up Cause T he P urge r P late (C ap per) is n ot in the ex pected p osition to allow C arriag e m o vem en t. R em ov e and re install all Jet P ack B o ard s for th at color. A d justm e nt m ay also b e req uired a t the P u rg er P late A ir C y lin der. P ress E S C to en ter the D iagn ostic M od e. the W o rk station m o n itor and k ey b o ard m ust b e c o n n ecte d to th e P rin ter C ontro ller. Caution: T he D ia gn ostic M od e is in ten ded to be u sed by trained F ield Service E ng ineers o nly. T h e diag no stic fun ctions are describ ed on the pages th at fo llow. N o rm al p rinter op eratio ns are su spen ded w hen the p rinter is in the D iagn ostic M od e. Troubleshooting 6-9 . T h is is do ne by turnin g th e A -B S w itch (located on th e rig ht side of th e U ltraVu W orksta tio n C P U C a rd C ag e) to th e "B " po sition (P rinter C o ntroller). P lea se b e aw a re th at u sing this m od e w ill disable all p rin ter safety fea tures. U se cau tio n arou nd th e m a chine.Printer Diagnostic M ode Entering the Diagnostic Mode To en ter the d iag nostic m od e o n th e U ltraVu x30 0 D igital P rintin g S ystem . A value must be entered to Exit. The Edge Detector status will change from black to white when the Edge Detector is in front of the material. The Black Color Selection Button moves the Carriage right. The Yellow Color Selection Button moves the Carriage left. 5 Display Head Temperature Displays Jet Pack temperature. 6 Interlace Mode ON or OFF Enable or disable Interlace Mode (Also selectable in the UltraVu Software). The ↓ arrow key will stop the movement.242. and ESC to exit. With the Workstation keyboard and monitor connected to the Printer Controller (refer to Diagnostic Mode above). the ← and → arrow keys will move the Carriage in that direction continuously. . 10 6-10 Change Step Sizes C hapter 6 Default value is 1. (Field Service use only) 3 Test Purger Plate When active. No – Edge Detector is inactive. 7 Change Edge Detector Yes – Edge Detector is active. Should be 84° F+/-1°. (Field Service use only) 9 Edge Detector Setup Used to verify the Edge Detector is properly adjusted for detecting material. raises and lowers the Print Head Purger Plate with keys 1 (raise) and 2 (lower).P rinter D iagnostics F unctions Key Code Function Description 0 Exit 1 Fault history X Servo Displays HH:MM since printer AC power turned ON. 4 Test Mesh Motor Press M to start. 8 Display Servo Peaks Displays peak values for servo parameters. S to Stop. (Field Service use only) 2 Fault history Y Servo Displays HH:MM since printer AC power turned ON. It will display the Linear Encoder’s position as a number. This value will increase when the Carriage moves right and decrease when Carriage moves left. value must be entered to exit. Y Position Readout (T/F) 8. Default is 3. (Field Service use only) Troubleshooting 6-11 . Paper Edge (T/F) 3. Solvent Level Override (T/F) 6. 17 Switch Status Checks the functionality of Control Panel Buttons. Has no effect when using test pattern functions. 20 Set Left Print Edge Adjust left margin. 18 Y Servo Encoder Position Displays Y Servo position. E-Stop Buttons. Adjusts start of printing to the physical edge of the material. Jet Pack Override (T/F) 2. After changing this value. Level Sensors. you must save the defaults using Key Code 15 (above). (Field Service use only) Moves Carriage from left to right to left. and Limit Switches. Purger Plate Override (T/F) 5. 16 Check and Set Servo Settings Displays servo settings and updates firmware (Field Service Use Only). 9.P rinter D iagnostics Functions (Continued) Key Code 11 Function Overrides (Defaults in bold) Description 1. Color Order (YMCK/MYCK) 12 Carriage Shuttle 13 Not Active 14 Set Purger Plate Position Adjusts value to position Carriage under Purger Plate station. This adjustment compensates for the difference in the slight light direction between different edge detectors. Default value is close to 18.25".3 inches. Machine Type (5300/3300) A. Weep Count [0-30] (20) C. Beeper Override (T/F) 7. 19 Check and Reset Minimum and Maximum Step Sizes Allows for adjustment of the print step setting using Test 5. This is also settable through the UltraVU Software. then reset the controller. Wiper Override (Not Available) 4. Jam Detect Override (T/F) D. 15 Save Default Values Saves default values to disk. Maximum Media Accuracy[≤0. This function is activated only when printing images.001] (Y/N). Weep Period [0-50] (10) B. (Field Service use only) 6-12 C hapter 6 . prints only when carriage moves to right. If set to B. prints only when carriage moves to left.P rinter D iagnostics Functions (Continued) Key Code Function Description 21 Print Delay = 0 Delays carriage at each end of print line to maximize image quality. 23 Unidirectional Printing If set to R. sets Takeup Roller Adjustment Tension to a range of 50-150%. prints in both the left and right directions. 22 Take-up Tension Roller Operator selectable in UltraVu. If set to L. Use the Maximum Media Accuracy Setting under the UltraVu Setup – Printer Settings screen. Increments by seconds. • B o ot th e V X 30 0 P rog ra m . the p rinte r can still b e restored to w orking o rd er the X 3 00 P rinter R e cov ery P ro gram .Corrective Procedures Recovering from RO M Disk Failure If th e X 30 0 R O M D isk beco m es inacc essible fo r any reaso n. T his p ro gram w ill perfo rm s th ree tasks: • D o w n loa d th e S ervo P aram eter F ile an d w rite to th e S ervo s.com S im ply do w nload the p ro gram .R E C 20 4. and fo llo w th e instru ctions on the scre en.E X E .vu teksu pp ort. • R eform at of the P rinter R O M D isk. run. Troubleshooting 6-13 .E X E fro m th e V U T E k S upp ort W eb P age: http:://w w w. You c an o b tain the latest v ersion o f R E C 2 0 4 . Printer Controller Printer Controller Overview T he U ltraVu x3 00 D igital P rintin g S y stem uses a D O S -based C ontro ller to m an age th e data tra nsfe r to the W orkstation as w e ll as con trol all prin ter fu nctio ns. B IO S values. T he follo w in g sectio n w ill prov id e an overv iew of th e P rinter C on troller layo ut. Figure 6-1 Printer Controller Block Diagram 6-14 C hapter 6 . bo ard p in -o uts an d fu nctio nality. Printer Controller CPU Bios Values T he B IO S values listed b elo w are p ro vided for inform ation p urpo se s on ly. T hese va lues m ust n ot b e m o dified. Bios for 2A59CM2G (200 MHz) Processor Troubleshooting 6-15 . 6-16 C hapter 6 . Bios for 2A591M2D (233 MHz) Processor Troubleshooting 6-17 . 6-18 C hapter 6 . Figure 6-2 Printer Controller Backplane (Left Side) Troubleshooting 6-19 . • C ab le distribu tio n p oin t.Printer Controller Layout T his sectio n w ill de tail the C o ntro lle r C ard C ag e lay outs. T h e U ltraVu x3 00 D igital P rinting S ystem p assive back plane p ro vid es fo r: • In tercon nectin g bo ard fo r P rinte r C o ntroller C ircuit B o ard s. • P ow e r S up ply Test P oin ts. p in ou ts and bo ard fun ctionality. Figure 6-3 Printer Controller Board Configuration 6-20 C hapter 6 . • F lop py D rive Inte rface fo r firm w are installatio n Figure 6-4 Printer Controller – CPU Module (233 MHz) Troubleshooting 6-21 .Printer Controller CPU M odule: P7028-A T he U ltraVu P rinte r C o ntroller C P U M o dule (2 33 M H z. P en tium ) prov id es the fo llow ing fu nction s: • In teracts w ith V G A In terfa ce M od ule to display the P rinter C o ntroller ’s p ara m eters an d diagn ostics • K ey bo ard In terfac e for softw a re in pu t and interac tio n • In teracts w ith the P C I In terface M odu le to transfer im ag e in fo rm ation from the U ltraVu W o rk station C ontro ller. CPU Module (200 MHz) N o te: M em ory m ust be a dd ed to b oth versio ns of P rin ter C o ntroller C P U M o du les. Pentium) Figure 6-5 Printer Controller .For 32 Head Upgrade Versions Only.(200 MHz. 6-22 C hapter 6 Q ty P /N D escriptio n 2 P 72 29 -A 4-M B M em ory . Controller Board: AA70012 T he C o ntro ller In terfa ce B oard m on ito rs an d con trols the fo llow ing :: • • • • • S w itches H ea ter S trip s/C o oling F an Vacuu m Tak e-u p/R e-direct M oto rs S olen oids • • • • • C arriage P ositio n B eep er E rror R ep ortin g L ig hts E dg e D etecto r Figure 6-6 Printer Controller – Controller Interface Troubleshooting 6-23 . Figure 6-7 Printer Controller – Pixel Board 6-24 C hapter 6 .Pixel Board: AA70176 T he tw o P ixe l B o ard s in th e P rinte r C ontro ller a re iden tic al (see F ig ure 6-7). O n e bo ard transfers y ellow /m agen ta d ata to the P rin t H e ads w hile th e sec ond boa rd tran sfers the cy an/black data.e. y ellow /m agen ta or cy an/bla ck) a P ixel B o ard w ill process. T h e interface cab les determ ine w hich color d ata (i. RS422 Interface Board: AA70021 T he P rinte r C on troller R S 4 22 Inte rface B oa rd p ro vid es these fun ction s: • • • • C o m m u nicates to X S ervo th ro ug h C om 1 (C P U M od ule C om 1 o ff) C o m m u nicates to Y S ervo th ro ug h C om 2 (C P U M od ule C om 2 o ff) A d ju sts the L C D intensity w ith P o ten tio m e ter R 18 P ro vid es D ata for L C D R e ado ut D isplay Figure 6-8 Printer Controller – RS422 Interface Troubleshooting 6-25 . N o te: S etting s a re a s indicate on R O M D isk B oa rd sh ow n b elo w. T he resid ent firm w are is easily up -g rad ed from flop py d isk. Figure 6-9 Printer Controller – ROMDisk 6-26 C hapter 6 .ROM DISK Board: P7029-A T he R O M D isk B o ard stores rep etitiv e instru ctions (firm w are) in m em ory (see F ig ure 6-9). Figure 6-10 Printer Controller – VGA Monitor Interface Troubleshooting 6-27 .VGA Monitor Interface: P7127-A T he V G A M onito r In terface M od ule lin ks a m o nitor to the P rinter C o ntroller (see F igu re 6 -1 0). T he V G A B o ard fo r the P rin ter C o ntroller prov id es a d ire ct com m un icatio ns po rt into the P rinter C o ntro ller allow ing access to set u p param eters and initiate diag no stic s. N o te: T his b oa rd m ay b e u sed w ith 3 2 H ea d U p gra des (2 00 M H z P ro cessor w itho ut video p ort). rem ov able m edia an d C D -R O M • P C I Interface M o du le to tran sfer im age inform a tio n to P rin ter C o ntroller • P arallel C om m un ication s P o rt (L PT ) – for D on gle atta chm ent and com m un icatio n N o te: T he U ltra Vu Wo rkstatio n C on troller and the U ltra Works R IP Station (o ption al) a re co nfigu red sim ila rly a nd are typically co nn ected as a netw o rk for file tran sfer fu nction s. T he W orkstation C o ntro lle r in terfac es w ith (see F ig ure 6-11 ): • V G A Interface M od ule to allow disp lay of N T W ind ow s and U ltra Vu S oftw a re • K ey bo ard /B all/M o use fo r softw are inp ut an d in teraction • 1 0 0 B a se -T E th ern et n etw o rk c ard for p eer-to -p e er file tran sfer fu nctio ns • S C S I C ontro ller to interact w ith h ard d rives. flop py disk . 6-28 C hapter 6 . in clu ding the use of a S ecurity D o ngle fo r th e prop rietary softw are.Workstation Controller Workstation Controller Overview T he U ltraVu x3 00 D ig ita l P rin tin g S ystem inclu des a W ind ow s N T W orksta tio n th at func tio ns as the file m an ager fo r th e printer. T he w o rk station s h ave iden tica l con figuration s. T he custom er h as the o ption o f using a seco nd W in do w s N T -based w o rk station th at can b e u sed as th e U ltraW o rk s R IP S tation . Figure 6-11 Printer Workstation Block Diagram Troubleshooting 6-29 . flop py disk . N o te: T he U ltra Vu Wo rkstatio n C on troller and the U ltra Works R IP Station (o ption al) a re co nfigu red sim ila rly a nd are typically co nn ected as a netw o rk for file tran sfer fu nction s.UltraWorks RIP Station O verview T he U ltraW orks R ip S tation interfaces w ith: • V G A Inte rface M o dule to allow disp lay o f N T W in do w s and U ltraW orks R IP S oftw are • K ey bo ard /M ouse for so ftw are in put and inte ractio n • 10 0B a se -T E th ern et netw o rk c ard for peer to p eer file tran sfe r fu nctio ns via a 3 -C o m F o ur P ort H ub • S C S I C ontro ller to interact w ith h ard d rives. rem ov able m edia an d C D -R O M • C o m m u nica tio ns P ort (L PT ) – (for S ec urity D on gle a ttac hm ent) T he w orkstatio n uses a passiv e back pla ne to interco nn ect w orkstatio n m odu les. 6-30 C hapter 6 . Bios for 2A69KN09 (400 MHz) Processor Troubleshooting 6-31 . T h e U ltraVu x 30 0 D ig ital P rin tin g S ystem W orkstatio n a nd th e U ltraW o rk s R ip S tatio n u se the sam e B io s v alues. T h ese values m u st no t be m od ified . A n incorrect da te in the B io s valu es m ay rend er the system ino pera ble. C a u tion : It is very im p ortant tha t th e d ate be set correctly in th e Wo rkstation C P U B ios b efo re the U ltra Vu prog ram is run .Workstation and RIP Station Bios Values T he B io s v alues listed o n the follo w in g p a g es are p ro vid ed for in fo rm ation p urpo ses o nly. 6-32 C hapter 6 . Troubleshooting 6-33 . Workstation Controller Layout T his sectio n w ill de tail the W o rk station C ontro ller C ard C ag e L ayo ut. T he P rinter W orkstation p assive b ackp lan e p ro vides fo r: • In tercon nec tin g bo ard fo r W orkstatio n C o ntro ller circuit m od ules • P ow e r S up ply test po in ts • C ab le distribu tio n po in t Figure 6-12 Workstation Controller Backplane (Right Side) 6-34 C hapter 6 . pin ou ts and b oard functio nality. Figure 6-13 Workstation Controller Board Configuration Troubleshooting 6-35 . UltraVu Workstation CPU M odule T he U ltraVu W orkstatio n C P U M odu le (40 0 M H z. and F lo pp y In tercon nec tio n S C S I D riv e In teraction Figure 6-14 UltraVu Workstation CPU Module (400 MHz) 6-36 C hapter 6 . P arallel. 25 6 M B ) con trols the fo llow ing fun ction s: • • • • W orkstatio n D a ta P ro cessing K ey bo ard and Trackb all Interco nn ection ID E . P entiu m . P arallel. 256 M B ) con trols th e fo llo w ing fun ction s: • • • • R IP S tatio n P rocessing K ey bo ard and Trackb all Interco nn ect ID E .UltraWorks RIP Station CPU M odule T he U ltraW orks R IP S tatio n C P U M o du le (400 M H z. and F lo pp y In tercon nec t S C S I D riv e In teraction Figure 6-15 UltraWorks RIP Station CPU Module (400 MHz) Troubleshooting 6-37 . P entium II. N o te: T he P rinter C o ntroller ’s P C I Interface B o ard an d th e Wo rkstation C on tro ller ’s P C I In terfa ce B oa rd a re id entica l. T he J4 and J5 la bels (see F igu re 6-16 ) o n th e P rinter C on to ller ’s versio n is la beled J3 an d J4 . Figure 6-16 PCI Interface Board (Printer Controller version shown) 6-38 C hapter 6 .PCI Interface Board: AA70175 / AA 70203 T he W orkstation’s P C I In terface bo ard c om m unicate s d irectly w ith the P rinter C on troller ’s P C I In terface B oard. resp ectively. except for J C on nector la beling . T he P rinter C on troller ’s P C I In terface b oard translates th e U ltraW o rk s im ag e d ata be fo re transferring it to th e jet driv er circu itry. on the Wo rkstaion’s version . Print Head Control Jet Pack M odule: AA70185-32 T he Jet P ack M o dule assem bly (1 6 pe r un it) tran slates im a ge da ta pu lses in to ink d ro plets o n th e substrate m a terial. T his m o dule con tain s sm all re se rv oirs o f ink to su pp ly th e piezo jets d uring printin g and is m od ular fo r easy rep lacem en t Figure 6-17 Jet Pack Driver Troubleshooting 6-39 . It also m on ito rs th e E dge D etecto r.Jet Driver Board: AA70181 T he Jet D river B oard receiv es p ix el data from th e P rin ter C on tro ller ’s P ixel B oards an d send s it to the Jet P acks. Figure 6-18 Jet Driver Board 6-40 C hapter 6 . In k L ev el S ensors and S oleno id s. V R 1 adjusts th e bia s for the Te m p era ture C o ntrol C ircuit. H eater/C ooler A sse m b ly. Carriage Backplane Board: AA70184 Figure 6-19 Carriage Backplane Troubleshooting 6-41 . Carriage Backplane Connections: AA70184 Figure 6-20 Carriage Backplane Connectors 6-42 C hapter 6 . To H eate r C o ntrols J26 .F ro m C o ntro lle r B o ard J24 .F ro m P ow er S up ply J22 .To Ink P u m p D riv er J23 .To P u rg er P la te and L inear E nco der S o len oid s J25 .F ro m P ow er S up ply Figure 6-21 Power Supply Distribution Connectors (Bottom) Troubleshooting 6-43 .To Take-up C lu tch J20 .Pow er Distribution System Pow er Board: AA70233 T he U ltraVu x3 00 p ow er b oard distribu tes vo lta ges and co ntro ls sign als to an d fro m the fo llow ing conn ecto rs: J17 .To C arriag e J19 .To B eeper/S o leno id s J18 .To R elay b ox J21 . Figure 6-22 6-44 C hapter 6 Power Supply Distribution Connectors (Top) . Pow er Distribution Panel Layout T he U ltraVu x3 00 P o w er D istributio n P a nel co ntro ls the follow in g: • P ow e r to C on tactor B ox • S w itches M a in P ow er o ff/o n • P ro vid es ind iv idu al circu it b reak er p ro tection to the fo llow ing : -S ervo s -P laten /P reh eate rs -S u bstrate D ry er H eaters -W o rk station and P rinter C o ntro lle rs -Vac uum M o to r -Take-up and R edirect M otors Figure 6-23 Power Breaker Panel Troubleshooting 6-45 . Pow er Distribution Contactor Panel T he U ltraVu x3 00 C on tacto r P an el rec eive s ipow er from the M a in P ow e r D istribu tion P anel toand d istrib ute s it to individual circuits (see F igu re 6 -2 4). T h is p ow er is inte rrup ted w hen the E m ergen cy S to p bu tto ns are en gag ed. Figure 6-24 Power Distribution Contactor Panel 6-46 C hapter 6 . H e at fro m the H eater R elay dissipates th ro ugh th e fin n ed h ea t sin k . Pow er Supply Distribution Box: AA70028 T he U ltraVu x3 00 P o w er S u pp ly D istrib ution B ox co ntains th e D C P ow e r S up ply an d the F use P an el. A lso located in the P ow er D istribu tion B o x are the fuses fo r each voltag e area o r pe riphe ral. Figure 6-25 DC Power Supply Distribution Box Troubleshooting 6-47 . N o te: A fu se is open (d efective) if its corresp on din g L E D is on . L ocated in the P ow er D istribu tion B o x are the + 55V and + 24 V Test P o ints an d th e Tak eup /R ed irect M o to r P ow er Te st P o in ts. T he P o w er S up ply prov id es vo ltag es fo r all of the d ifferen t circuits w ithin th e printer. Figure 6-26 Distribution Box (Top View) 6-48 C hapter 6 . using a m ou se. yo u can im m ed iately b egin usin g th e R IP W orkstatio n w ith out hav ing to read th e o nline S criptW orks M an ual (U ltraW o rk s is a cu stom ized ve rsio n of S c riptW o rk s). U sing it as a Q u ick R eferen ce G uide.Chapter 7 RIP Station •••••• UltraWorks Overview T his ch apter is in ten ded to fam iliarize yo u w ith th e m ain featu res o f U ltraW orks R IP (R aster Im ag e P roce ssing ) S oftw are. T h is m anu al is no t m eant to te ach yo u P ostscript. includ ing so m e state-of-the-art color m an age m en t softw are. it is also h elp fu l if y ou have a b asic un derstan din g of th e P ostscrip t fo rm at. in d epth S c riptW o rk s M anu al has been installed in P D F form at on the R IP W orkS tation H ard D rive. bu t it w ill po in t o ut som e o f th e m ain P ostsc rip t pitfalls that can o ccur w hen w o rk in g w ith U ltraW orks. T he A d obe A c ro bat ap plication ha s also b een su pp lied so th at yo u can refer to th e m an ual onlin e. T he full. A ru dim e ntary k no w led ge o f basic com pu ter skills is assum ed. A ll d ocu m en ts are in th e A crob at fo rm at a nd can be accessed th ro ug h the U ltraW o rk s D ocu m entatio n sho rtcut o n th e W indo w s N T D esk to p. such a s. P lease tak e the tim e to re ad th e lite rature su pp lie d on th e hard driv e. V U T E k has sup plied sev eral oth er im p ortan t re ferenc e d ocu m ents for y ou r con ven ien ce. R ead th is chap ter to “g et started ” and then read the full onlin e S crip tW orks M an ual w hen a m o re de tailed ex pla nation is req uired. R IP S tation 7-1 . and so fo rth. A V U T E k servic e e ngineer w ill w alk y ou throug h th is cha pter. F o r th is train in g. un derstan ding files an d fold ers. Additional Docum entation In ad ditio n to this m an ual and th e o nline S crip tW o rk s M an ual. pd f V 1.1 9 4.0 94.0 3.0 7.0 9 • C R D .29 • S pot fu nction s.04 .06 .p df V 1 .0 96.8 96.1 94.pd f (D etailed R IP O perato rs M an ual) • IC C M an ual.T he do cum en t set co nsists o f: • H arlequins in stall n otes • C o lor S y nc W hite P ap er (A p ple C olor S yn c S p ecific atio ns for M ac users) • R IP F u ll.p df V 1 .0 7.12 • T he G enL in utility prog ra m .0 9.0 4.0 9 6.pdf V 1 .15 • P S S etu ps.10 • U tilities.0 96 .09 .0 3.26 • In tel P en tiu m C hip s.p df V 1.0 95.07 • H arlequin S creenin g L ib rary.0 4 RIP Station Features T he U ltraVu D igital P rinting S y stem s are p ro vid ed w ith tw o iden tical R IP W orkS tatio ns.0 4.pdf (P o stscript 3 P review ) • C o m p osite F o nts.4 9 6.pdf V 1 .05 • C u stom iz e.0 96 .p df V 1 .0 96 .2 9 • M o risa w a fo nt su pp ort.p df V 1.07 • P erform ance.01 • N am ing.11 .0 7.p df V 1.p df (IC C and C olor M anag em ent O perato rs M a nual) • IC C 33 .4 96 .p df 9 4.pdf (IC C S pec ification M anu al) • P s3 .pd f V 1 .11 .0 94.10.03 • N T N o tes 2.0 3. B oth syste m s in clu de th e features listed below : • • • • 7-2 C hapter 7 M icro soft N T O p era tin g S ystem N etw o rk read y (1 00 B ase-T E th ernet card ) M acintosh A ppleTalk protoco l in the R IP 12 8M B R am .p dfV 1 .4 9 6.04 .2 96 .pd f V 1 .p df V 1 .p df V 1 .pd f V 1 . o ne intern al to th e p rinter and a separate system fo r re m o te setu p.0 6 • D isk P e rform ance.10 • N T N o tes.6 • F ireW orks.2 0 • T IF F it.pd f V 1 .12 .0 96 . O ver-sam pled im ag es o n the other ha nd create large file sizes. k eeping size of the files sm all. re fer to ch apter 8. the reb y. in that they h ave no half to ne freq uen cy.5 P P I.• • • • • D u al H a rd D rives R em ov able Jaz D rive 17 " S on y M o nitor U ltraW orks .C o lo r correction at p re press o r prin ter Postscript / Vector Mode T his is th e stand ard U ltraVu P rinter op eratio n m ode. Im ag es in T IF F form a t are rasterized in to a fine do t pattern. N o te: W h en w o rkin g w ith im ag es. but do n ot necessarily enh ance the qu ality of the fina l ou tpu t.5 0 P P I rasterized C T in pu t .Very qu ick and easy . T he V U T E k C T file m od e supp orts th e fo llo w ing: . T his form at prin ts at 18 .7 5 P P I or 3 7. U n der-sam p led im a ges ten d to app ear gra in y (p ixelized ). co de o r E P S /vector inform ation. bu t ha ve sm all file sizes. N either prod uces an effect th at is d esirab le.S m aller file siz es . CT File Mode T he C T (C o ntinu ou s To ne) im ag e is sim ilar to T IF F (Tagg ed Im age F ile F orm a t) o r B M P (B it M app ed) im ages. R IP S tation 7-3 .cu stom ized versio n of the H arlequ in R IP S o ftw are P osterW orks (M ac or W ind ow s N T Versio n) Printer O perating Modes T he U ltraVu D ig ital P rin ting S yste m and the U ltraW orks R IP S oftw are can p ro cess in on e of tw o file operating m o des: C T an d P ostscrip t. P ostscrip t m ode is a print descrip tio n fo rm at that w ill allow v ecto r te xt to be enlarged to any size w itho ut lo ss of detail. yo u sho uld a void bo th u nd errasterizin g an d over-rasterizin g the im a ge.F on ts app lie d in P ho to S h op . P rep ress).1 8. F or a m o re detailed exp lan ation o f th e C T fo rm at.75 P P I an d 37 . a ssu m e a pixel from an im age created w ith P ho to S h op ha s a value of 0% cyan . In this ex am ple. and o th ers. O nly the w hite of the su bstrate m ate rial w ill sho w.T IF F 6. Jap ane se .IC C P ro file Tw eeke r Understanding UltraWorks T he U ltraW orks R IP (R aster Im a ge P ro cessor) S oftw are is u se d to con vert a P ostscrip t (o r ve ctor line draw ing ) im ag e into a pattern of o n and off d ots (see F igure 7-1).A ccepts P ostscript L evel 2 files .IC C P ro file fo r S W O P & U ltraVu . black and yellow hav e 0% values.P ho to S h op C M Y K S ep aratio n Tab les . or “cell” of on an d o ff do ts. T he specific pixel w ill b e represented u sing U ltraW orks as a g ro up . 5 0% m agen ta. 0% yello w and 0 % black.0 o r T IF F -IT ra ster files . 1 50 .3.3 00d pi text (or selected resolu tion) .R e so lu tio ns of 300 . Figure 7-1 Pixel to Cell Processing Representation F or ex am p le. U ltraW o rk s w ill p rocess these th re e co lo rs to h ave no d ots in this cell.4 and TrueTyp e fon ts .Ty pe O fon ts (C hin ese.) .T he P ostsc rip t file m od e supp orts th e fo llo w ing featu res: .S W O P – U ltraVu L ineariza tio n as D efault .P re se t “plug an d play” calibration and line arization .C o lo r correction at P repress or R IP . the cy an. M age nta w ill 7-4 C hapter 7 . 75 an d 50 dp i . 10 0.A ccepts Typ e 1 . A rab ic. v ute ksup po rt. P erio dic ally. w hich m ea ns U ltraWorks can expa nd o r con tract your file. In processin g the file U ltraW o rk s ran do m izes th e d ots so the im ag e app ears sm oo th to the ey e. you should d o the follow in g: 1 To reinstall UltraWorks copy the latest Ultra Folder from the removable disk and replace the old UltraWorks Folder in its entirety.hav e 5 0% o f the cell area co vered w ith d ots of in k and the other half of th e cell w ill h ave n o do ts. open the Start Menu. select VUTEk and click UltraWorks. V U T E k w ill p ro vide up grade s to the U ltraW o rk s S oftw are. ho w ev er. Figure 7-2 UltraWorks Screen R IP S tation 7-5 . N o te: T he cell area ca n be a ny size. To in stall U ltraW ork s. th en it w ill hav e to b e re installe d from th e o riginal C D -R O M su pp lie d w ith th e system . This will start the UltraWorks application (see Figure 7-2). T he up grades are m ade availab le th roug h V U T E k’s W eb page: w w w. go the Windows NT Desktop. UltraWorks will require you to enter a password for selected features. T h is is typ ica lly p reset in P osterWorks so you do n ot ha ve to b e con cerned w ith im a ge size a nd rota tion a nd ca n qu ickly p ro cess the file fo r prin tin g. Installation Installing UltraWorks U ltraW orks com es installe d on th e R IP S tation hard d rive. 2 To start UltraWorks.co m If U ltraW orks beco m es co rrup t for an y reason . Configure RIP Extras Screen 7-6 C hapter 7 5 Enter the password for each of the features (see Figure 7-4) with a "Yes" listed along its side. select OK.3 Select UltraWorks from the main menu bar and click the Configure RIP Option (see Figure 7-3). Figure 7-3 UltraWorks – Configure RIP Screen 4 Select the Extras Button and the Configure RIP Extras Screen will appear (see Figure 7-4). 6 When finished. The passwords are written to the Harlequin Dongle. Figure 7-4 UltraWorks . . ensure th at it is p ro perly installed .Working with the UltraWorks Dongle U ltraW orks uses a D o ngle. open the Start Menu on the Windows NT Desktop. 4 Select the Devices menu to view all of the installed device drivers (see Figure 7-5). select the Multimedia icon and the Multimedia Properties Screen will be displayed. This will open the Install Drivers Screen. select Add to open the Install Drivers Screen. To rem ed y this. Select Unlisted or Updated Drivers. then yo u m ay still get a “D on gle N ot F o un d” m essage. first ch eck th at a D o ngle is atta ched and th at it has no t com e lo ose du ring sh ipp in g. it will need to be installed. If you get an error m essage th at “N o D o ngle is attached to th e com pu ter”. T h e D on gle req uires a key and co de to activate the U ltraW orks prog ram . If the Sentinel for i386 Systems Driver is not present. you m ay have to reinstall th e softw are d river for th e D ongle. 2 3 Select Settings. E ven if it app ears attach ed. Within the Control Panel Screen. 5 6 To install. and select OK. Figure 7-5 Multimedia Properties Screen R IP S tation 7-7 . w hich is a hardw are d evice th at resides on th e p aralle l po rt o f th e U ltra W o rks R IP S tation . If y ou hav e just installed or h ave o verw ritten the existin g W in dow s N T S ystem . then Control Panel. 1 To verify that the Sentinel Driver is installed. 9 Select the desired settings. This will load the required driver (see Figure 7-6).7 Within the UltraWorks folder there is a folder labeled Sentinel. and click OK.Configure RIP Options Screen 7-8 C hapter 7 . Select Sentinel for i386 Systems and click OK. This will open the Configure RIP Options Screen (see Figure 7-7). N o te: U se these settin gs fo r p rocessing u ltra-w id e im a ges. Figure 7-6 Add Unlisted or Updated Driver 8 From the Config RIP Screen click the Options Button. Figure 7-7 UltraWorks . For example. P osterWorks is su pp lied o n the printer ha rd d rive in b oth M acintosh an d N T versio ns. The UltraWorks software will first read in the file and then perform the RIP on the file. Figure 7-8 UltraWorks . The RTL File is now ready for printing with the UltraVu Software. Finally. and UltraWorks. R IP S tation 7-9 . select Start Menu. refer to cha pter 8. using no color correction. P repress. VUTEk. do th e follow in g: 1 From the Windows NT Desktop.Print File Screen 3 Select the Postscript File you wish to RIP. 4 Select the page setup you require.UltraWorks Operation Getting Started To perform a R IP to a file w ith th e U ltraW ork s P rogram . This will launch the application. UltraWorks will perform a standard RIP. Includ ed on the h ard drive is a n excellen t m a nu al o n w orking w ith P ostS crip t and large ou tpu ts (M ann tful. select UltraWorks. The Print File Window is displayed (see Figure 7-8). N o te: F o r a m ore detailed exp lan ation of h ow to prep are a P ostscript file. and click the Print File Option. it will output an RTL File to the specified hard drive. rotation or image scaling. 2 From UltraWorks Program Menu Bar.p df). if you select Default Page Setup. it w ou ld red uce the o utput RT L file size to ab ou t 2 50 M B . th e b etter th e qu ality of the o utp ut im age. F o r exam p le. and an im ag e of a person . Ta ke th e files to create the billb oard an d process th em throu gh P osterW o rk s to set the size an d rota tio n. N o te: L ow ering th e reso lu tio n of the im ag e w ill not ch an ge the sp eed of th e p rinter. H ow ever. then a R IP w ill ta ke lo ng er th an if th is w as n ot the case. Determ ining Input File Size D eterm inin g an o ptim al in pu t file size w hen u sing U ltra W o rk s is sam pling a m atter of tra din g off the tim e it req uires to R IP p ro cess a file against ou tp ut im ag e q uality. Worst Case Scenario C o nsid er th e w o rst case scen ario of a typ ical 1 4 ft x 48 ft b illbo ard prin ted at 15 0 D P I. In g eneral. T he efficie ncy o f the R IP proc ess m ust b e co nsidered as a n im po rtant facto r. Best Case Scenario If y ou process the sa m e billb oard at 1 8. If yo u w ere to p ro cess th is sam e file at 7 5 D P I. rip th e 100 + M B file to create a 1 G B RT L file. T his is largely determ ined by the lev el o f digital sam pling used to cre ate th e b it m ap ped im ages. th is gen era lizatio n is true o nly to a ce rtain ex ten t. To b etter un derstan d th e com plexity o f th e factors inv olv ed. A dd a log o and som e P ostS crip t tex t gen era ted in Q u ark X P ress an d sav ed as an E P S file. then no R IP w ill b e req uired . o r y ou r disk driv e is fragm en ted . before sa vin g it a s a P ostS crip t (. You w ou ld h ave sup plied U ltraW o rk s w ith m o re inform a tio n th an it really ne eds to reprod uce the im ag e. U sing U ltraW ork s. yo u w o uld p ro du ce a 10 ft x 1 0 ft at 30 0 D P I (fou r-bit) RT L ou tp ut file. L ater on in th e c hap ter w e’ll de sc ribe ho w to o ptim ize R IP sp eed. th e larg er th e file size. If yo u h ave lim ited hard drive space availab le. B o th scena rio s assu m e th at U ltraW orks u ses the stan dard R IP con figuration .P S ) file. A 1 29 M B file is saved from P hotoS ho p as a C T and then printed as a norm al V U T E k file . w e h ave given yo u tw o scenario s to con sid er: a b est case and a w orst case. it w ill m ake you r file m an ag em en t and R IP o utp ut easier to dea l w ith d ue to the m o re m ana gea ble file sizes. H o w ev er. T he w h ole R IP process w ill take abo ut 15 m in utes.Determ ining RIP Speed T here are m any fac tors th at ca n in fluen ce th e proc essing speed of a R IP.75 D P I in th e C T m o de. if yo u w ere to p ro cess a 1 0 ft x 10 ft at 3 00 D P I (32 -b it) T IF F file one -to on e. A ssum e the billb oard uses tw o 5 0 M B T IF F files: an im ag e of a so da b ottle. T h is w as caused by o ver- 7-10 C hapter 7 . an ex am ple o f un dersam pling . you w ill n eed to p erform the follow in g step s: 1 From the UltraWorks Main Menu. N o te: T he a bo ve exam ples a re fo r T IF F im a ges on ly. Custom izing the Page Set-up To create a cu stom page set-u p . and then select Page Setup Manager Option (see Figure 7-9). yo u see a v ery different situatio n. If yo u w ere go to th e oth er ex trem e and p ro cess a n extrem ely sm all T IF F file. it h as no effect o n file size. m u ch faster than the p rev io us ov er-sam ple d exam p le. O v er-sam pling a dds very little to th e fin al qu ality of th e im age w h ile se verely d egrading the tim e it tak es to R IP th e file. S in ce P ostscript text is com pletely sca lab le.Page Setup Manager Screen R IP S tation 7-11 . T he ke y to d eterm ining a n op tim u m file size is to no t ov er o r un dersam ple the o riginal bit m a pped im ag e. but the qu ality o f th e im age w ou ld h ave de graded to an u nac ceptable level. O nly b y ex perim entin g w ill yo u kn ow h ow m u ch sam pling y ou w ill need fo r yo ur partic ular situ ation .sam pling the in put T IF F file. Figure 7-9 UltraWorks . T he file w o uld process very qu ick ly. select UltraWorks. Yo u w ill see larg e pix elized squ ares o n th e im age. Select Save As. T he pa ge la you t sho uld be defin ed prior to p rinting .g. For more information on color calibration curves. The Calibration Setup allows you to load a set of lookup curves. Notice the two pull-down menus. The New Page Setup Screen will display (see Figure 7-10). By selecting the Copy command the existing settings from the Default Page Setup can be used. N o te: W hen p ro cessin g a T IF F file. Rotate 90). refer to Generating Custom Calibration Curves later in this section. C a u tion : D o n ot select the E dit F u nction . th is w ill o verw rite th e existing defau lt settin gs. Select a curve adjustment from the Calibration Menu. Figure 7-10 New Page Setup Screen N o te: F o r the rem aining steps of th is proced ure a ssum e tha t th e im a ge need s to b e ro ta ted by 90 ° an d a n existing curve correction need s to b e ap plied to the file.2 Select the Default Page Setup and then click Copy. 7-12 C hapter 7 . The Color Setup Menu will allow to load an ICC Profile. 3 4 5 6 From the menu Select Rotate and the desired rotation setting. At the prompt enter a logical name for the setting (e. Calibration and Color Setup. it m u st be pre-sized in P h otoSh op or P osterWorks to the finish ed size. Make any adjustment for media size and image placement. This will open the Page Layout Screen (see Figure 7-11). click OK.7 From the New Page Setup Screen. Figure 7-11 Page Layout Screen 8 Once you have made your choices. R IP S tation 7-13 . This will set the page layout parameters. select Page Layout. Figure 7-12 RTL Printer Configuration Screen 7-14 C hapter 7 . d o th e follow ing: 1 From the New Page Setup window.Working with RTL Files Destination Disk Selection .RTL File T his p ro cedu re is u sefu l if y ou req uire m ore disk sp ace and w ish to setu p ano th er de stin ation d riv e fo r th e ou tpu t file. select Configure Device. N o te: T h e drive letter sh ow n in F igu re 7-12 w ill va ry d epending o n yo ur con figura tio n. To setu p th e d estin ation d rive. The RTL Printer Configuration Screen will display (see Figure 7-12). Workspace File To select a disk for you r w ork sp ace file.2 Select the Output Folder Button and the destination drive or folder. This will place the next output file in the specified folder. The destination folder will appear in the box next to the Output Folder Button.Configure RIP Screen 2 To select a new destination for the working scratch disk of the RIP. select Change. Figure 7-13 UltraWorks . select UltraWorks and Configure RIP Option (see Figure 7-13). The Select Folder Screen will be shown (see Figure 714). d o the follow in g: 1 From the Menu Bar. Destination Disk Selection . Figure 7-14 Select Folder Screen R IP S tation 7-15 . Once selected.3 Select the appropriate disk or folder for your workspace file and click OK. To set th e op tions for each p rin ter resolution . Select the Edit function and then Options. F on t substitu tion are disa bled w h en th e ’A bort th e jo b if any fo nts are m issing ’ settin g is selected. . select Fonts. Select List Fonts. d o th e follow in g: 1 Select UltraWorks from the main menu bar and select Page Setup Manager Option. 2 3 Select the desired resolution. Figure 7-15 Page Setup Options Screen A n im porta nt o ption assigned to the prin t reso lu tio n is th e use of fon t sub stitution s. Selecting Options E ach p rint resolu tion (50 /75 /1 00 /15 0/300 dpi) can be assig ned its ow n characteristic s throug h vario us op tion settin gs. 150 dpi. for example. the Page Setup Options Menu will appear with the default settings shown (see Figure 7-15). To view th e availab le fon ts resid en t in U ltraW ork s: 1 2 7-16 C hapter 7 From the Main Menu bar of UltraWorks. Each Page Setup Screen contains a Page Setup Options Menu. P ro bab ly th e easiest w ay to calibrate prep ress colors to th e U ltraVu prin ter is to use th e D efault P age S etu p. T he m ain variable to co nsid er from th is po int o n is sub strate m aterials u sed. O n e so lu tio n is to separate th e files as S W O P 20 % . Select the Configback.ps. T his can b e do ne w ith a C M Y K S can ner or by lo ading th e S W O P 20 % settin gs su pp lie d in P h oto S ho p an d separating from R G B to C M Y K .ps as a normal Postscript File. Default Page Setup U ltraW orks req uires th at a color c orrected. RIP this file as you would any Postscript file. This will restore the original page and calibration settings. 1 50 a nd 3 00 d pi. T here are d efau lt p age setu ps fo r 5 0. Calibrating Colors T he k ey to an y co lo r ca lib ratio n is k no w ing h ow th e file w as orig in ally separate d from R G B to m ake C M Y K . Id eally yo u sho uld ob tain the R G B files fro m the client an d m ake the separation s y ou rself. run Config.Backing Up (Restoring) RIP Settings To b acku p or restore the R IP settings. N o te: V U T E k h as ad op ted the SW O P C urve Setting a s a d efa ult R IP setting in U ltra Works fo r a ll p rinters sh ip ped a fter 1 5 Jun e 199 8. 3 To restore the setting. This will place a file called Config. C M Y K im ag e b e prepared . N o te: If during the resto ration of the backup file C o nfig. 7 5. C hang ing from one vin yl m anufacturer to an oth er w ill lik ely lead to d ifferent colo r d en sities and colo r sh ifts. If the sou rce is un kno w n . 10 0.ps in the Utility Folder. th en it m ay hav e been se parated as a S W O P F ile. R IP S tation 7-17 . you w ill n eed to p erform th e follow in g step s: 1 2 Select the Print File Menu under UltraWorks. A less desirab le w ay is to gu id e the client o n ho w to sep arate their files from R G B to C M Y K . it w ill o verw rite existin g file and substitu te th e ba ckup file. th e R IP fin ds a file w ith th e sam e n am e as the b acku p restoratio n.ps File that resides found in the Utility Folder. you w ill n eed to p erform the follow in g step s: 1 From the main menu. and Options. The SWOP ink and separation setup must be loaded in order for the tables to take effect. Figure 7-17 PhotoShop . To p erform color correction . select UltraWorks. 2 In order to get the file color corrected from the prepress. Figure 7-16 PhotoShop .PhotoShop Color Correction C o lor correc tio n in P h oto S hop can be acc om plished usin g th e D efault P age S etu p in U ltraW o rk s. Page Setup Manager. Figures 7-16 and 7-17 show the SWOP Inks Setup and the SWOP Separation Screens.Printing Inks Setup Screen 3 Scan the image in as a RGB File and separate it into CMYK format. This will load the SWOP Color Separation and Ink Setup Tables that are supplied with PhotoShop. load the SWOP (Coated) Separation Setup that is supplied with PhotoShop.Separation Setup Screen 7-18 C hapter 7 . b ut V U T E k d oes no t recom m end it. and m ak es a color a dju stm ent in th e D efault M o de. and export the completed image as a Postscript file. Q uarkX P ress or Illu stra tor and then u se the P ho to S h op L inear setting in U ltraW orks. If a T IF F F ile is sent d irectly to U ltraW o rk s. 48% Magenta and 47% Yellow. A neutral gray area will have equal amounts of Magenta and Yellow with slightly higher Cyan values. U ltraW orks w ill au tom atically select th e app ro priate lo oku p cu rv e an d prod uce a n ou tp ut w ith th e co rrect am o un t of C M Y K . T his m eth od w ill a llo w for m o re a ccu ra te sizing as w ell as providin g a d yna m ic link to th e fon ts. N o te: T h e printer is cap able of con sisten tly prin tin g a 2% d ot. add any vector-based text or graphics. C M Y K . T his curve correction a ssu m es a ra w lin ear file.4 Apply the desired color balancing. ap ply th e P h oto S hop L inear P age S etup to rip the file. N o te: T he p referred m eth od o f gen erating a P ostscript file is to first ou tpu t an E P S fro m Q uarkX P ress. T hen ru n th e im age thro ug h P osterWorks. T he R IP m ak es a d ensity adjustm en t from a S W O P 2 0% separation an d perform s a sligh t color correction b y low ering the C yan co ntributio n to the color m ix. F or ex am p le. You sh ould to refer to F on t E rrors discussed later in this ch ap ter fo r m ore d eta ils. th e file m u st be an un com pressed . If an R G B im age is proce ssed w ith U ltraW o rk s u sing th e D efault m od e. If yo u create a graph ic in an ap plication like P ho toS h op . a midtone Gray might consist of 61% Cyan. T he cu rve correction in P ho toS ho p L inea r P a ge S etu p Screen w ill n ot w o rk for im ag es tha t have b een sep arated from R G B to C M Y K . it w ill o utpu t th e correct C Y M K values to th e prin ter. or send it to a page layout program like QuarkXPress or PageMaker. 50 % M agen ta an d 23 % Yello w and 0% B lac k. If the image is sent to a page layout program. if yo ur im ag e u ses P anton e 5 07 c. W h en bu ildin g a file in U ltraW o rk s. 5 Send the image directly to UltraWorks as a TIFF File. because the sepa ration tables u sua lly ha ve a 20 % D ot G ain a pp lied at th e sa m e tim e th at the file is sepa rated . a C M Y sep aratio n w ith an em pty blac k chan nel w ill be prod uced. For example. U ltraW orks app lies the dispersed screening to each co lo r. th e P an to ne color w ill c onv ert to 15 % C yan . PhotoShop Linear Page Setup T his pag e setup w ill app ly a cu rv e co rrection to a lin ear C M Y K file. R IP S tation 7-19 . an d in IB M form at. T h e U ltraVu prin ter m ay prov id e the desire d effects. UltraVu Page Setup T he U ltraVu P ag e S etup w ill ap ply a curve co rrection to a C M Y K F ile. T h e targe t inp ut file in th is case is a C G AT S W O P C oate d S eparation S etu p. This will allow for a curve adjustment to be made to your incoming files. d o th e follow in g: 1 2 3 Select Output from the UltraWorks Menu Bar. Select Calibration Manager (see Figure 7-18). exc ept it is don e as a sp ectral ad justm e nt u sing IC C P ro files. ICC SWOP Mode T he IC C S W O P M o de p erform s the sam e fu nction as the S W O P 2 0% setting doe s. In oth er w ords. F o r m ore inform ation see th e H arleq uin IC C M a nu al. Select the desired setting. It p rovides a go od starting p oint if yo u need to follow IC C C olor C alibration S tan dards. PhotoShop Linear. the RT L F ile can b e v iew ed. you w o uld apply th e U ltraVu se parations in stead o f th e color co rrection s p rior to proc essing throu gh U ltraW o rk s.e. Generating Custom er Calibration Curves To gen erate a cu stom calib ration cu rve. It w orks in the sam e w ay as the de fau lt settin g abo ve. Preview Page Setup W h en th is setting is se lected. i. Figure 7-18 Calibration Manager Screen 7-20 C hapter 7 . bu t it is n ot nece ssary to ap ply a m id-to ne 5 0% redu ced to 30 % w hich is applied at th e R IP. 4 5 Ensure the Device Menu is set to UltraVu. This curve setting will then appear in your page setup choices. The Edit Uncalibrated Target for UltraVu Screen will be displayed (see Figure 7-19). 6 Select the new setting. R IP S tation 7-21 . select Copy. 7 If you are going to modify an existing curve. Figure 7-19 Edit Uncalibrated Target for UltraVu Screen 8 After making your curve changes. This step will create a new setting. or work from an existing set of curves. You can either create a new set. select Ok and save the settings with a new name. This will ensure that an existing setting is not overwritten. Select a Calibration setting such as PhotoShop Linear and then select Copy. N o te: W hen u sin g th e IC C settin gs. T he co nditions o f th is golden state are specified in the H arlequ in R IP C olor M anag em ent S o ftw are. F or a detaile d explanatio n on ho w to u se the IC C P ro files. U ltraWo rks w ill take lon ger to process th e file. T he D efa ult S etu ps is th e q uickest w a y to p rocess th e rip ped files. w e ask y ou to refer to th e IC C S ta nda rd Sp ecifica tio ns (see A dd ition al D o cum en tation ea rlier in th is se ctio n). In add ition tw o prepared p age setup s labeled. A pp le. com p ensating for th e p igm en tatio n o f the in ks. bu t it also take s in to ac cou nt th e pig m entatio n of the inks and slig ht co lorin g of th e v in yl. K od ak. L inotyp e H ell an d others hav e ado pted IC C P rofiles as a sta ndard . • T he U ltraW orks IC C P ro file is sup plied w ith the prin ter and ca n be fo un d on the hard d rive. so it is easy to pass an IC C P ro file from on e p latform to another. Working with the SW OP ICC Page Setup T he IC C D efa ult se tup app lie s a cu rv e correction to th e file to allow for any d ot gain an d then the c olo rs are shifted into th e g am ut of th e d evice. A rang e o f test targe ts (w ith abo ut 20 00 tiles) are sen t to the target dev ice a nd w he re ea ch tile is read for its spectral values. It is called an IC C O utp u t P ro file and is n o t o n ly spe cific to this p rinter ’s characteristic s. T he valu es are th en com p ared w ith w hat w as ask ed for a nd w hat w as a ctu ally outpu t. • In divid ual IC C P rofile s can be ob tained fro m each m anu facturer ’s w eb site. T his IC C P age S etu p assum es a co lo r corre cted S W O P F ile as its inp ut. such as. th e co lor o f th e vinyl and am b ien t lig ht co nd ition s. IC C S etting s.Using ICC Profiles T he IC C P ro file is th e b uilding blo ck up on w h ich yo u ca n p ut to gether a closed loo p colo r m anag em ent p ro cess. Te ktron ix . T he m anu factu rers of dig ital co lor equ ip m ent. • IC C P ro files are no w w idely u se d. H ere are so m e co nsid eratio n y ou nee d to k eep in m ind w h en usin g IC C P ro file: • A ll th e m ajor m an ufactu re rs in the digital co lor im aging m arke t (M icroso ft. K oda k an d o th ers) ag reed up on th is form a t early on . hav e also b een prov ided fo r y our use. T he IC C P rofile w ill c orrect each pix el in the T IF F F ile fo r color. 7-22 C hapter 7 . T hen a cu rv e corre ctio n is ap plied to a llo w for the do t gain of th e U ltraVu P rinter. P ostS crip t E rrors.e. D isk F u ll E rrors. For more information you will need to refer to the ICC RIP Operator’s Manual supplied on the printer hard drive under the Documentation Folder. Select Copy to modify existing settings for a new setup. In order to h and le th e file. It also shows the type of file the color management program is expecting in order to make the proper adjustment. Select the Device. In this instan ce. an d F ont E rrors. U ltraW o rk s w ill first try to sto re th e file in to m em ory. If the size of th e file exceed s the av ailable R A M . UltraVu.To use the E d it C olor S etu p S creen (see F igu re 7-20): 1 2 3 Select Color from the UltraVu Main Menu Bar. T he erro rs usu ally fall in to o ne of the follow in g cate gories. Disk Full Errors U su ally a disk full erro r is an indication of U ltraW orks trying to w rite its ou tpu t file to a full d isk. or the file b ein g w ritten . w h ich is a indication of an inte rface p ro ble m . is hav in g trou ble com m un icatin g w ith the disk . U ltraW orks w ill generate an erro r m essage. either th e im ag e file bein g read. This window reveals the conditions that the ICC Profiles were made under. T he “w orkspa ce area” is sim ilar to a scra tch d isk for U ltraW o rk s. Figure 7-20 Edit Color Setup Screen Encountering RIP Problem s If a p ro ble m is enco un tered d urin g the R IP. T his typ e p ro blem cou ld also show u p as an IO E rror. It also co uld b e try ing to u se a w o rk sp ace area th at is to o sm all. i. th e app lication w ill th en try to use a po rtio n of th e h ard d rive as a tem po rary R IP S tation 7-23 . ob jects o r lo go s an d blend s o f m any o f th ese. T his w ill u su a lly in dicate w h en yo u are ru nning o ut o f d isk spac e. T he solution to this ty pe of p ro blem is to rem ake th e file. P ossib ilities in clud e a cu stom filter app lied to the orig in al file th at w a s n ot sen t w ith th e file. P o sterW orks has sup plied th e m eans fo r ch ecking an d trou ble sh oo tin g file s for P o stscript e rrors. If the file u ses a fon t. T h e file sho uld con tain everythin g th at U ltraW orks re quires to build an d th en rend er th e file. It m ay be w o rthw hile to call th e c lien t to discu ss w hat files a nd prog ram s w ere used to prep are th e file. or a C o re l D raw F ile has be en em bed ded in an A do be Illu stra tor graph ic. Font Errors T he last categ ory of erro rs are th e font erro rs. T he prob lem is usually an in com plete file. try m ov ing the w orkspace (see D estin ation D isk S election . a poo rly assem b led file . U sing the disk as a b uffer w ill ce rtainly slo w do w n the R IP. tex t. Postscript Errors M o st o f th e o th er prob lem s enco un tered w ill likely be P o stscrip t errors. im ages. P rep ress. In correctly processed im age files. C h eck to see if there is an y un usu al elem e nt in th e orig ina l Q u ark X P ress F ile. try m ov ing the o utp ut file (see D e stin atio n D isk S electio n RT L F ile d iscu sse d earlier in this ch apte r). th en th ese problem s u sually disappe ar. or a file w ith an u nrecog niz able P ostS crip t com m and . A P ostscript file is m ade up o f v arious elem ents. po ssibly con tainin g an u nrecog nized com m an d or the so ftw are trying to w rite an illeg al co m m an d w ill c ause m any o f th e prob lem s a sso ciated w ith P o stscript F iles. R e view the file at the P re press p hase. If the d isk fu ll error o ccurs du rin g th e’S en ding Im age to P rin ter ’ m o de o f th e R IP process.m em ory space. If yo u get a d isk full erro r w hile U ltraW orks is try in g to process the file du ring a ’P rintin g to disk’ fun ction. If th e file is b uilt an d processe d in-ho use. F o r m ore in fo rm ation o n th is to pic y ou sh ould refer to C h apte r 8. T h e su rest w ay to avo id P ostS c rip t erro rs is for yo u to d o yo ur ow n prepress w hen build ing the file an d run it thro ugh P osterW orks to em b ed th e fon ts and che ck for errors be fo re m ak in g it a P ostscrip t file. T he solution to disk fu ll errors is to clo sely m on itor the U ltraW orks W in d o w m essag es a s the file is b e ing p ro cessed . b ut w ill allo w y ou to com plete a larg e job w itho ut run nin g ou t of m em ory. fo r 7-24 C hapter 7 .W orksp ace F ile discussed earlier in this c hap ter). True Type F on ts can often prod uce in con sisten t resu lts. th e file w ill p ro cess co rrectly w ith no fon t w arning s. If y ou d isable this feature. • P osterW orks w ill no tify yo u w hich fo nt is m issing an d then allow y ou to e m b ed it in to the P ostsc ript file. either at the E P S stage o r the P ostscript stage. B o th Q u ark X P ress an d P ageM aker hav e features to sho w th e fo nts. • B y d efa ult U ltraW o rk s has been setup to sto p p ro cessing the file if the correct fo nt is n ot av ailable.com ) prod uces softw a re called F lightcheck tha t w ill check the file prior to p ro cessing throu gh U ltraWorks an d w a rn of an y m istakes that m a y exist in th e file. sin ce the fon ts are in clu ded w ith the file. N o te: M a rkzw are (w w w. w h ich m ay or m ay n ot loo k like the req uested fon t.Tel: (71 4) 75 6-51 00 or from w ithin th e U S (800 ) 300 -3 53 2. th en a fo nt erro r w ill occu r. E ras bold. U se this featu re to ch eck the file fo r fon ts. To av oid fo nt errors.m a rkzw are. • T he fo nt sho uld b e em b edd ed in th e file du ring th e P repress F un ction w h en the file is crea ted. N o te: V U T E k stro ng ly recom m en ds tha t you use A do be Type 1 F on ts rath er tha n Tru e Typ e F on ts. bu t co ntinu e processing th e file. C on ta ct M arkzw a re . th e fo llo w ing su ggestio ns shou ld b e rem em b ered . R IP S tation 7-25 .exam p le. im ag es and o the r elem en ts n eede d for the file. then U ltraW orks w ill su bstitu te the clo sest sim ilar typeface . If the fon ts are no t includ ed w ith th e file. a co py of the relev ant fon t folders m u st a ccom pa ny th e file. A typ ical Q u ark X P ress (o r P age M ake r) do cum en t receiv ed from a client sho uld h ave a set o f fo nt fo ld ers w ith the specified fon ts in it a nd a folder con tainin g th e graph ic file2 o f ev ery bit m ap im age in the file. W hen con figured this w ay. 7-26 C hapter 7 . an d som e basic kn ow led ge of produ cin g P ostS crip t F iles fro m Q uarkX P ress do cum en ts. R ip the P osterW o rk s P o stscrip t F ile u sin g th e U ltra W o rk s R aster Im ag e P roce sso r. th e k eyb oard. T his ch apter assum es yo u have a w o rk ing kno w ledg e of the W ind ow s 95 /98 /N T and th e M acinto sh O p eratin g S y stem s. F iles are p rep ared using P ho to S h op . M o st of th ese term s are self ex planatory an d are defin ed in th e g lo ssa ry at the en d of m a nua l. includ ing h ow to use a m o use. You are expe cted to h ave a w o rk ing kn ow led ge o f som e d ig ital prepress term in olo gy. Printing Guidelines T he follow in g gu idelin es are recom m end ed for p rep aring a file fo r th e th e U ltraVu D ig ita l P rin tin g S yste m : • • • • • • S ave yo ur im age file as a T IF F in P ho to S h op . if necessary. P rint th e P o sterW orks do cum en t to a P ostsc ript file. O p en th e T IF F in Q u arkX P ress and g enerate text. Includ ed in this c hap ter are step-by -ste p in struction s fo r prep aring a n im ag e from start to fin ish u sing a v ariety o f tools (no t in clu ded w ith yo ur U ltraVu x3 00 ). m enu s an d com m an d key s. Q u ark X P ress and P o sterW orks. P lace th e Q u ark X P ress E P S file in a P osterW orks do cum en t. P repress 8-1 . C reate an E P S file in Q uarkX P ress. Illu strato r.Chapter 8 Prepress •••••• Quick Start Overview T his ch apter co nta ins in fo rm ation fo r prep aring a la rg e fo rm at im a ge file for o utput to th e V U T E k U ltraVu D igital P rinting S y stem s. R IP Station . you can create an im age w ith a larger file size. A good rule to follow w hen sam pling an im age is to use a file size of about 150 M B for a final output size m easuring 14’ x 48’. but it w ill not im prove the quality of the output. How ever. if the final output dim ension is 14’ x 24’. nam ely that it will affect final output quality. if a 4 M B file is used for the sam e size output im age (14’x 24’) as that in the previous exam ple. N o te: You shou ld refer to C h apter 7. if yo u n eed ad ditio nal in form ation on C o lo r C orrectio n. you w ill n eed to p erform th e follow in g step s: 1 Start PhotoShop and open an image file for printing. 2 Make the necessary color corrections to the file. the im age would not contain enough usable data for the output size needed and would result in obvious pixelization. Figure 81 shows a TIFF file opened with PhotoShop. the im age file size should be approxim ately 75 to 150 M B. under-sam pling has its ow n set of problem s. For exam ple. For instance. it w ill only create an unnecessarily large (over-sam pled) file. The im age file should contain as m uch data as possible w ithout oversam pling the im age for its intended final output. Figure 8-1 PhotoShop – Showing TIFF Image 8-2 C hapter 8 . O f course.Creating A File in Adobe PhotoShop To create a file in P h otoSh op. Files may include image scans and imported files with other formats. Figure 8-3 PhotoShop .Separation Setup Screen P repress 8-3 .PhotoShop Printing Inks Setup To use P h otoS h op ’s P rin t In ks S etu p F un ction. selec t C olor S etting s an d th en P rin ting In ks S etu p. R IP S tatio n. T h e P rin t In ks S etu p S c reen w ill app ear (see F igu re 8 -2 ). you w ill n eed to perform th e follow in g steps: 1 From the PhotoShop File Menu. This will display the PhotoShop Separation Setup Screen (see Figure 8-3). you w ill n eed to p erform th e follow in g step s: F ro m th e P h oto S h op F ile M enu .Printing Inks Setup Screen PhotoShop Separation Set-up To use P h otoS h op ’s Sep aration fun ction. if you need additional information. select Color Settings and then Separation Setup. for add ition al in fo rm ation o n th e P rin t Inks S etu p P aram eters. RIP Station. You m ay n eed to re fer to ch apter 7. Figure 8-2 PhotoShop . You should refer to Chapter 7. Ensure that Black Ink Limit is set to 75% and Total Ink Limit is set to 300%. The Image Size Screen will appear (see Figure 8-4). select Image Size. .5” X 12” (8. For the purpose of this discussion.6 meters) billboard. N o te: T here is a w ide ran ge of valu es for th ese tw o settings. 3 From the Image Menu. Figure 8-4 PhotoShop . 5 Save the file with a TIFF format. the same aspect ratio as a 14’ X 48’ (4. assume the image size is 3. You will need to use this information later.9 cm X 30 cm). These dimensions maintain an aspect ratio of a 3.2 Select the UCR Option for the Separation Type.Image Size Screen 8-4 C hapter 8 4 Write down the image size given in the Image Size Window. B la ck In k L im it: 75 -9 0% Total Ink L im it: 22 0-300 % In k shou ld b e varied acco rd ing to m aterial a nd en viron m en tal con ditio ns.2 meter X 14.43:1. To create a file in Q u ark X p ress. 6 Select File and Save Page as an EPS file. T he ou tp ut file w ill b e in E P S form a t. 2 Select the rectangle tool and drag a box to the same size as the page you have created. This creates a new QuarkXPress document page.5” X 12”) into the dialog box as were found in PhotoShop. Select the image created in PhotoShop and import it into QuarkXPress (see Figure 8-5). Size the image to fill the box. 5 Select the Text/Hand tool (box with an ‘I’ beam and hand in it) to add text to your sign. P repress 8-5 . This creates a borderless background image for your text. Figure 8-5 shows Postscript text placed over the a TIFF image. Figure 8-5 QuarkXPress . p erform th e follow in g steps: 1 From the File Menu select New and type the same sizes (3.PostScript Text Over Image N o te: A d obe Illu strator F iles th at are saved in th e E P S fo rm at ca n b e used d irectly w ith P osterWorks w itho ut th e need for perform ing the Q u arkX P ress p rocedure.Creating a File in QuarkXPress Q u ark X P ress is u sed to p ro vide pa ge lay ou t fu nction s n eed ed to com b ine b oth text an d im ag es in th e sam e file. 3 4 Select File and the Get Picture Option. such a s error ch ecking . P o w erP C . pa inted o r rend ere d im ag es are im porte d in C Y M K T IF F form at.Trim Area Setup Screen 8-6 C hapter 8 . 2 3 4 From the PosterWorks’ File menu. Enter the dimensions required for the actual output size of the image you want to print. N o te: P o sterWo rks n eeds a tile size g rea ter tha n th e im age size.0 00 squ are feet on any P o stscript d evice. Figure 8-6 PosterWorks . S cann ed. perform th ese step s: 1 From the Windows NT Desktop double click the PosterWorks icon. This will launch the PosterWorks application. If you want to keep the corner marks. Click the Color button from the Print Format Option. T his sectio n describ es the proc edu re for g enerating a file for U ltraW orks. H ow ever. and M icrosoft W ind ow s 3. the fo llow ing p ro ced ures are all that is req uired to prepare a file fo r U ltraW orks. Typ e a nd g rap hic e lem ents are im p orted in E P S fo rm at fo r the la you t. 5 Select Trim and select all of the checked boxes (see figure 8-6).1 /95 /9 8/N T p latfo rm s. It en ables y ou to co m p ose and p rin t lay ou ts u p to 10 . P o sterW orks gen erates a P o stscrip t file. yo u w ill d isco ver it co ntains m any ad van ced featu re s.Creating a File in PosterWorks P osterW orks is a color p oster prod uctio n app lication for the A pple M acintosh. do not deselect the corner box. A s yo u exp lo re P osterW o rk s. select Tile Setup. To create a file in P osterW ork s. You m u st in crea se the tile size by 1 ” in both X an d Y d im ensio ns to com pen sate for th is and gen erate a tile w ith the p rop er dim ension s. Placed Image Screen P repress 8-7 . Locate the EPS or TIFF File you want to place in PosterWorks and click OK. 9 Select the grabber tool and place the tool on the lower right hand corner of the preview image. Figure 8-7 PosterWorks . select Place. A new window will appear with the tile sized correctly for the requested output size (see Figure 8-7). Click and drag until the image fills the tile (see Figure 8-8). select Ok twice. Figure 8-8 PosterWorks .6 When complete.Page Layout Screen 7 8 From the File menu. 10 From the Arrange menu, select Layout Options. The Layout Options Window will appear (see Figure 8-9). Figure 8-9 PosterWorks - Layout Options Screen 11 Select the ‘Shrink layout down to the edges of all elements’ Option. Figure 8-10 shows the reduced print area created by cropping the layout down to the exact size of the image itself. Figure 8-10 PosterWorks – Showing Cropped Image 8-8 C hapter 8 12 From the File Menu select Print. A dialog box will appear listing the options available for printing the file (see Figure 8-11). Figure 8-11 PosterWorks - Print Screen 13 14 15 16 17 Ensure that All is selected for Print Range. Check the ’Print To PostScript File’ Option. Select the Layout Option for Source. Select the Level 2 Option for PostScript and click the Option Button. Select the ’Allow Interpreter To Process Variable Area’ Option and select Ok. 18 Click the Font Usage Button. Fonts that are not embedded in the EPS file will appear without a black mark next to them. 19 Select Link or Link All to embed the fonts. 20 Locate the folder with these fonts and select each font. You must select Adobe Postscript Printer Fonts. 21 Select Print when you have linked all fonts to the file. 22 Name the file (include the .PS extension). 23 Click OK. PosterWorks will generate a Color PostScript File that is now ready to be processed by the UltraWorks RIP Software. 24 Save the new Postscript file to a removable disk. P repress 8-9 8-10 C hapter 8 Chapter 9 Specifications •••••• UltraVu 5300 S pecifications 9-1 UltraVu 3300 9-2 C hapter 9 T he follow in g pag es deta il th at design .Appendix A Ventilation Hood Design •••••• V U T E k do es n ot su pp ly a ventilation sy stem fo r th e U ltraVu x30 0 D igital P rinting S y stem s. Ventilation H ood D esign A -1 . b ut d oes recom m end a v entilatio n ho od design . A -2 A ppendix A A B C D 21.5 [546] 21.5 [546] .75 [ .75 [ A A 2.5 [ 4 SHUTTER 34.5[876] LONG 6 PLACES TYP PLENUM 3.0 [ GAP 1.0 [ SECTION A - A 72.0 [1829] 4 65.0 [1651] BOTTOM VIEW DIMS: MATERIAL: INCHES [MM] 2 400-500 CFM[17-20 M @ 1.5-2.0" [38-50MM] H 6"-8"[150-200] INLET DIA VELCRO CLARIFICATION A SCALE 3/24/98 3/24/98 SIZE DATE: JD WINONA TITLE CHECKED: APPROVED: DRAWN: SUGGESTED BLOWER SPECIFICATIONS GAP HOLDING BRACKET PLENUM 24 GA GALV STEEL HOLDING BRACKET RIVET IN PLACE HOOD/SHEET METAL 3 SHUTTER F 5/26/99 JPP JD JD JD APPRD 1 VELCRO HOOK NONE EXHAUST 1 Winona Drafting Service RR 1 Box 153A, Winona Rd. Ashland, NH 03217 DRAWING NO. . LAYER SHEET AA73126 ASSY 3300 HOOD/CURTAINS 1 OF 5 F REV. 3300 3332 PROJECT VINYL CURTAIN HOOD RT 104, WAUKEWAN STREET, MEREDITH, NH 03253, TEL (603) 279-4635 INC. VELCRO LOOP GROUP 12.0 [305] ECN 589 ECN-Q 566 ECN 402 ECN-Q 486 ECN-Q 477 ECN NO. QTY PER 1 DETAIL VELCRO APPLICATION APPLY VELCRO LOOP .75 [20] ALONG BOTTOM ALL 4 SIDES TYP SEE DETAIL 44.0 [1118] PLENUM DIMENSIONAL CHANGES D 9/1/98 JD RIGHT END VIEW HANGER BRACKET WITH EYE BOLT 6 PLACES TYP MIDDLE CURTAIN DIM C 6/25/98 E 10/19/98 CHG TITLE BLKS DIMENSIONAL CHANGES B 6/15/98 DESCRIPTION RELEASE A 3/24/98 REV DATE 144.0 [3658] 2 FRONT VIEW L-1 X 1 X 1/8 [L-25 X 25 X 3] FOR CENTER CURTAIN HOLDING BRACKET 3.0 X 3.0 [76 X 76] 5 PLACES TYP 3.0 X 2.0 [76 X 50] 2 PLACES TYP 1.0 [ PLENUM 74.0 [1880] FLANGE 8" IN CENTER OR LEFT OF CENTER PREFERRED 3 A B C D 3300 A B C D END CURTAIN VELCRO LOOP VELCRO HOOK 4 VINYL HOOD DETAIL OUTSIDE CURTAINS AT TOP 3 VELCRO HOOK VINYL 3 PRINTER FRAME Ventilation H ood D esign INCHES [MM] DIMS: 2 DRAWN: A SCALE 3/24/98 3/24/98 SIZE CHECKED: JD WINONA DATE: APPROVED: TITLE FRONT CURTAIN END CURTAIN SHEET METAL HOOD 2 END CURTAIN NONE 1 Rainer Rall PoBox 7, Winnisquam, NH 03289 EXHAUST DRAWING NO. 1 LAYER SHEET AA73126 ASSY 3300 HOOD/CURTAINS GROUP 22.0 [559] 2 OF 5 F REV. 3300 3332 PROJECT REAR CURTAIN 21.0 [533] 18.0 [457] QTY PER 1 RT 104, WAUKEWAN STREET, MEREDITH, NH 03253, TEL (603) 279-4635 INC. 26.0 [660] 44.0 [1118] RIGHT END VIEW 1 PLOT DEVICE HPDM SIZE C ZALL:X-28.9Y43.6,X282.5Y-175.4 CURTAINS .030-.040 [0.7-1.0 MM] VINYL 3/4" VELCRO MATERIAL: HOOD/VINYL CURTAINS VELCRO HOOK (ON CURTAINS) TO VELCRO LOOP (ON HOOD) .75 [20] ALL CUTAINS TYP SEE DETAIL 144.0 [3658] FRONT VIEW VELCRO LOOP DETAIL FRONT CURTAINS AT BOTTOM 4 PIECES @ 36-0" [914] OR 3 PIECES @ 48-0" DEPENDING ON AVAILABLE MATERIAL 44.0 [ 4 A B C D 3300 A -3 3300 A -4 A ppendix A END VIEW LEFT FRONT VIEW SHEET METAL HOOD 144.0 [3658] 44.0 [1118] VUTEk VUTEk 78.000 [1981.20] VUTEk 3300 Digital Printing System FLOOR EXHAUST HOOD INSTALLATION UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN INCHES TOLERANCES ARE: FINISH 32 XX|.032 DRAWN: WINONA APPROVED: JD CHECKED: 3/24/98 DATE: INC. RT 104, WAUKEWAN STREET, MEREDITH, NH 03253, TEL (603) 279-4635 DECIMALS ANGLES 3/24/98 TITLE PROJECT 0°10' ASSY 3300 HOOD/CURTAINS SIZE A SCALE DRAWING NO. GROUP CURTAINS NONE 3300 3332 Winona Drafting Service RR 1 Box 153A, Winona Rd. Ashland, NH 03217 REV. AA73126 LAYER . SHEET F 3 OF 5 3300 CURTAIN SET HANDLING INSTRUCTIONS 1. All surfaces where Velcro is applied must be free of oil, grease and ink residue. Clean sheet metal surfaces with Acetone or equivalent. 2. Follow the instructions on drawing AA73126 precisely. The Velcro cannot easily be removed and reapplied. h 3. These curtains are expensive and are easily scratched. Do not use solvents to clean the curtains - clean with a mild detergent only. Instruct operator to avoid putting them on the floor or near objects with sharp corners. Front and Back curtains have velcro applied on both sides. If you need to remove one curtain you can stick it to the curtain beside it. This avoids putting the cuurtains on the ground or bench where they can be damaged. Ventilation H ood D esign UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN INCHES TOLERANCES ARE: FINISH INC. RT 104, WAUKEWAN STREET, MEREDITH, NH 03253, TEL (603) 279-4635 DECIMALS ANGLES 32 TITLE XX|.032 PROJECT 0°10' DRAWN: WINONA APPROVED: JD CHECKED: 3/24/98 DATE: 3/24/98 ASSY 3300 HOOD/CURTAINS SIZE A SCALE GROUP DRAWING NO. CURTAINS NONE 3300 3332 REV. AA73126 Winona Drafting Service RR 1 Box 153A, Winona Rd. Ashland, NH 03217 LAYER 200 F SHEET 4 OF 5 A -5 3300 A -6 A ppendix A VINYL CURTAINS REAR FABRICATED SHEET METAL HOOD END CURTAIN VUTEk 3300 PRINTER VINYL CURTAINS FRONT CURTAIN SET INSTALLATION UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN INCHES TOLERANCES ARE: FINISH 32 XX|.032 DRAWN: WINONA APPROVED: JD CHECKED: 3/24/98 DATE: INC. RT 104, WAUKEWAN STREET, MEREDITH, NH 03253, TEL (603) 279-4635 DECIMALS ANGLES 3/24/98 TITLE PROJECT 0°10' ASSY 3300 HOOD/CURTAINS SIZE A SCALE DRAWING NO. GROUP CURTAINS NONE 3300 3332 Winona Drafting Service RR 1 Box 153A, Winona Rd. Ashland, NH 03217 REV. AA73126 LAYER . SHEET F 5 OF 5 75 [ A A 72.0 [5436] FRONT VIEW 3 DIMS: SHUTTER INCHES [MM] GAP 2 600-700 CFM[17-20 M @ 1.0 [ GAP 1.5 [ Ventilation H ood D esign 4 SHUTTER 34.75 [ .5[876] LONG 6 PLACES TYP PLENUM 3.0 [ PLENUM 107. . 5300 5332 PROJECT VINYL CURTAIN HOOD RT 104.75 [20] ALONG BOTTOM ALL 4 SIDES TYP SEE DETAIL RR VELCRO LOOP VELCRO CLARIFICATION DATE: 0°10' PLENUM E 5/26/99 D 10/19/98 CHG TITLE BLKS DIMENSIONAL CHANGES B 6/16/98 DESCRIPTION RELEASE A 12/4/95 REV DATE CHECKED: JD WINONA XX|.A B C D 21.SHEET METAL L-1 X 1 X 1/8 [L-25 X 25 X 3] FOR CENTER CURTAIN HOLDING BRACKET 3. NH 03217 DRAWING NO.0 [ SECTION A .0 [2718] HANGER BRACKET WITH EYE BOLT 8 PLACES TYP 3 A B C D 5300 A -7 . NH 03253.0 X 3.0 [ 2. QTY PER 1 DETAIL VELCRO APPLICATION APPLY VELCRO LOOP . LAYER SHEET AA70126 1 OF 5 E REV. MEREDITH.0 [1118] RIGHT END VIEW JPP JD JD APPRD VELCRO HOOK INC. Winona Rd. WAUKEWAN STREET.5 [546] 21.5-2.5 [546] .0 [305] ECN 589 ECN-Q 566 ECN 402 ECN-Q 477 ECN NO.A 4 BOTTOM VIEW 70.0" [38-50MM] H 6"-8"[150-200] INLET DIA DIMENSIONAL CHANGES C 9/1/98 A SCALE 9/19/97 9/19/97 SIZE TITLE 1 44. TEL (603) 279-4635 ASSY 5300 HOOD/CURTAINS GROUP 12.0 [1778] 214.0 X 2.0 [76 X 50] 2 PLACES TYP 1.0 [76 X 76] 5 PLACES TYP 3. Ashland. NONE EXHAUST 1 Winona Drafting Service RR 1 Box 153A.032 DECIMALS ANGLES APPROVED: DRAWN: 32 FINISH UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN INCHES TOLERANCES ARE: SUGGESTED BLOWER SPECIFICATIONS HOLDING BRACKET PLENUM 24 GA GALV STEEL HOLDING BRACKET RIVET IN PLACE MATERIAL: 2 FLANGE 8" IN CENTER OR NEAR LEFT END PREFERRED HOOD . 0 MM] VINYL 3/4" VELCRO INCHES [MM] MATERIAL: DIMS: 2 A SCALE 9/19/97 9/19/97 SIZE DATE: 0°10' TITLE CHECKED: JD WINONA XX|.032 DECIMALS ANGLES APPROVED: DRAWN: 32 FINISH UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN INCHES TOLERANCES ARE: FRONT CURTAIN END CURTAIN SHEET METAL HOOD 2 HOOD .0 [559] QTY PER 1 RT 104.VINYL CURTAINS 53.030-. 26.0 [1118] RIGHT END VIEW 1 A B C D 5300 . 1 LAYER SHEET AA70126 ASSY 5300 HOOD/CURTAINS GROUP 2 OF 5 E REV.7-1. TEL (603) 279-4635 INC.75 [20] ALL CURTAINS TYP DETAIL OUTSIDE CURTAINS AT TOP END CURTAIN VELCRO HOOK 44. NH 03253. Winnisquam.0 [533] 18.040 [0.A -8 A ppendix A A B C D VELCRO LOOP 4 VINYL HOOD 3 VELCRO HOOK VINYL 3 PRINTER FRAME CURTAINS .0 [660] 44.0 [1118] 4 END CURTAIN 21.0 [457] NONE 1 Rainer Rall PoBox 7. MEREDITH.0 [5436] FRONT VIEW VELCRO LOOP DETAIL FRONT CURTAINS AT BOTTOM VELCRO HOOK (ON CURTAINS) TO VELCRO LOOP (ON HOOD) . WAUKEWAN STREET. NH 03289 EXHAUST DRAWING NO.5 [1359] DEPENDING ON AVAILABLE MATERIAL 214. 5300 5332 PROJECT REAR CURTAIN 22. MEREDITH. Winona Rd.032 DRAWN: WINONA APPROVED: JD CHECKED: 9/19/97 DATE: INC. AA70126 LAYER .5300 END VIEW LEFT FRONT VIEW SHEET METAL HOOD 214.20] UltraVu 5300 Digital Printing System FLOOR EXHAUST HOOD INSTALLATION Ventilation H ood D esign UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN INCHES TOLERANCES ARE: FINISH DECIMALS ANGLES 32 XX|. RT 104. WAUKEWAN STREET. TEL (603) 279-4635 9/19/97 TITLE PROJECT 0°10' ASSY 5300 HOOD/CURTAINS SIZE A SCALE DRAWING NO. Ashland. SHEET E 3 OF 5 A -9 .000 [1981.0 [1118] VUTEk VUTEk 78. GROUP CURTAINS NONE 5300 5332 Winona Drafting Service RR 1 Box 153A. NH 03217 REV. NH 03253.0 [5436] 44. This avoids putting the cuurtains on the ground or bench where they can be damaged. All surfaces where Velcro is applied must be free of oil.clean with a mild detergent only. Instruct operator to avoid putting them on the floor or near objects with sharp corners. Do not use solvents to clean the curtains . Ashland. 2. Clean sheet metal surfaces with Acetone or equivalent. If you need to remove one curtain you can stick it to the curtain beside it. NH 03217 LAYER 200 SHEET E 4 OF 5 . WAUKEWAN STREET. Front and Back curtains have velcro applied on both sides. NH 03253. UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN INCHES TOLERANCES ARE: FINISH INC. AA70126 Winona Drafting Service RR 1 Box 153A. MEREDITH. The Velcro cannot easily be removed and reapplied 3. grease and ink residue. These curtains are expensive and are easily scratched. CURTAINS NONE 5300 5332 REV.032 PROJECT 0°10' DRAWN: WINONA APPROVED: JD CHECKED: 9/19/97 DATE: 9/19/97 ASSY 5300 HOOD/CURTAINS SIZE A SCALE GROUP DRAWING NO.5300 A -10 A ppendix A CURTAIN SET HANDLING INSTRUCTIONS 1. Follow the instructions on drawing AA7012 precisely. RT 104. TEL (603) 279-4635 DECIMALS ANGLES 32 TITLE XX|. Winona Rd. NH 03217 REV. Ashland. GROUP CURTAINS NONE 5300 5332 A -11 Winona Drafting Service RR 1 Box 153A. RT 104. AA70126 LAYER . SHEET E 5 OF 5 . MEREDITH. Winona Rd. WAUKEWAN STREET.032 DRAWN: WINONA APPROVED: JD CHECKED: 9/19/97 DATE: INC. NH 03253.5300 FABRICATED SHEET METAL HOOD VINYL CURTAINS REAR END CURTAIN UltraVu 5300 PRINTER VINYL CURTAINS FRONT CURTAIN SET INSTALLATION Ventilation H ood D esign UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN INCHES TOLERANCES ARE: FINISH DECIMALS ANGLES 32 XX|. TEL (603) 279-4635 9/19/97 TITLE PROJECT 0°10' ASSY 5300 HOOD/CURTAINS SIZE A SCALE DRAWING NO. A -12 A ppendix A . Glossary •••••• Air cylinders Am bient - pn eum atic dev ices. Ink level sensor - flo at sw itch in secon dary in k tan k w hich senses ink lev el in tank . Contouring - Control m onitor - C RT m onito r w h ich d isp lay s the U ltraVu con trol softw are. Color pressure gauges - sheet-m etal bo xes on the to p of each en d of the prin ter. Blotching - m o ttled ap pearance in prin ted im a ge. turns th e p laten shaft. pu lley s and m ou nting plates. electron ic m od ule o n th e ca rriag e w hich sen se s the edg e of the sub strate on the p late n. causes all jets to fire at full den sity for testing . Ink pum p - G lossary G-1 . air-activated m od ule w hich m ov es ink from p rim ary ink tan k to sec ond ary ink tan k. re se t. Console covers - step s in w h at sho uld be eve n color g ra dation s in th e prin ted im a ge.an e lectric al dev ice w hic h prov ides th e com p uter w ith in fo rm ation o n carriage p ositio n. an d th e drive b elt an d en cod er cou pler. cap stan .ball bearing assem blies w h ich su pp ort th e p rint head carria ge on the T ho m son rails. Carriage ribbon cables . g aug es w hich sho w th e am o un t of reg ula ted air pressure su pp lied to the color jets. or re so lu tio n ch ang e.au to m a tica lly lo aded in to prin ter at p ow er-up . te m p erature of air in th e ro om w he re eq uip m ent is located. Carriage drive assem bly - Carriage m otor - D C m otor u sed to m o ve th e carriage. w h ich raise an d lo w er the p late n. carriage m o tor. an d enco der. Default Lookup . Carriage bearings . the ir bearin gs. w h ere p rinter co ntrols a re lo cated . Harm onic drive - gearbo x on the step per m o to r.m ulti-color 2 ~ p in flat ca bles w hich in tercon nect the circu it b oards on the carriage. Edge detector - Encoder . of any w id th. in the prin ted im age.sm all d epo sits of ink scattered abou t th e ink drop let.Ink pum p solenoid valve - electric v alv e w hich co ntrols air flo w in to in k pu m p . po ly eth ylen e tu be betw een se con dary in k tan k and jet. app earing in g ro ups or ran do m ly. Posterization - see C o ntou rin g. Nozzle - ny lon skeleton w hich sup po rts an d protects th e tub es and cables in th e um bilical assem bly. o rifice in jet assem b ly w hich discharg es a stream of atom ized in k drop s.rub ber-co ated ro ller w h ich m o ves the su bstrate fro m the feed ro ller to the take-up roller. . M otor pulley - too the d m etal gear b y w h ich th e ca rriag e m o tor turns the driv e b elt. T his effect o ccurs in th e ho rizon tal d irection o f th e p rint an d usu ally m a nifests itself to th e user as a “ha lo”. 1 m m or less in diam eter. sm all w h ite spo ts in the im ag e. Secondary ink tank - G-2 G lossary sm all ink tank o n carriage. of any w id th. Prim ary ink tank - 5 -liter pla stic ta nks lo cate d in the in k draw e r assem bly. Ink supply tubes - cable w hic h interco nn ects th e im ag e c om pu ter an d the Interface cable - V U T E k prin ter. Nylatrac Panels - flat sheet-m etal pieces w h ich co ver the p rinte r's fram ew ork. Sateliting of artifacts . in the prin ted im age. prov ide s sp ecial v oltag e u sed by printer. Printer controller - intern al com p ute r w h ich c ontro ls all p rinter op eratio ns. Jet tube Lines - h orizo ntal stripes. m etal b a rs w h ich su p p o rt p laten sha fts at b oth Platen support arm s - end s. Printer pow er supply Sanding v ertica l stripe. Pinch Rollers - Platen . Pinholes - rub ber w he els below p late n: h old su bstrate a gainst platen to preve nt slipp ing . large b ox in rear of c ontro ller co m p artm ent. lo ng po lye thy len e tu bes betw een in k p um ps and th e prin t head carriag e. Spatter - ‘do ts’ o n p rinted im ag e that app ear to b e fo rm ed of d enser in k. Stepper m otor - Stepper torsion bar - m etal bar con necting stepp er m o tor to p late n sup port arm . co ntro ls torqu e m o to r directio n: forw ard (w in d). m otor w hich tu rns the p late n. Waves - G lossary G-3 . an d th e den sito m e ter co m po nen ts. Um bilical assem bly - tu bes and cables en clo sed by N ylatrac. off o r re verse (un w ind ). sim ilar to w av es in w ater. Transition boards . hardw are w hich im m ov ably fixes tw o ad joining N y latrac seg m e nts to su pp ly ex tra su pp ort. Torque m otor - tu rn s take-up ro ller. Tension sw itch - Thom son (Trade Nam e) rails - p rec isio n ra ils on w hich th e carria ge travels. Spray shield - m etal plate on fro nt o f jet assem bly.Skewing - su bstrate tra cking u nev enly on p late n and take-up . Sludge - m u d-lik e substance form ing in in k can s fro m ink p articles. Takeup tension control - po ten tiom eter w h ich co ntro ls am oun t of to rq ue on takeup roller. Um bilical link lock Valve assem bly - air m o dulato r va lves an d th e b ox h ou sing them . ex cessiv e ink or su bstrate resultin g in v ery un even d ry in g.sm all circuit bo ard s w hich in tercon nect the p rinte r con troller. the prin t head s. G-4 G lossary . Index •••••• A About xxi. 6-9 Directional Solenoids 1-6 Disk Full Errors 7-23 Dongle 3-46 Duplications Screen 3-37 Index I-1 . 3-20 Control Panel Layout 1-8. 1-12 Controls and Indicators 1-8 Conventions xxii Cooling Fan 2-3 Creating A File in Adobe PhotoShop 8-2 Creating a File in QuarkXPress 8-5 CT File Format 3-22. 6-41 Carriage Backplane Board 6-41 Carriage Backplane Connections 6-42 Carriage Belt Adjustment Layout 5-16 Carriage Belt Layout 5-15 Carriage Components 2-3 Carriage Cooling Fan 1-6 Carriage Drive Motor/Gear Box 1-5 Carriage Height Adjuster 1-6 Changing Gearbox Oil 5-7 Check Color Filter 6-7 Checking Belt Tension 5-14 Checking Ink Viscosity 3-12 Cleaning the Ink Level Sensor 5-12 Cleaning the Primary Ink Tank Filters 5-12 Cleaning the UltraVu x300 5-3 Color Correction In PhotoShop 7-18 Color Function Buttons 1-7 Color Overflow 6-7 Color Pack Error 6-8 Color Supply Low 6-7 Configure RIP Options Screen 7-8 Control Panel 1-7. 3-31 About This Manual xxi About UltraVu by VUTEk Screen 3-48 Add Unlisted or Updated Drive 7-8 Additional Documentation 7-1 Adjusting the Carriage Drive Belt 5-14 Adjusting the Edge Detector 5-20 Adjusting the Jet Pack Temperature 5-23 Advance 1-7 Advance Button 1-11. 3-14. 7-3 Cyan 1-7 D DC Fuse Panel 1-6 DC Power Supply 1-6 Default Page Setup 7-17 Defaults Path Screen 3-45 Determinig Input File Size 7-10 Determining RIP Speed 7-10 Diagnostic Functions 6-10 Diagnostic Mode 5-6. Solvent and Waste Lines 2-8 Aligning the Encoder Wheel 5-21 Aligning the Jet Plate 5-18 Aligning the Rail 4-5 Auto-Dry 3-31 B Backing Up (Restoring) RIP Settings 7-17 Bail 1-7 Bail Actuators 1-7 Bail Button 1-11 Banner Fabric Kit 4-8 Bi-Directional Adjustment Setting 3-44 Bi-Directional Alignment 3-23 Black 1-7 Blotter Material 3-11 Blotter Material Enclosure 3-7 Borders Screen 3-36 C Calibrating Colors 7-17 Calibration Manager Screen 7-20 Capper Regulato 2-10 Capper Stuck Down or Capper Stuck Up 6-8 Caring for the Jet Pack 5-3 Carriage 2-3 Carriage Backplane 1-6. 3-17 Air 1-5 Air Pressure Regulator 1-5 Air Pressure Regulators And Solenoids 2-10 Air Requirements 4-5 Air Solenoids 1-5 Air. 1-9. 3-17. 2-9 In-line Ink Filter 5-11 Installation Requirements 4-5 Installing the Banner Kit Option 4-8. and Solvent) 1-6 Fire Jets Setting 1-13 Font Errors 7-24 Function Buttons 1-7 G Generating Custom Calibration Curves 7-20 H Heater Control LCD 1-14. 6-40 Jet Pack 2-1 Jet Pack Arrays 1-6 Jet Pack Boards 2-3 Jet pack Boards 1-6 Jet Pack Driver 6-39 Jet Pack Module 6-39 Jet Plate Alignment 5-17 Jet Plate Alignment Screw Location 5-18 Jet Plate Alignment Test Pattern 5-17 L LCD Display Error Messages 6-2 Linear Encoder Alarm 6-5 Linear Encoder Sensor 1-6 Lo Res Mode 3-24 LookUp Menu 3-40 Lubricating the Carriage Rail 5-10 M Magenta 1-7 Main Pressure Regulator 2-10 Maintaining the Printer 5-1 Maintaining the Thermoelectric Cooler 5-14 Maintenance Schedule 5-25 Material Advance Encoder 1-5 Maximum Media Size Setting 3-44 Media Advance 3-31 Media Hub Installation Layout 3-6 Media Layout Screen 3-36 Media Step Size Setting 3-43 . 4-9 Installing the Jet Packs 5-5 Installing the Power Conditioning System 4-7 Installing UltraWorks 7-5 Invalid Date with Last Checked 6-1 J Jet Driver 6-40 Jet Driver Board 1-6. 2-9 INK PURGE 3-14 Ink Purge Setting 1-13 Ink Supply Lines 2-7 Ink.E E Stop Error 6-6 Edge Detector 1-6. 2-4. 5-2 Edit Color Setup Screen 7-23 Edit Luts Screen 3-41 Edit Uncalibrated Target for UltraVu Screen 7-21 Emergency Stop Buttons 1-5 Empty Pack Setting 1-13 Encoder Wheel 3-11 Encoder Wheel Adjustment Layout 5-21 Encoder Wheel Assembly (right side) 3-11 Enhanced Mode 3-24 Entering the Diagnostic Mode 6-9 Environment 4-4 Erase Error 6-5 Error 1-7 Error Button 1-11 Error Jogging X 6-3 Error Jogging Y 6-5 Error Messages 6-1 Error Receiving Y 6-5 F Features 1-2 File Information Screen 3-35 File Menu 3-33 Filters (Ink. Solvent and Air Supply Layout 2-7. Air. 3-19 Heater/Cooler 2-3 Heating Elements 1-6 Help 3-31 Help Menu 3-47 Help Pull-Down Menu 3-47 High Speed 3-24 I ICC SWOP Mode 7-20 Image Control 3-21 Ink and Solvent Carriage Components 2-5. 2-6 Ink and Solvent Control 2-4 I-2 Index Ink and Solvent System Solenoid Functions 2-8 Ink Level Sensors 2-4 Ink Prime 5-6 Ink Prime Setting 1-13 Ink Pumps 1-5. 2-16 Pneumatic Pinch Rollers 1-5 PosterWorks 8-6 PosterWorks .Image Size Screen 8-4 PhotoShop .Printing Inks Setup Screen 7-18 PhotoShop .Mesh Kit Enabled setting 3-44 Mesh Kit Option 3-6 Mesh Kit Settings Screen 3-44 Mesh Kit Takeup Spool 1-7 Mesh Paper Holders 3-8 MO Cartridge 3-28 Motor Encoders 2-15 Multimedia Properties Screen 7-7 Multiple Rolls 3-5 N New Page Setup Screen 7-12 No Paper Detected 6-7 O On/Off Switch 1-12 Online 1-7 Online Button 1-9 Open 3-31 Operator Requirements 1-3 Output Resolutions Screen 3-38 P Page Layout Screen 7-13 Page Setup Options Screen 7-16 Password Entry Screen 3-46 PCI Interface Board 6-38 PhotoShop . 2-11 Print Head Control 6-39 Print Heads 2-4 Print Menu 3-34 Print Menu Screen 3-34 Print Mode Screen 3-35 Print Parameters Selected Screen 3-39 Printer Component Location 1-3 Printer Controller 2-4 Printer Controller – Controller Interface 6-23 Printer Controller – CPU Module 6-21 Printer Controller – Pixel Board 6-24 Printer Controller – ROMDISK 6-26 Printer Controller – RS422 Interface 6-25 Printer Controller – VGA Monitor Interface 6-27 Printer Controller Backplane 6-19 Printer Controller CPU 1-6 Printer Controller CPU Bios Values 6-15 Printer Controller Layout 6-19 Printer Controller System Block Diagram 6-14 Printer Firmware Revision Level Screen 3-48 Printer Function Buttons 1-9 Printer Function Selector Switch 1-7. 1-12 Printer Operating Modes 7-3 Printer Selector Switch 3-12 Printer Selector Switch Logic 2-8 Printer Status LCD 1-7.Placed Image Screen 8-7 PosterWorks – Showing Cropped Image 8-8 PosterWorks . 1-9 Printer Workstation Block Diagram 6-29 Printing Guidelines 8-1 Purger Plate 2-11 Index I-3 .Separation Setup Screen 7-18 PhotoShop – Showing Tiff Image 8-2 PhotoShop Linear Page Setup 7-19 PhotoShop Printing Inks Setup 8-3 PhotoShop Printing Inks Setup Screen 8-3 PhotoShop Separation Set-up 8-3 PhotoShop Separation Setup Screen 8-3 Piezo Jet Fill and Fire Waveform 2-1 Piezo Jet Operation 2-2 Piezo Principle 2-1 Pinch Roller Regulator 2-10 Pixel Board 6-24 Pixel to Cell Processing Representation 7-4 Platen 1-7 Platen Alignment Fixture Layout 5-23.Trim Area Setup Screen 8-6 PosterWorks Layout Options Screen 8-8 PosterWorks Page Layout Screen 8-7 PosterWorks Print Screen 8-9 PostScript 3-22 Postscript / Vector Mode 7-3 PostScript Errors 7-24 PostScript File Format 3-22 Potentiometer Location on Jet Driver Board 5-25 Power Board 6-43 Power Breaker Panel 6-45 Power Conditioning System (PCS) 4-4 Power Distribution Contactor Panel 6-46 Power Distribution Panel 1-5 Power Distribution Panel Layout 6-45 Power Distribution System 6-43 Power On/Off 1-7 Power Requirements 4-4 Power Supply Distribution Box 6-47 Preview Page Setup 7-20 Primary Ink Cans 1-5 Primary Ink Reservoir 2-9 Priming the Jet Packs 3-14 Print 3-31 Print Error # 1 6-2 Print Head Capper 1-7. 5-24 Platen Stepper Motor 1-5 Platen/Preheater 1-7. 1-14. Purpose 1-1 Q QuarkXPress . 3-17 TIFF 3-22 Too Many Rolls 6-8 U Ultra Mode 3-24 UltraVu 3-29 UltraVu 3300 9-2 UltraVu 3300 Digital Printing System 4-2 UltraVu 5300 9-1 UltraVu 5300 Digital Printing System 4-3 UltraVu Controling Software 3-1 UltraVu Head Cleaning Fluid 5-1 UltraVu Menu 3-29 UltraVu Menu Structure 3-30 UltraVu Page Setup 7-20 UltraVu Printer Control Program Menu 3-29 UltraVu Workstation 3-25 UltraVu Workstation CPU 1-6 UltraVu Workstation Keyboard 1-6 UltraVu Workstation Monitor 1-6 UltraVu Workstation Peripheral Devices 1-6 UltraWorks 7-1 UltraWorks .Configure RIP Screen 7-15 UltraWorks – Configure RIP Screen 7-6 UltraWorks .Page Setup Manager Screen 7-11 UltraWorks . 2-13 Substrate Platen/Preheater 1-7 Substrate Source Roller 1-7 R Rail Alignment 4-7 Rail Relaxation and Alignmen 4-6 Ready Setting 1-14 Recovering from ROM Disk Failure 6-13 Redirect and Takeup Motor Drawing 5-8 Redirect Roller 1-7 Removable Disk Cartridges 3-28 Removing the Jet Packs 5-4 Rename Error 6-5 Replacing the Ink and Air Filter 5-10 Reset 1-7 Reset Button 1-11 RIP Problems 7-23 RIP Station 3-25 Roll Detector Error 6-8 ROMDISK Board 6-26 RS422 Interface Board 6-25 RTL Printer Configuration Screen 7-14 S Secondary Ink Reservoir 2-7 Secondary Ink Tanks 1-6 Select Folder Screen 7-15 Select Luts for this Job Screen 3-40 Select Printing Areas Screen 3-38 Selects Mesh Mode 3-32 Servo Controller Layout 2-13 Servo Controllers 1-5. 3-43 Setting the Print Gap 5-19 Setup Menu 3-42 Setup Pull-Down Menu 3-42 Shift Register Error 6-6 Shutting Off the Printer 3-2 SIte Preparation 4-1 Solenoids 2-7 SOLVENT FLUSH 3-14 Solvent Flush 5-6 Solvent Flush Setting 1-13 Solvent Purge Setting 1-13 Solvent Reservoir 2-10 Solvent Supply Low 6-7 Standard Speed 3-23 I-4 Index T Takeup 1-7 Takeup and Redirect Drive Assemblies 1-5 Takeup and Redirect Rollers 2-12 Takeup Button 1-11 Takeup Roller Drive System Diagram 2-12 Takeup Rollers 1-7 Takeup Tension Setting 3-43 Test 1-7 Test Button 1-10.Configure RIP Extras Screen 7-6 UltraWorks .Print File Screen 7-9 UltraWorks Screen 7-5 Umbilical Error 6-6 Understanding Print Speeds 3-23 Understanding UltraWorks 7-4 Units Screen 3-37 Update Firmware Screen 3-45 Use Selected Area 3-32 . 2-13 Set Button 3-20 Set Printer Parameters Screen 3-10. 3-4 Substrate Feed Roller 1-7.PostScript Text Over Image 8-5 Start Print Timeout Error 6-6 Starting the Printer 3-2 Substrate Dryer 1-7 Substrate Feed Path 3-3. Using ICC Profiles 7-22 Using the Internal Test Patterns 3-17 V Vacuum Pump Motor 1-5 Ventilation 4-4 Verifying Platen Alignment 5-22 Verifying the Jet Plate Alignment 5-17 VGA Monitor Interface 6-27 View Pull Down Menu 3-39 W Waste Can Full 6-7 Waste Out Line 2-8 Waste Tank 5-2 Working with RTL File 7-14 Working with RTL Files 7-14 Working with the SWOP ICC Page Setup 7-22 Workstation CPU Module 6-36 Workstations 3-25 X X Servo Controller 2-14 X Servo Drive Controller 2-12 X Servo Echo Error 6-3 X Servo Echo Timeout 6-3 X Servo Error 6-2 X Servo Linear Encoder 2-15 x300 Digital Printing System 1-3. 1-4 Y Y Runaway Detected 6-4 Y Servo Controller 2-14 Y Servo controller 2-14 Y Servo Drive Controller 2-12 Y Servo Echo Error 6-4 Y Servo Echo Timeout 6-3 Y Servo Error 6-3 Y Servo Rotary Encoder 2-15 Yellow 1-7 Y-Position Timeout 6-4 Index I-5 . I-6 Index .