Operator's Guide - Kodak

KODAK VERSAMARK 

VX5000/5000e Printing Systems 

Operator’s Guide

KODAK VERSAMARK 

VX5000/5000e Printing Systems 

Operator’s Guide 

Roll-Roll Configuration

FCC Compliance Statement 

This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to Part 15 of the FCC Rules. These 

limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. 

This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instruction manual, 

may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference, 

in which case the user will be required to correct the interference at his own expense. 

Note: Good quality, shielded (braided shielded) cables must be used for the RS-232-C and Centronics interfaces. 

Canadian EMI Compliance Statement 

Le présent appareil numérique n’émet pas de bruits radioélectriques dépassant les limites applicables aux appareils numériques de la classe A 

prescrites dans le Règlement sur le brouillage radioélectrique édicté par le ministère des Communications du Canada. 

This digital apparatus does not exceed the Class A limits for radio noise emissions from digital apparatus set out in the Radio Interference Regulations 

of the Canadian Department of Communications. 

EMI-CISPR 22/EN 55 022/CE Marking 

Warning: This is a Class A product. In a domestic environment, this product may cause radio interference in which case the user may be 

required to take adequate measures. 

KODAK VERSAMARK VX5000/5000e Printing Systems Operator’s Guide 

Part Number Medium Revision Date Description ECN 

0114304-602 

0114304-603 

Print 

PDF 

001 04/2005 

Initial release, roll-to-roll configuration. Includes 

page correlation, HEPA, web cleaner, CS300/ 

400/600, DT90/91/92. 

K5223 

© Eastman Kodak Company, 2005. All rights reserved. 

This document contains proprietary information of Kodak Versamark, Inc. or its licensors and is their exclusive property. It may not be 

reproduced without a written agreement from Kodak Versamark, Inc. No patent or other license is granted to this information. 

The software described in this document is furnished under a license agreement. The software may not be used or copied except as provided in 

the license agreement. 

Kodak Versamark, Inc. makes no warranty of any kind with regard to the contents of this document, including, but not limited to, the implied 

warranties of merchantability and fitness for a particular purpose. Kodak Versamark shall not be liable for any errors or for compensatory, 

incidental or consequential damages in connection with the furnishing, performance, or use of this document or the examples contained herein. 

Information concerning products not manufactured by Kodak Versamark, Inc. is provided without warranty or representation of any kind, and 

Kodak Versamark, Inc. will not be liable for any damages resulting from the use of such information. 

Kodak and Versamark are trademarks of Eastman Kodak Company. 

0114304-602 

0114304-603 05/2005 Printed in U.S.A.

Scope 

The VX5000 Printing System and the VX5000e Printing System are 

modular printing systems that offer the full range of variable, color inkjet 

printing. 

This Operator’s Guide describes procedures used to operate, maintain, 

and troubleshoot the printing systems, including any purchased options. 

As needed, the operator should refer to separate documents for operating 

the controller (the KODAK VERSAMARK CS300 system controller, KODAK 

VERSAMARK CS400 system controller, or KODAK VERSAMARK CS600 system 

controller) or the KODAK VERSAMARK DT9000 series print stations. 

Note: Due to continuing improvement in the controller products, small differences 

between the actual software and the screen representations in this 

book may be seen. 

The current revision of the Operator’s Guide provides updated information 

on new or revised components that provide page correlation, web 

cleaning, and air filtration. Sections have been added to document 

system-wide procedures that use the controller software, and that information 

includes complete reference to the specific software displayed by 

each controller. Some additional minor edits have been made to clarify 

existing material. 

Refer to the printing system Safety Labels for complete definitions of all 

labels and a description of all precautions to be taken while operating the 

printing system. 

Only trained personnel should operate the printing system. Trained 

personnel include users who are trained by Kodak Versamark, Inc. 

employees or who have received training from company-trained personnel. 

Training includes the safety instructions as well as instructions on 

mechanical functions and equipment operation. 

This document does not describe diagnostic procedures or equipment 

service. Only Kodak Versamark, Inc. service technicians or servicetrained 

personnel should perform diagnostics and equipment service. 


iii

Scope 

Text Notations 


This manual uses the following typographical conventions. 

This style 

Ready 

go 

ENTER 

[NEXT] 

Save 

File → Open 

ALT+F1 

ALT, TAB 

xx,yy 

jobfile.dat 

Refers to 

Text displayed by the software. 

Anything you type, exactly as it appears, whether referenced 

in text or at a prompt. 

Special keys on the keyboard, such as enter, alt, and 

spacebar. 

Buttons and lights on the printer operator panel. 

Software command buttons and sections of dialog boxes, 

such as group boxes, text boxes, and text fields. 

A menu and a specific menu command. 

Pressing more than one key at the same time. 

Pressing more than one key in sequence. 

Variable in error messages and text. 

File names. 

Safety Notations 

The following definitions indicate safety precautions to the operator. 

Note: Information that needs to be brought to the reader’s attention. 

Caution: A situation where a mistake could result in the destruction of data or 

system-type damage. 

! WARNING 

A potential hazard that could result in serious injury or death. 

! DANGER 

An imminent hazard that will result in serious injury or death. 

iv 

VX5000/5000e Printing Systems

Scope 


Service and Support 

Technical equipment support is available 24 hours a day, 7 days a week. 

Software and applications support is available 8:00 a.m. to 5:00 p.m. 

EST/EDT, Monday through Friday. 

Call for telephone or on-site technical support; to order parts or supplies; 

to request documentation or product information. 

U.S.A., Canada, and 

worldwide 

Phone 

+1-800-472-4839 

+1-937-259-3739 

Fax 

+1-937-259-3808 

Europe +41-22-354-1400 +41-22-354-1480 

Asia/Pacific Rim +65-6744-6400 +65-6744-6700 

Japan +81-3-5621-2220 +81-3-5621-2221 

Updated service 

information 

Customer support 

http://www.kodakversamark.com 

customer@kodakversamark.com 


v

Contents 

Chapter 1. Operator Controls 

Control Box Controls......................................................................................... 1-2 

Transformer Controls........................................................................................ 1-3 

Compressor Controls........................................................................................ 1-3 

Unwind Unit Controls ........................................................................................ 1-4 

External Unwind Unit Controls ................................................................... 1-4 

Internal Unwind Unit Controls..................................................................... 1-7 

Spacer Unit Controls......................................................................................... 1-9 

Web Cleaner Controls .................................................................................... 1-10 

Print Tower Controls ....................................................................................... 1-11 

Print Tower A Controls ............................................................................. 1-11 

HEPA Filters............................................................................................. 1-14 

Printhead Position Controls...................................................................... 1-15 

Print Towers B and C Controls................................................................. 1-16 

Print Tower D Controls............................................................................. 1-17 

Operator Display, Print Tower D .............................................................. 1-19 

Main Screen—Printing Speed Control............................................... 1-19 

APU Screen—Unwind Control........................................................... 1-22 

Web Screen—Tension Control .......................................................... 1-23 

Pull Ratio Screen—Gripper Roller Control ........................................ 1-24 

Dryer Screen—Temperature Control................................................. 1-26 

Registration Screen—Printhead Position Control.............................. 1-28 

Error Screen ...................................................................................... 1-29 

IJP Cover Screen............................................................................... 1-30 

Dryer Error Screen............................................................................. 1-30 

Printhead Lateral Error Screen .......................................................... 1-31 

APU Cover Screen ............................................................................ 1-31 

APU Error Screen .............................................................................. 1-31 

APR Cover Screen ............................................................................ 1-32 

APR Error Screen .............................................................................. 1-32 

Still Picture Unit Controls ................................................................................ 1-32 

Rewind Unit Controls ...................................................................................... 1-35 

Controller ........................................................................................................ 1-37 

Print Stations .................................................................................................. 1-38 

Chapter 2. Basic Operations 

Overview........................................................................................................... 2-1 

Procedures While Printing a Job................................................................ 2-2 

Recovering from Problems......................................................................... 2-3 

Turning off the System ............................................................................... 2-3 

Preliminary Operations ..................................................................................... 2-3 

Turning the Printing System On ................................................................. 2-3 

Webbing the Printing System..................................................................... 2-4 

Loading and Unloading Paper at the Unwind Unit............................... 2-4 

Roll Position on the Unwind Shaft ....................................................... 2-8 

Loading and Unloading Paper at the Rewind Unit............................... 2-8 

Webbing the Unwind Unit .................................................................. 2-10 

Adjusting the Web Guide ................................................................... 2-12 

Operator’s Guide vii

Contents 

Webbing the Spacer Unit ................................................................... 2-13 

Jogging the Web ................................................................................ 2-14 

Adjusting the Gripper Rollers ............................................................. 2-14 

Webbing the Print Towers.................................................................. 2-15 

Webbing the Dryer ............................................................................. 2-17 

Alternative Webbing Routes............................................................... 2-18 

Webbing the Turnbar ......................................................................... 2-19 

Webbing the Still Picture Unit............................................................. 2-19 

Webbing the Rewind Unit................................................................... 2-20 

Setting the Units of the Speed Display............................................... 2-22 

Selecting the Motor Direction ............................................................. 2-22 

Changing a Web Weight Value .......................................................... 2-22 

Tightening the Web................................................................................... 2-23 

Printhead Activities ................................................................................... 2-24 

Raising and Lowering the Cover ........................................................ 2-24 

Moving a Printhead to Service Position.............................................. 2-24 

Moving a Printhead to Printing Position ............................................. 2-25 

Adjusting the Printing Position ........................................................... 2-26 

Setting Printhead Height .................................................................... 2-26 

Setting Printhead Skew...................................................................... 2-28 

Enabling an Existing Printhead .......................................................... 2-29 

Disabling an Existing Printhead.......................................................... 2-30 

Print Job Operations ....................................................................................... 2-30 

Positioning the Cue Sensor ...................................................................... 2-30 

Positioning the Web Break Sensor ........................................................... 2-32 

Adjusting the Dryer Temperature.............................................................. 2-34 

Setting Up a Print Job............................................................................... 2-35 

Printing Test Pages .................................................................................. 2-41 

Printing a Print Job ................................................................................... 2-42 

Adjusting the Data Registration ................................................................ 2-43 

Adjusting the Printhead Registration ........................................................ 2-45 

Adjusting the Duplexed Registration......................................................... 2-46 

Reprinting Data......................................................................................... 2-47 

Setting Up Page Correlation ..................................................................... 2-48 

Positioning the Page Correlation Sensors ................................................ 2-51 

Saving the Job Settings ............................................................................ 2-52 

Recovering From an Emergency Stop...................................................... 2-52 

Selecting a New Printing Speed ............................................................... 2-53 

Turning the Printing System Off................................................................ 2-53 

Unwind Unit Operations .................................................................................. 2-58 

Setting the Roll End Detection.................................................................. 2-58 

Rewind Unit Operations .................................................................................. 2-59 

Chapter 3. Advanced Operations 

Identifying Printheads........................................................................................ 3-2 

Baseline System Numbering ...................................................................... 3-2 

Eight-Rail Numbering.................................................................................. 3-4 

Multiple Print Bank Numbering ................................................................... 3-5 

Adding a Printhead to the Configuration..................................................... 3-6 

Using an MPC Manual Setup ..................................................................... 3-7 

Setting Up Printing for the CS300............................................................... 3-8 

Setting the Web Tension .......................................................................... 3-16 

Zeroing the Printhead Position........................................................................ 3-17 

Aligning and Positioning the Web Guide......................................................... 3-18 

Adjusting the Cue Sensor ............................................................................... 3-19 

Adjusting the Sensitivity............................................................................ 3-19 

Setting the Cue Delays ............................................................................. 3-22 

Calculating the Speed Comp Value.......................................................... 3-27 

Placing the Page Correlation Marks ......................................................... 3-29 

Using Special Cueing ............................................................................... 3-30 

viii 


Contents 

Two Alternatives to Special Cueing ................................................... 3-30 

Implementing Special Cueing ............................................................ 3-31 

Chapter 4. Troubleshooting 

Controller Messages......................................................................................... 4-1 

Printing Machinery Messages........................................................................... 4-4 

APU ..................................................................................................... 4-8 

Printhead Lateral Error Screen................................................................. 4-14 

Chapter 5. Maintenance 

Daily Procedures .............................................................................................. 5-2 

Weekly Procedures........................................................................................... 5-2 

Print Towers ............................................................................................... 5-2 

Perform Print Station Maintenance...................................................... 5-2 

Monthly Procedures.......................................................................................... 5-2 

Unwind Unit................................................................................................ 5-2 

Supply Grease to the Unwind Unit....................................................... 5-2 

Supply Grease to the Unwind Unit Shaft Grip Adjust .......................... 5-4 

Print Tower Units........................................................................................ 5-5 

Supply Grease to the Printhead Worm Gear ....................................... 5-5 

Check the Web Cleaner Filters............................................................ 5-6 

Clean the Web Cleaner Internal Components ..................................... 5-6 

Check the HEPA Filter for Dust ........................................................... 5-7 

Rewind Unit................................................................................................ 5-8 

Supply Grease to the Rewind Unit....................................................... 5-8 

Quarterly Procedures........................................................................................ 5-9 

Print Towers ............................................................................................. 5-10 

Perform Print Station Maintenance.................................................... 5-10 

Replace the HEPA Pre-filters ............................................................ 5-10 

Replace the Web Cleaner Pre-filters ................................................. 5-10 

Annual Procedures ......................................................................................... 5-11 

Appendix A. Metric-English Conversion 

Glossary 

Index 


ix

Figures 

Figure 1.1 VX5000/5000e Printing Systems modules ................................. 1-1 

Figure 1.2 External controls, control box ..................................................... 1-2 

Figure 1.3 Transformer ................................................................................ 1-3 

Figure 1.4 External controls, compressor .................................................... 1-3 

Figure 1.5 Paper loading end, unwind unit .................................................. 1-4 

Figure 1.6 Air gun and deflation tool, detail ................................................. 1-5 

Figure 1.7 External controls, unwind unit OS............................................... 1-5 

Figure 1.8 Internal controls, unwind unit OS................................................ 1-7 

Figure 1.9 Web guide and web break sensors, unwind unit interior ............ 1-8 

Figure 1.10 Web guide components, unwind unit interior.............................. 1-9 

Figure 1.11 Spacer unit.................................................................................. 1-9 

Figure 1.12 Web cleaner unit....................................................................... 1-10 

Figure 1.13 Internal controls, print tower A, upstream door......................... 1-11 

Figure 1.14 Controls, print tower A, OS ....................................................... 1-12 

Figure 1.15 Web cleaner, box interior.......................................................... 1-14 

Figure 1.16 HEPA filter housing, print tower A ............................................ 1-15 

Figure 1.17 Printhead position controls, print tower A ................................. 1-15 

Figure 1.18 Controls, print towers B and C.................................................. 1-16 

Figure 1.19 Controls, print tower D .............................................................. 1-17 

Figure 1.20 Page correlation sensors, print tower D.................................... 1-19 

Figure 1.21 Main screen .............................................................................. 1-20 

Figure 1.22 APU screen............................................................................... 1-22 

Figure 1.23 Web screen............................................................................... 1-23 

Figure 1.24 Pull ratio screen........................................................................ 1-24 

Figure 1.25 Dryer screen ............................................................................. 1-26 

Figure 1.26 Registration screen................................................................... 1-28 

Figure 1.27 Error screen.............................................................................. 1-30 

Figure 1.28 IJP cover screen ....................................................................... 1-30 

Figure 1.29 Dryer error screen..................................................................... 1-30 

Figure 1.30 Printhead lateral error screen ................................................... 1-31 

Figure 1.31 APU cover screen..................................................................... 1-31 

Figure 1.32 APU error screen ...................................................................... 1-31 

Figure 1.33 APR cover screen..................................................................... 1-32 

Figure 1.34 APR error screen ...................................................................... 1-32 

Figure 1.35 External controls, still picture unit OS ....................................... 1-33 

Figure 1.36 Internal controls, still picture unit .............................................. 1-34 

Figure 1.37 External controls, rewind unit OS ............................................. 1-35 

Figure 1.38 Paper unloading end, rewind unit ............................................. 1-35 

Figure 1.39 Internal controls, rewind unit..................................................... 1-36 

Figure 1.40 Controllers ................................................................................ 1-37 

Figure 1.41 Print station and printhead........................................................ 1-38 

Figure 2.1 Main switch, transformer............................................................. 2-3 

Figure 2.2 Main switches, control box.......................................................... 2-4 

Figure 2.3 Air gun and deflation tool, detail ................................................. 2-5 

Figure 2.4 Roll released from lowered lift arms ........................................... 2-5 

Operator’s Guide xi

Contents 

Figure 2.5 Deflating bladder in shaft ............................................................ 2-6 

Figure 2.6 Inflating shaft in roll ..................................................................... 2-6 

Figure 2.7 Positioning end of roll sensor ...................................................... 2-7 

Figure 2.8 Using mandrel lateral adjustment................................................ 2-7 

Figure 2.9 Lift arm, rewind unit..................................................................... 2-9 

Figure 2.10 Access for inflating shaft bladder ................................................ 2-9 

Figure 2.11 Webbing diagram, unwind from top .......................................... 2-10 

Figure 2.12 Webbing diagram, unwind from bottom .................................... 2-11 

Figure 2.13 Webbing diagram, spacer unit .................................................. 2-11 

Figure 2.14 Web guide components, unwind unit interior ............................ 2-12 

Figure 2.15 Sensors, web guide................................................................... 2-12 

Figure 2.16 Gripper roller adjustment detail ................................................. 2-14 

Figure 2.17 Web cleaner box detail.............................................................. 2-15 

Figure 2.18 Webbing for simplex 1-up or 2-up ............................................. 2-16 

Figure 2.19 Webbing for 1-up or 2-up turned ............................................... 2-16 

Figure 2.20 Dryer housing and drum............................................................ 2-17 

Figure 2.21 Dryer webbing, single pass ....................................................... 2-17 

Figure 2.22 Dryer webbing, double pass...................................................... 2-18 

Figure 2.23 Webbing diagram, print tower turnbar detail ............................. 2-19 

Figure 2.24 Webbing diagram, still picture unit ............................................ 2-20 

Figure 2.25 Webbing diagram, rewind to top ............................................... 2-21 

Figure 2.26 Webbing diagram, rewind to bottom ......................................... 2-21 

Figure 2.27 Printhead in service position ..................................................... 2-25 

Figure 2.28 Printhead position controls........................................................ 2-26 

Figure 2.29 Printhead height measurement ................................................. 2-27 

Figure 2.30 Printhead position controls, print tower A.................................. 2-28 

Figure 2.31 Front cue sensor location, print tower A.................................... 2-30 

Figure 2.32 Back cue sensor location, print tower B .................................... 2-31 

Figure 2.33 Cue sensor location, still picture unit......................................... 2-31 

Figure 2.34 Cue sensors and bracket .......................................................... 2-32 

Figure 2.35 Web break sensor locations, unwind unit.................................. 2-32 

Figure 2.36 Web break sensor locations, print tower D ............................... 2-33 

Figure 2.37 Web break sensor locations, rewind unit .................................. 2-33 

Figure 2.38 Web break sensor and bracket ................................................. 2-34 

Figure 2.39 Printed area, physical printable and valid printed ..................... 2-36 

Figure 2.40 Page correlation sensor location, print tower D ........................ 2-51 

Figure 2.41 Main switches, control box ........................................................ 2-57 

Figure 2.42 Positioning end of roll sensor .................................................... 2-58 

Figure 3.1 Printhead numbering, baseline system ....................................... 3-2 

Figure 3.2 Printhead numbering for 2-up, 2-color ........................................ 3-3 

Figure 3.3 Webbing and numbering for 1-up; 2-over-2-color ....................... 3-3 

Figure 3.4 Webbing and numbering for duplex 4-color ................................ 3-4 

Figure 3.5 Webbing and numbering for 2-up 4-color.................................... 3-4 

Figure 3.6 Alternative numbering for 2-up 4-color........................................ 3-5 

Figure 3.7 Printhead numbering, 12-printhead system ................................ 3-5 

Figure 3.8 Printhead numbering, 16-printhead system ................................ 3-6 

Figure 3.9 Cut sheet modes ......................................................................... 3-9 

Figure 3.10 Pull ratio screen ........................................................................ 3-16 

Figure 3.11 Registration screen ................................................................... 3-18 

Figure 3.12 Printhead lateral error screen.................................................... 3-18 

Figure 3.13 Keyence sensor and amplifier, detail ........................................ 3-19 

Figure 3.14 Omron cue sensor, detail .......................................................... 3-20 

Figure 3.15 Sick cue sensor, detail .............................................................. 3-21 

Figure 3.16 Keyence sensor and amplifier, detail ........................................ 3-22 

Figure 3.17 Measuring the print differences for speed compensation ......... 3-29 

xii 


Contents 

Tables 

Figure 3.18 Page correlation marks............................................................. 3-30 

Figure 4.1 Application → Messages screen ................................................ 4-2 

Figure 4.2 Print screen................................................................................. 4-2 

Figure 4.3 Tools → connections screen ...................................................... 4-3 

Figure 4.4 Error screen................................................................................ 4-5 

Figure 4.5 APU error screen ........................................................................ 4-7 

Figure 4.6 APU cover screen....................................................................... 4-8 

Figure 4.7 IJP cover screen ....................................................................... 4-10 

Figure 4.8 Dryer error screen..................................................................... 4-11 

Figure 4.9 Printhead lateral motor error indicator ...................................... 4-12 

Figure 4.10 Printhead lateral positioning error indicator .............................. 4-12 

Figure 4.11 Printhead OS limit error indicator.............................................. 4-13 

Figure 4.12 Printhead OS over limit error indicator...................................... 4-13 

Figure 4.13 Printhead OS limit error indicator.............................................. 4-13 

Figure 4.14 Printhead GS over limit error indicator...................................... 4-14 

Figure 4.15 Printhead GS limit error indicator.............................................. 4-14 

Figure 4.16 Printhead lateral error screen ................................................... 4-14 

Figure 4.17 APR cover screen..................................................................... 4-15 

Figure 4.18 APR error screen ...................................................................... 4-16 

Figure 5.1 Grease locations, unwind unit, lift arms ...................................... 5-3 

Figure 5.2 Grease locations, unwind unit, OS interior ................................. 5-4 

Figure 5.3 Grease locations, worm gear, printhead, print tower .................. 5-5 

Figure 5.4 Web cleaner unit......................................................................... 5-6 

Figure 5.5 Web guide box, inside print tower A ........................................... 5-7 

Figure 5.6 HEPA filter housing, print tower A .............................................. 5-8 

Figure 5.7 Grease locations, rewind unit, GS lift arm .................................. 5-8 

Figure 5.8 HEPA filter housing, print tower A ............................................ 5-10 

Figure 5.9 Pre-filter and mesh filter, web cleaner unit ............................... 5-11 

Tables 

Table 1.1 Grammage and basis weight conversions for web weight.... 1-24 

Table 5.1 Operator maintenance ............................................................ 5-1 

Table A.1 Conversion table, fractional inch to mm.................................. A-1 

Table A.2 Conversion table, mm to fractional inch.................................. A-2 


xiii

Chapter 1. 

Operator Controls 

The KODAK VERSAMARK VX5000 printing system contains the standard 

modules shown in Figure 1.1. The following optional modules may be 

added to your printing system or replace the rewind unit: 

• Processing unit for punching, perforating, or punching and perforating 

the paper 

• Still picture unit 

• Sheeter-stacker unit 

• Folding unit. 

The printing system has printhead options for higher quality four-color 

process printing, designated by the name VX5000e. 

For supplying the print job information and data, the printing system 

installed in your plant may have a KODAK VERSAMARK CS300 system 

controller, a KODAK VERSAMARK CS400 system controller, or a KODAK 

VERSAMARK CS600 system controller. The term system controller can 

mean any of these products. 

Figure 1.1 

VX5000/5000e Printing Systems modules 

Unwind 

unit 

Spacer 

unit 

A 

B 

C 

Print towers 

D 

Spacer 

unit 

Rewind 

unit 

Operator’s Guide 1-1


Control Box Controls 

Control Box Controls 

The control box has external controls (Figure 1.7). Your printing system 

may have a second control box, which has the same external controls. 

Figure 1.2 

External controls, control box 

200-V power switch 


DANGER 

Dangerous voltage. Contact may cause electric shock or burn. 


On Off 

Switching 200-V power on provides power to the print stations, 

controller, unwind unit, print towers, and rewind unit (except for the 

rewind motor). Some components of these units include the PLC 

hardware, lights, fans, web guides, servo motors, and the powder 

brake. 

If your printing system has two control boxes, the second control box 

200-V power provides power to the same modules for the second set 

of print towers. 


On Off 

Switching 400-V power on provides power to the motor in the rewind 

unit and the dryer in print tower D. 

If your printing system has two control boxes, the second control box 

400-V power provides power to the dryer in the second print tower D. 

1-2 VX5000/5000e Printing Systems


Transformer Controls 

Transformer Controls 

The transformer (Figure 1.3) has one external or internal control. Your 

printing system may have a similar transformer supplied under special 

arrangement, or it may have an additional transformer if your printing 

system has a second control box. 

Figure 1.3 

Transformer 

Switch on/off 

DANGER 

Dangerous voltage. Contact may cause electric shock or burn. 

Main switch 

On Off 

Switching power on provides power to the control box(es) and all 

modules in the printing system. 

Compressor Controls 

Your printing system may include a compressor (Figure 1.4) if pressurized 

air is not available in sufficient amount from the facility. 

Figure 1.4 

External controls, compressor 

Air pressure gauge 

Temperature gauge 

Hours indicator 

Main switch on/off 



Unwind Unit Controls 


Displays the air pressure available to the printing system. 

Temperature gauge 

Displays the temperature and humidity of the provided air. 

Hours indicator 

Displays the hours of use for the compressor. 

Main switch 

On Off 

Switching power on provides pressurized air to the unwind unit, print 

towers, still picture unit and finishing (rewind unit). 


The unwind unit has external controls on the paper loading end (Figure 

1.5) and operator side (OS, Figure 1.7). The unit also has internal controls 

behind the OS doors (Figure 1.8) and the sliding panel (downstream end, 

Figure 1.9). In addition to these controls, some screens of the operator 

display at print tower D provide control of the unwind unit. See “Operator 

Display, Print Tower D” on page 1-19 for more information. 

External Unwind Unit Controls 

Operators load paper rolls at the unwind unit. Figure 1.5 shows the 

components used for this activity. 

Figure 1.5 

Paper loading end, unwind unit 

Roll end sensor 

Shaft 

Lift arms 

Access panels 

Air gun 

DANGER 

Danger of crushing from moving paper roll. Stand back from the lift arms 

and paper roll during operation. 

Access panels 

Allow clearance for raising and lowering the lift arms. 




Lift arms 

Hold a roll of paper in place while printing and bring a roll up or down 

for changing paper. 

Shaft (mandrel) 

Holds a roll of paper in place between the lift arms. Several shaft 

diameters are available, as needed for different sizes of paper cores. 

The shaft is not driven for web movement. Instead, the web is driven 

by gripper rollers, and this shaft is braked to avoid loose paper 

tension. 

Roll end sensor 

Allows detection of the end of paper on a roll in advance of emptying 

the core. The sensor can be positioned to allow more or less unused 

paper on the roll. 

Air gun 

Provides pressurized air for inflating the unwind shaft (Figure 1.6) and 

a deflation tool to press the nipple on the shaft and bleed air. In 

version 1 and version 2 machines, the air gun and inflation tool are 

parts of the same tool. In version 3 machines, separate tools are 

provided. 

Figure 1.6 

Air gun and deflation tool, detail 

Versions 1, 2 Version 3 

Deflation tool 

Air gun 

Figure 1.7 

External controls, unwind unit OS 

Shaft Brake Roll end Emergency Ready 

down/n/up off/on off/on 

stop 

Stop 

Jog 

Run slow 

Alarm 




DANGER 



Shaft 

Down N Up 

DOWN brings the lift arms down to change paper rolls, N keeps the lift 

arms from raising or lowering, and UP brings the lift arms up to load 

paper for printing. Whenever the control is released, it immediately 

returns to the N position. 

Brake 

Off On 

OFF disengages the powder brake to allow free paper movement, and 

ON engages the brake to control paper movement. 

Roll End 

Off On 

OFF disables the sensing of when the roll is nearly empty. ON enables 

the sensing of the end of the roll, and a nearly empty roll may cause 

the printing system to stop. 

This switch must be on before any selections made at the Operator 

display are used for roll end function. 

Emergency stop 

Pressing EMERGENCY STOP causes the following actions: 

• Stops printing, if an operating controller is connected to the 

printing system and print stations 

• Stops web movement immediately 

• Causes all EMERGENCY STOP buttons to blink on and off 

• Sends a shutdown command to the dryer(s) 

• Turns off power to the dryer blower(s). 

Note: The quick web stop may cause web breaks. Do not use EMERGENCY STOP 

to stop the printing system under normal conditions. 

The button latches in position after it is pressed. To release, turn the 

knob and allow it to release. Refer to “Recovering From an 

Emergency Stop” on page 2-52 for more information. 

Stop 

Select STOP to stop printing and web movement. 

When the controller is operating the printing system, the controller 

determines the actions and timing of a stop. If the printing system is 

not connected to an operating controller, after a wait of 2 seconds, the 

printing system PLC(s) will execute a controlled stop. 

Ready 

Sounds an alarm for 2 seconds, and allows selecting JOG, RUN SLOW, 

or RUN FAST during that period. 

Jog 

Moves the web as long as you press the button. To start jogging, you 

must hold the button until after the alarm stops, and then press the 

button again to start web movement. Jogging can occur while errors 

are active. Jog speed is selected by your service person. 




Run slow 

Moves the web as long as no errors are active, if the brake is on and 

the shafts are up. The speed used for Run slow operation is selected 

by your service person. 

Alarm 

Produces a warning sound after READY has been pressed. 

Internal Unwind Unit Controls 

Inside the OS doors of the unwind unit (Figure 1.8) are controls for the 

decurler (not implemented as of publication date), web guide, web 

tension, and shaft position. Inside the sliding door at the downstream end 

(Figure 1.9) are an interlock switch and sensors for the web guide and 

web break. Under the glass door on top (Figure 1.10) are the web guide 

components. 

Figure 1.8 

Internal controls, unwind unit OS 

Tension controller 

Web guide controller 

Mandrel lateral adjust 



Modifies how tension is maintained throughout the printing system. 

Refer to the manufacturer’s documents for further information. The 

tension controller in your printing system may look different from the 

one shown here. 


Sets up and operates the web guide sensing. Refer to the 

manufacturer’s documents for further information. 




Mandrel lateral adjust 

Positions the shaft and roll up to 2 inches (5 cm) forward and back 

between GS and OS. 


Shows the current air pressure available at the mandrel cylinders. 

Web guide sensor position 

Moves both edge sensors closer or further apart as a fine adjustment. 

(One or two edge sensors may be on your printing system.) 

Figure 1.9 

Web guide and web break sensors, unwind unit interior 

Web guide 

Interlock 

Web guide sensors 

Sliding door (open) 

Web break sensor 

Interlock 

Disables all RUN SLOW and RUN FAST controls while the top door is 

open. 


Sense the GS and OS edges of the web and provide the information 

to the web guide controller. Most printing systems have a web guide 

sensor at both the GS and OS edges. Some early printing systems 

may have a single web guide sensor at the GS of the web. 


Senses when paper is not webbed through this part of the module. 



Spacer Unit Controls 

Figure 1.10 

Web guide components, unwind unit interior 

Interlock 

Web guide sensor 

Web guide roller 

Interlock 

Disables all RUN SLOW and RUN FAST controls while the door is open. 


Sense the OS and GS edges of the web and provide the information 

to the web guide controller. Most printing systems have a web guide 



Web guide rollers 

As necessary to keep the web correctly positioned, these rollers 

move in various directions. 

Spacer Unit Controls 

A spacer unit (Figure 1.11) usually separates a set of print towers from 

modules that supply paper to the print towers. The spacer allows your 

crossing easily from the OS area to the GS area, and it includes a gripper 

roller for effective paper movement. 

Figure 1.11 

Spacer unit 

Door (open) 

Interlock 

Gripper rollers 

Interlock 




Web Cleaner Controls 

DANGER 

Danger of pinching from rollers. Keep hands and clothing away from 

rollers. 

Gripper rollers 

Pull the web at a controlled tension from the previous module (in this 

case, the unwind unit) and supply web to the next module. The 

gripper rollers are opened and closed with GRIPPER WHEEL OFF/ON in 

print tower A. 

Web Cleaner Controls 

At the first bank of print towers, a web cleaner usually stands behind the 

spacer unit. The web cleaner placement allows its flexible hoses to 

connect to additional components inside Print Tower A. These 

components brush dust and particles from the web as it moves into the 

Print Tower, and the free-standing module vacuums the foreign matter to 

its filters. 

The two filters in the free-standing module must be replaced regularly. 

Refer to “Replace the Web Cleaner Pre-filters” on page 5-10. 

Components inside the print tower must be cleaned regularly. Refer to 

“Clean the Web Cleaner Internal Components” on page 5-6. 

Figure 1.12 

Web cleaner unit 

Lid (closed) 

Main power 

Print tower A 

On-Off switch 

Lid 

Allows access to filters. 

Main power 

Provides input voltage to the vacuum motor. 

On/Off switch 

Controls the vacuum motor. 

Brush and vacuum assembly 

Inside Print Tower A, dislodges and removes dust and foreign objects 

from the web. 



Print Tower Controls 


Your printing system may have two to eight print towers, and each print 

tower may include one or two printheads, and in some cases no 

printheads, depending on the options installed. There are four different 

print towers. Every printing system has at least one Print Tower A and one 

Print Tower D. Two print towers are optional: Print Tower B and Print 

Tower C. 

Print Tower A Controls 

Print Tower A has internal controls behind the upstream sliding door 

(Figure 1.13) and OS doors (Figure 1.14). The tower holds printheads 1A 

and 1B (or 1 and 2) in place over the web. More complex printing systems 

may have more complex numbering for printheads, as discussed in 

“Identifying Printheads” on page 3-2. Above the OS doors is one external 

control. Printhead position controls are at hand when the cover is raised 

and the printheads are in service position (Figure 1.17). 

Figure 1.13 

Internal controls, print tower A, upstream door 

Cue sensor 

Interlock 


Web guide 

Web cleaner box 

Cue sensor 

Controls the timing of printing the next document. 

Interlock 



Sense the OS edge and GS edge of the web and provide the 

information to the web guide controller. Your printing system may 

have one or two sensors. Most printing systems have a web guide 






Web guide 

Maintains straightness of the web and prevents crossweb paper 

movement. 


Removes dust and other particles from the web. 

Figure 1.14 

Controls, print tower A, OS 

Cover up/down 

Web guide controller (option) 

Cue sensor position (option) 

Cue sensor (option) 

Air gun 

Stop Jog 

Ready Web tension 

infeed outfeed 

Gripper roller off/on 

(spacer) 

Gripper roller off/on 

(turnbar) 

Gripper wheel pressure 

(spacer) 


(turnbar) 

Interlock 

Cover up/down 

Raises and lowers the print tower cover. While lowering, alternating 

tones warn that the cover is moving. If a printhead interface may be 

hit by the moving cover, a warning of four short beeps sounds, and a 

message is displayed on the operator display. 

Stop 

Ready 

Jog 

This group of buttons is described in “External Unwind Unit Controls” 

on page 1-4. This group includes the only STOP button that may be 

hidden from view during normal operation. 

Cue sensor 

Controls the timing of printing the next document. This sensor, 

located downstream from the turnbar, reads cue marks for printing on 

the reverse side of the web, in duplex printing. 




Cue sensor position 

Positions the cue sensor placed after the turnbar. One or more cue 

sensors may be installed in the area below the printheads, and a cue 

sensor after the turnbar senses the location for printing on the reverse 

side of a duplex job. Additional information is available at “Positioning 

the Cue Sensor” on page 2-30. 

Web tension 

Infeed 

Moves the gripper rollers in the upstream spacer unit to feed web into 

print tower A. The web tension is raised for modules upstream from 

the spacer and lowered downstream from the spacer. 

Both INFEED WEB TENSION and OUTFEED WEB TENSION move the web 

and operate the gripper rollers. 

DANGER 

Danger of entangling. Keep hands and loose clothing away during 

operation. 

DANGER 

Danger of cuts from moving paper. Keep hands away from moving web. 

Web tension 

Outfeed 

Moves the gripper rollers in the downstream portion of print tower D 

to feed web into print towers B, C, and D. The web tension is raised in 

all print towers in the same bank. 

Gripper wheel 

Off On 

Controls the gripper rollers in the upstream spacer unit. 

DANGER 


rollers. 

Gripper wheel 

Off On 

Controls the gripper rollers at the turnbar. 


Controls air pressure for the gripper rollers in the upstream spacer 

unit. 


Controls air pressure for the gripper rollers at the turnbar. 

Interlock 



Removes paper dust, chad, and foreign particles from the web. The 

box has the following internal components. 




Figure 1.15 

Web cleaner, box interior 

Spacer unit, upstream 

Air duct 

Agitator 

brushes 

Vacuum tube 

Antistatic bar 

Agitator brushes 

Remove dust, chad, and foreign objects from the web as it passes 

between brushes. 

Antistatic bar 

Neutralizes any static charges built up by the contact between the 

brushes and the web. 

Air duct 

Suctions loosened matter from the web cleaner to the filters. 

Vacuum tube 

Carries loosened matter to the air duct. 

HEPA Filters 

On top of each print tower is a specialized housing for air filtration. The 

fans in the housing operate automatically when printing, and the filtration 

aids in printhead life and reliability. Inside the housing are two filters that 

must be changed regularly. The prefilter, accessible from the top, must be 

changed by operators. The HEPA (High efficiency particle air) filter, 

accessible from inside the print tower, must be changed by a service 

person. 

Note: In printing systems with the HEPA filter, a warning occurs if printing is run 

at a speed greater than 75 fpm (22 mpm) with the hoods open. If the 

warning exists for seven minutes, an error will occur and printing will stop. 




Figure 1.16 

HEPA filter housing, print tower A 

Prefilter and grill 

On/Off switch 

Grill 

Holds the prefilter in position. 

Prefilter 

Removes the largest dust and particles from air provided to the 

interior of the print tower. 

On/Off switch 

Controls the air fan inside the housing. 

Printhead Position Controls 

Several knobs and screws adjust the printhead to its print position, which 

is over the web and in relation to the desired print location on the web. 

Additional information is available at “Setting Printhead Height” on page 

2-26 and “Adjusting the Printhead Registration” on page 2-45. 

Figure 1.17 

Printhead position controls, print tower A 

Height adjust knob 

Set lever 


Skew adjust knob 




Height adjust knobs 

Optimum printhead height is 0.075 to 0.10 inch (1.90 to 2.54 mm) 

above the web. Measure the height with a feeler gauge. 

Set lever 

Sets the height and skew adjustments made with the knobs and 

prevents additional changes by turning the knobs. 

Printhead angle 

Screws at the OS and GS ends of the printhead bottom can adjust the 

printhead height to be parallel to the roller. 


Knob at the OS end of the printhead can adjust the print array 

horizontal position to be parallel to the roller at zero skew. 

Control of the printhead crossweb position is through the Operator display 

(see “Registration Screen—Printhead Position Control” on page 1-28). 

Refer to “Moving a Printhead to Service Position” on page 2-24 and 

“Moving a Printhead to Printing Position” on page 2-25 for setting the 

crossweb positions. Refer to the DT9000 series print stations Operator’s 

Guide for information on the effect on printing with the printhead height 

and skew adjustments. 

Print Towers B and C Controls 

Print towers B and C (Figure 1.18) hold printheads 2A and 2B (or 3 and 4) 

in tower B and printhead 3A and 3B (or 5 and 6) in place over the web, in 

a system with four print towers and eight printheads. More complex 

printing systems may have more complex numbering for printheads, as 

discussed in “Identifying Printheads” on page 3-2. The web passes 

underneath printhead 1 first. If a print tower is added, the identities of the 

printheads may change, depending on settings in the controller and for 

the printing network. For more information on numbering, refer to 

“Identifying Printheads” on page 3-2. 

Figure 1.18 

Controls, print towers B and C 

Print tower B 

Print tower C 

Cover up/down 

Cue sensor (option) 

Gripper roller 

Gripper wheel off/on 

Gripper pressure 




Cover up/down 





Cue sensor 

Controls the timing of printing the next document. This sensor reads 

cue marks for printing on the reverse side of the web, in duplex 

printing. 

Cue sensor position 

One or more cue sensors may be installed in the area below the 

printheads. Additional information is available at “Positioning the Cue 

Sensor” on page 2-30. 

DANGER 


rollers. 

Gripper wheel 

Off On 

Controls the gripper rollers in print tower C. These rollers are used 

only in duplex 1-up jobs, in which the web is routed from the dryer to 

the turnbar. 


Controls the amount of air pressure supplied to the gripper rollers. 

Print Tower D Controls 

Print tower D has the following controls as shown in Figure 1.19, and 

holds printheads 4A and 4B (or 7 and 8) in place over the web in a system 

with four print towers and eight printheads. More complex printing 

systems may have more complex numbering for printheads, as discussed 

in “Identifying Printheads” on page 3-2. 

Figure 1.19 

Controls, print tower D 

Cover up 


Operator display 

Alarm 

Emerg. reset 

Operator key 

Gripper wheel off / on 





Cover up/down 






Operation described at “Emergency stop” on page 1-6. 

Operator display 

Provides software control of the unwind unit, processing unit, and 

print towers, as described in “Operator Display, Print Tower D” on 

page 1-19. 

Alarm 

Produces a warning sound after READY has been pressed. 

Operator key 

Disables or enables normal printing speeds and interlocks on 

operator doors. 

• On: RUN SLOW and RUN FAST are disabled; open OS doors, 

sliding doors, and top covers do not cause an emergency stop. 

The JOG indicator lights on the Main screen, Operator display at 

print tower D. 

• Off: All running speeds are enabled; open doors cause an 

emergency stop and disable printing. 

Emerg. reset 

Resets the printing system after an error has caused a stop or after 

EMERGENCY STOP has been pressed. 

Cue sensor position (optional) 

One or more cue sensors may be installed in the area below the 

printheads. Additional information is available at “Positioning the Cue 


DANGER 


rollers. 

Gripper wheel 

Off On 

Controls the gripper rollers in print tower D. 

Note: The location of the gripper rollers controlled here varies in the 

printing systems with two banks of print towers. The control in the 

first print tower D controls the gripper rollers in this first print tower 

D; and the control in the second print tower D controls the gripper 

rollers in the downstream spacer unit. 


Controls the amount of air pressure supplied to the gripper rollers. 




Figure 1.20 

Page correlation sensors, print tower D 

Knobs 

Page corr. sensors 

for front 

Knobs 

Sensor amplifiers 


for back 

The page correlation components normally are located inside print tower 

D. However, installations with finishing equipment for printing additional 

data, such as magnetic ink character recognition (MICR) encoding, may 

have the components at other locations. 

Page correlation sensors 

Detect correlation marks printed on the documents. Two sensors are 

above the web, and two below the web to sense marks on the front 

and back, GS and OS pages. 

Knobs 

Place a sensor over or below the correlation marks printed on the 

documents. 

Sensor amplifiers 

Adjust the sensitivity to marks printed on the documents. 

Operator Display, Print Tower D 

The operator display is conveniently placed at the OS of print tower D. 

The display allows control of the unwind unit, processing unit, and print 

towers. Some controls enable other operator displays at the sheeterstacker 

unit and folding unit to control the printing system temporarily. 

Main Screen—Printing Speed Control 

The Main screen automatically displays when the printing system 

software is ready for operation or after pressing MAIN in the screen 

selection column (Figure 1.21). 




Figure 1.21 

Main screen 

Screen selection column 

Screen Selection Column Five controls in the screen selection 

column allow control of major printing functions: 

Registration 

Displays a screen for selecting the print position of the printheads 

(see “Registration Screen—Printhead Position Control” on page 1- 

28). 

Dryer 

Displays a screen for selecting dryer temperature (see “Dryer 

Screen—Temperature Control” on page 1-26). 

Web 

Displays a screen for selecting paper weight and web tension (see 

“Web Screen—Tension Control” on page 1-23). 

APU 

Displays a screen for controlling the unwind unit (see “APU Screen— 

Unwind Control” on page 1-22). 

Main 

Displays the Main screen. 

Main Control Area The following controls provide control of speed 

and data for printing. 

Jog 

Indicates position of the OPERATOR KEY by its color: 

• Red: The key is on, and RUN SLOW and RUN FAST are disabled; 

open OS doors, sliding doors, and top covers do not cause an 

emergency stop. 

• Background color: The key is off, and all running speeds are 

enabled; open doors cause an emergency stop and disable 

printing. 

APR 

Selects a finishing option, if the button is pressed for more than three 

seconds. The control indicates the enabled finishing option by its text: 

• APR: rewind unit (maximum speed 1000 fpm, 300 mpm) 

• MAPZ: folding unit (maximum speed 750 fpm, 225 mpm) 

• APS: sheeter-stacker unit (maximum speed 500 fpm, 150 mpm). 

Note: If you select a finishing option that is not installed, errors will occur. 

The errors will clear if you select another option that is installed. 




Speed mpm (fpm) 

Indicates the current speed of the printing system. To change the 

speed displayed to feet per minute (fpm) or meters per minute (mpm), 

see “Setting the Units of the Speed Display” on page 2-22. 

Dryer 

Displays the dryer status (Ready, Standby, Shutdown, or Alloff). 

VST state 

Indicates the enabled speed control: 

• Online: Data availability to the DC300 actively controls the 

transport, dryer, and printing speed, depending on the data that is 

available to print. 

• Offline: Constant speed control by the SC400, SC600 or SC220. 

Web break 

Enables or disables the web break sensors throughout the printing 

system. When enabled, a web break will cause an error indication 

and a fast stop. When disabled, a web break causes no error or stop, 

which can be useful while webbing the printing system. 

Speed Selection Block The following 18 buttons control the web 

speed. 

Job speed buttons (up to 16 preset speeds) 

Increases or decreases speed to the button pushed, except as limited 

by the type of printhead used or the finishing option. 

Job speed buttons (2 arrows) 

Increases or decreases speed while the button is pushed. 

Print Control Block The following 8 buttons control printing the job. 

Normal stop 

Stops printing in an ordered fashion by completing the printing of all 

documents that have already started printing. 

If the button is grayed out, the connection to a controller is not active, 

and IMAGE TEST and IMAGE DATA are disabled. 

Note: This function is not currently implemented as described. 

Image test 

Selects a file for printing that can be used to set registration 

consistently and to check for printing defects. 

Image data 

Selects the current job file for printing. Selecting among possible job 

files is done at the system controller or data host. Refer to the 

appropriate operator’s guide for additional information. 

The following criteria must be met before IMAGE DATA can result in 

printing: 

• The system controller must be running. 

• A job must be properly loaded. Using the SC400, SC600 or 

SC220, a job must be selected, and a starting document number 

must be set. Using the CD300, a job must be queued from the 

host computer to the KODAK VERSAMARK Printing System. 




Fast stop 

Slows and stops web movement in the printing system. 

• When the button is lit red, the printing system is not ready for 

printing or an EMERGENCY STOP button is locked. Pressing the 

button may clear the condition. 

• A red bar beside the button indicates a Stop condition has 

occurred in print tower A. The stop button in print tower A is 

hidden from view, behind the right front door. 

• When the button is flashing, the stop condition is locked in. 

• When the button is not lit, all printing operations can continue. 

Ready 

Sounds an alarm, prepares the printing system to move the web, and 

enables JOG, RUN SLOW, and RUN FAST for 5 seconds. 

Jog 

Enabled within 5 seconds after pressing READY, pressing this button 

and keeping it pressed sounds an alarm and moves the web at jog 

speed. Releasing the button stops web movement. 

Run slow 


moves the web at a preset, slow speed. 

Run fast 


moves the web at the last speed selected with the job speed buttons. 

APU Screen—Unwind Control 

The APU screen displays after pressing APU in the screen selection 

column. Use this screen to select how the printing system responds to an 

empty roll in the unwind unit and to a seam detected in the middle of a 

roll. 

Figure 1.22 

APU screen 

See “Screen Selection Column” on page 1-20 for a description of the 

controls in the right portion of the screen. 

Processing Unit Control Block Eight controls in the screen 

selection column allow control of processing unit functions. If a 

processing unit is not installed, the controls have no function. 

APU 

Displays the APU screen (“APU Screen—Unwind Control” on page 1- 

22). 

Note: The MS900 is the software that controls the processing unit. 




Roll End Block If ROLLEND ON is selected at the unwind unit, the 

following selections determine how the printing system responds after 

sensing the end of a roll. 

Stop 

Printing performs a fast stop. 

Run slow 

Printing slows to the run slow speed. 

Skip 

Printing continues without an indication that the roll is nearly empty. 

Web Seam Block If the seam detection option has been purchased 

and a seam is detected, the following selection determines how the 

printing system responds. 

Stop 

Printing performs a fast stop. 

Run slow 

Printing slows to the run slow speed. 

Skip 

Printing continues without an indication that a seam has been 

detected. 

Fast stop 

Ready 

Jog 

Run slow 

Run fast 

Refer to “Print Control Block” on page 1-21 for description of the web 

movement controls. 

Web Screen—Tension Control 

The Web screen displays after pressing WEB in the screen selection 

column or after pressing WEB WEIGHT in the Pull ratio screen. Use the 

screen to select the weight of the paper. 

Figure 1.23 

Web screen 






Web weight g/m 2 [9 buttons] 

Selects a paper weight for the current web and provides a standard 

set of pull ratios for each gripper roller. You change one or more pull 

ratios for the selected web weight; see “Pull Ratio Screen—Gripper 

Roller Control” on page 1-24. Only the grammage values in Table 1.1 

are valid. 

Table 1.1 

Grammage and basis weight conversions for web weight 

Grammage Bond Cover Newsprint Offset, book, text 

46.5 g / 2 cm 

12.3 # 17.2 # 28.5 # 31.3 # 

52.3 g / 2 cm 

13.9 # 19.3 # 32.1 # 35.3 # 

64.0 g / 2 cm 

17.0 # 23.6 # 39.2 # 43.2 # 

81.4 g / 2 cm 

21.6 # 30.1 # 49.9 # 54.9 # 

104.7 g / 2 cm 

27.8 # 38.7 # 64.2 # 70.6 # 

127.3 g / 2 cm 

33.8 # 47.1 # 78.1 # 85.9 # 

157.0 g / 2 cm 

41.7 # 58.0 # 96.3 # 105.9 # 

Web weight 

Selects the Web weight screen. 

Pull ratio 

Selects the Pull ratio screen. 

Pull Ratio Screen—Gripper Roller Control 

The Pull ratio screen (Figure 1.24) displays after pressing PULL RATIO in 

the Web screen. Use the screen to alter the tension applied to the web 

throughout the printing system. 

Figure 1.24 

Pull ratio screen 

Note: The screen displayed for your printing system may have small differences 

in the names of controls. 






Pull Ratio Block The following buttons provide control for all possible 

configurations of printing system options. The buttons are always 

displayed, although the options may not be installed. 

While running the printing system with RUN FAST, select a gripper roller 

identified in the Pull ratio block, and then alter its pull ratio with the 

Numeric control block. 

Punch (optional module) 

Selects the gripper rollers in the processing unit, an optional 

component. 

Infeed 1 

Infeed S 

Selects the gripper rollers in the first Spacer unit. 

D-Outfeed 1 

D-Outfeed S 

Selects the gripper rollers in the first print tower C. When the printing 

system is webbed for duplex, the gripper rollers pull the web routed 

closest to OS. 

Turn-bar S 

Selects the gripper rollers at the turnbar in print tower A. 

Outfeed 1 

Outfeed S 

Selects the gripper rollers in the Spacer unit between the dryer and 

the finishing option or, in printing systems with two banks of print 

towers, between the first and second banks of print towers. When the 

printing system is webbed for duplex, the gripper rollers pull the web 

routed closest to GS. 

Turn-bar 2 (optional module) 

Turn-bar M 

Selects the gripper rollers at the turnbar in print tower A. 

D-Outfeed 2 (optional module) 

D-Outfeed M 

Selects the gripper rollers in the second print tower C. 

Outfeed 2 (optional module) 

Outfeed M 

Selects the gripper rollers in the Spacer unit after the second print 

tower D. 

APS pull (optional module) 

Selects the gripper rollers in the infeed of the sheeter-stacker unit. 

MAPZ pull (optional module) 

Selects the gripper rollers in the infeed of the folding unit. 

Option 1 

Option 2 

Indicates that optional modules are not installed. 

Numeric Control Block While running the printing system with RUN 

FAST, use any of the following buttons to increase or decrease the pull 

ratio of a selected gripper roller, and then press ENTER to complete the 

action. The change to the pull ratio is measured in percentage of the 

standard pull, from -0.99% through +0.99%. 

Note: Low web tension may cause problems in registration. High web tension 

may cause frequent web breaks. 




+ 0 [.] 0 0 

Displays your entry for the percentage change to the pull ratio. 

+ - paired buttons 

Determines whether your entry increases or decreases the pull ratio. 

Arrow paired buttons 

Increases or decreases the pull ratio by 0.10% (left buttons) or 0.01% 

(right buttons) with each press of an arrow button. 

Enter 

Applies the change in pull ratio. 

Web weight 

Selects the Web weight screen. 

Pull ratio 

Selects the Pull ratio screen. 

Dryer Screen—Temperature Control 

The Dryer screen displays after pressing DRYER in the screen selection 

column. Use the screen to select how the dryer functions. 

• The dryer has 2 zones for heating the drum, which can be used 

separately or together. The zones are the OS and GS portions of the 

dryer. 

• The dryer has 2 thermostats and 2 sensors, one each in each heating 

zone. 

• The dryer has 6 air heaters staggered around the drum and 3 heating 

elements for each air heater (18 total). 

• The dryer has 1 sensor in each air heater (6 total) for checking the 

temperature of heated air. 

Figure 1.25 

Dryer screen 


controls in the right portion of the screen. Refer to “Adjusting the Dryer 

Temperature” on page 2-34 for procedures in using these controls. 

DANGER 

Do not touch the dryer covers or drum while the status is Ready, Standby, 

or Shutdown. Danger of burns. 




Dryer status 

Indicates one of five possible statuses: 

• Off when power is off and the drum is cold 

• Stand-by when power is on and the goal temperature has not 

been reached 

• Ready when the goal temperature has been reached 

• Shutdown when power is off and the drum is being cooled 

• Error when a problem prevents dryer operation. 

Drum temp 

Indicates the temperature goal for the dryer drum, in units that were 

set during installation of the printing system (degrees Celsius or 

Fahrenheit). Select the right button to change the temperature goal 

with the arrow buttons. The temperature may be set to any number 

from 0 to 140. 

Air temp 

Indicates and changes the temperature goal for the dryer exhaust, in 

units that were set during installation of the printing system (degrees 

Celsius or Fahrenheit). Select the right button to change the 

temperature goal with the arrow buttons. The temperature may be set 

to any number from 0 to 140. 

Drum 

Indicates and changes the portions of the dryer used: OS half-drum, 

GS half-drum, or OS+GS full-drum. Select the right button to display 

the options. 

Air 

Indicates the air heaters selected: from 2 to 6 heaters may be used. 

Select the right button to change the options. 

Web 

Displays the current paper weight selected. 

On 

Off 

Supplies power to the dryer, and warms the dryer to the drum 

temperature. The displayed status is “Stand-by” until that temperature 

is reached, and then the status is “Ready.” 

Turns off power to the dryer. The displayed status is “Shutdown” until 

the dryer has cooled, and then the status is “Off.” 

Drum OS temp 

Displays the current temperature of the OS half of the dryer drum. 

Drum GS temp 

Displays the current temperature of the GS half of the dryer drum. 

Air [number] temp 

Displays the current temperature of the air heaters. 

Stand-by temp 

Displays the current temperature goal when the dryer is in stand-by 

mode. 

Corrected temp 

Displays the amount of additional temperature used at 500 fpm. 

Additional heating is provided in proportion to the printing speed. 




Arrow buttons 

Increase or decrease the goal temperature of the selected drum or 

exhaust. 

Error 

Displays the Dryer error screen. See “Dryer Error Screen” on page 4- 

11. 

Registration Screen—Printhead Position Control 

The Registration screen displays after pressing REGISTRATION in the 

screen selection column. Use this screen to move printheads in the 

crossweb direction. To move the printing from one or more printheads in 

the direction of web movement, refer to discussion of “cue delay,” 

“registration,” or “y position” in operator documents or online help for the 

controller. 

Figure 1.26 

Registration screen 


controls in the right portion of the screen. See “Moving a Printhead to 

Service Position” on page 2-24 and “Moving a Printhead to Printing 

Position” on page 2-25 for procedures in using these controls. 

Printhead Block The controls in this block allow you to select a 

printhead for movement. The printhead names 1A, 1B, 2A, and so on may 

be different on the display for your printing system. The names are set by 

the installers of the printing system. 

1A 2A 3A 4A 

1B 2B 3B 4B 

Allows selection of one or more printheads for movement. Printhead 

1A is usually the first GS printhead to print and printhead 1B is usually 

the first OS printhead to print, depending on settings in the system 

controller. 

Home (8 small buttons) 

When lit, indicates the printhead is in service position. 

Home 

Selects printhead movement to the service position. 

Return 

Selects printhead movement from the service position to the printing 

position. 




WARNING 

Danger of crushing from the side. Keep hands away from the moving 

printhead and gears. 

Caution: Remove the catchpan and service tool before moving the printhead to the 

printing position. 

Start 

Initiates printhead movement to the service position or the printing 

position. 

Lateral 

Performs an unknown function. 

Error 

Displays the Printhead lateral error screen. See “Printhead Lateral 

Error Screen” on page 4-14. 

Stop 

Stops printhead movement immediately. 

Lateral Registration Block The controls in this block allow you to 

enter a distance for moving a printhead. 

[Number] 

Displays the distance currently entered. 

Inch / mm 

Selects the units of measurement for printhead movement. 

Keypad 

Each number pressed places a digit for the distance. The C button 

clears all displayed numbers. 

OS 

Selects movement toward the operator. 

GS 

Selects movement away from the operator. 

Error Screen 

The Error screen (Figure 1.27) displays when any error occurs in the 

unwind unit, any gripper roller, or the rewind unit. Refer to “Error Screen” 

on page 4-5 for additional information. 




Figure 1.27 

Error screen 



After correcting the source of an error indication, press MAIN to clear the 

error indicated on the Operator display. 

IJP Cover Screen 

The IJP cover screen (Figure 1.28) displays when any cover is open in 

any print tower. Refer to “IJP cover screen” on page 4-10 for additional 

information. 

Figure 1.28 

IJP cover screen 

Dryer Error Screen 

The Dryer error screen (Figure 1.29) displays when any error occurs in 

the dryer. Refer to “Dryer Error Screen” on page 4-11 for additional 

information. 

Figure 1.29 

Dryer error screen 


Printhead Lateral Error Screen 



The Printhead lateral error screen (Figure 1.30) displays when any error 

occurs while moving a printhead. Refer to “Printhead Lateral Error 

Screen” on page 4-14 for additional information. “Printhead Lateral 

Errors” on page 4-12 provides information about more specific screens. 

Figure 1.30 

Printhead lateral error screen 

APU Cover Screen 

The APU cover screen (Figure 1.31) displays when any error occurs in 

the unwind unit, any gripper roller, or the rewind unit. Refer to “APU Cover 

Screen” on page 4-8 for additional information. 

Figure 1.31 

APU cover screen 

APU Error Screen 

The APU error screen (Figure 1.32) displays when an error occurs in the 

unwind unit, the upstream Spacer unit, or the processing unit. (The 

processing unit information displays even if the module is not installed.) 

Refer to “APU Error Screen” on page 4-7 for additional information. 

Figure 1.32 

APU error screen 



Still Picture Unit Controls 

APR Cover Screen 

The APR cover screen (Figure 1.33) displays when a cover is opened in 

the rewind unit. Refer to “APR Cover Screen” on page 4-15 for additional 

information. 

Figure 1.33 

APR cover screen 

APR Error Screen 

The APR error screen (Figure 1.34) displays when an error occurs in the 

unwind unit, any gripper roller, or the rewind unit. Refer to “APR Error 

Screen” on page 4-16 for additional information. 

Figure 1.34 

APR error screen 


Your printing system may include a still picture unit, depending on the 

options installed. The information here applies to components in any 

configuration. The still picture unit has external controls (Figure 1.35) and 

internal controls (behind the OS doors, Figure 1.36). 




Figure 1.35 

External controls, still picture unit OS 

Upper camera control 

Lower camera control 

Camera position 

Zoom - 

Iris - 

Iris + 

Zoom + 

Snapshot 

Joystick controls 

Focus + 

Focus - 

Camera position 

Rocker arm to move the camera toward the OS or the GS. 

Iris + 

Allows more light to reach the camera. 

Iris - 

Allows less light to reach the camera. 

Zoom + 

Increases the magnification of the photo area. 

Zoom - 

Decreases the magnification of the photo area. 

Focus + 

Increases the sharpness of the photo area. 

Focus - 

Decreases the sharpness of the photo area. 

Snapshot 

Takes a photo to be displayed on the monitor. 




Joystick controls 

Advance and delay the camera flash until the portion for viewing is 

under the camera. 

Figure 1.36 

Internal controls, still picture unit 

Upper camera on/off 

Lower camera on/off 

Computer indicator 

Upper camera on/off 

Provides power to the camera, motor, and monitor for the upper 

camera. 

Lower camera on/off 

Provides power to the camera, motor, and monitor for the lower 

camera. 

Computer indicator 

Indicates the computer is operating. 



Rewind Unit Controls 


Your printing system may include a rewind unit, depending on the options 

installed. The information here applies to components in any 

configuration. The rewind unit has external controls (Figure 1.37) and 

internal controls (behind the OS doors, Figure 1.39). 

Figure 1.37 

External controls, rewind unit OS 

Rewinder tension 

on/off 


under/over 

Taper setting 

Tension setting 

Tension meter 

Gripper on/off 

Rewinder shaft down/n/up 

Figure 1.38 

Paper unloading end, rewind unit 

Static brush 

Shaft 

Access panels 

Access to shaft 

Lift arms 

Air gun 

Full roll sensor 




Figure 1.39 

Internal controls, rewind unit 



Dancer tension controller 

Gripper 

air pressure 

Lift arm 

air pressure 

Tension setting 

Selects the tension from the rewind motor. The TENSION METER 

indicates the selected tension. 

Taper setting 

Adjusts the tension variation with the size of the rewound roll. This 

setting avoids coning on the roll. 


Under Over 

Selects the direction of shaft movement. 

• Under: the paper goes underneath the shaft before it wraps 

around. 

• Over: the paper wraps around the shaft from above. 


On Off 

Engages the rewind motor, which operates with a dancer roller that 

comes up to maintain web tension. ON must be selected before RUN 

SLOW or RUN FAST can operate. 

Tension meter 

Indicates the selected tension. Suggestion: use 1 kg for each inch 

(2.5 cm) of web width. 

DANGER 


rollers. 



Controller 

Gripper 

On Off 

Controls the gripper roller just before the rewind shaft and, when on, 

keeps tension on the dancer roller. Turning this control ON locks the 

paper in place when you change rolls or when you splice a break, or 

when you shut down at the end of shift. 

The gripper roller it controls does not feed paper downstream. 

Rewinder shaft 

Down 

N 

Up 

DOWN brings the lift arms down to change paper rolls, N keeps the lift 

arms from raising or lowering, and UP brings the lift arms up to load 

an empty core for continued printing. Whenever the control is 

released, it immediately returns to the N position. 

Dancer tension controller 

Controls the tension supplied by the dancer rollers. 

Gripper air pressure 

Controls the air pressure of the gripper roller before the rewind shaft. 

Lift arm air pressure 

Controls the air pressure of the lift arm. 

Controller 

Figure 1.40 

Controllers 

The printing system may use one of three controllers: the CD300, the 

CS400, or the CS600 (Figure 1.40). Refer to the following documents for 

operating the controller: 

• CD300 online Help 

• CS400 online Help 

• CS600 online Help. 

CD300 CS400 CS600 



Print Stations 

Print Stations 

The printing system uses the DT9000 series print stations and the DH90, 

DH91, or DH92 printheads (Figure 1.41). Refer to the following 

documents for operating the print station and its printhead: 

• DT9000 series print stations Operator’s Guide (part 0113917-602) 

• Controller online Help 

• DH9000 series printheads Replacement and Packing Guide (part 

0114071-602). 

Figure 1.41 

Print station and printhead 

Printhead 

interface 

Printhead 

Electronics 

umbilical 

Heated 

umbilical 

Fluidics 

umbilical 

Remote control 

Print station 

Fluid containers 

Ink 

Cleaner 

Replenisher 

Waste 


Chapter 2. 

Basic Operations 

Every operator frequently uses the basic operations described in this 

chapter. Advanced procedures for key operators and more experienced 

operators are in Chapter 3. Operator actions in response to error 

messages are in Chapter 4. Operator service procedures are in Chapter 

5. 

Overview 

In a typical work day, an operator will use all sections of this chapter, often 

in the following order: 

1. Use “Turning the Printing System On” on page 2-3. 

2. Raise the covers of all print towers (“Raising and Lowering the Cover” 

on page 2-24). 

3. If the system is not webbed, use “Loading and Unloading Paper at the 

Unwind Unit” on page 2-4. 

Note: If the roll has been left in the printing system overnight, apply air to the 

shaft again before running the system. 

4. If the system is not webbed, use “Webbing the Printing System” on 

page 2-4, which may include the following sections: 

a. “Webbing the Unwind Unit” on page 2-10. 

b. “Webbing the Spacer Unit” on page 2-13. 

c. “Webbing the Print Towers” on page 2-15. 

d. “Webbing the Dryer” on page 2-17. 

e. “Webbing the Turnbar” on page 2-19. 

f. “Webbing the Still Picture Unit” on page 2-19. 

g. “Webbing the Rewind Unit” on page 2-20. 

In addition, you may need the following procedures: 

• If you are changing the width of paper, use “Adjusting the Web 

Guide” on page 2-12 and “Adjusting the Gripper Rollers” on page 

2 - 20. 

• If you are changing the outside face on the output roll, use 

“Selecting the Motor Direction” on page 2-22 for the rewind unit. 

• If you are changing the type of paper, use “Changing a Web 

Weight Value” on page 2-22. 

• If the system has just been webbed, use “Loading and Unloading 

Paper at the Rewind Unit” on page 2-8. 



Overview 

5. Move all printheads to the service position (“Moving a Printhead to 

Service Position” on page 2-24). 

6. If necessary in your plant, provide your login information to the 

network for your controller, and start the controller software. 

7. Ready all the printheads that the print job requires for printing. Refer 

to the DT9000 series print stations Operator’s Guide if necessary. 

8. Use “Adjusting the Dryer Temperature” on page 2-34 to ready the 

dryer(s). 

9. You may need to use “Tightening the Web” on page 2-23. 

10. If you are printing a test only for a few of the installed printheads, use 

“Enabling an Existing Printhead” on page 2-29. 

11. If the printheads are all ready, move them to their printing positions 

with “Moving a Printhead to Printing Position” on page 2-25. 

12. Use “Printing Test Pages” on page 2-41. 

13. If the test pages show the printhead positions are incorrect, adjust the 

position of each printhead with the following procedures. Some 

procedures may not be necessary. 

• “Setting Printhead Skew” on page 2-28 

• “Adjusting the Printing Position” on page 2-26 

• “Setting Printhead Height” on page 2-26. 

14. Set up a job to print with the following procedures: 

a. At the system controller, load a print job. Refer to the system 

controller online help. 

b. “Setting the Cue Delays” on page 3-22 

c. “Adjusting the Data Registration” on page 2-43 

d. “Adjusting the Printhead Registration” on page 2-45 

e. “Adjusting the Duplexed Registration” on page 2-46 

f. “Setting Up Page Correlation” on page 2-48 

g. “Positioning the Cue Sensor” on page 2-30 

h. “Setting the Roll End Detection” on page 2-58. 

Procedures While Printing a Job 

While running a print job (“Printing a Print Job” on page 2-42), the 

following adjustments may be needed: 

• “Adjusting the Dryer Temperature” on page 2-34 

• “Adjusting the Printing Position” on page 2-26 

• “Selecting a New Printing Speed” on page 2-53. 



Preliminary Operations 

Recovering from Problems 

When the routine of printing is interrupted by web breaks or printing 

problems, the following procedures may be necessary: 

• “Recovering From an Emergency Stop” on page 2-52 

• “Moving a Printhead to Service Position” on page 2-24 

• “Reprinting Data” on page 2-47 

• “Selecting a New Printing Speed” on page 2-53. 

For recovery from problems with the printheads, refer to the Operator’s 

Guide for the DT9000 series print stations. 

Turning off the System 

Use “Turning the Printing System Off” on page 2-53. 


Operators need to perform the following actions before printing a job or to 

allow continued job printing. 

Turning the Printing System On 

Use the following procedure. 

1. If necessary, turn on the main switch at each print station. The print 

stations will start after turning on the control box. Refer to the DT9000 

series print stations Operator’s Guide if necessary. 

2. If necessary, turn on the system controller. Its software will start 

automatically within a few minutes after turning on the control box. 

Refer to the system controller Introduction if necessary. 

3. If your printing system has a transformer (Figure 2.1), turn on its MAIN 

SWITCH. 

Figure 2.1 

Main switch, transformer 

Switch on/off 




4. Inside the front door of the still picture unit, turn on the power switch. 

5. At the primary control box (Figure 2.2), turn on 200-V POWER. 

6. Turn on 400-V POWER. 

7. If a secondary control box is present, turn on its 200-V POWER, and 

then turn on its 400-V POWER. 

Figure 2.2 

Main switches, control box 



8. Go to “Raising and Lowering the Cover” on page 2-24 to continue 

system operations. 

Webbing the Printing System 

Several activities assure that the printing system has paper for printing. 

This section provides general information for webbing the printing system, 

including changing rolls of paper. Refer to “Alternative Webbing Routes” 

on page 2-18 for discussion of the topics you may consider for special 

print jobs. 

Several options are available for webbing the printing system. Use the 

illustrations in “Webbing the Spacer Unit” on page 2-13 to guide the 

overall work for simplex (single-sided) print jobs. Additional illustrations 

are shown in “Webbing the Turnbar” on page 2-19 for duplex print jobs. 

Loading and Unloading Paper at the Unwind Unit 

Changing rolls of paper requires the air gun and deflation tool (Figure 

2.3), which is hung near the OS of the unwind unit. 




Figure 2.3 

Air gun and deflation tool, detail 


Deflation tool 

Air gun 

1. At the unwind unit OS, select BRAKE OFF. 

2. Select ROLLEND OFF. 

3. At the empty roll, unroll some paper to give some slack in the web. 

4. Tear the web. 

5. Beside the Operator display, print tower D, select ON to allow opening 

covers. 

6. At the empty roll, open the access panels. 

Caution: Do not place your hands, arms, legs, or feet in the path of the lift arms or 

roll. 

7. Select SHAFT DOWN until the lift arms release the shaft (Figure 2.4). 

Figure 2.4 

Roll released from lowered lift arms 




Figure 2.5 

Deflating bladder in shaft 


8. Release air pressure in the shaft (Figure 2.5). 

9. Remove the shaft from the core. 

10. Install the shaft in a new roll. Position the gears on the shaft at the 

GS. The roll may unwind from the top or bottom, as required by any 

preprinted matter. 

Note: The shaft may be centered in the roll or to one side. For print jobs on 

narrow paper, the roll may be positioned at the GS or OS end of the shaft. 

Refer to “Roll Position on the Unwind Shaft” on page 2-8 and “Alternative 

Webbing Routes” on page 2-18 for additional information. 

11. Roll the paper to the lift arms. 

12. Select SHAFT UP to bring the roll slightly off the floor. 

13. Apply air to the shaft (Figure 2.6). 

Figure 2.6 

Inflating shaft in roll 


DANGER 



14. Select SHAFT UP to bring the roll into the top position. 




15. Open the OS doors. 

16. If necessary, position the end of roll sensor (Figure 2.7) near the roll 

center. 

Figure 2.7 

Positioning end of roll sensor 

Versions 1 & 2 Version 3 

End of roll sensor 

Figure 2.8 

Using mandrel lateral adjustment 

17. Inside the unwind unit, flip up and turn MANDREL LATERAL ADJUST 

(Figure 2.8) until the roll is at the correct position between GS and 

OS. After the roll position is correct, flip down MANDREL LATERAL 

ADJUST, and close the unwind door. 

18. Splice the new roll to the webbed printing system. 

19. Select ROLLEND ON. 

20. Use one or more of the following procedures: 

• Go to “Loading and Unloading Paper at the Rewind Unit” on page 

2-8. 

• Go to “Webbing the Unwind Unit” on page 2-10. 

• If the printing system is webbed, select BRAKE ON. 

• Continue running the current print job. 

• Go to step 5 in “Overview” on page 2-1 to continue system 

operations. 




Roll Position on the Unwind Shaft 

The position of the web in the unwind unit and other modules of the 

printing system depends on the position of the roll on the unwind shaft. 

The best position on the unwind shaft depends on the width of the web 

and the complexity of the print job: 

• Web width 6 to 9.99 inches (152 to 253.9 mm), simplex print job: 

Place the GS edge of paper at the center of the unwind shaft, and 

web the paper on the OS half of the machinery. 

• Web width 6 to 9.99 inches (152 to 253.9 mm), duplex print job: Place 

the OS edge of paper at the center of the unwind shaft, and web the 

paper on the GS half of the machinery for the first pass under the 

printheads. The second pass under the printheads occurs on the OS 

side, and the web is in best position for the sheeter-stacker unit or 

folding unit. 

• Web width 10 inches and wider (254 mm and wider): Place the center 

of the paper at the center of the unwind shaft, and web the paper 

centered in the machinery. 

Experienced operators may choose to place the OS edge of paper at the 

OS edge of the machinery. The use of other machinery may require a 

specific roll position on the unwind shaft. Web guides immediately before 

these machineries can make small corrections in the web position. 

Loading and Unloading Paper at the Rewind Unit 

Changing rolls of paper requires the air gun and deflation tool (Figure 

2.3), which are hung near the OS of the rewind unit. 

1. STOP the transport. 

2. At the rewind unit, select GRIPPER ON. 

3. At the empty roll (unwind) or full roll (rewind), unroll some paper to 

give some slack in the web. 

4. Tear the web. 


covers. 

6. At the empty roll, open the access panels. 

DANGER 



7. Select REWIND SHAFT DOWN until the lift arms release the shaft (Figure 

2.4). 

8. Release air pressure in the shaft (Figure 2.5). 

9. Remove the shaft from the core. 

10. Install the shaft in an empty core. The shaft gears fit at the GS. 

Note: The shaft may be centered in the roll or to one side. For duplex print jobs, 

the roll may be positioned at the GS or OS end of the shaft. Refer to 

“Alternative Webbing Routes” on page 2-18 for additional information. 




11. Roll the empty core to the lift arms. 

DANGER 



12. Select REWIND SHAFT UP to bring the roll into the top position, or select 

REWIND SHAFT UP to bring the roll slightly off the floor. 

13. Position the shaft on the lift arms at the key way (Figure 2.9), and 

allow the shaft indent to ride on the cam follower. 

Figure 2.9 

Lift arm, rewind unit 


Key way 

Cam follower 

14. Stretch the paper from the webbed printing system to a centered 

position on the empty core. 

15. Move the core by hand until it is centered on the shaft or at the correct 

position. 

16. Using double-sided tape, tape the paper down. 

17. At the access for the nipple to the shaft bladder, inflate the bladder 

(Figure 2.10). 

Figure 2.10 

Access for inflating shaft bladder 




18. If you are running the system for the first time of the day, reduce the 

TENSION SETTING to 0. 

19. Select GRIPPER OFF. 

20. Allow the dancer roller to go to its lowest position, then select TENSION 

ON. 

21. Select READY, then select JOG, and allow the core to reach five or 

more rotations. 

22. Increase the TENSION METER reading to a setting for the paper. 

(Standard paper is setting 11 for an 11-inch web, lighter paper may be 

a setting of 5.) 

23. If your printing system has a movable full roll sensor, position the 

sensor to a desired position on the roll. 

24. Select the direction for the rewind motor: 

• If the paper goes underneath the shaft before it wraps around, 

select REWINDER TENSION UNDER. 

• If the paper wraps around the shaft from above, select REWINDER 

TENSION OVER. 


• Go to “Webbing the Unwind Unit” on page 2-10. 

• Continue running the current print job. 

• Go to a step in “Overview” on page 2-1 to continue system 

operations. 

Webbing the Unwind Unit 

The paper may roll from the top or bottom of the roll, usually dependent 

on any pre-print on the paper. The web route varies only slightly in each 

case. 

1. As needed, roll the web in for unwinding from the top (Figure 2.11) or 

bottom (Figure 2.12). 

Figure 2.11 

Webbing diagram, unwind from top 

Decurler 

(option) 

Web guide 

Web break 

sensor 

Tension 

detect 




Figure 2.12 

Webbing diagram, unwind from bottom 

Decurler 

(option) 

Web guide 

Web break 

sensor 

Tension 

detect 

2. Use “Loading and Unloading Paper at the Unwind Unit” on page 2-4 

as necessary for loading the roll. 

3. Unroll about 5 m, 15 ft of paper, and guide it as shown. 

4. At the web guide controller, select SERVO-CENTER to allow webbing. 

5. At the web guide, pull the paper over each roller, and through the 

sensor(s) (Figure 2.14). If necessary, use “Adjusting the Web Guide” 

on page 2-12 to move the sensors to the OS or GS for duplex print 

jobs. 

6. At the web guide controller, select AUTOMATIC. 

7. Guide the paper through to the Spacer unit and its gripper roller 


8. Go to one of the following sections: 

• “Adjusting the Web Guide” on page 2-12 

• “Webbing the Spacer Unit” on page 2-13. 

Figure 2.13 Webbing diagram, spacer unit 

Print tower A 


Spacer unit 

Web cleaner 




Adjusting the Web Guide 

A web guide is inside the unwind unit (Figure 2.14). A web guide is also in 

any print tower that includes a turnbar and in the rewind unit. These web 

guides use the same configuration, including sensors to detect the edges 

of the paper. These sensors can be mounted at both GS and OS edges or 

at either the GS or OS. Refer to the BST Web Guiding Systems Operating 

Manual if one was supplied with your printing system. The following 

procedure may be changed without notice by another manufacturer. 

Figure 2.14 

Web guide components, unwind unit interior 

Web guide rollers 

Web guide sensor 

Most printing systems have a web guide sensor at both the GS and OS 

edges. Some early printing systems may have a single web guide sensor 

at the GS of the web. 

Note: The following steps are necessary only if the edges of the rewind roll are 

irregular or if a paper with a different width is being loaded. The printing 

system must be webbed. 

1. Open the OS doors, top cover, and sliding doors to access the web 

guide and web guide controller. 

2. On the web guide controller, select SERVO-CENTER to center the web 

guide roller on the paper path. 

3. Loosen the set screw(s) (Figure 2.15) at the web guide sensor. 

Figure 2.15 

Sensors, web guide 

Coarse position adjust 

Sensor, GS edge 

Set screw 

Sensor, OS edge 

4. Move the sensor(s) away from the paper path. 




5. Select READY and JOG to remove any slack from the paper at the web 

guide. 

6. Select RUN SLOW, and closely watch the paper position in reference to 

the edges of all rollers. 

7. Once the paper is positioned correctly on the rollers, select RUN FAST, 

and move paper at 50 fpm for 2 minutes. 

8. Select RUN SLOW or RUN FAST. 

9. Select STOP. 

Note: In the BST documents, “left” and “right” are used as you look along 

the web movement, toward the rewind. 

10. Slide the OS web guide sensor over the paper edge until the yellow 

LED is positioned as shown, between the two vertical arrows. 

11. If the web guide uses two sensors, slide the GS sensor over the other 

paper edge to position the yellow LED between the left arrows. 

12. Tighten the set screw(s). 

13. Select AUTOMATIC. 

14. If the LED moves away from the arrows, turn the fine adjustment in 

the direction that returns the LED between the arrows. 

15. Select READY, and then select RUN SLOW. 

16. Check the yellow LED position, and turn the fine adjustment if 

necessary. 

17. Once the paper is positioned correctly in the sensors, select RUN 

FAST, and move paper at 50 fpm for 2 minutes. 

18. Check the yellow LED position, and turn the fine adjustment if 

necessary. 

19. Close the OS doors, top cover, and sliding doors. 


• Go to “Webbing the Spacer Unit” on page 2-13 to continue 

webbing. 

• Go to a step in “Overview” on page 2-1 to set the web tension in 

the print tower. 

• Go to step 15 in “Tightening the Web” on page 2-23. 

Webbing the Spacer Unit 

The web comes from the unwind unit or from print tower D. The following 

steps assume this is the first pass into the print towers. 

1. At print tower A, select GRIPPER WHEEL OFF to lift the gripper roller. 

2. At the spacer unit, guide the paper between the infeed roller and the 

gripper roller (Figure 2.13). 

3. At print tower A, select GRIPPER WHEEL ON to close the gripper roller. 




4. If necessary, use “Adjusting the Gripper Rollers” on page 2-14 to 

assure even pull on the paper. Final adjustment of the gripper roller 

will be made later. 

5. Jog the paper through to feed paper to the next roller in the print 

tower (“Jogging the Web” on page 2-14). 

6. Use one of the following options, depending on the print job and the 

options installed in your printing system: 

• Go to “Webbing the Print Towers” on page 2-15. 

• Go to “Webbing the Still Picture Unit” on page 2-19. 

• Go to “Webbing the Rewind Unit” on page 2-20. 

Jogging the Web 

Several controls for jogging are placed conveniently for use: 

• Unwind unit exterior (Figure 1.7) 

• Print tower A (Figure 1.14) 

• Operator display, Main screen (Figure 1.21) and other screens 

• Rewind unit exterior (Figure 1.37). 

The operator display does not show a web speed while jogging the web. 

1. Press READY until the alarm stops. 

2. Press and hold JOG until the web has moved as far as desired. 

3. Continue with system operation. 

Adjusting the Gripper Rollers 

This procedure and the next two are usually done together first for the 

rewind unit. Then the procedures are repeated for the unwind unit. 

1. Check the location of the web passing through the gripper rollers. 

2. If either roller is close to the center or edge of the web, adjust its 

position. 

• Each roller should be 1 /4 of the distance in from each edge of the 

web. 

• The position release above the roller loosens the assembly on 

the rail (Figure 2.16). 

Figure 2.16 Gripper roller adjustment detail 

Position release, roller 





3. At the controlling module, select the gripper roller to engage it. 

4. Check the amount of pressure from a gripper roller on the pull roller. 

5. If necessary, adjust the roller pressure using the following bullets: 

• If the web slips between the rollers, the pressure is too light. 

Increase the air pressure with the knob and pressure gauge near 

the roller on/off button. 

The air pressure controls are described at the following locations: 

“Gripper pressure” on page 1-17, “Gripper pressure” on page 1- 

18, “Gripper air pressure” on page 1-37. 

• If the web is damaged or wrinkled by the rollers, the pressure is 

too great. Decrease the air pressure. 

Webbing the Print Towers 

Your printing system may have one or two groups of print towers. Each 

group may have from two to four print towers. Each group will have at 

least print towers A and D. 

1. Jog the web to feed paper through the web cleaner. (Open the web 

cleaner box, and feed paper through the outlet, Figure 2.17.) 

Figure 2.17 

Web cleaner box detail 

Lid, web cleaner box 

Outlet, web cleaner box 

2. Jog the web to feed paper for one of the following options: 

• If the web needs to be turned, route the paper through the 

turnbar. See “Webbing the Turnbar” on page 2-19. Use Figure 

2.19 to route paper through the turnbar first. 

• If the web from the Spacer unit has the side for printing facing up, 

route the paper through the web guide. See “Adjusting the Web 

Guide” on page 2-12 if necessary. Use Figure 2.18 to route paper 

through the web guide. 

3. Jog the web to feed paper through the gripper rollers, around the tach 

roller, and to the first printhead. 




4. Guide the web under all GS printheads, and over all rollers. For splitweb, 

half-width, one-up and duplex jobs, the webbing passes under 

the GS printheads first. 

Note: It is important to have the web supported by a roller directly beneath each 

print array. 

5. In print tower D, guide the web through the page correlation sensors. 

6. Go to “Webbing the Dryer” on page 2-17. 

Figure 2.18 

Webbing for simplex 1-up or 2-up 

Page 

correlation 

sensors 

Gripper 

roller 

Cue 

sensor 

Tach 

roller 

Dryer 

Web 

guide 

Turnbar 

Web cleaner 

Print tower A Print tower B Print tower C Print tower D 

Figure 2.19 

Webbing for 1-up or 2-up turned 

Page 

correlation 

sensors 

Gripper 

roller 

Cue 

sensor 

Tach 

roller 

Dryer 

Web 

guide 

Turnbar 

Web cleaner 

Print tower A Print tower B Print tower C Print tower D 




Additional illustrations are shown in “Webbing the Turnbar” on page 2-19 

for duplex print jobs and in “Identifying Printheads” on page 3-2 for other 

print jobs. For split-web, half-width, one-up and duplex jobs, the webbing 

passes under the GS printheads first, then through the dryer and into the 

turnbar. The reverse side then passes under the OS printheads, through 

the dryer, and into the next set of print towers or into the rewind unit. 

Webbing the Dryer 

Caution: If printing has occurred, the dryer will be hot. Allow the dryer to cool at 

least 15 minutes before moving the dryer housing and webbing the dryer. 

Route paper through the dryer with the following steps: 


covers. 

2. Open the OS doors of print tower D. 

3. Open the GS doors of print tower D. 

4. Push the dryer housing back to expose the dryer drum (Figure 2.20). 

Figure 2.20 

Dryer housing and drum 

Housing pushed back 

Dryer housing 

Drum 

Handle 

Figure 2.21 

Dryer webbing, single pass 

Page 

correlation 

sensors 

Dryer 

Print tower C 

Print tower D 




Figure 2.22 

Dryer webbing, double pass 

Page 

correlation 

sensors 

Print tower C 

Print tower D 

5. Use one of the following options, depending on the print job: 

• If the print job requires simplex (single-side) printing, use Figure 

2.21 and go to step 6. 

• If the print job requires duplex (double-side) printing and the web 

has not been turned, use Figure 2.22 and go to “Webbing the 

Turnbar” on page 2-19. 

• If the web has been turned for duplex printing, and the web has 

gone through the dryer twice, use Figure 2.21 and go to step 6. 

6. Route the web into the Spacer unit. 

7. From outside the GS, push the dryer housing back into the print 

tower. 

8. From the OS, inside the print tower, close the dryer housing 

completely. 

9. Use one of the following options, depending on the print job and the 

options installed in your printing system: 

• Go to “Webbing the Turnbar” on page 2-19. 

• Go to “Webbing the Still Picture Unit” on page 2-19. 

• Go to “Webbing the Rewind Unit” on page 2-20. 

Alternative Webbing Routes 

When you are printing a duplex or two-up print job, the portion with 

process color or with tighter registration requirements should be printed 

with the printheads closer to the OS. The printhead positions near the OS 

allow for more accurate registration and easier adjustment of the 

printhead position. Refer to “Identifying Printheads” on page 3-2 for 

additional information. 




Webbing the Turnbar 

Several options are available for duplex (double-sided) print jobs. Use the 

following illustrations to guide the overall work. Additional illustrations are 

shown in “Webbing the Spacer Unit” on page 2-13 for duplex print jobs. 

Figure 2.23 

Webbing diagram, print tower turnbar detail 

6 

5 

4 

3 

2 

1 

1. Use one of the following options: 

• Route the web from the Spacer unit to the upstream roller directly 

underneath the turnbar. 

• Route the web from the dryer (Figure 2.22) to the gripper roller 

(Figure 1.18), over the two rollers in print towers C and B, and 

under the downstream roller directly underneath the turnbar. 

2. Using Figure 2.23, web the turnbar. 

Hint: The web runs from the inside of each diagonal roller to the 

outside of the gripper roller at the turnbar. 

3. Go to “Webbing the Print Towers” on page 2-15. 

Webbing the Still Picture Unit 

Use the following steps: 

1. Jog the web from the gripper roller in the Spacer unit. (Refer to 

“Webbing the Spacer Unit” on page 2-13 if needed.) 

2. Bring the web under the infeed roller, and over the two rollers 

underneath or between the camera(s) (Figure 2.24). 




Figure 2.24 

Webbing diagram, still picture unit 

Camera front 

Cue 

sensor 

Camera rear 

3. Assure the web is positioned correctly over the sensor and between 

the cameras. 

4. Bring the web under the outfeed roller. 

5. Continue with webbing of the next module. 

Webbing the Rewind Unit 


1. Jog the web from the gripper roller in the Spacer unit. (Refer to 

“Webbing the Spacer Unit” on page 2-13 if needed.) 

2. Guide the paper through the web guide and to the gripper roller. 

3. Jog the paper through to feed paper through the final four rollers and 

to the rewind shaft, rewinding at the top (Figure 2.25) or bottom 





Figure 2.25 

Webbing diagram, rewind to top 

Web 

guide 

Gripper 

roller 

Web break 

detector 

Dancer 

roller 

Figure 2.26 

Webbing diagram, rewind to bottom 

Web 

guide 

Gripper 

roller 

Web break 

detector 

Dancer 

roller 

4. Use “Loading and Unloading Paper at the Unwind Unit” on page 2-4 

as necessary for loading an empty core. 

5. Go to “Selecting the Motor Direction” on page 2-22 to continue 


6. Go to a step in “Overview” on page 2-1 to continue system operations 

or go to “Tightening the Web” on page 2-23. 




Setting the Units of the Speed Display 

The speed can be displayed in feet or meters. The procedure for 

changing the display units is performed by service persons. 

Selecting the Motor Direction 

The following procedure depends on how the web rolls onto the rewind 

shaft. See step 24 in “Loading and Unloading Paper at the Rewind Unit” 

on page 2-8. 


• If the paper goes underneath the shaft before it wraps around, 

select REWINDER TENSION UNDER. 

• If the paper wraps around the shaft from above, select REWINDER 

TENSION OVER. 


• Go to step 25 in “Loading and Unloading Paper at the Rewind 

Unit” on page 2-8. 

• Go to step • in “Overview” on page 2-1 to continue system 

operations. 

Changing a Web Weight Value 

Use this procedure to add a new web weight or to change a web weight 

value already on the screen. 

1. At print tower D, operator display Main screen, select WEB. 

2. If the weight is displayed, select the WEIGHT. 

Note: If the proper weight is not displayed, select a displayed value that is 

close, and use “Tightening the Web” on page 2-23 to modify the 

tension settings. 

3. If the paper weight has not been run before, use “Tightening the Web” 

on page 2-23 to correct the default tension settings. 

Note: “Tightening the Web” on page 2-23 is also recommended to adjust 

tension for heavy or light ink use, changed dryer temperatures, or 

humidity in the facility. 




Tightening the Web 

Use this procedure after the printing system is webbed. The procedure 

can be used for any of the following reasons: 

• Using a paper type or weight that has not been run before 

• Adjusting the settings for a print job that prints more or less ink than 

the previous print job 

• Adjusting the settings for higher or lower humidity 

• Adjusting the settings for higher or lower dryer settings 

• Correcting excessive paper drift (a sign of loose web tension) 

• Correcting excessive web breaks or snapping sounds while printing 

(signs of high web tension). 

Note: Tension control from the system controller is not implemented at the date 

of publication. 

Note: The procedure assumes all optional modules are installed. Some steps 

may be skipped if your printing system does not include optional modules. 

1. On the web guide controller, select SERVO-CENTER to center the web 

guide roller on the paper path. 

2. Select READY, and then select JOG. 

3. Engage the following gripper rollers: 

• Print tower A: GRIPPER WHEEL ON 

• Turnbar, print tower A: GRIPPER WHEEL ON 

• Print tower C: GRIPPER WHEEL ON 

4. At the unwind unit, select BRAKE ON. 

5. In the first print tower A, press OUTFEED WEB TENSION. This selection 

operates the gripper rollers in the Spacer unit between two banks of 

print towers. The selection tightens the web inside the upstream print 

towers. 

6. In the second (downstream) print tower A, press INFEED WEB TENSION. 

This selection tightens the web from the outfeed of the first print 

towers to the turnbar in the second print tower A. 

7. In the downstream print tower A, press OUTFEED WEB TENSION. This 

selection tightens the web in the downstream print towers and makes 

the web slacker downstream. 

8. Choose the next steps depending on the options used. 

Roll-to-roll 

a. On the rewind unit, tighten the web by hand. 

b. Select REWIND TENSION OFF. 

c. Take up the slack by moving the rewind roll by hand until it feels 

tight, until the dancer roller begins to raise from its bottom 

position. 

d. Select REWIND TENSION ON with the other hand. The mandrel will 

start to rotate. 

e. Go to step 9. 

9. At the Operator display, select READY, and then select JOG. 




10. Close the doors to all modules. 

11. Near the Operator display, print tower D, turn off OPERATOR KEY. 

12. Run slow for about 2 minutes to allow paper to move the entire 

distance from the unwind unit to the last finishing module. 

13. Near the Operator display, print tower D, turn on OPERATOR KEY. 

14. Check all web guides for correct positioning of the web. If necessary, 

perform “Adjusting the Web Guide” on page 2-12. 

15. Near the Operator display, print tower D, turn off OPERATOR KEY. 

16. Select READY, and then select RUN SLOW. 

17. Go to step 12 in “Overview” on page 2-1 to continue system 

operations. 

Note: Do not use “Setting the Web Tension” on page 3-16 unless the 

web is extremely tight or loose. Allow the system to print on and dry 

the web before setting the web tension. 

Printhead Activities 

The following procedures allow close work with the printheads. 

Raising and Lowering the Cover 

Use the following procedure: 

DANGER 

Danger of crushing from above. Keep hands and clothing away from 

gears. Do not operate with guard removed. 

1. Press COVER UP. An alarm sounds while the cover is moving. 

Note: In printing systems with the HEPA filter, a warning occurs if printing 

is run at a speed greater than 75 fpm (22 mpm) with the hoods 

open. If the warning exists for seven minutes, an error will occur 

and printing will stop. 

2. To lower the cover, press COVER UP. 

3. Continue with printhead operations or printing system operations. 

• If you are starting the printing system, go to step 3 in “Overview” 

on page 2-1. 

• If the printing system is webbed, and you are resuming a job, go 

to “Moving a Printhead to Service Position” on page 2-24. 

Moving a Printhead to Service Position 

All printhead movement is controlled from the Operator display at print 

tower D. Use the following procedure: 

1. At the Operator display at print tower D, press REGISTRATION. 

2. Select printheads by pressing one or more printhead buttons. 

3. Press HOME. 




4. Press START. The printhead moves immediately. 

Figure 2.27 

Printhead in service position 

5. Perform a printhead operation, such as the following options. Refer to 

the DT9000 series print stations Operator’s Guide for details. 

• Readying one or more printheads 

• Selecting service clean 

• Swabbing a printhead. 

6. Go to a step in “Overview” on page 2-1 to continue system 

operations. 

To return the printhead to the operating position, use “Moving a Printhead 

to Printing Position” on page 2-25 

Moving a Printhead to Printing Position 



1. Remove the catchpan or other attached items. 


3. Select printheads by pressing one or more printhead buttons. 

4. Press RETURN. 

5. Press START and answer “OK” to the request to remove the catchpan. 

The printhead moves immediately. 

Note: The printhead must be far enough from the cover to allow full 

closure. If the printhead is too far OS, a repeated beep indicates 

the cover cannot close safely. Refer to “Adjusting the Printing 

Position”. 

Note: In printing systems with the HEPA filter, a warning occurs if printing 

is run at a speed greater than 75 fpm (22 mpm) with the hoods 

open. If the warning exists for seven minutes, an error will occur 

and printing will stop. 




Adjusting the Printing Position 



1. Start printing test patterns or a print job (see “Printing Test Pages” on 

page 2-41). 


3. If one or more printheads are at the service position, move the 

printhead(s) to the printing position. 

4. Select a printhead by pressing a printhead button. 

5. If desired, press INCH or MM to change to the alternate unit of 

measurement. 

6. Using the keypad, enter a value for the distance to move. 

7. Press OS or GS. The printhead moves immediately. 

8. Check the preprint on the web, and repeat from step 2 for the same 

printhead or other printheads. 

• Printhead locations at the end of this procedure are their printing 

positions until any later change. 

• When moving a printhead from service position, pressing RETURN 

moves the printhead back to this printing position. 

9. If the printhead is to print a cue mark, go to “Positioning the Cue 


10. Resume system operations or go to “Printing a Print Job” on page 2- 

42. 

Setting Printhead Height 

Refer to the DT9000 series print stations Operator’s Guide for information 

on the effect on printing with these adjustments. 

Figure 2.28 

Printhead position controls 


Set lever 






Optimum printhead height is 0.075 inch (1.90 mm). However, for certain 

substrates, the printhead may be as high as 0.10 inch (2.54 mm). 

Measure the height with a feeler gauge without paper in the printing 

system. Improper printhead height can cause print defects, such as 

blurred or smeared print. See the DT9000 series print stations Operator’s 

Guide for details. 

Figure 2.29 

Printhead height measurement 

Air dam 

Eyelid 

Air dam 

Air dams 

0.075-0.100" 

Substrate 

1. Position the printhead over the area where printing will occur. 

2. Using a feeler gauge, measure the distance between the air dam on 

one side of the printhead and the substrate immediately below. (The 

gauge should have a small amount of drag.) 

3. If the height is not between 0.075 to 0.100 inch, turn the HEIGHT SET 

LEVER counter-clockwise. 

4. Turn the left and right HEIGHT ADJUST KNOB clockwise to lower the 

printhead or counterclockwise to raise it. 

Note: Turning the height adjust screws unequal amounts can affect the 

angle of the printhead. 

5. When the height is correct, tighten the HEIGHT SET LEVER. 

6. Measure the printhead height again, and make any necessary 

corrections. 

7. Repeat step 1 through step 6 for each printhead in the printing 

system. 


• Go to “Setting Printhead Skew” on page 2-28. 

• If all colors have been set for skew and height, go to “Adjusting 

the Printhead Registration” on page 2-45. 




Setting Printhead Skew 

Screws at the OS and GS ends of the printhead bottom can adjust the 

print array horizontal position to be parallel to the roller. Zero skew aligns 

the print array perpendicular to the edge of the web. 

This procedure is best performed with two persons. One person observes 

the result of each adjustment with a loupe at the last roller of print tower 

D; the other person makes small adjustments to skew at the printhead. 

Note: For printing systems that print four-color process or spot color, perform 

this procedure first with the printheads that are most upstream. (In fourcolor 

systems, the C (cyan) printhead(s) are the most upstream.) Then 

perform this procedure for the next color downstream (M (magenta) 

printheads in a four-color system). Next, the K (black) printheads, and, 

finally, the Y (yellow) printheads. 

1. At the system controller software, enable printing by the first 

printheads to print, and disable printing by all other printheads. Refer 

to “Enabling an Existing Printhead” on page 2-29 and “Disabling an 

Existing Printhead” on page 2-30. 

These first printheads include all those that print cyan in a process 

color system. Refer to figures in “Identifying Printheads” on page 3-2 

for the printhead identifies. 


• If your printing system does not include a processing unit, move 

the printhead(s) to print at the extreme sides of the web. 

• If your printing system uses a processing unit, use the punched 

holes as a measure of skew. Move the printhead(s) to print inside 

each set of punched holes. When skew is correctly adjusted, the 

printed lines should occur at the same point of the punched 

holes. 

• If your printing system includes a processing unit, but its punch 

cylinder is not engaged, move the printhead(s) to print at the 

extreme sides of the web. 

3. Start printing a test pattern (“Printing Test Pages” on page 2-41). 

Figure 2.30 

Printhead position controls, print tower A 


Set lever 






4. Turn the HEIGHT SET LEVER counter-clockwise (Figure 2.30). 

5. Turn the SKEW ADJUST KNOB until the cross-web lines printed in the 

test pattern are perpendicular to the edge of the paper. 

6. Select Stop printing and web movement. 

7. At the system controller software, enable printing by the next set of 

printheads. Refer to “Enabling an Existing Printhead” on page 2-29. 

With each repetition of the procedure, leave the first set of printheads 

enabled, and enable the printheads in one other print tower. Use the 

printing from the first set of printheads as a reference for other 

printheads. 

8. As needed, repeat step 3 through step 7. For process color systems, 

use the following combinations: 

• Cyan and magenta 

• Cyan and black 

• Cyan and yellow. 

9. At the system controller software, enable printing by all printheads. 

10. Go to “Adjusting the Printhead Registration” on page 2-45. 

CS400 

Enabling an Existing Printhead 

The following procedure may be used to enable a printhead that was 

disabled in a previous print job. The procedure also completes the 

process of installing an additional printhead in the printing system. After 

installing the additional printhead, a key operator can use “Adding a 

Printhead to the Configuration” on page 3-6 before using this procedure. 

1. Using the Job Setup Sheet, determine the printheads required with 

the report displayed after selecting Job → IJPDS or Job → MPC at 

the controller. 

2. Select Job → Printers. 

3. Drag the correct printhead icon from the correct data station to the 

correct printer. 

4. Select that RIP number. 

5. Select Apply to save your changes. 

6. If the printhead is to print a cue mark, select Options. 

7. Select Cue mark in the printer that contains the printhead. 

8. Define the cue mark location and size. 


10. Using the Job Setup Sheet, verify the printheads required with the 

report displayed after selecting Tools → Report. 



Print Job Operations 

CS400 

Disabling an Existing Printhead 

The following procedure may be used to disable a printhead that is not 

needed in the current print job. The procedure is also needed when 

correcting printhead skew and registration. 

1. Select Job → Printers. 

2. Drag the printhead icon from the printer to a data station. 

3. Deselect that RIP number. 



An operator uses the following operations to start printing a job. 

Positioning the Cue Sensor 

Several cue sensors may be located in the printing system: one cue 

sensor is in print tower A, another sensor is present for the turnbar 

(Figure 2.32), and several sensors are present if the page correlation 

option is installed (Figure 2.40). 

Caution: Doesn’t the still picture unit have a cue sensor also? (Figure 2.33). 

Figure 2.31 

Front cue sensor location, print tower A 

Cue sensor for front 




Figure 2.32 

Back cue sensor location, print tower B 

Cue sensor for back 

Figure 2.33 

Cue sensor location, still picture unit 

Cue sensor rail 

Cue sensor 

You may see one of two different cue sensors (Figure 2.34). 

1. Perform the following steps at each cue sensor: 

a. Loosen the set knob, and slide the sensor over the cue mark 


b. Tighten the set knob. 

2. If necessary, go to “Adjusting the Cue Sensor” on page 3-19 to 

continue cue sensor setup. 

3. Jog the web, and check each cue sensor for sensing the cue marks. 


operations. 




Figure 2.34 

Cue sensors and bracket 

Cue sensor 

Cue sensor 

Set knob 

Positioning the Web Break Sensor 

Several web break sensors may be located inside the unwind unit (Figure 

2.35) and print tower D (Figure 2.36), and rewind unit (Figure 2.37). 

Figure 2.35 

Web break sensor locations, unwind unit 

Web break rail 





Figure 2.36 

Web break sensor locations, print tower D 


Figure 2.37 

Web break sensor locations, rewind unit 

Web break rail 





1. Perform the following steps at each web break sensor: 

a. Loosen the set knob, and slide the sensor over the web (Figure 

2.34). 

b. Adjust the angle so the sensor beam is perpendicular to the web. 

c. Tighten the set knob. 

Figure 2.38 

Web break sensor and bracket 

Set knob 


Web 


operations. 

Adjusting the Dryer Temperature 

The drying temperature can vary widely. The necessary temperature for 

complete drying depends on humidity in the facility, the type of paper, the 

speed of printing, and the amount of ink coverage. Generally, a higher 

drying temperature is needed if the paper is coated, tightly calendered, or 

otherwise treated to produce a very close surface. Use the following steps 

to change the dryer temperature. 

1. Stop printing. 

2. From the Main screen, print tower D, select Dryer. 

3. To select the portion(s) of the drum to be used, select Drum. If the 

drum portion selection is correct, go to step 5. 

4. Press Up arrow or Down arrow to select the portion of the drum that 

is used (OS, GS or OS+GS). 

5. To set the temperature in the drum, select Drum temp. If the drum 

temperature is correct, go to step 7. 

6. Press Up arrow or Down arrow to change the current displayed 

value for the target temperature. 

7. To select the air zones, select Air. 




8. Press Up arrow or Down arrow to select the zones. 1 through 6 

zones may be used, and a temperature is selected for each zone. 

9. Select Air temp. 

10. Press Up arrow or Down arrow to change the current displayed 

value for the target temperature. 

11. If desired, repeat step 7 through step 10 for each of the air exhaust 

routes used. 

12. If you are ready to print, select On. Printing can start after the Dryer 

status displays Ready. 

Setting Up a Print Job 

Use the following steps before printing a new print job or starting a 

different job. 

1. Using a Job Setup Sheet or other documents that describe the print 

job, verify the setup of the printing system matches the job 

requirements. Check the following items: 

• 1-up or 2-up 

• Simplex or duplex 

• Preprinted cue marks, cue marks printed in the job, or no cue 

marks 

• Number of documents, pieces, forms, or pages for each cue mark 

• Document size 

• Ink color 

• Number of printheads 

• Paper type. 

2. With printing stopped, and at the controller, select a template file or 

setup file with the following lettered steps: 

a. Select Application. 

b. Select File → New to create a file, or select File → Open to 

select an existing file. 

3. If the configuration is changing, set up the new configuration with the 

following lettered steps: 

a. Select Transport. 

b. Select Model. 

c. Add or delete modules to match the configuration required by the 

Job Setup Sheet. 

Refer to the controller online help for additional detail about the 

meanings of the module icons and how this screen works. 

4. Select Job → Setup. Use the following group of substeps depending 

on your controller. 




CS600 

a. Modify the Physical printable area by providing a width and 

length of what is to be printed, including any cue marks, register 

marks, or page correlation marks to be printed. Refer to Figure 

2.39 

Figure 2.39 

Printed area, physical printable and valid printed 

Cue mark 

Physical printable area 

Valid printed area 

Job data 

Register mark 

Page correlation mark 

Suscipit lorem ipsum 

dolor sit amet, con 

sectetuer adipiscing elit, 

sed diam nonnumy nibh 

euismod tempor inci dunt 

ut labore et dolore magna 

ali quam erat volupat. Ut 

wisi enim ad minim 

veniam, quis nostrud 

exerci tation ullamcorper 

suscipit laboris nisl ut 

aliquip ex ea commodo 

con sequat. Duis autem 

vel eum irure dolor in 

henderit in vulputate velit 

esse con sequat. 

Vel illum dolore eu 

feugiat nulla facilisi at 

vero eos et accusam et ius 

to odio dignissim qui 

blandit prae seent 

luptatum zzril delenit 

aigue duos dolore et 

molestias exceptur sint 

occaecat cupiditat non 

simil pro vedit tempor 

sunt in culpa qui officia 

deserunt mollit anium 

ib est abor um et dolor 

fuga. Et harumd dereud 

facilis est er expedit 

distinct. Nam liber 

tempor cum soluta 

nobis eligend option 

congue nihil impediet 

doming id quod maxim 

placeat facer possim 

omnis voluptas 

assumenda est, omnis 

repellend. 

Temporibud auteui 

quinusd et aur office 

debit aut tum rerum 

necessit atib saepe 

eveniet ut er molestia 

non recusand. Itaque 

earud rerum hic ten tury 

sapiente delectus au aut 

prefer zim endis dolorib 

asperiore repellat. Hanc 

ego cum tene senteniam, 

quid est cur verear ne ad 

eam non possing 

accomodare nost ros quos 

tu paulo ante cum 

memorite tum etia ergat. 

Nos amice et nbevol, 

olestias access potest fier 

ad augend ascum consci 

ent to factor tum poen 

legum odio que civiuda. 

Et tamen in busdam 

neque nonor imper ned 

libiding gen epular reli 

guard cupiditati quas nul 

la praid om undat. 

Improb pary minuit, 

potios im flammad ut 

coercend magist and et 

dodencendesse 

videantur. Inviat tur 

vera ratio bene sanos 

adzum justiatiam, 

aequitated. 

Fidem neque hominy 

infant aut inuiste fact 

est cond qui neg facile 

efficerd possit duo 

conetud notiner si 

effercerit, et opes vel 

fortunag vel ingen 

liberalitat magis 

conveniunt, da but 

tuntung ben evolent sib 

conciliant, et aptis sim 

est ad quiet. Endium 

caritat prae sert cum 

omning nul sit 

causoeccand quaert en 

imigent cupidat a natura 

proficis vacile explent 

sine julla inura autend 

b. Modify the Valid printed area to specify the area for printed 

material used in the finished piece. 

• Provide, in the X (in.) and Y (in.) entries, the starting point 

from the upper left corner of the Physical printable area. 

• Provide the actual size of the printed area in the Width (in.) 

and Length (in.) entries. 

c. Modify the Media for the front and back sides, by selecting 

options from the drop-down lists, as needed. 

d. Modify the Ink for the front and back sides, by selecting options 

from the drop-down lists, as needed. 




e. Modify the Calibration entries as needed. 

• The Front X1, Front X2, Back X1, and Back X2 entries define 

the cross-web positions of up to four spectrophotometers. 

There is no need for a Y position. 

• The four spectrophotometers can be positioned in different 

cross-web locations, to keep each measurement discrete. 

• Front X1 is always used. 

• Front X2 is used in a 2-up job. 

• Back X1 is used in a duplex job. 

• Back X2 is used in a two-up duplex job. 

• The Web speed of 25 is used only during color calibration. 

f. Select Apply to save your changes. 

g. Go to step 5 on page 2-39. 

CS400 

a. Select the Type of the job file from the options shown. 

b. Identify the file location. 

c. Press Apply to save your changes. 

In the function bar, the IJPDS or MPC button enables to match 

the job type you selected. 

d. Verify the information displayed for the file(s) and RIP(s) with 

information in your Job Setup Sheet. 

e. Select IJPDS or MPC, depending on the type of job. 

f. Verify the displayed information with in formation in your Job 

Setup Sheet. See “Using an MPC Manual Setup” on page 3-7 for 

detailed instructions for using the MPC screen. 




g. Go to step 5 on page 2-39. 

CS300 

Note: The following steps require an operator who is experienced with 

graphic arts, especially with a process-color background. For more 

information on any of the lettered steps, see “Setting Up Printing for 

the CS300” on page 3-8. 

a. Select Forms. Select a form from the options shown, create a 

new form, or change one of the existing forms. 

b. Select Colors. Map the system colors used in the Job Setup 

Shee to printheads printing on the front or back of the web. Press 

the Front or Back color button until the correct color is selected. 

(Colors have been identified with the Transport → Setup → 

Printhead screen.) 

c. Select Setup. Select the print options from the options shown. 

d. If your printing system produces process color product, select 

Spot. Select an OCA color, and then identify its component colors 

by selecting one or more system colors and setting the intensity 

of each. 

e. If your printing system prints spot colors that are either true spot 

colors or colors composed of two or more inks, select Highlight, 

and define these highlight colors. 

f. If your process colors should use color correction, select Correct. 

g. If your data includes an area to be compared from form to form, 

select Bit region to identify the area. 

h. From the subsystem bar, select Transport. 

i. From the Transport work area, select each Printhead. 

j. If necessary, modify its information for Cue sensor, RIP, Mount, 

Color, and Page correlation. 




k. Press Apply to save your changes. 

l. Select each printhead, and repeat from step i. 

m. From the Transport work area, select Cue sensor A. 

n. Change the cue definition to match the Job Setup Sheet. 

o. Press Apply to save your changes. 

p. Select each cue sensor to be used in the job, and repeat from 

step m. 

q. From the Transport work area, select Unwind. 

r. Enable the module and set the unwind tension. 

s. Press Apply to save your changes. 

t. From the Transport work area, select each Print tower. 

u. Enable the module. 

v. Press Apply to save your changes. 

w. From the Transport work area, select each Dryer. 

x. Enable the module and set the dryer temperature. 

y. Press Apply to save your changes. 

z. From the Transport work area, select each Turnbar 

aa. Enable the module. 

ab. Press Apply to save your changes. 

ac. From the Transport work area, select Rewind or another finishing 

option. 

ad. Enable the module. 

ae. Press Apply to save your changes. 

af. Go to step 16. 

CS600 & CS400 5. From the function bar, select Printers, and use the following lettered 

steps. 

a. Drag all appropriate printheads from the data station column (left 

side) to the printer column (right side). 

• Each printer accepts one or more printheads from a given data 

station. 

• Printheads from the same data station will be used as a single 

stitched unit. 




Select the RIP and its printheads 

b. Select all appropriate RIPs for Printers 1 through 8. 

c. If appropriate, use the Arrow Up and Arrow Down buttons to 

correct any RIP identities. 

6. From the subsystem bar, select Print. 

7. From the function bar, select Verify to compare the displayed printing 

system to the job requirements. 

8. Respond to any warnings or errors as needed. 

9. From the Print work area, select each Printhead. Use the following 

lettered steps. 

a. If necessary, modify its information for Cue sensor, RIP, Mount, 

Color, and Page correlation. 

b. Press Apply to save your changes. 

c. Select another printhead. 

10. From the Print work area, select each Cue sensor. Use the following 

lettered steps. 

a. If necessary, change the cue definition to match the Job Setup 

Sheet. 

b. Change the cue definition to match the Job Setup Sheet. 

c. Press Apply to save your changes. 

11. From the Transport work area, select Unwind. 

a. Enable the module and set the unwind tension. 





12. From the Transport work area, select each Print tower. 

a. Enable the module. 


13. From the Transport work area, select each Dryer. 

a. Enable the module and set the dryer temperature. 


14. From the Transport work area, select each Turnbar 



15. From the Transport work area, select Rewind or another finishing 

option. 



16. Go to “Printing Test Pages” on page 2-41 or “Printing a Print Job” on 

page 2-42. 

Printing Test Pages 

Use the following steps after the printheads have been brought to ready 

and after all cue sensors are properly positioned. 

1. Verify all printheads are ready for printing. At the system controller, 

the printhead icons should be green. 

2. At each print tower with an open cover, press UPPER COVER to close 

the cover. 

Note: Printing with the covers open causes a warning. If the warning is 

ignored, an error causes printing to stop. 

3. At print tower D, the Operator display, press Main. 

4. Verify that DRYER is in ready state. 

5. Verify that all persons are clear of the printing system. 

! DANGER 

The moving parts of the printing system can seriously injure persons who 

are not clear of the printing system. 

6. Press Ready at the bottom of the screen. An alarm will sound. 

7. Press Run slow or Run fast, as desired, within two seconds of the 

alarm. 

• If Run slow is pressed, the printing system runs at a preset slow 

speed. 

• If Run fast is pressed, the printing system runs at the printing 

speed that was used last. 




8. When the printing system has reached printing speed, use one of the 

following options: 

• If the printing system is set up for standard jobs (the transport and 

system controller share I/O), at the Operator display, print tower 

D, select Image test. 

• If the printing system is set up for testing (no I/O shared between 

the transport and system controller), at the system controller, 

select Print → Test pattern. 

9. If necessary, use “Adjusting the Printhead Registration” on page 2-45 

to move printheads into position for printing multi-color jobs. 

Printing a Print Job 

Use the following steps after the printheads have been brought to ready 

and they are properly registered, and after all cue sensors are properly 

positioned. 

1. If you are starting a new print job or changing the print job, perform 

“Setting Up a Print Job” on page 2-35. 

2. Verify all printheads are ready for printing. At the system controller, 

the printhead icons should be green. 

3. At each print tower with an open cover, press UPPER COVER to close 

the cover. 

Note: Printing with the covers open causes a warning. If the warning is 

ignored, an error causes printing to stop. 

4. At the system controller, select the print job with the following steps: 

CS600 

a. Select Start. 

The job will start when your computer operator sends the job. 

(The computer operator is also known as the JES (job entry 

system) operator.) 

b. Go to step 5. 

CS400 

a. Select Job → Setup. 

b. Select the Type of the file, and identify the File path. 

c. Select APPLY. 

d. Go to step 5. 

CS300 

a. Select Ready. 


(The computer operator is also known as the JES (job entry 

system) operator.) 

b. Go to step 5. 

5. At print tower D, the Operator display, press Main. 




6. Verify that DRYER is in ready state. 

7. Verify that all persons are clear of the printing system. 

! DANGER 

Moving parts can seriously injure persons who are not clear of the printing 

system. 

CS220 8. Press Ready at the bottom of the screen. An alarm will sound. 

CS220 9. Press Run slow or Run fast, as desired, within two seconds of the 

alarm. 

• If Run slow is pressed, the printing system runs at a preset slow 

speed. 

• If Run fast is pressed, the printing system runs at the printing 

speed that was used last. 

CS220 

10. When the printing system has reached printing speed, use one of the 

following options: 

• If the printing system is set up for standard jobs (the transport and 

system controller share I/O) press Image data. 

• If the printing system is set up for testing (no I/O shared between 

the transport and system controller), at the system controller, 

select Print. 

11. You may need to make preliminary adjustments to cue delays to 

register printing at the same location on the web. (See “Adjusting the 

Data Registration” on page 2-43.) 

12. You may need to make final adjustments to printhead position to 

register color printing. (See “Adjusting the Printhead Registration” on 

page 2-45.) 

Adjusting the Data Registration 

This procedure registers the print in the direction of web movement 

(upstream and downstream). You will first position the printhead(s) most 

upstream, and then position each printhead downstream from the last. 

All data positioning is controlled from the Operator display at the system 

controller. If the print job uses page correlation, the data registration must 

be more exact. Faulty data registration can cause page correlation errors 

that will stop printing of the job. 

1. If any printheads have been recently installed, or if any printhead 

interfaces have been changed or added, perform “Setting Printhead 

Skew” on page 2-28. The procedure adjusts skew for all the 

printheads in the printing system. 

2. If the system configuration has changed the locations of printheads or 

cue sensors, a key operator must perform “Setting the Cue Delays” 

on page 3-22. 

3. Start printing the print job (“Printing a Print Job” on page 2-42). Use a 

slow printing speed. 

4. Position the data printed in print tower A to lay ink where desired, with 

the following steps, depending on your controller: 




CS400 and CS600 

These steps assume that the first printhead—the most upstream 

printhead in a grouping—is accurately positioned by measuring the 

distance from the cue sensor to the printhead. The steps adjust the 

positions of all downstream printheads to the first. 

a. At the system controller, select Print and the next printhead 

downstream. 

b. Enter the following information: 

Field Value Detail 

Used by 

printer 

Cue sensor 

Cue delay 

Speed 

compensation 

As marked 

Selected in the Job → MPC screen. 

A, B, C, or D Identity of the cue sensor immediately 

upstream of this printhead. (A is most 

upstream.) 

As measured 

on the web 

0.10 or as 

measured 

Distance from the nearest upstream cue 

sensor to the print array. See step 10 on 

page 3-23 for printing a cue mark for use 

by downstream cue sensors. 

See “Calculating the Speed Comp Value” 

on page 3-27. 

Registration 0.0 This will be changed later. 

c. Save your entries for each printhead by selecting Apply. 


CS300 





a. At the system controller, select Transport, and the next 

printhead downstream. 

b. Enter the following information: 


Enable As marked Selected in the Job → MPC screen. 

Cue sensor 

A, B, C, or D Identity of the cue sensor immediately 

upstream of this printhead. (A is most 

upstream.) 

Cue delay 

Speed 

compensation 

As measured 

on the web 

0.10 or as 

measured 






on page 3-27. 






Mount Front or back Front is OS, back is GS. 

Position As measured The offset from normal print position. 

Color As entered Selected in the Job → Colors screen. 

Page 

correlation 

As entered 

This will be changed later. 

c. Save your entries for each printhead by selecting Apply. 


CS220 





a. At the system controller, select Print → Registration. 

b. Select the printhead. 

c. Adjust the slider to move the printed data to the correct position, 

toward or away from the preprinted cue mark and other 

preprinted material. 


5. Check the print position from each printhead in comparison to the 

preprinted cue mark, other preprinted material, and printing from 

other upstream printheads. Use one of the following bullets: 

• If the print position of the selected printhead is not correct in 

reference to the prior printhead(s), repeat from step 4.b (step 4.c 

for CS220) for the same printhead. 

• If the print position is correct, repeat from step 4.a for each of the 

next printheads downstream. 

6. Go to “Adjusting the Printhead Registration” on page 2-45 to continue 


Adjusting the Printhead Registration 

This procedure registers the print across the web (OS and GS). You will 

first position the printhead(s) most upstream, and then position each 

printhead downstream from the last. 


tower D. For best results, perform “Adjusting the Data Registration” on 

page 2-43 before using the following steps. 

1. Start printing the print job (“Printing a Print Job” on page 2-42). 




2. Position the printheads in print tower A to lay ink where desired, with 

the following steps: 

a. At the Operator display at print tower D, press Registration. 

b. Select the printhead by pressing one of the printhead buttons. 

c. Enter a value for the distance to move the printhead. 

d. If desired, press Inch or mm to change to the alternate unit of 

measurement. 

e. Press OS or GS. The printhead moves immediately. 

3. Check the print on the web, and repeat from step 2.a for each of the 

next printheads. Check the print position from each printhead in 

comparison to the printing from other upstream printheads. 

Note: Do not move printheads in the upstream print towers once they have 

been registered. 

4. Go to one of the following procedures to continue system operations: 

• “Printing a Print Job” on page 2-42 

• “Adjusting the Duplexed Registration” on page 2-46 

• “Setting Up Page Correlation” on page 2-48 

• “Saving the Job Settings” on page 2-52. 

Adjusting the Duplexed Registration 

In some cases, stopping printing while running a duplex print job can 

result in mismatched documents on the two faces of the web. Use the 

following steps to correct the duplex product. For best results, perform 

“Adjusting the Data Registration” on page 2-43 before using the following 

steps. 

1. Check the completed product at the rewind unit, and discard all 

product that is mismatched front-to-back. 

2. At the system controller, perform the following lettered steps: 

CS600 

a. Select Print → Clear buffers. 

b. Ask your computer operator to perform a backspace command to 

start at or before the last document that was printed correctly. 

c. Select Ready. 



CS400 

Normally the controller will select the last completed document and 

restart on the next document. If a different restarting document is 

needed, use the following steps. 

a. Back through the data to the last correctly printed product. 

b. Resume printing the job. 

c. Go to step 3. 




CS300 


b. Enter the new starting document number and, if desired, an 

ending document number. 

c. Ask your computer operator to perform a backspace command to 


d. Select Ready. 



3. Resume printing the job. 

4. After the spoiled product has cleared the printing system, discard the 

spoiled product, and splice in the correctly printed web. 

5. Resume printing the print job. 

Reprinting Data 

It will be necessary to reprint some data when checking the registration or 

when seeing other print problems. Use the following steps: 

1. Select Fast stop to stop printing. 

2. If a problem with a module exists, correct the problem. 

3. Check the completed product at the rewind unit, and discard all 

product that is mismatched front-to-back. 

CS600 & CS400 

CS300 

CS220 

4. Determine the last document that was printed correctly. 

Refer to the Job Setup Sheet to determine the document count 

(CS600, CS400, and CS220) or piece count (CS300). For example, a 

single page, document, piece, or form may be a single address, or it 

can be print to fill an area of 17.92 x 11.0 inches on both sides of the 

web. In some cases, it can be even more printed output than the 

examples given. Usually each cue mark causes a document or piece 

to print. 

The document count displayed is the last completely printed 

document. 

The piece count displayed is the last completely printed piece. 

The document count displayed is the last completely printed 

document. 

5. At the system controller, perform the following lettered steps: 

CS600 


b. Enter the new starting document number and, if desired, an 

ending document number. 

c. Ask your computer operator to perform a backspace command to 


d. Select Ready. 






CS400 

a. Back through the data to the last correctly printed product. 

b. Resume printing the job. 

c. Go to step 6. 

CS300 


b. Ask your computer operator to perform a backspace command to 


c. Select Ready. 



6. After the spoiled product has cleared the printing system, discard the 

spoiled product, and splice in the correctly printed web. 

7. Resume printing the print job. 

Setting Up Page Correlation 

A group of four sensors downstream from the last printhead provide page 

correlation (Figure 2.40) with the CS300 and CS400 controllers. (Page 

correlation is not available for CS220. Page correlation is a future release 

for the CS600.) 

The most useful size of a page correlation mark is 0.125 high by 0.25 

inches wide (0.318 by 0.635 cm) to avoid false errors from any web 

wandering and to conserve space in the non-used product that is usually 

not in the final piece. The smallest allowable size is 0.125 tall by 0.125 

inches wide, and the largest allowable size is 0.25 by 8.96 inches, 

assuming the mark is placed at the 0 position of the width. 

Use the following steps for setting up and using page correlation: 

1. Perform “Adjusting the Data Registration” on page 2-43. 

2. Perform “Adjusting the Printhead Registration” on page 2-45. 

3. If necessary, perform “Adjusting the Duplexed Registration” on page 

2-46. 





4. At the system controller, select Transport → Page, and then use the 

Page Correlation screen to configure the feature: 

a. With the Check Page Correlation checkbox, disable the page 

correlation feature. (You will enable the feature at a later point.) 

b. With the Generate Marks button, enable printing of page correlation 

marks by printheads, if desired. Disable printing of page 

correlation marks if the substrate has preprinted marks. 

c. If the Generate Numbers button is active, enable or disable printing 

a document number along with the page correlation marks. 

d. In the Position field, enter the location from the first line of the 

document where the page correlation mark is printed. Usually the 

location should be 1 /8 inch or further down the page. 

e. In the Height field, enter the size of each segment of the page 

correlation mark. This value can be 0.125 ( 1 /8) to 0.25 inch wide 

(0.318 to 0.635 cm). 

f. In the Distance field, enter the distance of the sensors from the 

first cue sensor. (This distance is best determined with “Setting 

the Cue Delays” on page 3-22.) 

g. With the Sensor polarity buttons, select the sensor polarity to 

invert the polarity. Leaving the polarity unchecked is more 

common. 

h. Select Apply. 

5. At the system controller, select Print and a printhead that prints 

black ink, and then use the Print screen to configure the printhead: 

a. In the Mark Position field, enter the location from the GS edge of 

the printed document where the page correlation mark is printed. 

Usually the location should be 0.125 ( 1 /8) inch (0.318 cm) or 

further from the left edge of the printhead, but the value is allowed 

to be 0.0 to 8.96 inches (0.0 to 22.76 cm). 

b. In the Mark Width field, enter the size of the page correlation 

mark. 

Usually this value is at least 0.125 ( 1 /8) inch, and usually 0.25 

inch wide (0.318 and 0.635 cm). The mark can be as narrow as 

0.063 inch ( 1 /16 inch, 0.159 cm) and as wide as the printhead 

(8.96 inches, 22.76 cm). Sizes at the extremes of the range may 

facilitate page correlation errors due to substrate wandering 

underneath the sensors. 

c. With the Sensor buttons, select the sensor that will detect the 

marks printed by—or preprinted for—this printhead. Select Not 

used if the page correlation marks can be ignored for this printhead 

and others in line with it. 

d. Select APPLY. 

6. Repeat step 5 for each printhead that prints black, then go to step 10. 




CS300 

7. At the system controller, select Transport and Page, and then use 

the Page Correlation screen to configure the feature: 

a. With the Check Page Correlation checkbox, disable the page 

correlation feature. (You will enable the feature at a later point.) 

b. With the Generate Marks button, enable printing of page correlation 

marks by printheads, if desired. Disable printing of page 

correlation marks if the substrate has preprinted marks. 

c. If the Generate Numbers button is active, enable or disable 

printing a document number along with the page correlation 

marks. 

d. In the Position field, enter the location from the first line of the 

document where the page correlation mark is printed. Usually the 

location should be 1 /8 inch or further down the page. 

e. In the Height field, enter the size of each segment of the page 

correlation mark. This value can be 0.125 ( 1 /8) to 0.25 inch wide 

(0.318 to 0.635 cm). 

f. In the Distance field, enter the distance of the sensors from the 

first cue sensor. (This distance is best determined with “Setting 

the Cue Delays” on page 3-22.) 

g. With the Sensor polarity buttons, select the sensor polarity to 

invert the polarity. Leaving the polarity unchecked is more 

common. 

h. Select Apply. 

8. At the system controller, select TRANSPORT and a printhead that 

prints black ink, and then use the Page correlation area to configure 

the printhead: 

a. In the Mark Position field, enter the location from the GS edge of 

the printed document where the page correlation mark is printed. 

Usually the location should be 0.125 ( 1 /8) inch (0.318 cm) or 

further from the left edge of the printhead, but the value is allowed 

to be 0.0 to 8.96 inches (0.0 to 22.76 cm). 

b. In the Mark Width field, enter the size of the page correlation 

mark. 

Usually this value is at least 0.125 ( 1 /8) inch, and usually 0.25 

inch wide (0.318 and 0.635 cm). The mark can be as narrow as 

0.063 inch ( 1 /16 inch, 0.159 cm) and as wide as the printhead 

(8.96 inches, 22.76 cm). Sizes at the extremes of the range may 

facilitate page correlation errors due to substrate wandering 

underneath the sensors. 

c. With the Sensor buttons, select the sensor that will detect the 

marks printed by—or preprinted for—this printhead. Select NOT 

USED if the page correlation marks can be ignored for this printhead 

and others in line with it. 

d. Select Apply. 




9. Repeat step 8 for each printhead that prints black, then go to step 10. 

10. Use one of the following actions: 

• If the printheads are to print correlation marks, start the job and 

print documents until a correlation mark should be detected by 

each used sensor. 

• If the web has preprinted correlation marks, jog the web to bring 

page correlation marks to all used sensors. 

11. Use “Positioning the Page Correlation Sensors” on page 2-51 for 

each correlation sensor. 

Positioning the Page Correlation Sensors 

Four page correlation sensors are on a double rail just downstream from 

the last printhead (Figure 2.40). Use the following steps to adjust the 

sensor positions across the web. 

Figure 2.40 

Page correlation sensor location, print tower D 


for front 

Knobs 


for back 

1. Perform the steps in “Setting Up Page Correlation” on page 2-48. 

2. At print tower D, rotate a knob to move a sensor to its correlation 

mark. 

• Rotate the knob left to move the sensor to GS. 

• Rotate right to move it OS. 

3. Repeat step 2 for each used sensor. 

4. If necessary, go to “Adjusting the Cue Sensor” on page 3-19 to 

continue cue sensor setup. 

5. Print the job at a slow speed, and check each sensor for detecting the 

page correlation marks. 

6. If necessary, use step 2 again to fine-tune the sensor position. 




7. At the system controller, select Transport and Page. Then select the 

Check page correlation button to enable the page correlation feature. 

CS300 

CS600 & CS400 

Note: It is possible to enable and disable individual sensors for careful 

positioning. 

Select Transport and a printhead. 

Select Print and a printhead. 

8. At the system controller, set the starting document to where you want 

to start printing with page correlation. 

9. Perform “Saving the Job Settings” on page 2-52. 

10. Resume printing the job. 

Saving the Job Settings 

Perform the following steps: 

1. Select Application. 

2. Select File. 

3. Select Save to use the existing file name or Save as... to name a new 

file. 

Recovering From an Emergency Stop 


1. If you have pressed an EMERGENCY STOP button, twist the 

EMERGENCY STOP knob clockwise. The knob springs out to the 

original position. 

2. At print tower D, check the Operator display for any errors. 

• If the screen has a red Error, press the button to display an Error 

screen. 

• If the screen has a red Alarm, press the button to display the 

Error setting screen. 

• All error screens and corrective actions for the transport are 

discussed in Chapter 4, “Troubleshooting”. 

• Errors and corrective actions for the controller are discussed in 

online help. 

3. Correct the error condition, or call a key operator or service person to 

perform the following actions: 

• Resetting breaker switches 

• Checking for clutch failure 

• Checking for relay failure. 

4. At the Operator display, perform the following steps if Fast stop is red 

or flashing red: 

a. Press Fast stop. The button will flash on and off. 

b. Press EMERG. RESET to reset the transport. 

c. Press Fast stop. The button will return to its normal color. 




5. At the rewind unit, reduce the TENSION SETTING to 0. 

6. Select GRIPPER OFF. 

7. Allow the dancer roller to go to its lowest position, then select TENSION 

ON. 

8. Select Ready, then select Jog, and allow the core to reach five or 

more rotations. 

9. Increase the TENSION METER reading to a setting for the paper. 

(Standard paper is setting 11 for an 11-inch web, lighter paper may be 

a setting of 5.) 

10. Still at the rewind unit, select Ready, and then select Run slow. 

11. At an Operator display, use one of the following alternatives: 

• Select Run fast to resume printing at full speed. 

• Select a new speed (“Selecting a New Printing Speed” on page 

2-53). 


operations. 

Selecting a New Printing Speed 

You can select a new speed at the Operator display in print tower D or at 


Note: When the printing system has an active controller, the printing speed 

controls are delayed by a few seconds at print tower D. 


1. At the Main screen, Operator display, print tower D, use one of the 

following steps: 

• Select a speed shown as a Job speed button. 

• Press a Job speed arrow to increase or decrease the speed. 

2. Continue system operations. 

Turning the Printing System Off 


1. At the operator display or system controller, select Stop to stop the 

job and stop printing. 

2. At the operator display, from the Main screen, select Dryer and then 

Off to turn off the dryer. 

3. At the rewind unit, select GRIPPER ON to maintain the web tension. 




4. Use the following options for placing the print stations in a standby 

condition. Refer to the DT9000 series print stations Operator’s Guide 

for additional information. 

• Idle time from 1 to 4 hours 

Normally, leave the printhead in Ready. 

Or place the printheads in Clean Mode, with the following lettered 

steps. You will leave the print station powered on. 

a. Select PSI from the subsystem bar. 

b. Select the appropriate Printhead from the subsystem bar. 

c. From the work area, select Clean. 

d. Repeat these steps for each printhead. 


• Idle time from 4 hours to 88 hours (3 days and 16 hours) 

Place the printheads in Wakeup Mode, with the following lettered 

steps. You will leave the print station powered on. 

a. Check the external supply of ink. Each print station in 

wakeup mode requires 0.4 L ( 1 /2 qt) ink for each 8 hours. A 

normal weekend requires nearly 3 L ( 3 /4 gallon) per print 

station that uses the same ink. If any ink supplies are low, 

replace the supply using “Replacing an Empty Ink Container” 

in the print station Operator’s Guide. 

b. From the subsystem bar, select PSI. 

c. From the function bar, select Wakeup, which displays the 

Wakeup screen. 

Print station check box 




d. In the work area, specify the printheads to be placed in sleep 

mode: 

• To select a specific printhead, click on the appropriate 

printhead check box. 

• To select all connected printheads, select Select All. 

• To clear all selected printheads, select Clear All. 

Note: Any printheads not selected for wakeup are left in their current states. 

e. From the Wakeup Time spin box, select the time and use 

the arrows to change the time value. The startup time must 

be greater than 30 minutes from the current time. 

f. From the Startup Date drop-down list, select the arrow to 

display the month view calendar. The current date is circled 

in red. 

g. Select the date when the idle period should end. The startup 

date can be set up to three days and two shifts (88 hours) in 

advance. 

h. Select Enable. 

The print station begins bringing the selected printheads to 

XFLUSH. The Wakeup status will read ENABLED and show 

the time remaining until startup. 

Note: Some errors that can occur during this mode will prevent bringing the 

printhead to SERVCLEAN when the wakeup time is reached. 

i. To start printing at the end of the wakeup period, go to 

“Completing Wakeup Mode” in the print station Operator’s 

Guide. 

j. Go to step 5. 




• Idle time for more than 3 days 

Bring all printheads to SHUTDOWN. You may power off the print 

station when the printhead state is ALL OFF. 

a. If the printhead is in catch and the catchpan is not 

installed, close the eyelid before attempting to shut 

down a printhead. Refer to “Changing Eyelid Positions” 

in the print station Operator’s Guide. 

b. From the subsystem bar, select PSI. 

c. From the function bar, select Summary. 

d. Select Shutdown All. 

During the shutdown sequence, SHUTDOWNPRG 

appears in the Sequence text field. When shutdown is 

complete, “0” appears in the Time Remaining text field, 

and “Finished” appears in the Sequence text field. 

After the shutdown sequence is complete, the printhead 

is placed in ALLOFF state, as shown in the Sequence 

text field. 



Idle time is less than 3 days 

Leave the controller running. The controller must remain active 

to respond to any printer errors and to wake up printers at the 

desired time. 

Stop turning the printing system off here. 

Do not turn off any print stations or the controller. 

CS220 

a. If the idle time is more than 3 days, allow the shutdown to 

complete. 

b. At the system controller, quit the PSI software. 

c. Turn off the system controller computer. 


CS300 CS400 & CS600 

a. If the idle time is more than 3 days, select Application. 

b. Select Shutdown. 




c. Select Begin shutdown. 

After you confirm the selection, the controller initiates the 

shutdown sequence for all printheads. 

During the shutdown sequence, if you are monitoring the 

process from the PSI screen, SHUTDOWNPRG appears in 

the Sequence text field. When shutdown is complete, “0” 

appears in the Time Remaining text field, and “Finished” 

appears in the Sequence text field. 

After the shutdown sequence is complete, the printhead is 

placed in ALLOFF state, as shown in the Sequence text 

field. 

d. Allow the shutdown to complete. 

e. Select Shutdown controller. 

After you confirm the selection, the controller shuts down 

the software and, depending on your settings, the operating 

system. 

f. When notified by the computer operating system, shut off 


g. Go to step 6. 

6. At the control box, turn both switches off (Figure 2.41). 

7. If the printing system has a second control box or a transformer, turn 

off the power switches at these units. 

Figure 2.41 

Main switches, control box 





Unwind Unit Operations 

Unwind Unit Operations 

The following procedures are presented in other parts of this Operator’s 

Guide: 

• “Loading and Unloading Paper at the Unwind Unit” on page 2-4 

• “Webbing the Unwind Unit” on page 2-10 


• Setting the position and tension of gripper rollers. Refer to “Adjusting 

the Gripper Rollers” on page 2-14 

• “Jogging the Web” on page 2-14 

• “Positioning the Web Break Sensor” on page 2-32. 

Setting the Roll End Detection 

Roll end detection sets up stopping a print job before the unwind roll is 

empty. With roll end detection, roll changes can be done without needing 

to reweb the unwind unit. Use the following steps: 

1. At the unwind unit, select ROLLEND ON. 

2. At the Operator display, print tower D, select APU. 

3. Select PAPER END to display the Paper end screen. 

4. Select APU. 

5. In the Roll end section of the screen, select Stop or Run slow. 

• Stop causes the printing system to stop at the end of the roll. 

• Run slow causes the printing system to slow down. 

6. Check the position of the roll end sensor, and move it if necessary to 

a location near the paper core. 

Figure 2.42 

Positioning end of roll sensor 


End of roll sensor 

7. Continue printing the job. 



Rewind Unit Operations 

8. When the Paper end error occurs near the end of the roll, stop 

printing and change the roll (“Loading and Unloading Paper at the 

Unwind Unit” on page 2-4). 

9. At the Operator display, print tower D, press OK or MAIN to clear the 

error and resume printing. 

Rewind Unit Operations 

The following procedures are presented in other parts of this Operator’s 

Guide: 

• “Loading and Unloading Paper at the Rewind Unit” on page 2-8 

• “Webbing the Rewind Unit” on page 2-20 


• Setting the position and tension of gripper rollers. Refer to “Adjusting 

the Gripper Rollers” on page 2-14 

• “Jogging the Web” on page 2-14 

• “Positioning the Web Break Sensor” on page 2-32 

• “Selecting the Motor Direction” on page 2-22 

• “Tightening the Web” on page 2-23. 


Chapter 3. 

Advanced Operations 

The procedures in this chapter are appropriate for key operators and 

service technicians who have received training in advanced procedures. 



Identifying Printheads 


The identifying of a printhead involves three modules—the print tower, the 

print stations, and the system controller—and the cabling between these 

modules. Each of the modules identifies the printheads in a unique way. 

The correct printhead numbering can help you identify which printhead is 

connected to a given print station, and the numbering can indicate which 

part of the job file provides information for printing at that printhead. This 

section shows how setting up each module in support of the printing 

system can simplify the printhead numbering. 

Baseline System Numbering 

A baseline printing system with two print towers and no upgrades can 

have up to four printheads. The printheads are numbered 1 through 4 

usually, and printhead 1 is the first to print on the web. Figure 3.1 shows 

the suggested printhead positions and identities when the printing system 

is printing single-page process color and each printhead provides a 

different color. 

Figure 3.1 

Printhead numbering, baseline system 

C 

1 

1A 

M 

2 

2A 

K 

3 

3A 

Y 

4 

4A 

Page Corr. 

Web cleaner 

In a process color configuration, the order of color printing is cyan (C) 

from printhead 1, followed by magenta (M), black (K), and yellow (Y). The 

Printhead summary screen identifies the same printheads as 1A, 2A, 3A, 

and 4A. These identities use a number for the print station and a letter for 

the printhead. Thus this configuration has four print stations, each with 

one printhead. 

The configuration of two print towers can be used for printing two colors 

two-up also, but the numbering of the printheads changes to identify the 

colors and printhead locations (Figure 3.2): 1A, 1B, 2A, and 2B. The 

configuration has two print stations, each with two printheads. 

3-2 VX5000/50003 Printing Systems



Figure 3.2 

Printhead numbering for 2-up, 2-color 

K L 

1 

1A 

K R 

2 

1B 

S L 

3 

2A 

S R 

4 

2B 

K = Black 

S = Spot 

R=Right 

L=Left 

Page Corr. 

Web cleaner 

The same configuration can use the turnbar and the same numbering for 

printing two colors over two colors (2 over 2, Figure 3.3). In this 

configuration, printhead 1A places black ink on the obverse (the front 

side, shown with the black path), and 1B prints black on the reverse after 

the web has gone through the turnbar, shown with the gray path. 

Figure 3.3 

Webbing and numbering for 1-up; 2-over-2-color 

K = Black 

S = Spot 

R=Reverse 

O=Obverse 

K O 

1 

1A 

K R 

2 

1B 

S O 

3 

2A 

S R 

4 

2B 

Page Corr. 

Web cleaner 




Eight-Rail Numbering 

Print towers B and C can be part of the printing system. The print towers 

are located between print towers A and D. This configuration can provide 

two standard alternatives to use with process color: 

• Duplex process color (4 over 4, Figure 3.4) 

• Two-up process color (4-C 2-up, Figure 3.5). 

In both cases, four print stations with two printheads each are used. 

Figure 3.4 

C = Cyan 

M=Magenta 

K = Black 

Y = Yellow 

Webbing and numbering for duplex 4-color 

C O M O K O Y O 

1 2 

3 4 

1A 2A 3A 4A 

C R M R K R Y R 

5 6 

7 8 

1B 2B 3B 4B 

Page Corr. 

R = Reverse 

O = Obverse 

Web cleaner 

Figure 3.5 

C = Cyan 

M=Magenta 

K = Black 

Y = Yellow 

Webbing and numbering for 2-up 4-color 

C L M L K L Y L 

1 2 

3 4 

1A 1B 2A 2B 


5 6 

7 8 

3A 3B 4A 4B 

R = Right 

L = Left 

Page Corr. 

Web cleaner 




Figure 3.6 

Alternative numbering for 2-up 4-color 

Best registration occurs when the four colors are printed by adjacent 

printheads. However, specific applications may use a third arrangement 

of how the print is laid (Figure 3.6). 

C = Cyan 

M=Magenta 

K = Black 

Y = Yellow 

C L C R M L M R 

1 2 

3 4 

1A 1B 2A 2B 

K L K R Y L Y R 

5 6 

7 8 

3A 3B 4A 4B 

R = Right 

L = Left 

Page Corr. 

Web cleaner 

Other types of printing jobs can also be completed with the same 

configurations. However, printing more than four colors before drying is 

not recommended. 

Figure 3.7 

Multiple Print Bank Numbering 

The VX5000 printing system may be purchased with two banks of print 

towers, or the printing system may be upgraded at any time to add print 

towers. Customers often prefer to upgrade in steps from four printheads 

to eight, and from eight printheads to twelve or sixteen. 

The upgrade to twelve printheads requires a fifth and a sixth print tower. 

The configuration allows printing a single-color reverse—usually black— 

in a duplex print job, which can make use of two printheads that use the 

same color ink from one print station (Figure 3.7). The configuration also 

allows printing black and a spot color. 

Printhead numbering, 12-printhead system 

K = Black 

S = Spot 

K L 

1 

1A 

R=Right 

L =Left 

K R 

2 

1B 

S L 

3 

2A 

S R 

4 

2B 

C = Cyan 

M=Magenta 

K = Black 

Y = Yellow 


5 6 7 8 

3A 3B 4A 4B 

R = Right 

L = Left 


9 10 11 12 

5A 5B 6A 6B 

Page Corr. 

Web cleaner 




The upgrade to sixteen printheads requires a seventh and an eighth print 

tower. Printhead locations may use configurations similar to those 

discussed already, but for use on the reverse of a two-up, duplex process 

color print job (Figure 3.8). 

Figure 3.8 

Printhead numbering, 16-printhead system 

R = Right 

L = Left 


1 2 3 4 

1A 1B 2A 2B 


5 6 7 8 

3A 3B 4A 4B 

C = Cyan 

M=Magenta 

K = Black 

Y = Yellow 


9 10 11 12 

5A 5B 6A 6B 

R = Right 

L = Left 


13 14 15 16 

7A 7B 8A 8B 

Page Cor 

Web cleaner 

The eight print towers also provide many other alternatives, using a 

mixture of spot colors laid out in simplex or duplex, one-up or two-up 

formats. The job may use three different colors, with two printheads laying 

ink that is the same color as other printheads, or as many as eight 

different colors. 

This section does not describe all possible printhead configurations and 

print job requirements. 

Adding a Printhead to the Configuration 

Printheads must be identified in the following three places for correct use 

in a printing job: 

• In the PSI configuration 

• In the current job 

• In the displayed model of the printing system. 

If a printhead is not identified in all three places, an error or warning may 

alert you to a problem, or expected controls for the printhead will be 

unavailable. Identifying the printhead in the PSI configuration is typically 

in the hands of the persons who install and set up the printing system. 

Identifying the printhead in the job is in the hands of the persons who 

build the print job and its data. 

The following steps focus on the direct controls that an operator has, and 

the procedure should be needed only after installing an additional 

printhead to the printing system. 

1. Ask your service person to check all print stations for their INet 

addresses and to enter the addresses in the PSI → Config screen. 

2. At the controller, select Transport → Model, and add the printhead(s) 

at the proper location(s) in the system schematic. 




3. Select Print, and verify that the printhead appears in the correct 

location in the schematic. 

4. Select the Printhead, and perform the following steps to define the 

printhead: 

a. Select the Cue sensor that the printhead’s cue delay is 

measured from. 

b. Enter the Cue delay. “Setting the Cue Delays” on page 3-22 

describes measuring the cue delay. 

c. Enter a Speed compensation value, if known. “Calculating the 

Speed Comp Value” on page 3-27 describes the process. 

d. Enter a Registration value, if required. 

CS600 & CS400 e. Verify the data station and RIP assignment. 

CS300 f. Select Front or Back for the printhead position. 

g. Enter a mount Position, if known. 

CS600 & CS400 h. If the printhead is a 1” or 4” printhead, define the Tower, Rail, and 

Bucket. 

i. Verify the ink Color that the printhead prints. 

j. If Page correlation is used, enter a Mark position (its height), a 

Mark width, and select a Sensor that reads the page correlation 

mark. 

k. Select Apply. 

5. Go to “Enabling an Existing Printhead” on page 2-29 if the printhead 

is to be used in the current print job. 

Using an MPC Manual Setup 

This section will be provided at a later date. 

When an MPC job is loaded, the job parameters are provided to the 

controller. It is possible to modify some parameters for customizing the 

job. This section will document the modifications that are available. 




Setting Up Printing for the CS300 

Setting up a process-color job or a job that prints spot color from data 

supplied to a CS300 is a part of job setup. You will find the full job setup 

process in “Setting Up a Print Job” on page 2-35. Setting up the CS300 

job demands the skills of an experienced graphic arts operator, because 

the CS300 allows you to tune the printed color to a very fine degree. This 

section guides use of the Job subsystem. 

1. Select Forms. Select a form from the options shown. If the desired 

form is not shown, create a new form or change one of the existing 

forms by using the following lettered steps. 




a. On the New form screen or Change form screen, enter a 

descriptive name for the form. Then set the dimensions and the 

location for the top left corner of the page. In the Cut sheet block, 

determine how the pages of the document should be handled 

while they are being printed. 

Figure 3.9 

Cut sheet modes 

1 2 2 1 

Force left/right 

Force right/left 

1 2 2 1 

Force inverted left/right 

Force inverted right/left 

GS 

1 

OS 

Web direction 

2 3 

Incoming 1-up 

IPDS data stream 

to CS300 

b. The Reserved button selects a special swapping arrangement 

that forces inverted left/right on the back side and forces noninverted 

right/left on the front side. 

2. If the Job Setup Sheet indicates that the job data requires color 

printheads, select Transport → Setup → Printhead to identify colors 

available for the front and back printheads. This information is used in 

step 3. 

Note: Print stations built after 2003 automatically report the ink installed 

and its color, and this step can be used to verify the settings. Some 

older print stations that do not report the ink require this step for 

accurate recording of the ink used by a printhead. 

3. Select Colors. Map the system colors used in the Job Setup Shee to 

printheads printing on the front or back of the web. 




For each system color to which you assign printhead colors, your 

selection of a printhead color will select all printheads printing that 

color on one side of the web. If your printing system has CMKY 

printheads, the most workable settings are shown in the following 

table. 

System color Front Back 

Cyan Cyan Cyan 

Magenta Magenta Magenta 

Black Black Black 

Yellow Yellow Yellow 

All others Black Black 

a. Select a System color. 

b. Press the Front or Back color button until the correct color is 

selected. 

c. Repeat step a and step b for any number of System colors. 

• Exactly sixteen System colors are available, as listed on the 

screen. 

• System colors are identified in the job data for specific portions of 

the printed product. For example, a company logo may be printed 

always with System color Dark Blue, and when the logo appears 

in the data, it is assigned that System color. 

• Because the System color is mapped here to an ink color and a 

printhead, the data that is printed may or may not be the same 

color as the selected System color. 

• If your printhead configuration supports it, the same System color 

may be provided the same or different printhead colors on the 

back and front. 

• If an ink color does not exist for a match to a System color, your 

Job Setup Sheet may guide your selections here. 




4. Select Setup. Select the print options from the options shown. 

a. Select an IPDS resolution, which should be listed in the Job 

Sheet. Selecting Auto resolution may be used if the IPDS 

resolution is not known. 

b. Select a Print resolution. Only two choices are allowed. 

c. Enable or disable Clear memory for security. If selected, as 

soon as the data has been sent to the printhead for printing, the 

data is removed from the buffer. Thus, for example, it is possible 

to miss printing a document if one of the printheads has a charge 

short, printing was stopped, and printing was resumed without 

performing a backspace. 

d. Enable or disable Position marking. If selected, when data is 

being printed outside the selected form, a mark is printed 

automatically at the edge of the print area. 

e. Code page is set to a default that should not be changed. 

f. Select an Orientation. The selection controls the orientation of 

the form, not of the pages within a form. The page orientation is 

selected as part of defining the form. 

g. Select End of job operations. Selecting Purge will cause a stop 

of printing between jobs, allowing changes of rolls or other transition 

work. Selecting Continue allows printing the next job iimmediately. 

h. Select, locate and give the dimensions and color of any cue mark 

to be printed on the front. 

i. Select, locate and give the dimensions and color of any cue mark 

to be printed on the back. 

j. If desired, select the 2D Bar code characteristic that allows for 

reduced size of each element in the bar code. A selection here 

does not reduce the size of the bar code itself. Selecting 0 




provides no reduction, 1 reduces the bar code by one dot, 2 by 

two dots. Values greater than 2 are not recommended. Using 

reduction may correct dot gain in the printed document. 

5. If your printing system has printheads that use process color inks, 

select Spot, and define any composite colors with the following 

lettered steps. If your printing system has printheads that print black 

and one or more spot colors, you may need to modify this screen to 

duplicate the mapping set in step 3, with 100% intensity from a single 

system color. 

Print jobs that require OCA colors will typically require some 

adjustment through using this screen. Your work here will select each 

OCA color and then identify the intensities of each of its CMKY 

component colors. (Print jobs that use highlight colors and CMKY 

inks may require some adjustment through using the Highlight 

screen.) The selections here of intensity and any mixing of system 

colors for the resulting OCA color may affect the arrangement of data 

that is sent to each printhead. An intensity of less than 100% will 

cause dithering in the data for the printhead, and the printed result 

from two or more printheads will be the desired OCA color. 

• For example, any OCA colors of pure CMKY tones use 100% 

intensity of that system color of the same tone. Only the cyan 

printhead(s) receive(s) data identified as OCA cyan. 

• Using a more complex OCA color for another example, OCA 

mustard is composed of 0% cyan, 14% magenta, 23% black, and 

64% yellow. The printhead(s) printing magenta, black, and yellow 

are all provided dithered portions of the data identified as OCA 

mustard. 

a. If a file exists, select Open to select the file. The default 

configuration is exactly matched from OCA color to System color. 

The file names for these spot selections use .clr as an extension. 

If the file stdoca.clr is present in the .\clr directory, it contains the 

default settings. 




b. To define a new OCA color or to modify the contents of an 

opened file, select an OCA color. 

c. Identify the component colors by selecting one or more system 

colors and setting the intensity of each. 

d. Select Apply to save the color definition. 

e. Repeat step b through step d for each OCA color desired. 

f. Select Save to make a file of your changes to OCA color 

mapping. 

6. If your printing system prints spot colors that are either true spot 

colors or colors composed of two or more inks, select Highlight, and 

define these highlight colors with the following lettered steps. 

Print jobs that require highlight colors may require some adjustment 

through using this screen. Your work here will select each highlight 

color and then identify the intensities of each of its component system 

colors. (Print jobs that require spot colors through the use of CMKY 

inks may require some adjustment through using the Spot screen.) 

The selections here of intensity and any mixing of system colors for 

the resulting highlight may affect the arrangement of data that is sent 

to each printhead. An intensity of less than 100% will cause dithering 

in the data for the printhead, and the printed result from two or more 

printheads will be the desired highlight color. 

a. If a file exists, select Open to select the file. The default 

configuration is exactly matched from System color to highlight 

color. 

The file names for these highlight selections use .clr as an 

extension. If the file stdoca.clr is present in the .\clr directory, it 

contains the default settings. 

b. To define a new highlight color or to modify the contents of an 

opened file, select or name a highlight color. 




c. Identify the component colors by selecting one or more system 

colors and setting the intensity of each. 

d. Select Apply to save the color definition. 

e. Repeat step b through step d for each highlight color desired. 

f. Select Save to make a file of changes to highlight color mapping. 

7. If your process colors should use color correction, select Correct. 

Use the following information for the type of color data in your print 

job. 

Your print data has CYMK colors 

a. Use the Look-up tables section for selecting a LUT for each 

color. 

• Each color will use a different LUT. 

• The selections can range from Full (100%) to None (0%). 

b. Select Apply to save the look-up table definition. 

Your print data has RGB colors or CMYK colors for offset 

presses 

a. Select Enable ICC color correction. 

• If your data has RGB colors, select the Default RGB input. 

• If your data has CMYK colors formatted for offset presses, select 

a Default CMYK input. 

• Select the CMYK output. 

• If your data may have unsupported colors, select a 

Transformation method. (This is also known as Rendering intent.) 

The selection allows you to map any unsupported colors to a 

color that can be printed. Four options are available, and Relative 

Color Metric usually has the best results. 

b. Select Apply to save the ICC color correction definition. 




8. If your data includes an area to be compared from form to form, 

perform the following lettered steps: 

a. Use the PSI screens to make the printheads in the system ready 

to print. 

b. Select Job → Bit region to enable the data comparison function. 

c. Ask your computer operator to send data from the host computer. 

d. Wait for data to show in the buffer. 

9. If your data includes an area to be compared from form to form, select 

Bit region to identify the area. Use the following lettered steps. 

a. Use the first scroll bar to display a position and printhead color 

that has data to be checked. The names of these positions are 

identified by your selections on the Colors and Spot screens 

(shown here as “Front, Black” and “Front, Blue”). 

b. Select the position and printhead color. 

c. Select Checking, if desired. 

d. If you want the data to be cleared after it has been checked—and 

before it will be printed, select Clearing. 

Note: From this point on, you may use some of the steps, and not all, to 

define the location of data to be checked. 

e. If desired, you can enter the starting location of the data to be 

checked in the X and Y fields. The values appear in fields near 

the lower scroll area. 

f. If desired, you can enter the size of the data to be checked in the 

Width and Length fields. The values appear in fields near the 

lower scroll area, and the area is shown in the scroll area. 




g. In the lower scroll area, enter a document number that contains 

the data to be checked. Alternatively, use the arrows to page 

through the document numbers. 

h. Select Fit to page or 1:1. The lower scroll area adjusts accordingly. 

i. Place the cursor at the top left corner of the data to be checked, 

and drag to the lower right corner. The values appear in fields in 

the upper scroll area and in fields near the lower scroll area. 

j. Select Apply to save the area information. 

k. Exit this setup activity by choosing another screen. 

10. If you are performing “Setting Up a Print Job” on page 2-35, return to 

step 6 on page 2-40. 

Setting the Web Tension 

Web tension is more critical at higher printing speeds. The tension should 

not be adjusted until after some printing has occurred. You should 

observe the effects of printing and drying on the web before changing the 

web tension. The following procedure fine-tunes the work of “Tightening 

the Web” on page 2-23. 

1. If the web is not moving already, select elect Run slow or Run fast. 

2. At the operator display, select Web. 

3. Select the web weight for the paper. 

4. Select Pull ratio. The following steps use the Pull ratio screen (Figure 

3.10). 

Figure 3.10 

Pull ratio screen 

Note: In the following steps, leave the setting for INFEED 1 unchanged at 

0.00%. Its pull ratio is a reference for all gripper rollers 

downstream. 



Zeroing the Printhead Position 

5. Adjust the gripper rollers in downstream order, tightening the web 

with the following steps: 

a. Select the gripper roller. 

b. Observe the paper upstream from the gripper roller. 

• If the tension is too loose, use Up arrow to add 0.01 to 0.05%. 

Excessive paper drift is one sign of loose web tension. Excessive 

ink coverage may occur when printing with loose web tension. 

• If the tension is too tight, use Down arrow to subtract 0.01 to 

0.05%. 

Snapping sounds while printing is one sign of high web tension. 

Excessive web breaks and coning of the rewind roll also indicate 

high web tension. 

Note: If the change crosses the zero point (0.00), you must press 

Positive or Negative to continue making a change in the same 

direction. 

c. Select Enter. 

d. Wait a minute or more, and check the paper tension again. 

e. If necessary, repeat the pull ratio adjustments for the gripper 

roller. 

f. Repeat step 5 for each of the downstream gripper rollers. 


• Go to step a in “Overview” on page 2-1 to start printing a job 

• Go to “Selecting a New Printing Speed” on page 2-53 

• Resume printing a job. 

Zeroing the Printhead Position 

Zero the printhead(s) if the electronic record of a printhead location is 

different from the printhead’s actual location. In most cases, the printing 

system will display an error about lateral registration. However, zeroing 

may be done at any other time. Use the following procedure: 

1. At the Operator display at print tower D, select Registration. The 

following screen appears: 



Aligning and Positioning the Web Guide 

Figure 3.11 


2. Select the printhead(s) with the zeroing error by pressing one or 

more printhead buttons. 

3. Select Error to display the Lateral positioning screen. 

Figure 3.12 


4. Select Start to move the printhead(s) to zero position. 

5. When the printhead(s) stop moving, and the Error screen displays 

again, select Return. to display the Registration screen. 

Aligning and Positioning the Web Guide 

Refer to the manufacturer documents provided with the printing system 

for aligning the web guide. 



Adjusting the Cue Sensor 


Your printing system has one or more cue sensors (Figure 3.14, Figure 

3.15, and/or Figure 3.13), whose locations are described in “Positioning 

the Cue Sensor” on page 2-30. Your printing system has four page 

correlation sensors described in “Positioning the Page Correlation 

Sensors” on page 2-51. 

The procedure for aiming the sensors at cue marks are basic operations. 

Refer to “Positioning the Cue Sensor” on page 2-30 or “Setting Up Page 

Correlation” on page 2-48. 

Figure 3.13 

Keyence sensor and amplifier, detail 

Sensor under the web 

Sensor above the web 

Adjusting the Sensitivity 

A sensor is held in place above the moving web by a rail parallel to a 

roller. The sensor creates a beam of light that is reflected in different 

amounts when a cue mark or unprinted web is under the beam. Adjusting 

the sensitivity helps the sensor respond correctly for the different values 

of reflected light. 

Different brands of cue sensors are used, depending on when the system 

was built and what options were ordered. The brands have the following 

control markings: 

Brand name Omron Sick Keyence 

Mode selector 

TEACH 

RUN 

(not used) 

TEACH 

RUN 

ADJUST 

(none) 

Threshold indicator (none) Row of red LEDs Green LED numbers 

Mark indicator 

Method of 

determining cue 

(none) 

TEACH 

button 

Row of green 

arrow LEDs 

SET button 

Sensor status LED is off; 

High red LED numbers 

Crossing threshold 




Omron cue sensor 

Use the following steps to adjust the sensitivity. 

1. Move the sensor or the web to place a cue mark under the sensor. 

2. Select TEACH with the MODE SELECTOR. 

3. Press the TEACH button. 

4. Move the sensor or the web to place unprinted web under the sensor. 

5. Press the TEACH button. 

6. Select RUN with the MODE SELECTOR. 

7. Continue operation. 

Figure 3.14 

Omron cue sensor, detail 

Light source and sensor 

Mode selector 

Teach button 

Sick cue sensor 


1. On the amplifier, unscrew the cover to reveal the controls. 

2. Move the sensor or the web to place a cue mark under the sensor. 

3. Select TEACH with the MODE SELECTOR. 

4. Press SET. The row of green arrow LEDs should light. 


6. Press SET. 

7. If the row of red rectangle LEDs light, repeat the procedure. 

8. Select RUN with the MODE SELECTOR. 

9. Close the cover and continue operation. 




Figure 3.15 

Sick cue sensor, detail 

Mode selector 

Red LED row 

Green LED row 

Set button 

Light source and sensor 

Keyence cue sensor 


1. On the amplifier (Figure 3.16), flip the cover to reveal the controls. 

2. Move the sensor or the web to place a mark under the sensor. The 

SENSOR STATUS LED should not light. 

3. Note the mark value shown by the RED LED NUMBER. 


The SENSOR STATUS LED should light. 

5. Note the non-mark value shown by the RED LED NUMBER. 

6. With the THRESHOLD SELECTOR ROCKER, change the value of the 

GREEN LED NUMBER to midway between the two readings. 

7. Test the setting by moving the mark under the sensor and away. The 

SENSOR STATUS LED should turn off and on. 

8. Close the cover and continue operation. 




Figure 3.16 

Keyence sensor and amplifier, detail 

Mode selector 

Threshold selector rocker 

Red LED numbers 

Green LED numbers 

Set button 

Sensor status LED 

Setting the Cue Delays 

Usually this procedure occurs just after system installation or 

reconfiguring for a new print job. Adjustments of cue delays affect the 

location of printing along the direction of web movement. The cross-web 

location of printing is controlled by moving the printhead from the 

Operator display at print tower D. 

Required Tools 

• Marking pen 

• Tape measure, 50 ft (15 m) or longer. 

1. Web the full printing system for a configuration required by a print job. 

• The webbing configuration may be for a typical print job. 

• The configuration may be unique, or a new type of print job. 

2. Perform “Adjusting the Sensitivity” on page 3-19 for any cue sensors 

that have not been adjusted. 

3. Using a black marker, mark the web at each beam from the cue 

sensors. Name each location on the web, beside your mark. Your 

printing system may include the following sensors: 

• Print tower A (See “Cue sensor” on page 1-11.) 

• Print tower A, reverse side (See “Cue sensor” on page 1-12.) 

• Print tower B or C (See “Cue sensor” on page 1-17.) 

• Print tower D (See “Page correlation sensors” on page 1-19.) 

4. Move all printheads to approximately the cross-web location of the 

cue marks, using the following steps. 

a. At the Operator display at print tower D, select Registration. 




b. Select one Printhead or more by pressing the printhead 

button(s). 

c. Enter a value for the distance to move the printhead(s). 

d. If desired, select Inch or mm to change to the alternate unit of 

measurement. 

e. Select OS or GS. The printhead moves immediately. 

f. If necessary, repeat step 4 for each printhead. 

5. At each printhead, mark the web immediately beneath the print array. 

Name each location beside the mark on the web. The closer your 

mark is to the actual array location, the less correction you will need 

to provide later. 

6. If your system includes a rewind unit, tear the web before it enters 

that module. 

7. Jog the web so the mark for the most upstream cue sensor is clear of 

the printing system. 

8. Tear the web to remove the entire length of marked web, and lay the 

web face up on the floor. 

9. Measure the distances from the first cue sensor to each downstream 

cue sensor, and mark the distances on the web at each cue sensor. 

10. Measure the distances from each printhead to the nearest upstream 

cue sensor, and mark the cue distances on the web at each 

printhead. 

• If the print job(s) will not use a preprinted cue mark, the first set of 

printheads will use a virtual cue. It is likely that one of the 

printheads will print a cue mark with black ink for use 

downstream. 

• If a set of printheads does not have a cue sensor upstream, the 

printheads will use a virtual cue. 

• For the virtual cue, the first printhead’s cue distance is 1.00 inch 

(2.54 mm), and the cue distance for each printhead downstream 

uses the distance from the first printhead plus 1.00 inch. 

11. At the system controller software, enter the cue distances as the CUE 

DELAY and provide other values as described for the system controller 

in your printing system. (Go to “CS300” on page 3-26, or “CS400 and 

CS600” on page 3-24.) 





a. From any screen, select Transport. 

b. Select Model, if necessary, to add modules such as print towers, 

printheads, cue sensors, and turnbars that depict your configuration. 

c. Select Job and Printers, if necessary, to drag and drop printheads 

to RIPs. 

d. Save your entries for the RIP assignments by selecting Apply. 

e. Select Print, then select each Printhead, and enter the following 

information: 


Used by 

printer 

As marked 

Selected in the Job → Printers screen. 

Cue sensor A, B, C, or D Identity of the cue sensor upstream of this 

printhead. (A is most upstream.) 

Cue delay 

Speed 

compensation 

As measured 

on the web 

0.010 or as 

measured 






on page 3-27. 


S120/1RIP 1 

Identifies the data source and RIP for the 

printhead, configured with Job → 

Printers. 

Mount 

Position 0.00 or 8.97 0.00: near the GS. 

8.97: near the OS. 

Color As filled 

Page correlation 

Mark Position 0.0 to 8.96 The location for the left edge of the page 

correlation mark. See “Placing the Page 

Correlation Marks” on page 3-29. 

Mark Width 0.063 to 8.96 The width of the page correlation mark. 

See “Placing the Page Correlation Marks” 

on page 3-29. 

Sensor Not used, 1, 

2, 3, or 4 

The sensor that will detect marks for this 

printhead. 




f. Save your entries for each printhead by selecting Apply. 

g. Repeat step e and step f for each printhead. 

h. Select each Cue sensor, and enter the following information: 


Used by 

printhead 

Compensation 

Cue interval 

As measured Distance from the leading edge of one 

cue mark to the next. 

Cue tolerance 0.01 to 0.25 A larger tolerance allows shifting of the 

printed material to cue marks. 

Max. missed 

cues 

0 or 3 to 6 0: missing cue marks cause generated 

cue marks. 

3 to 6: consecutive missing cues over the 

number cause an error. 

Override As needed Applies only to the first sensor. 

Generate As needed 

Generate 

count 

Generate 

internal 

Dark cue mark 

OR 

Light cue mark 

As needed 

As needed 

If more than one document is printed for 

each due, provide the number of 

additional documents per cue. 

If more than one document is printed for 

each due, provide the length of each 

document. 

Describe the cue mark. 

Startup delay 

documents 0 Applies only to the second and later 

sensors. 

distance As measured Distance from the nearest upstream cue 




i. Save your entries for each cue sensor by selecting Apply. 

j. Repeat step h and step i for each cue sensor. 

k. Go to step 12 on page 3-27. 




CS300 

a. From any screen, select Transport. 

b. Select Model, if necessary, to add modules such as print towers, 

printheads, cue sensors, and turnbars that depict this configuration. 

c. Select each Printhead, and enter the following information: 


Enable 

Selected 

Type 9300 

Color As filled 

Cue A, B, C, or D Identity of the cue sensor upstream of this 

printhead. (A is most upstream.) 

Mount front or back Front: prints on the front side of the web. 

Back: prints on the reverse. 

Position 0.00 or 8.97 0.00: near the GS. 

8.97: near the OS. 

Cue delay As measured 

on the web 





Speed 

compensation 

0.010 or as 

measured 


on page 3-27. 


d. Save your entries for each printhead by selecting Apply. 

e. Repeat step c and step d for each printhead. 

f. Select each Cue sensor, and enter the following information: 


Cue interval 

or 

As measured Distance from the leading edge of one 

cue mark to the next. 





Same as form Selected 

Cue tolerance 0.01 to 0.25 

Max. missed 

cues 

Startup delay: 

documents 

Startup delay: 

distance 

Requires definition of form size on 

Job→Forms screen. 

A larger tolerance allows shifting of the 

printed material to cue marks. 

0 or 3 to 6 0: missing cue marks cause generated 

cue marks. 

3 to 6: consecutive missing cues over the 

number cause an error. 

0 

As measured Distance from the nearest upstream cue 




g. Save your entries for each cue sensor by selecting Apply. 

h. Repeat step f and step g for each cue sensor. 

i. Select Print. 

j. Go to step 12 on page 3-27. 

12. Go to “Adjusting the Data Registration” on page 2-43. 

13. Go to “Adjusting the Printhead Registration” on page 2-45. 

Calculating the Speed Comp Value 

Speed compensation corrects the print registration for different 

characteristics of low-speed and high-speed printing. Providing this value 

may be optional. The value is needed more for jobs that may be run at 

both high speeds and low speeds or at very high speeds. 

The procedure prints test pages at a slow speed and then at a high 

speed. At a high speed, the ink drops will shift upstream without speed 

compensation, and this shift is noticed in comparison to any preprinted 

cue marks, text, or graphics. Use the following steps to calculate the best 

speed comp value for each printhead. 


• Web preprinted with cue marks or image with a clear leading edge 

• Measuring loupe, 7X minimum, scale intervals 0.005 or smaller. 

1. If possible, use web that is preprinted with cue marks or other preprint 

for each document. 

• The downstream edge of the cue mark or preprint will be used as 

a common measurement point. 

• If the web is not preprinted, the downstream edge of the image or 

text printed by the first printhead (the most upstream printhead) is 

used as the common measurement point. 

2. At the controller, set the Speed compensation to 0.000 for each 

printhead, using one of the following bulleted items. 

Note: If the web is not preprinted, set the first printhead’s speed 

compensation to 0.100 inch (0.254 cm). 




CS600 & CS400 • Select Print, then select each Printhead, and enter the value in 

the screen. 

Speed compensation 

CS300 • Select Transport, then select each Printhead, and enter the 

value in the screen. 

Speed compensation 

3. Print test patterns at a slow speed: 25 feet per minute (7 meters per 

minute) or no more than 50 fpm (15 mpm). (See “Printing Test Pages” 

on page 2-41.) 

4. Stop printing, cut out a print sample, and resplice the web. 

5. Increase the printing speed to the maximum and take another print 

sample. If possible, use 500 fpm (152 mpm). 

6. On the slow speed sample, as accurately as possible, measure the 

distance from the leading edge of the cue mark to the leading edge of 

print from each printhead. 

7. On the fast speed sample, measure the distance from the leading 

edge of the cue mark to the leading edge of print from each printhead. 

8. For each printhead, find the difference between the two samples’ 

measurements for each printhead. Typically the difference will be 

near 0.10 inch (0.254 cm). 




Figure 3.17 

Measuring the print differences for speed compensation 

25 fpm, 7 mpm 500 fpm, 152 mpm 

0.684 

0.577 0.608 

0.50 in, 1.270 cm 0.672 in, 1.706 cm 

Suscipit lorem 

ipsum dolor sit 

amet, con 

sectetuer 

adipiscing elit, 

sed diam 

nonnumy nibh 

Suscipit lorem 

ipsum dolor sit 

amet, con 

sectetuer 

adipiscing elit, 

sed diam 

nonnumy nibh 

9. Calculate the speed compensation Value for each printhead: 

• Using English units, use the following formula. 

Value = Difference in inches x 500 ÷ maximum speed 

• Using metric units, use the following formula. 

Value = Difference in cm x 152 ÷ maximum speed 

10. Enter the Value in each printhead’s definition, as in step 2. The range 

is 0.000 to 0.500 inches (0.000 to 1.27 cm). 

11. Check the registration at the low and maximum speeds again to make 

sure that the calculated value is appropriate. The differences should 

be less than 0.003 inch (0.007 cm), which is finer than the 

specification for holding register in the transport system. 

Placing the Page Correlation Marks 

Page correlation allows printing and reading of a block of encoded marks 

that is printed on each page. These encoded marks are added to the data 

while it is being ripped, and their use is not equivalent to data checking. 

The block of marks identifies a location on the web that should receive 

print data from one printhead that relates to print data from another 

printhead for the opposite side of the paper or for a page printed side-byside 

on the web. Up to four locations can be correlated, indicating four 

printed faces that are destined for the same printed product. These faces 

are the front left, front right, back right and back left sides in a two-up 

duplex print job. 

The block of encoded marks has six areas reserved for a printed mark or 

a white space, representing a number from 0 to 31. An operator can 

identify the position and size of the block with entries at the system 

controller, as described in “Setting Up Page Correlation” on page 2-48. 

Figure 3.18 shows the resulting marks printed for the 26th page or 

document, using the operator entries given. 

When “Generate numbers” is selected, a two-part number is printed after 

the correlation mark. The first part is the copy number, and the second 

part is the full document number. The two numbers are separated by a 

colon. 




Figure 3.18 

Page correlation marks 

Required 3.0 inches unprinted space before mark 

Position 0.25; Mark position 0.25 

Cue mark 

1:445242 

Height 0.25 

Position 0.25; Mark position 8.46 

Mark width 0.25 

Numbers produced with “generate numbers” 

1:445242 

Direction of web 

Placing the page correlation marks in a different area from the cue mark 

will avoid confusing the two marks. The cue mark can occur at the same 

point across the page, but it should be separated by twice the width of the 

sensor beam. The cue mark can be at the same point along the web, but 

it must be either more than 3.0 inches (7.62 cm) before the correlation 

mark or more than the distance set with Print → Cue sensor → Cue 

tolerance at the controller. 

Using Special Cueing 

Some installations need to print documents that are to be synchronized to 

a sheeter-stacker unit, folding unit, or other finishing equipment. Using 

special cueing can identify the cue sensor that provides the primary cue 

signal to this other equipment. Typically, any other cue sensors operate in 

a normal mode. 

The information in this section refers to sheeting requirements, but it can 

also be used for folding, stacking, eject gates, and many other finishing 

operations. 

Two Alternatives to Special Cueing 

Other means of achieving the same effect include the following alterations 

to the printing system or job data: 

• Position the cue sensor that actuates the sheeting at a greater 

distance upstream from the sheeter. This allows the cue signal to be 

registered before printed documents arrive at the sheeter, and may 

allow some period for the blade to be servoed to the correct sheeting 

location. 




For calculating the optimum location, multiply one half the sheet 

length times the number of revolutions to servo the sheeter cylinder 

one inch toward a new sheet mark. Then position the cue sensor that 

number of documents’ distance upstream. 

• Arrange for additional documents to be printed before the first 

document that must be well sheeted. 

For calculating the optimum number of additional documents, multiply 

one half the sheet length times the number of revolutions to servo the 

sheeter cylinder one inch toward a new sheet mark. Then begin 

printing with that number of documents’ data before the first nonscrap 

document. 

Implementing Special Cueing 

The following procedure is a manipulation of parameters in the controller 

software to achieve a result that was not originally intended. 

When using special cueing, some configurations use the first cue sensor 

in the printing system. The signal for that cue sensor is provided to the 

sheeting controls. Assuming that the first cue sensor is a long distance 

from the sheeter allows the sheeting action to adjust well before the first 

printed document reaches the sheeter. However, the calculations need 

occasional adjustment for paper stretching and shrinking due to humidity 

and temperature changes. In addition, any compensator adjustments in a 

slit-merge module may alter the true distance between the cue sensor 

and sheeter. 

CS600 & CS400 

CS600 & CS400 

The CS400 and CS600 controllers can allow manipulations of how a cue 

sensor is described that may provide special cueing with some accuracy. 


1. At the controller, select Tools, and then select Tach/Cue. 

2. In the Cue setup box, select Separate cue intervals for each sensor. 

3. Select APPLY. 

4. Select PRINT, and select the Cue A icon. 

5. If necessary, deselect Override. 

6. Set the Cue tolerance to 0.01 inches. 


8. Repeat step 4 through step 7 for all other active cue sensors.Set the 

Cue tolerance to the desired value (typically 0.1 inches). 




CS300 

CS300 

CS300 controllers can allow manipulations of how a cue sensor is 

described that may provide special cueing with some accuracy, but it is 

implemented through other controls. 


1. At the controller, select TRANSPORT. You may need to select Setup. 

2. For each cue sensor, deselect Same as form. 


4. Select PRINT, and select the Cue A icon. 

5. If necessary, deselect Override. 

6. Set the Cue tolerance to 0.01 inches. 


8. Repeat step 4 through step 7 for all other active cue sensors.Set the 

Cue tolerance to the desired value (typically 0.1 inches). 


Chapter 4. 

Troubleshooting 

The errors and warnings discussed in this chapter are only those 

displayed at the operator displays on the transport. Refer to controller 

online help for discussions of print station and controller errors. 

For web movement to occur for Run slow or Run fast speeds, the 

following seven conditions must be met: 

• All doors must be closed. 

• For printing at speeds higher than 75 fpm (28 mpm), the covers on 

the print towers must be closed. 

• The printing system must be webbed correctly. See “Webbing the 

Printing System” on page 2-4. 

• The web break sensors must be aligned to sense the web is in place. 

See “Positioning the Web Break Sensor” on page 2-32. 

• The OPERATOR KEY(S) must be switched off. See “Operator key” on 

page 1-18. 

• All gripper rollers must be engaged. 

• No indicators may be flashing red. Note that one indicator is placed 

behind the OS doors of print tower A. See “Print Tower A Controls” on 

page 1-11. 

• The correct finishing option must be selected at the Main screen, 

Operator display at print tower A. See “APR” on page 1-20. 

• If the rewind unit is the selected finishing option, the rewind control 

selections must include GRIPPER OFF and REWINDER TENSION ON. See 

“Rewind Unit Controls” on page 1-35. 

Controller Messages 

When errors occur in the print station, controller or print job, full 

information is available at the controller. To find the corrective actions 

needed for each warning or error, access the online help for each 

message when it displays. 

Error and status information is available in detail when you select 

Application, then select Messages. The messages screen (Figure 4.1) 

displays a log of all messages that have occurred since the log has been 

cleared. 




Figure 4.1 

Application → Messages screen 

The log includes many status messages that document the normal 

functions of starting the printing system, changing configurations, loading 

print jobs, and shutting the printing system down. Mixed in with these 

normal messages, you may find error and warning messages. 

• A green checkmark identifies a normal message. 

• A yellow exclamation point identifies a warning message. 

• A red x identifies an error message. 

General status of each component is available when you select Print. 

The print screen (Figure 4.2) indicates a status of each module with a 

green, yellow, or red bar at the base of each icon. 

Figure 4.2 

Print screen 

• The green checkmark shown here indicates that messages are 

available for display. Select the component that shows a green 

checkmark, yellow exclamation point, or red x for more detailed 

information. 




• When a warning or normal message is activated, its text is displayed 

for a short time at the bottom of the screen. 

• When an error is active, its text is displayed at the bottom of the 

screen until the condition is fixed and the message is cleared. 

• When a component is not used, it has no status bar, as shown for cue 

sensor B. 

The general status of each component is available when you select 

Tools, and then select Connections. The tools connection screen 

(Figure 4.3) reports the status of cabling connections and network 

identities. Its information is most useful to service persons. 

Figure 4.3 

Tools → connections screen 

The detailed print station and printhead status is available when you use 

the following steps to display detailed information for a specific printhead. 

1. From the subsystem bar, select PSI. 

2. From the work area, select the appropriate Printhead. 



Printing Machinery Messages 

3. From the work area, select More Detail. 

CS400 

You can also view the general status of system components while 

shutting the printing system down. (Select Application, then select 

Shutdown. 

• This status is most useful to monitor the proper closing down of each 

unit before shutting down the controller. 

• The status of each module is indicated by a green, yellow, or red bar 

at the base of each icon. 

• Select the module to display a list of the currently active messages for 

the module. 


When errors occur in the unwind unit, print towers, still picture unit, or 

rewind unit, the printing system does not allow some operations. The 

controller indicates the unit that has detected a problem on the application 

→ messages screen and the print screen. More information is available at 

the operator display at print tower D. The operator display helps identify 

what caused the error. 

When correcting the problem, refer to “Recovering From an Emergency 

Stop” on page 2-52 as needed to completely prepare the printing system 

for printing. 




Error Screen 

The Error screen displays when any error occurs. Press the red button to 

find more information about an error. 

Figure 4.4 

Error screen 

After correcting the source of an error indication, press Main to clear the 

error indicated. 

PRINT ERROR 

Explanation: 

Action: 

The system controller reported an error at a print station or printhead. 

Use messages displayed by PSI for correcting the problem. 

WEB BREAK 

Explanation: 

Action: 

A web break occurred. 

Reweb and splice the web at the break. 

• If another button is active, it indicates the location of the web break. 

• If no other button is active, the web break occurred in a print tower. 

DIAMETER MAXIMUM 

Explanation: 

Action: 

The roll is full at the rewind unit. 

Replace it with an empty core. 

PAPER END 

Explanation: 

Action: 

The roll is empty at the unwind unit. 

Replace it with a full roll. 

APU ERROR 

Explanation: 

Action: 

An error occurred at the unwind unit. 

Press this button for additional information, and see “APU Error Screen” 

on page 4-7. 

APU COVER OPEN 

Explanation: 

Action: 

A door is open at the unwind unit. 

Press this button for additional information, and see “APU Cover Screen” 

on page 4-8. 




MOTOR [NUMBER] ERROR 

Explanation: 

Action: 

GRIPPER ROLL ERROR 

Explanation: 

Action: 

An error occurred at a motor. 

Contact your service person. 

An error occurred at a gripper roller. 


APR ERROR 

Explanation: 

Action: 

An error occurred at the rewind unit. 

Press this button for additional information, and see “APR Error Screen” 

on page 4-16. 

IJP COVER OPEN 

Explanation: 

Action: 

A door is open at a print tower or spacer unit. 

Press this button for additional information, and see “IJP Cover Screen” 

on page 4-10. 

DRYER ERROR 

Explanation: An error occurred at the dryer in print tower D. 

Action: 

Press this button for additional information, and see “Dryer Error Screen” 

on page 4-11. 

APR COVER OPEN 

Explanation: 

Action: 

A door is open at the rewind unit. 

Press this button for additional information, and see “APR Cover Screen” 

on page 4-15. 

ERROR 

SEND MAIL 

Explanation: Displays an error detail screen, depending on the error. 

Action: See “APU Cover Screen” on page 1-31, “APR Error Screen” on page 4- 

16, “IJP Cover Screen” on page 1-30, “Dryer Error Screen” on page 4-11, 

or “APR Cover Screen” on page 1-32. 

Explanation: 

Sends an e-mail message to notify service dispatching that the error 

occurred, if the function is implemented at your facility. 

Note: Only authorized service persons or key operators should use this control. 




APU Error Screen 

The APU error screen displays when an error occurs in the unwind unit, 

the upstream spacer unit, or the processing unit. (The processing unit 

information displays even if the module is not installed.) 

Figure 4.5 

APU error screen 

ARM UP-DOWN 

Explanation: 

Action: 

The position of the lift arm is unusual for current settings. 

Move the lift arm to engage the unwind gears. If the lift arm operation 

appears to be correct, contact your service person. 

INTERLOCK ON 

Explanation: 

Action: 

The lock-down bearing on the unwind shaft fails to release. 


INTERLOCK OFF 

Explanation: 

Action: 

The lock-down bearing on the unwind shaft fails to close. 


COMPRESSOR 

Explanation: 

Action: 

The compressor has failed. 


JOG OVER SPEED 

Explanation: 

Action: 

PUNCH REGURATION 

Explanation: 

Action: 

PUNCH BLOWER 

Explanation: 

Action: 

The jog speed has exceeded the governor setting. 


The servo control of the punch regulator has failed. 


The servo control of the punch blower has failed. 


PUNCH SCREW 

Explanation: 

Action: 

The screw control of the punch machinery has failed. 





COMPEN MOTOR 

Explanation: 

Action: 

The compensator motor of the perf machinery has failed. 


GRIPPER ROLL 

Explanation: 

Action: 

The gripper roller in the first spacer unit is not engaged. 

Turn on the gripper roller. If engaging the gripper roller does not clear the 

error, contact your service person. 

APU Cover Screen 

The APU cover screen displays when any error occurs in the unwind unit, 

the upstream spacer unit, or the processing unit. 

Figure 4.6 

APU cover screen 

APU 

The following covers are on the unwind unit. 

UPPER COVER 

Explanation: 

Action: 

The glass cover is open. 

Close the cover, press OK, and select Main, APU, Web, Dryer, or 

Registration. 

GS1 COVER 

Explanation: 

Action: 

The GS door is open. 


Registration. 

GS2 COVER 

Explanation: 

Action: 



Registration. 

SLIDE COVER 

Explanation: 

Action: 

The sliding door at the downstream end is open. 


Registration. 




ARM GS COVER 

Explanation: 

Action: 

ARM OS COVER 

Explanation: 

Action: 

The GS access panel is open. 


Registration. 

The OS access panel is open. 


Registration. 

Processing No. 1 

The following covers are on the first processing unit. 

(The processing unit information displays even if the module is not installed.) 

UPPER COVER 

Explanation: 

Action: 



Registration. 

GS1 COVER 

Explanation: 

Action: 



Registration. 

SLIDE COVER 

Explanation: 

Action: 



Registration. 

PUNCH COVER 

Explanation: 

Action: 

The cover over the punch unit is open. 


Registration. 

Processing No. 2 

The following covers are on the second processing unit. 

(The processing unit information displays even if the module is not installed.) 

UPPER COVER 

Explanation: 

Action: 



Registration. 

GS1 COVER 

Explanation: 

Action: 



Registration. 




SLIDE COVER 

Explanation: 

Action: 



Registration. 

COMPEN COVER 

Explanation: 

Action: 

The cover over the compensator unit is open. 


Registration. 

IJP Cover Screen 

The IJP cover screen displays when any error occurs in the print towers 

or dryer. 

Figure 4.7 

IJP cover screen 

A UNIT STEP COVER 

Explanation: 

Action: 

A UNIT OS1 COVER 

Explanation: 

Action: 

A UNIT OS2 COVER 

Explanation: 

Action: 

The door to the spacer unit is open. 


Registration. 

The OS door to print tower A is open. 


Registration. 

The OS door to print tower A is open. 


Registration. 

C UNIT COVER 

Explanation: 

Action: 

The OS door to print tower C is open. 


Registration. 

D UNIT STEP COVER 

Explanation: 

Action: 

The spacer unit downstream from print tower D is open. 


Registration. 




D UNIT SLIDE COVER 

Explanation: 

Action: 

D UNIT DRYER COVER 

Explanation: 

Action: 

The sliding door of print tower D is open. 


Registration. 

The cover to the dryer is open. 


Registration. 

Dryer Error Screen 

The dryer error screen displays when any error occurs in the dryer. 

Figure 4.8 

Dryer error screen 

COVER OPEN 

Explanation: 

Action: 

The dryer cover is open during dryer operation. 

Close the dryer cover. 

DRUM OVERHEAT 

Explanation: 

Action: 

The drum temperature is too high. 

Correct the dryer temperature. If the error appears again, contact your 

service person. 

AIR OVERHEAT 

Explanation: 

Action: 

An intake air temperature is too high. 

Correct the air setting or air temperature setting. Check the air intake 

vents for obstructions. If the error appears again, contact your service 

person. 

AIR PRESS. DOWN 

Explanation: 

Action: 

AIR [NUMBER] HEATER BREAK 

Explanation: 

Action: 

Dryer air flow is failing. 

Check the air intake vents for obstructions. If the error appears again, 

contact your service person. 

The air heater has failed. 





DRUM [NUMBER] HEATER BREAK 

Explanation: The dryer heater has failed. 

Action: 


BLOWER ERROR 

Explanation: 

Action: 

A blower is not functioning properly. 


RESET 

Explanation: 

Action: 

Clears an error. 

If the cause of the error has been corrected, continue operations. 

Otherwise, contact your service person. 

NEGLECT BREAK 

Explanation: 

Action: 

Ignores a web break error and allows use by service persons while 

checking and correcting the problem. 

Operators should not use this control. 

MAIN 

Explanation: 

Action: 

Displays the dryer screen. 

None. 

Printhead Lateral Errors 

One of the seven printhead lateral errors will display when a zeroing error 

occurs in a printhead. One or more highlighted printhead numbers 

indicate where the error occurred. 

Figure 4.9 

Printhead lateral motor error indicator 

LATERAL MOTOR ERROR 

Explanation: 

Action: 

The motor that moves a printhead in the OS-GS direction has an error. 

Select OK to display the printhead lateral error screen and correct the 

problem. 

Figure 4.10 

Printhead lateral positioning error indicator 




WARNING: LATERAL ZERO POSITIONING NOT POSSIBLE DURING MACHINE RUNNING 

Explanation: 

Action: 

Zeroing a printhead was attempted while printing. Zeroing can only occur 

while the printing system is stopped. 


problem. 

Figure 4.11 

Printhead OS limit error indicator 

WARNING: OS LIMIT ERROR DO LATERAL ZERO POSITIONING 

Explanation: 

Action: 

A printhead has been moved beyond the OS position. 


problem. 

Figure 4.12 

Printhead OS over limit error indicator 

WARNING: OS OVER LIMIT 

Explanation: 

Action: 



problem. 

Figure 4.13 

Printhead OS limit error indicator 




WARNING: OS LIMIT ERROR DO LATEL ZERO POSITIONING 

Explanation: 

Action: 



problem. 

Figure 4.14 

Printhead GS over limit error indicator 

WARNING: GS OVER LIMIT 

Explanation: 

Action: 



problem. 

Figure 4.15 

Printhead GS limit error indicator 

WARNING: GS LIMIT ERROR DO LATERAL ZERO POSITIONING 

Explanation: A printhead has been moved beyond the OS position. 

Action: 


problem. 

Printhead Lateral Error Screen 

The printhead lateral error screen displays when any error occurs in the 

positioning mechanism for a printhead. 

Figure 4.16 





[PRINTHEAD NUMBER] 

MOTOR ERROR 

Explanation: 

Action: 

LATERAL ZERO POSITIONING 

START 

Explanation: 

Action: 

LATERAL ZERO POSITIONING 

STOP 

Explanation: 

Action: 

The motor for the identified printhead needs to be zeroed. 

Zero the printhead position. See “Zeroing the Printhead Position” on page 

3-17. 

Starts the zeroing for the selected printheads. 

Wait until printhead movement stops, then select Main, APU, WEB, DRYER, 

or REGISTRATION. 

Stops the zeroing for the selected printheads. 

Select printheads and press Start again. 

RESET 

Explanation: 

Action: 

This button displays the printhead registration screen. 

None. 

SEND MAIL 

Explanation: 

Action: 

Not implemented. 

None. 

RETURN 

Explanation: 

Action: 

Moves the selected printheads to their original positions. 

None. 

APR Cover Screen 

The APR cover screen displays when a cover is opened in the rewind 

unit. 

Figure 4.17 

APR cover screen 

UPPER COVER 

Explanation: 

Action: 



Registration. 




GS1 COVER 

Explanation: 

Action: 



Registration. 

GS2 COVER 

Explanation: 

Action: 



Registration. 

SLIDE COVER 

Explanation: 

Action: 

The upstream sliding door is open. 


Registration. 

ARM GS COVER 

Explanation: 

Action: 

ARM OS COVER 

Explanation: 

Action: 

The GS access panel cover is open. 


Registration. 

The OS access panel cover is open. 


Registration. 

APR Error Screen 

The APR error screen displays when an error occurs in the unwind unit, 

any gripper roller, or the rewind unit. 

Figure 4.18 

APR error screen 

ARM UP-DOWN 

Explanation: 

Action: 

The position of the lift arm is unusual for current settings. 

Move the lift arm to engage the unwind gears. If the lift arm operation 

appears to be correct, contact your service person. 

INTERLOCK ON 

Explanation: 

Action: 

The lock-down bearing on the unwind shaft fails to release. 





INTERLOCK OFF 

Explanation: 

Action: 

SLITTER MOTOR 

Explanation: 

Action: 

REWINDER INVERTOR 

Explanation: 

Action: 

REWINDER INVERTOR FAN 

Explanation: 

Action: 

The lock-down bearing on the unwind shaft fails to close. 


The motor for the optional slitter has failed. 


Exceeding the limits for paper movement has cause a failure in the 

inverter. 

Lower the tension, or use a lighter paper, and contact your service person 

to reset the inverter. 

The fan in the inverter has failed. 


TENSION OFF 

Explanation: 

Action: 

No tension is applied to the rewind unit. 

Turn on the tension control. If the error is not cleared, contact your service 

person. 

Miscellaneous Errors 

Some errors are indicated by display of a special notice. 

OVERHEATUNG IS UNUSUAL THE BREAKER OF A HEATER IS TURNED OFF 

Explanation: A circuit breaker has tripped for the dryer. 

Action: 


PLC BATTERY LOW 

Explanation: 

Action: 

SERVO BATTERY LOW 

Explanation: 

Action: 

The battery backup for RAM on the PLC computer is low. 

Press ok, notify a service person, and continue your print job. 

The battery backup for RAM on the servo computer is low. 

Press ok, notify a service person, and continue your print job. 

PROCESS UNIT OIL PUMP ERROR 

Explanation: Oil is low in the processing unit. 

Action: 

Perform “Supply Grease to the Processing Unit”. 

WARNING: UPPER COVER CLOSED 

Explanation: The cover to the print tower is closed, and printhead movement is not 

allowed. 

Action: 

Open the cover, and select the printhead movement again. 




WARNING: HIT TO COVER 

Explanation: 

Action: 

The printhead struck the cover to the print tower. 

Open the cover, and select the printhead movement again. 

WARNING: REMOVE CATCHPAN OR SERVICE TOOL 

Explanation: The catchpan or service tool was installed when you requested printhead 

movement. 

Action: 

Remove the catchpan or service tool, and select the printhead movement 

again. 


Chapter 5. 

Maintenance 

Operators must perform the regular maintenance shown in Table 5.1. 

Table 5.1 

Operator maintenance 

Procedure 

“Perform Print Station Maintenance” on page 5-2 

“Supply Grease to the Unwind Unit” on page 5-2 

“Supply Grease to the Unwind Unit Shaft Grip Adjust” 

on page 5-4 

“Supply Grease to the Printhead Worm Gear” on page 

5-5 

“Check the Web Cleaner Filters” on page 5-6 

“Clean the Web Cleaner Internal Components” on page 

5-6 

“Check the HEPA Filter for Dust” on page 5-7 

“Supply Grease to the Rewind Unit” on page 5-8 

“Perform Print Station Maintenance” on page 5-10 

“Replace the HEPA Pre-filters” on page 5-10 

“Replace the Web Cleaner Pre-filters” on page 5-10 

Frequency 

Weekly or as required 

Monthly 

Monthly 

Monthly 

Monthly 

Monthly 

Monthly 

Monthly 

Quarterly 

Quarterly or as 

required 

Quarterly or as 

required 



Daily Procedures 

Daily Procedures 

Perform the following maintenance daily, usually at the end of each shift. 

There are no daily procedures for the unwind unit or print towers or 

rewind unit. 

Weekly Procedures 

Perform the following maintenance weekly. 

There are no weekly procedures for the unwind unit or the rewind unit. 

Print Towers 

Perform Print Station Maintenance 

Refer to the Operator’s Guide for the DT9000 series print stations for 

maintaining components at the printhead interface and vacuum cabinet. 

Monthly Procedures 

Perform the following maintenance monthly. 

Note: All the procedures except for “Print Tower Units” on page 5-5 must be 

performed with power off for the full printing system. As desired, all 

procedures may be performed at the same time, and the final step of 

each procedure, turning on the printing system, can be ignored until all 

procedures are complete. 

Unwind Unit 

Perform the following monthly procedures. 

Supply Grease to the Unwind Unit 


1. At the unwind unit, bring the lift arms down, to move any roll away 

from the work area. (Use the first steps of “Loading and Unloading 

Paper at the Unwind Unit” on page 2-4.) 

2. Turn off the printing system, using the full procedure “Turning the 

Printing System Off” on page 2-53. 




Figure 5.1 

Grease locations, unwind unit, lift arms 

GS interior wall 

OS interior wall 

5 

7 

6 

8 

4 

1 

2 

3 

3. Repeat the following lettered steps for a total of eight times at the 

following locations: 

• OS lift arm and OS interior wall: (1) Interlock bearing, (2) End 

stop bearing, (3) Lower support bearing, (4) Control end pivot 

• GS lift arm and GS interior wall: (5) End stop bearing, (6) 

Interlock bearing, (7) Lower support bearing, (8) Control end 

pivot. 

1 

2 

5 

4 

6 

3 

7 8 

a. Attach the grease gun connector to a grease fitting shown in 

Figure 5.1. 

Note: The grease gun is supplied as an operator tool. The connector may 

be detached from the grease gun for easy storage in the supplied 

tool box. 




b. Pump the grease gun handle two or three times. Stop pumping if 

grease squeezes out at the fitting. 

c. Wipe any remaining grease off the fitting and adjacent surfaces. 

4. Turn on the printing system to raise the lift arms, or continue with the 

next monthly procedure. 

Supply Grease to the Unwind Unit Shaft Grip Adjust 




2. Attach the grease gun connector to a grease fitting shown in Figure 

5.2. 



tool box. 

3. Pump the grease gun handle two or three times. Stop pumping if 


4. Wipe any remaining grease off the fitting and adjacent surfaces. 

5. Continue with the next monthly procedure. 

Figure 5.2 

Grease locations, unwind unit, OS interior 

Grease fitting 




Print Tower Units 

Perform the following monthly procedures. 

Supply Grease to the Printhead Worm Gear 

At each printhead, use the following procedure: 

1. Stop printing or web movement. 

2. At each print tower, press Press COVER UP. An alarm sounds while 

the cover is moving. 

3. Move the printheads to service position. (See “Moving a Printhead to 

Service Position” on page 2-24.) 

4. At the back of the printhead carriage, attach the grease gun 

connector to a grease fitting shown in Figure 5.3. 



tool box. 

5. Pump the grease gun handle two or three times. Stop pumping if 


6. Wipe any remaining grease off the fitting and adjacent surfaces. 

7. Return the printhead to print position. (See “Moving a Printhead to 

Printing Position” on page 2-25.) 

8. Press COVER UP to lower the cover. An alarm sounds while the cover 

is moving. 

9. Repeat this procedure for each printhead. 

10. Continue with the next monthly procedure or printing operations. 

Figure 5.3 

Grease locations, worm gear, printhead, print tower 

Grease fitting 




Check the Web Cleaner Filters 


1. At the web cleaner, turn off power (Figure 5.4). 

2. Remove the cover of the web cleaner housing. 

3. Inspect the prefilter for accumulated dust or chad. 

4. If the filter is dirty, perform “Replace the Web Cleaner Pre-filters” on 

page 5-10. 

5. Replace the cover. 

6. Turn on power to the web cleaner, and return to printing operations. 

Figure 5.4 

Web cleaner unit 

Lid (closed) 

Main power 

Print tower A 

On-Off switch 

Clean the Web Cleaner Internal Components 

The following procedure contains information provided by the 

manufacturer of the web cleaner. Its content is subject to change without 

notice. Refer to operator instructions provided with the web cleaner for 

additional information. 


• Hand-held vacuum cleaner with soft brush attachment. 




2. Slide open the access door at the input to print tower A. 

3. Inside the print tower, open the web cleaner box (Figure 5.5). 




Figure 5.5 

Web guide box, inside print tower A 

Web guide 

Web cleaner component 

Spacer unit 

4. Tear the web to access the lower web cleaner brushes. 

5. If better access is needed, pop off the hydraulic damper on the end. 

Caution: Points on the anti-static bars are sharp, and they may cause injury. 

6. With a soft brush attachment, vacuum the brushes, antistatic bar, and 

brush emitter pins. 

7. Route the web through the web cleaner, and splice the web. 

8. Close the web cleaner box, and close the access door to print tower 

A. 

9. Continue with the next monthly procedure, or turn on the printing 

system to continue printing operations. 

Check the HEPA Filter for Dust 


1. Using a safety ladder or scaffold, lift the grill at the top of the HEPA 

filter housing. 

2. Inspect the prefilter for any accumulation of dust or crystallized ink. If 

the filter is dirty, perform “Replace the HEPA Pre-filters” on page 5- 

10. 

3. Replace the grill, and return to printing operations. 




Figure 5.6 



On/Off switch 

Rewind Unit 

Perform the following monthly procedures when the rewind unit is in use. 

Supply Grease to the Rewind Unit 


1. At the rewind unit, bring the lift arms down, to move any roll away 

from the work area. (Use the first steps of “Loading and Unloading 

Paper at the Rewind Unit” on page 2-8.) 



Figure 5.7 

Grease locations, rewind unit, GS lift arm 

1 

2 

4 

5 

3 

6 

7 



Quarterly Procedures 

3. Repeat the following lettered steps for a total of six times at the 

following locations: 

• OS lift arm and OS interior wall: (1) Interlock bearing, (2) Lower 

support bearing, (3) Lift arm bearing, 

• GS lift arm and GS interior wall: (4) Interlock bearing, (5) Lower 

support bearing, (6) Lift arm bearing, . 

a. Attach the grease gun connector to a grease fitting shown in 

Figure 5.7. 



tool box. 

3 4 

6 

1 

5 

2 

b. Pump the grease gun handle two or three times. Stop pumping if 


c. Wipe any remaining grease off the fitting and adjacent surfaces. 

4. Turn on the printing system, and raise the lift arms. 

5. Attach the grease gun connector to grease fitting (7) shown in Figure 

5.7, and apply grease. The fitting is at the OS end of the shaft and OS 

lift arm that are now in the lifted position 

7 

6. Continue with another next monthly procedure, or continue with 

printing operations. 

Note: Remember to raise the lift arms at the unwind unit. 

Quarterly Procedures 

Perform the following maintenance quarterly. 

There are no quarterly procedures for the unwind unit or rewind unit. 


Print Towers 

Perform Print Station Maintenance 

Refer to the Operator’s Guide for the DT9000 series print stations for 

maintaining components at the printhead interface and vacuum cabinet. 

Replace the HEPA Pre-filters 

Use the following procedure at each print tower: 

1. Using a safety ladder or scaffold, remove the grill at the top of the 

HEPA filter housing. 

2. Remove the prefilter and discard it. 

3. Inspect the mesh filter for any accumulation of dust or crystallized ink. 

If the filter requires replacement, contact your service person. 

4. Install a replacement prefilter. 

5. Replace the grill, and return to printing operations. 

Figure 5.8 



On/Off switch 

Replace the Web Cleaner Pre-filters 

Parts 

• 0195293 pre-filter 

• 0195294 mesh filter. 

Use the following procedure at each print bank: 

1. At the web cleaner, turn off power (Figure 5.4). 

2. Remove the cover of the web cleaner housing. 

3. Remove the pre-filter and discard it. 

4. Inspect the mesh filter for any accumulation of dust. If the filter is dirty, 

remove and discard the filter. Install a replacement mesh filter.


Annual Procedures 

5. Install a replacement pre-filter. 

6. Replace the cover. 

7. Turn on power to the web cleaner, and return to printing operations. 

Figure 5.9 

Pre-filter and mesh filter, web cleaner unit 

Pre-filter 

Mesh filter 

Annual Procedures 

None identified. 


Appendix A. Metric-English 

Conversion 

Table A.1 

Conversion table, fractional inch to mm 

Some operator screens require a web width in millimeters. The following 

table assists in those conversions. 

inch mm inch mm inch mm inch mm inch mm inch mm inch mm 

6 152.4 8 1/8 206.4 10 1/6 258.2 12 1/4 311.2 14 1/3 364.1 16 3/8 415.9 18 1/2 469.9 

6 1/8 155.6 8 1/6 207.4 10 1/4 260.4 12 1/3 313.3 14 3/8 365.1 16 1/2 419.1 18 5/8 473.1 

6 1/6 156.6 8 1/4 209.6 10 1/3 262.5 12 3/8 314.3 14 1/2 368.3 16 5/8 422.3 18 2/3 474.1 

6 1/4 158.8 8 1/3 211.7 10 3/8 263.5 12 1/2 317.5 14 5/8 371.5 16 2/3 423.3 18 3/4 476.3 

6 1/3 160.9 8 3/8 212.7 10 1/2 266.7 12 5/8 320.7 14 2/3 372.5 16 3/4 425.5 18 5/6 478.4 

6 3/8 161.9 8 1/2 215.9 10 5/8 269.9 12 2/3 321.7 14 3/4 374.7 16 5/6 427.6 18 7/8 479.4 

6 1/2 165.1 8 5/8 219.1 10 2/3 270.9 12 3/4 323.9 14 5/6 376.8 16 7/8 428.6 19 482.6 

6 5/8 168.3 8 2/3 220.1 10 3/4 273.1 12 5/6 326.0 14 7/8 377.8 17 431.8 19 1/8 485.8 

6 2/3 169.3 8 3/4 222.3 10 5/6 275.2 12 7/8 327.0 15 381.0 17 1/8 435.0 19 1/6 486.8 

6 3/4 171.5 8 5/6 224.4 10 7/8 276.2 13 330.2 15 1/8 384.2 17 1/6 436.0 19 1/4 489.0 

6 5/6 173.6 8 7/8 225.4 11 279.4 13 1/8 333.4 15 1/6 385.2 17 1/4 438.2 19 1/3 491.1 

6 7/8 174.6 9 228.6 11 1/8 282.6 13 1/6 334.4 15 1/4 387.4 17 1/3 440.3 19 3/8 492.1 

7 177.8 9 1/8 231.8 11 1/6 283.6 13 1/4 336.6 15 1/3 389.5 17 3/8 441.3 19 1/2 495.3 

7 1/8 181.0 9 1/6 232.8 11 1/4 285.8 13 1/3 338.7 15 3/8 390.5 17 1/2 444.5 19 5/8 498.5 

7 1/6 182.0 9 1/4 235.0 11 1/3 287.9 13 3/8 339.7 15 1/2 393.7 17 5/8 447.7 19 2/3 499.5 

7 1/4 184.2 9 1/3 237.1 11 3/8 288.9 13 1/2 342.9 15 5/8 396.9 17 2/3 448.7 19 3/4 501.7 

7 1/3 186.3 9 3/8 238.1 11 1/2 292.1 13 5/8 346.1 15 2/3 397.9 17 3/4 450.9 19 5/6 503.8 

7 3/8 187.3 9 1/2 241.3 11 5/8 295.3 13 2/3 347.1 15 3/4 400.1 17 5/6 453.0 19 7/8 504.8 

7 1/2 190.5 9 5/8 244.5 11 2/3 296.3 13 3/4 349.3 15 5/6 402.2 17 7/8 454.0 20 508.0 

7 5/8 193.7 9 2/3 245.5 11 3/4 298.5 13 5/6 351.4 15 7/8 403.2 18 457.2 20 1/8 511.2 

7 2/3 194.7 9 3/4 247.7 11 5/6 300.6 13 7/8 352.4 16 406.4 18 1/8 460.4 20 1/6 512.2 

7 3/4 196.9 9 5/6 249.8 11 7/8 301.6 14 355.6 16 1/8 409.6 18 1/6 461.4 20 1/4 514.4 

7 5/6 199.0 9 7/8 250.8 12 304.8 14 1/8 358.8 16 1/6 410.6 18 1/4 463.6 20 1/3 516.5 

7 7/8 200.0 10 254.0 12 1/8 308.0 14 1/6 359.8 16 1/4 412.8 18 1/3 465.7 20 3/8 517.5 

8 203.2 10 1/8 257.2 12 1/6 309.0 14 1/4 362.0 16 1/3 414.9 18 3/8 466.7 20 1/2 520.7 

Operator’s Guide A - 1

Appendix A. Metric-English Conversion 

Table A.2 

Conversion table, mm to fractional inch 

Some operator screens require a document length or fold length in whole 

inches and fractions of an inch. The following table assists in those 

conversions. 

mm inch mm inch mm inch mm inch mm inch mm inch mm inch mm inch 

101.6 4 222.3 8 3/4 342.9 13 1/2 463.6 18 1/4 558.8 22 679.5 26 3/4 800.1 31 1/2 920.8 36 1/4 

104.8 4 1/8 224.4 8 5/6 346.1 13 5/8 465.7 18 1/3 562.0 22 1/8 681.6 26 5/6 803.3 31 5/8 922.9 36 1/3 

105.8 4 1/6 225.4 8 7/8 347.1 13 2/3 466.7 18 3/8 563.0 22 1/6 682.6 26 7/8 804.3 31 2/3 923.9 36 3/8 

108.0 4 1/4 228.6 9 349.3 13 3/4 469.9 18 1/2 565.2 22 1/4 685.8 27 806.5 31 3/4 927.1 36 1/2 

110.1 4 1/3 231.8 9 1/8 351.4 13 5/6 473.1 18 5/8 567.3 22 1/3 689.0 27 1/8 808.6 31 5/6 930.3 36 5/8 

111.1 4 3/8 232.8 9 1/6 352.4 13 7/8 474.1 18 2/3 568.3 22 3/8 690.0 27 1/6 809.6 31 7/8 931.3 36 2/3 

114.3 4 1/2 235.0 9 1/4 355.6 14 476.3 18 3/4 571.5 22 1/2 692.2 27 1/4 812.8 32 933.5 36 3/4 

117.5 4 5/8 237.1 9 1/3 358.8 14 1/8 478.4 18 5/6 574.7 22 5/8 694.3 27 1/3 816.0 32 1/8 935.6 36 5/6 

118.5 4 2/3 238.1 9 3/8 359.8 14 1/6 479.4 18 7/8 575.7 22 2/3 695.3 27 3/8 817.0 32 1/6 936.6 36 7/8 

120.7 4 3/4 241.3 9 1/2 362.0 14 1/4 482.6 19 577.9 22 3/4 698.5 27 1/2 819.2 32 1/4 939.8 37 

122.8 4 5/6 244.5 9 5/8 364.1 14 1/3 485.8 19 1/8 580.0 22 5/6 701.7 27 5/8 821.3 32 1/3 943.0 37 1/8 

123.8 4 7/8 245.5 9 2/3 365.1 14 3/8 486.8 19 1/6 581.0 22 7/8 702.7 27 2/3 822.3 32 3/8 944.0 37 1/6 

127.0 5 247.7 9 3/4 368.3 14 1/2 489.0 19 1/4 584.2 23 704.9 27 3/4 825.5 32 1/2 946.2 37 1/4 

130.2 5 1/8 249.8 9 5/6 371.5 14 5/8 491.1 19 1/3 587.4 23 1/8 707.0 27 5/6 828.7 32 5/8 948.3 37 1/3 

131.2 5 1/6 250.8 9 7/8 372.5 14 2/3 492.1 19 3/8 588.4 23 1/6 708.0 27 7/8 829.7 32 2/3 949.3 37 3/8 

133.4 5 1/4 254.0 10 374.7 14 3/4 495.3 19 1/2 590.6 23 1/4 711.2 28 831.9 32 3/4 952.5 37 1/2 

135.5 5 1/3 257.2 10 1/8 376.8 14 5/6 498.5 19 5/8 592.7 23 1/3 714.4 28 1/8 834.0 32 5/6 955.7 37 5/8 

136.5 5 3/8 258.2 10 1/6 377.8 14 7/8 499.5 19 2/3 593.7 23 3/8 715.4 28 1/6 835.0 32 7/8 956.7 37 2/3 

139.7 5 1/2 260.4 10 1/4 381.0 15 501.7 19 3/4 596.9 23 1/2 717.6 28 1/4 838.2 33 958.9 37 3/4 

142.9 5 5/8 262.5 10 1/3 384.2 15 1/8 503.8 19 5/6 600.1 23 5/8 719.7 28 1/3 841.4 33 1/8 961.0 37 5/6 

143.9 5 2/3 263.5 10 3/8 385.2 15 1/6 504.8 19 7/8 601.1 23 2/3 720.7 28 3/8 842.4 33 1/6 962.0 37 7/8 

146.1 5 3/4 266.7 10 1/2 387.4 15 1/4 508.0 20 603.3 23 3/4 723.9 28 1/2 844.6 33 1/4 965.2 38 

148.2 5 5/6 269.9 10 5/8 389.5 15 1/3 511.2 20 1/8 605.4 23 5/6 727.1 28 5/8 846.7 33 1/3 968.4 38 1/8 

149.2 5 7/8 270.9 10 2/3 390.5 15 3/8 512.2 20 1/6 606.4 23 7/8 728.1 28 2/3 847.7 33 3/8 969.4 38 1/6 

152.4 6 273.1 10 3/4 393.7 15 1/2 514.4 20 1/4 609.6 24 730.3 28 3/4 850.9 33 1/2 971.6 38 1/4 

155.6 6 1/8 275.2 10 5/6 396.9 15 5/8 516.5 20 1/3 612.8 24 1/8 732.4 28 5/6 854.1 33 5/8 973.7 38 1/3 

156.6 6 1/6 276.2 10 7/8 397.9 15 2/3 517.5 20 3/8 613.8 24 1/6 733.4 28 7/8 855.1 33 2/3 974.7 38 3/8 

158.8 6 1/4 279.4 11 400.1 15 3/4 520.7 20 1/2 616.0 24 1/4 736.6 29 857.3 33 3/4 977.9 38 1/2 

160.9 6 1/3 282.6 11 1/8 402.2 15 5/6 523.9 20 5/8 618.1 24 1/3 739.8 29 1/8 859.4 33 5/6 981.1 38 5/8 

161.9 6 3/8 283.6 11 1/6 403.2 15 7/8 524.9 20 2/3 619.1 24 3/8 740.8 29 1/6 860.4 33 7/8 982.1 38 2/3 

165.1 6 1/2 285.8 11 1/4 406.4 16 527.1 20 3/4 622.3 24 1/2 743.0 29 1/4 863.6 34 984.3 38 3/4 

168.3 6 5/8 287.9 11 1/3 409.6 16 1/8 529.2 20 5/6 625.5 24 5/8 745.1 29 1/3 866.8 34 1/8 986.4 38 5/6 

169.3 6 2/3 288.9 11 3/8 410.6 16 1/6 530.2 20 7/8 626.5 24 2/3 746.1 29 3/8 867.8 34 1/6 987.4 38 7/8 

171.5 6 3/4 292.1 11 1/2 412.8 16 1/4 533.4 21 628.7 24 3/4 749.3 29 1/2 870.0 34 1/4 990.6 39 

173.6 6 5/6 295.3 11 5/8 414.9 16 1/3 536.6 21 1/8 630.8 24 5/6 752.5 29 5/8 872.1 34 1/3 993.8 39 1/8 

174.6 6 7/8 296.3 11 2/3 415.9 16 3/8 537.6 21 1/6 631.8 24 7/8 753.5 29 2/3 873.1 34 3/8 994.8 39 1/6 

177.8 7 298.5 11 3/4 419.1 16 1/2 539.8 21 1/4 635.0 25 755.7 29 3/4 876.3 34 1/2 997.0 39 1/4 

181.0 7 1/8 300.6 11 5/6 422.3 16 5/8 541.9 21 1/3 638.2 25 1/8 757.8 29 5/6 879.5 34 5/8 999.1 39 1/3 

182.0 7 1/6 301.6 11 7/8 423.3 16 2/3 542.9 21 3/8 639.2 25 1/6 758.8 29 7/8 880.5 34 2/3 1000.1 39 3/8 

184.2 7 1/4 304.8 12 425.5 16 3/4 546.1 21 1/2 641.4 25 1/4 762.0 30 882.7 34 3/4 1003.3 39 1/2 

186.3 7 1/3 308.0 12 1/8 427.6 16 5/6 549.3 21 5/8 643.5 25 1/3 765.2 30 1/8 884.8 34 5/6 1006.5 39 5/8 

187.3 7 3/8 309.0 12 1/6 428.6 16 7/8 550.3 21 2/3 644.5 25 3/8 766.2 30 1/6 885.8 34 7/8 1007.5 39 2/3 

190.5 7 1/2 311.2 12 1/4 431.8 17 552.5 21 3/4 647.7 25 1/2 768.4 30 1/4 889.0 35 1009.7 39 3/4 

193.7 7 5/8 313.3 12 1/3 435.0 17 1/8 554.6 21 5/6 650.9 25 5/8 770.5 30 1/3 892.2 35 1/8 1011.8 39 5/6 

194.7 7 2/3 314.3 12 3/8 436.0 17 1/6 555.6 21 7/8 651.9 25 2/3 771.5 30 3/8 893.2 35 1/6 1012.8 39 7/8 

196.9 7 3/4 317.5 12 1/2 438.2 17 1/4 558.8 22 654.1 25 3/4 774.7 30 1/2 895.4 35 1/4 1016.0 40 

199.0 7 5/6 320.7 12 5/8 440.3 17 1/3 562.0 22 1/8 656.2 25 5/6 777.9 30 5/8 897.5 35 1/3 1019.2 40 1/8 

200.0 7 7/8 321.7 12 2/3 441.3 17 3/8 563.0 22 1/6 657.2 25 7/8 778.9 30 2/3 898.5 35 3/8 1020.2 40 1/6 

203.2 8 323.9 12 3/4 444.5 17 1/2 565.2 22 1/4 660.4 26 781.1 30 3/4 901.7 35 1/2 1022.4 40 1/4 

206.4 8 1/8 326.0 12 5/6 447.7 17 5/8 567.3 22 1/3 663.6 26 1/8 783.2 30 5/6 904.9 35 5/8 1024.5 40 1/3 

207.4 8 1/6 327.0 12 7/8 448.7 17 2/3 568.3 22 3/8 664.6 26 1/6 784.2 30 7/8 905.9 35 2/3 1025.5 40 3/8 

209.6 8 1/4 330.2 13 450.9 17 3/4 571.5 22 1/2 666.8 26 1/4 787.4 31 908.1 35 3/4 1028.7 40 1/2 

211.7 8 1/3 333.4 13 1/8 453.0 17 5/6 574.7 22 5/8 668.9 26 1/3 790.6 31 1/8 910.2 35 5/6 1031.9 40 5/8 

212.7 8 3/8 334.4 13 1/6 454.0 17 7/8 575.7 22 2/3 669.9 26 3/8 791.6 31 1/6 911.2 35 7/8 1032.9 40 2/3 

215.9 8 1/2 336.6 13 1/4 457.2 18 577.9 22 3/4 673.1 26 1/2 793.8 31 1/4 914.4 36 1035.1 40 3/4 

219.1 8 5/8 338.7 13 1/3 460.4 18 1/8 580.0 22 5/6 676.3 26 5/8 795.9 31 1/3 917.6 36 1/8 1037.2 40 5/6 

220.1 8 2/3 339.7 13 3/8 461.4 18 1/6 581.0 22 7/8 677.3 26 2/3 796.9 31 3/8 918.6 36 1/6 1038.2 40 7/8 

A - 2 


Glossary 

This appendix contains a glossary of terms used with the VX5000 printing 

system. 

1-up A data and print layout that results in printing a single document 

at any point on the web. 

2-up A data and print layout that results in printing separate documents 

side-by-side on the web. 

Advanced Function Printing (AFP) 1. A set of licensed programs, 

together with user applications, that use the all-points-addressable 

concept to print text, images, and graphics on a wide variety of printers. 

AFP includes creating, formatting, distributing, and printing information. 

Advanced Function Printing has evolved into Advanced Function 

Presentation. 

2. An architected print system that supports all-points-addressable 

printing on page printers, and that provides system management of the 

printer environment. 

air compressor A module that provides pressurized air to other 

modules of a printing system. The pressurized air may power lift arms, nip 

rollers, pull rollers, and other internal parts. 

AFP 

Advanced Function Printing. 

angle The position of the printhead and its print array that is measured 

in respect to the roller underneath the printhead. The optimum angle is 0°, 

or parallel to the roller. 

APR 

APU 

See rewind unit. 

See unwind unit. 

array The row of orifices in the printhead or a single line printed by a 

row of orifices. 

artificial cue A cue signal that is generated when an actual cue signal 

is not received from the cue sensor during the cue window. In some 

printing systems, cue compensation must be turned on before artificial 

cues are generated. See also cue. 

basis weight The weight in pounds of a ream of paper cut to a 

standard size for the grade of paper. Also grammage in metric 

measurements and web weight in American measurements. 

beater A component of a module that repeatedly brings the paper into 

a gripping component. 


Glossary 

bitmap An arrangement of dots that represents text or graphics in an 

arrangement of binary 1s and 0s to represent the presence and absence 

of ink drops. 

carriage The components that hold and position a printhead interface 

inside a print tower. 

catch The operation of a printhead during which the charge voltage is 

activated for all jets and all ink drops are deflected to the catcher. 

catcher The part of the printhead that attracts charged drops falling 

from the orifices. See also charge plate, filament, orifice, and stim. 

catchpan The part attached to a printhead during service procedures 

to collect ink drops that would normally fall to the substrate. 

charge plate A row of exposed electric leads in the printhead. If the 

data indicates a dot is not required on the substrate, an individual charge 

lead is activated, imparting a charge to the ink drop. As it falls, the 

charged drop is attracted to the grounded catcher for recovery. If the data 

indicates a dot is required on the substrate, the charge lead is inactive, 

and the uncharged drop falls to the substrate. See also catcher, filament, 

orifice, and stim. 

charge short An error that occurs in the printhead when a charge lead 

is connected to ground or to another charge lead. 

charge voltage A voltage that determines whether an ink drop 

receives a charge. An operator can adjust the charge voltage. See also 

charge plate. 

compensator A set of rollers used for split web operations that require 

passing one half of the web through a turnbar while passing the other half 

of the web in parallel through a series of rollers that require the same 

distance for web movement as does the turnbar. 

compressor 

system. 

A module that provides pressurized air to the printing 

coning The result of winding paper on a core under constant tension, 

in which the paper gradually moves off center. 

control box 

a main switch. 

A module that allows switching one or more modules with 

controller Usually refers to the system controller, the module of the 

printing system that receives jobs from the data source and that is used 

by an operator to control the printing of the jobs. 

conveyor A module that moves folded or collated pieces away from 

the finishing equipment. 

correlation mark A machine-readable code for a number that checks 

the portions of a document match. For example, that the front and back 

sides in a duplex print job are at the same location on the web. 

Correlation marks are read by sensor hardware set up for page 

correlation use. 

crooked jet An ink jet that leaves the orifice at an odd angle. Crooked 

jets can splatter ink on the substrate or put ink on the charge leads, 

sometimes causing charge shorts and poor print quality. 


Glossary 

cue A signal that represents the start of a document. A cue signal 

occurs each time the cue sensor detects the leading edge of a piece of 

substrate or a preprinted cue mark on a web. 

cue delay 1. A measure of the distance from a cue sensor to each 

downstream printhead array. 2. A measure of the distance from the first 

upstream cue sensor to each downstream cue sensor and from the 

downstream cue sensor to each downstream printhead array. 

cue interval The distance between cue marks on a web. This distance 

usually equals the document length plus the space between two 

documents. 

cue mark A preprinted mark on a web that is the reference point for the 

start of a new document. 

cue noise A false cue signal that results from some object or 

imperfection on the substrate that the cue sensor detects or from 

imperfections in the circuitry of the cue sensor. See also false cue. 

cue sensor A sensor that detects the beginning of a mark on a web or 

the leading edge of a piece of substrate. 

cue window 

expected. 

An interval during which a signal from the cue sensor is 

curtain The effect visible under a printhead when all ink jets are 

operating and out of catch. The faint shimmering is produced by the ink 

jets as they fall from the printhead. 

dark defect A dark area in the image caused by allowing more than 

one drop to fall for each dot or from allowing ink jets to release ink when 

they should not. The dark defect can occur throughout the width of the 

image, but it may be concentrated at the ends or near the center of the 

image. 

dark line A narrow line of ink that appears in half-tone images and 

under certain conditions in text printing. The symptom results from an ink 

jet that releases drops when it should not. The extra drops are released 

when an adjacent ink jet is on, which indicates the charge circuits are 

shorted together. 

data controller The module of the printing system that receives IPDS 

jobs from the data source and that is used by an operator to control the 

printing of the jobs. 

decurler A section of one or more modules that flattens the web to 

avoid curling, cupping, and cockling. 

document A unit of input data that is printed in one area of the 

substrate. A document may include more than one page. Most common 

data preparation establishes one document for each cue mark on a web 

or one document for each piece in cut-sheet printing. See also page. 

dot 1. The smallest mark that can be printed by the printing system. 

2. The distance between pixels (dots) in the printed image. With a 240-dpi 

resolution, a distance of 1 dot equals 1 /240 inch. 

downstream The direction that is the same as substrate movement. 

See also upstream. 

dpi 

Dots per inch. A measure of resolution. 


Glossary 

duplex 

To print on both sides of the page. 

edge guide 

See web guide. 

end raggedness A disturbance of the regular placement of ink drops, 

which is most noted at the ends of the image area. 

Ethernet A link-level standard for data communications over a local 

area network (LAN). 

eyelid The part of the printhead that opens to allow uncharged drops to 

fall to the substrate. When closed, the eyelid protects the interior of the 

printhead from damage and limits the ingestion of dust that could 

contaminate the ink. 

false cue A cue signal that occurs when a signal that exceeds the cue 

noise setting occurs outside of the cue window. See also cue noise. 

filament A short, continuous stream of ink that extends from the orifice, 

which is broken into drops by the measured application of a physical 

vibration. See also catcher, charge plate, orifice, and stim. 

fixed data Print fields containing text or graphics that are printed on 

every document or on selected documents. See also variable data. 

fixed message A text message composed during data preparation that 

can be printed on every document or on selected documents. 

fluid cabinet The part of the print station that supplies ink to the 

printhead, withdraws ink from the printhead, and allows an operator or 

technician to control the print station. 

font A collection of characters that have the same typeface, style, 

weight, and point size. In KODAK VERSAMARK printing systems, fonts can 

also contain graphics identified by one or more characters codes. 

fpm 

Feet per minute. Equivalent to 0.3048 meters per minute. 

ghosting A print sample that has a small band of intermittent dark and 

light portions, which is caused by an incorrect phase setting. 

grammage The basis weight of paper used in the printing system. Also 

web weight in American measurements. 

gripper pressure 

rollers. 

The amount of air pressure applied to the gripper 

gripper roller A mechanism that uses a driven roller and two or more 

grippers to pull web from the upstream modules and maintain tension in 

the printing system. 

gripper wheel 

See gripper roller. 

GS Gear side. The long side of the printing system that has direct 

access to facility power, facility air, dryer ducting and the print stations. 

height The position of the printhead and its print array that is measured 

in respect to the roller underneath the printhead. The optimum printhead 

height is 0.075 to 0.100 inch (1.90 to 2.54 mm) above the roller. 

HEPA 

High Efficiency Particulate Air. 


Glossary 

HEPA filter A type of air filtration that limits the environmental dust to a 

level suitable for printing with the KODAK VERSAMARK DH90, DH91, and 

DH92 printheads. 

IJP 

Inkjet Printer. See print tower. 

IJPDS Inkjet Printer Data Stream. The proprietary file format for job 

files used with KODAK VERSAMARK printing systems. See also job file. 

image A pattern of filled and unfilled dots. It can be a character, a line 

of characters, or a graphic. 

infeed 

module. 

A portion of a module that moves the web from the previous 

ink jet The stream of ink made up of the filament and drops coming 

from one orifice. 

ink pressure The pressure that helps to determine the length of an ink 

filament. Ink pressure, together with the stim, determines the length of an 

ink filament created before a drop breaks off. Pressure and stim also 

determine the size and speed of the drops. 

IP address Network address for stations on Ethernet using TCP/IP 

protocol. Also called internet address and inet address. 

IPDS Intelligent Printer Data Stream. 1. An all-points-addressable 

(APA) data stream that allows users to position text, images, and graphics 

at any defined point on a printed page. 

2. In printers, information the system sends to printers that contains 

decision-making capability. Generally, this information contains basic 

formatting, error recovery, and character data. 

3. An architected host-to-printer data stream that contains both data and 

controls defining how the text, image, graphics, and barcode are to be 

presented and that provides a device-independent interface for controlling 

APA printers, such as the IBM 3900 AFP Printer. 

jam detector A component of one or more modules that avoids an 

accumulation of wasted product due to a failure in a finishing operation. 

jet The stream of ink made up of the filament and drops coming from 

one orifice. 

job file A file that contains information describing a print job. The file 

can contain setup information, fixed messages, font information, and 

variable data. 

Job Setup Sheet A document prepared by the provider of a job file that 

specifies the machine configuration and special printing reqruirements of 

the job. 

jog To move the web at a predetermined slow speed as long as the 

JOG button is pressed. Jogging can occur while errors are active. 

lateral The cross-web direction, used in reference to printhead 

movement, spiral movement in the folding unit, and perforation 

orientation. 

LED Light emitting device. A diode or other semiconducting device that 

emits visible light when it is active. 


Glossary 

lift arm A section of an unwind unit or rewind unit that lifts a roll of 

paper and holds it in place. 

light print A constant difference in relative darkness between images 

printed by adjacent printheads. Light print tends to lower the contrast in 

graphic portions of the image. 

mandrel 

A shaft that can hold a core or other form for paper rolls. 

M master. The group of print towers that provide control information to 

another group of print towers in the printing system. 

mandrel lateral adjust A mechanism at the unwind unit that positions 

the shaft and roll up to 2 inch (5 cm) forward and back between OS and 

GS. 

manual clutch A section of an unwind unit or rewind unit that engages 

or disengages the web movement to or from the mandrel. 

misplaced end drops 

image area. 

Irregular printing at the ends of the vertical 

missing cue A cue signal that is not received from the cue sensor 

during the cue window. 

missing jet A white line that appears where ink should be, caused by 

high charge voltage, contamination on the eyelid or inside the eyelid, or 

an open circuit. 

mount The components of a carriage that allow attachment of the 

printhead interface to the carriage. 

open A break in the charge lead circuit that prevents signals from 

reaching the charge lead. The drops receive a sympathetic charge from 

the neighboring circuits and are deflected to the catcher. The deflected 

drops cause gaps in the pattern when one or a few adjacent circuits are 

open. When a large number of adjacent circuits are open, the end drops 

might be deflected and caught, but the center ones produce a streaker. 

orifice A small hole through which pressurized ink extends in a 

filament. A 4" printhead has a row of orifices, spaced 240 per inch. 

See also catcher, charge plate, filament, and stim. 

OS Operator side. The long side of the printing system that gives an 

operator direct access to operator controls, the internal components while 

webbing the system, and observing the progress of the print job. 

outfeed 

A portion of a module that moves the web to the next module. 

page The data for a document in a page buffer. If the document data is 

equal to or less than the page buffer length, there is one page per 

document. If the document data length is greater than the length of the 

page buffer, there are two or more pages per document. See also 

document. 

page buffer Memory in a RIP in which pages are assembled for 

printing. The buffer size is printer dependent. 

page correlation A feature of the printing system that assures that all 

pages of a document are produced at the correct location on the web. 


Glossary 

page length The number of dot rows to be printed. The page length 

can be set by the IJPDS SPL record to be longer or shorter than the 

image. If shorter, the image will be clipped. If longer, white space is 

printed to the end of the page. 

PIC box 

See printhead interface. 

pickout An area of an image sample that appears as an intermittent 

white line where ink should be, caused by a high charge voltage; also 

called a missing jet. 

piece A discrete segment of substrate upon which the image is printed. 

For example, an envelope. 

powder brake A component of the unwind unit that uses magnetic 

particles to stop the revolutions of the unwind shaft and web. 

print array The row of orifices in the printhead or a single line printed 

by a row of orifices. 

print field A portion of the complete document image that can be 

positioned and rotated separately. 

print position The location of a printhead when it places ink on the 

web in registration to the printing from other printheads. 

print station The component of the printing system that receives 

image data in bitmapped format from the data station and produces a 

printed image as output. Each print station contains a fluid cabinet, 

umbilical, and printhead. 

print tower A module that contains one or more sets of a carriage, 

mount, and printhead. 

print width The maximum width of the area that can be printed by the 

printhead. It is usually given in inches or dots. 

print window 

can occur. 

The range of charge voltage in which acceptable printing 

printhead The part of the print station that forms charged ink drops, 

allows uncharged drops to fall on the substrate, and recovers charged 

drops to be returned to the fluid cabinet. The printhead receives data in 

bitmapped format through a fiberoptic cable and uses ink and charge 

voltages from the fluid cabinet to create inkjet images. 

printhead interface The assembly that contains circuit boards, 

manifolds and sensors, and that holds the printhead in place over the 

substrate. 

processing unit 

punch or both. 

A module that contains a cross-perforator or marginal 

pull ratio A screen that allows alteration of the tension applied to the 

web throughout the printing system. 

pull roller A section of one or more modules that accepts the web 

input to the module and advances the web by its powered, gripping 

rollers. See gripper roller. 

punch-perforation A processing action that provides both marginal 

punch and cross-perforation to the web. 


Glossary 

raster 

A rectangular bitmap arranged in rows of dots. 

registration 

graphics. 

Positioning printing in relationship to preprinted text or 

registration, data A fine-tuning of cue delay that results in aligning the 

different planes of the printed product along the direction of web 

movement. 

registration, printhead A fine-tuning of registration that results in 

aligning the different planes of the printed product across the direction of 

web movement. 

resolution The degree of sharpness of an image created by a 

computer, measured in dots per inch (dpi). 

rewind unit 

A module that takes up the printed web into a roll. 

RIP Raster image processor. The part of the system controller that 

builds raster bitmaps from character data received from the print job and 

sends bit-mapped data to the printheads. 

roll end sensor A sensor that may be positioned to create a signal 

when the roll at the unwind has nearly emptied. 

run fast To run the web at a speed determined by the operator. Run 

fast may be selected while no errors are active, the brake is set to ON, the 

lift arms are up, and the operator key is set to ON. 

run slow To run the web at a predetermined speed that is faster than 

jog speed, while no errors are active, the brake is set to ON, the lift arms 

are up, and the operator key is set to ON. 

S slave. The group of print towers that receives control information 

from another group of print towers in the printing system. 

service position The location of a printhead when it is pulled away 

from print position and beyond the OS side of the printing system to allow 

full access to the printhead for cleaning, swabbing, replacement, or 

service. 

shaft The rotating assembly that holds the supply core and paper at 

the unwind unit or the take-up core and paper at the rewind unit. Also 

mandrel. 

sheeter-stacker unit A module that provides a complementary series 

of any of the following finishing actions on the web: slitting, collating, 

sheeting, and stacking. 

short An undesired electrical connection between two or more circuits 

for charge leads. When one of the shorted circuits receives a signal, the 

signal is also sent to the other charge circuits, causing drops that should 

reach the substrate to be deflected to the catcher. 

skew The position of the printhead and its print array that is measured 

in respect to the roller underneath the printhead. The optimum skew is 0°, 

or parallel to the roller. 

splatter 

Ink drops scattered across the substrate in unwanted places. 

s-pull roller A gripper roller that uses two rollers that pull the web 

without exerting pressure on another roller. 


Glossary 

still picture unit A module that photographs the printed image without 

stopping the printing operation and displays the image on a monitor. 

stim A regular vibration (stimulation) at a controlled amplitude that 

breaks the ink filaments extending from the orifices into drops. See also 

catcher, charge plate, filament, and orifice. 

stim phase A value that determines when a charge is given to the 

drops as they form. The cycle of forming a drop is divided into sixteen 

segments, which are called phases. Stim phases are the segments 

numbered 0 through 15. An operator can change the stim phase, using 

the parameter adjustments screen. 

stim tab An interior part of the printhead that detects the amplitude of 

stim and provides a feedback voltage to regulate the stim voltage. 

stim voltage The voltage applied to the crystal attached to the 

resonator in the printhead to create a stimulation of a certain amplitude 

and frequency. 

stitching The process where a single contiguous image is produced 

by two or more printheads. 

streaker A recurring streak of ink caused by one or more jets printing 

continuously or by ink dripping from a part of the printhead, creating a line 

(streak) on the substrate. 

strobe A section of the still picture unit that flashes in synchronization 

to the web speed and the length of the printed product, and that allows 

viewing of the print results without stopping the printing operation. 

substrate The surface on which an image is printed. The substrate can 

be a continuous sheet (web) or separate pieces of various types of 

material. 

system controller The component of a printing system that accepts 

input data, formats the data according to job setup instructions, and sends 

character-coded image data to the appropriate RIPs. 

tab An interior part of the printhead that detects the amplitude of stim 

and provides a feedback voltage to regulate the stim voltage. 

tach 1. A measure of distance, as measured by the tach encoder. 

When using 240 dpi resolution, one tach is 1 /240 inch (0.00416 inch, 0.105 

mm). 

2. A signal emitted by the tach encoder in response to the speed of the 

substrate. 

tach encoder A part that detects movement of the substrate and 

generates tach signals in relationship to the substrate speed. 

tension controller A component of the unwind unit or rewind unit that 

determines how tension is maintained throughout the printing system. 

test page A printed standard page that contains data that readily 

shows faults in registration, printhead skew, and other printhead 

characteristics. 

trailing A small dripping effect at the upstream edge of boldface 

characters and solid tones. 


Glossary 

transformer 

output. 

A module that converts an input voltage to a desired 

turnbar A section of one or more modules that turns the printed face of 

the web down and allows printing on the reverse face. 

umbilical The part of the print station that carries ink and signals 

between the fluid cabinet and the printhead through an assembly of 

hoses and wiring within a flexible, protective shield. 

unwind unit 

A module that lets out the web from a roll. 

upstream The direction that is opposite that of the substrate 

movement. See also downstream. 

variable data Print fields that change from document to document. 

See also fixed data. 

VST Variable speed transport. A mode of printing system control that 

allows the volume of data supplied by the SC300 to vary the speed of web 

movement and dryer intensity. 

waviness A disturbance of the regular placement of ink drops caused 

by air flow disrupting the paths of the uncharged drops from the orifice to 

the substrate. 

web 

A continuous sheet of substrate. 

web break sensor A section of one or more modules that detects 

cross-stream tears in the web and creates a signal that stops the web 

movement. 

web guide A component of one or more modules that keeps the web 

in the same cross-stream position. 

web joint detector A section of one or more modules that detects 

momentary changes in web thickness and creates a signal that can stop 

printing and finishing operations on that section of the web as it moves 

through the printing system. 

web weight The basis weight of paper used in the printing system. 

Also grammage in metric measurements. 

worm gear An assembly of a motor driving a fixed, long screw and a 

component that moves along the screw by means of an attached lateral 

gear box. 

zeroing The controlled, automatic alignment that moves a component 

to a known position and resets measurements from that known position. 


Index 

Symbols 

+ - paired buttons, on operator display 1-26 

+ 0[.]00, on operator display 1-26 

[Printhead number] motor error 4-15 

Numerics 

200-V power switch 1-2 


A 

A unit 

OS1 cover error 4-10 

OS2 cover error 4-10 

step cover error 4-10 

Access 

panels, unwind 1-4 

Activate button (Sleep Mode screen) 2-55 

Adjusting 

cue sensitivity 3-19–3-21 

gripper rollers 2-14–2-15 

web guide 2-12–2-13 

Air 

[number] heater break error 4-11 

[number] temp, on operator display 1-27 

gun 1-5 

on operator display 1-27 

overheat error 4-11 

press. down error 4-11 

pressure gauge 1-4, 1-8 

temp, on operator display 1-27 

Alarm 

external controls on unit 1-7 

All Off button (Details screen) 

emergency shutdown 2-54 

All Off button (Summary screen) 

shutting down all connected printheads 2-56, 2-57 

Annual maintenance 5-11 

APR 

cover open error 4-6 

cover screen 4-15–4-16 

error 4-6 

error screen 1-32, 4-16–4-17 


APS 


pull, on operator display 1-25 

APU 

cover open error 4-5 

cover screen 1-31, 4-8–4-10 

error 4-5 

error screen 1-31, 4-7–4-8 


screen 1-22–1-23 

Arm 

GS cover error 4-9, 4-16 

OS cover error 4-9, 4-16 

up-down error 4-7, 4-16 

Arrow buttons 


paired buttons, on operator display 1-26 

B 

Blower error 4-12 

Brake off-on 1-6 

C 

C unit cover error 4-10 

catch 

shutting down printheads 2-56 

catchpan 

shutting down printheads 2-56 

Changing 

print speed 2-53 

web weight 2-22 

CKMY printing order 3-2 

Compen 

cover error 4-10 

motor error 4-8 

Compensation, speed 3-27–3-29 

Compressor 

description 1-3 

error 4-7 

Control box, description 1-2 

Controls 

+ - paired buttons, on operator display 1-26 

+ 0[.]00, on operator display 1-26 



air [number] temp, on operator display 1-27 

air gun 1-5 

air pressure gauge 1-4, 1-8 

air temp, on operator display 1-27 

air, on operator display 1-27 

alarm 1-7 

angle, printhead 1-16 

APR, on operator display 1-20 

APS pull, on operator display 1-25 

APS, on operator display 1-20 

APU, on operator display 1-20 


Index 

arrow buttons, on operator display 1-28 

arrow paired buttons, on operator display 1-26 

brake off-on 1-6 

corrected temp, on operator display 1-27 

cover up/down 1-12, 1-17, 1-18 

cue sensor 1-11, 1-12, 1-17 

cue sensor position 1-13, 1-17, 1-18 

dancer tension controller 1-37 

d-outfeed 1, on operator display 1-25 


d-outfeed M, on operator display 1-25 

d-outfeed S, on operator display 1-25 

drum GS temp, on operator display 1-27 

drum OS temp, on operator display 1-27 

drum temp, on operator display 1-27 

drum, on operator display 1-27 

dryer status, on operator display 1-27 

dryer, on operator display 1-20, 1-21 

emerg. reset 1-18 

emergency stop 1-6, 1-18 

enter, on operator display 1-26 

error, on operator display 1-28, 1-29 

fast stop, on operator display 1-22 

finishing option, correct selection of for printing 1-20 

gripper air pressure 1-37 

gripper on-off 1-37 

gripper pressure 1-17, 1-18 

gripper wheel off-on 1-13, 1-17, 1-18 

GS, on operator display 1-29 

height adjust 1-16 

home, on operator display 1-28 

hours indicator 1-4 

image data, on operator display 1-21 

image test, on operator display 1-21 

inch / mm, on operator display 1-29 

infeed 1, on operator display 1-25 

infeed S, on operator display 1-25 

job speed buttons, on operator display 1-21 

jog 1-6, 1-12 

jog key 1-18 

jog, on operator display 1-20, 1-22 

keypad, on operator display 1-29 

lateral, on operator display 1-29 

lift arm air pressure 1-37 

main switch (compressor) 1-4 

main switch (transformer) 1-3 

main, on operator display 1-20 

mandrel lateral adjust 1-8 

MAPZ pull, on operator display 1-25 

MAPZ, on operator display 1-20 

normal stop, on operator display 1-21 

off, on operator display 1-27 

on, on operator display 1-27 

operator key 1-18 

option 1, on operator display 1-25 

option 2, on operator display 1-25 

OS, on operator display 1-29 

outfeed 1, on operator display 1-25 

outfeed 2, on operator display 1-25 

outfeed M, on operator display 1-25 

outfeed S, on operator display 1-25 

printhead angle 1-16 

printhead height adjust 1-16 

printhead skew adjust 1-16 

printhead tilt 1-16 

pull ratio, on operator display 1-24, 1-26 

punch, on operator display 1-25 

ready 1-6, 1-12 

ready, on operator display 1-22 

registration, on operator display 1-20 

return, on operator display 1-28 

rewinder shaft down-n-up 1-37 

rewinder tension on-off 1-36 

rewinder tension under-over 1-36 

roll end off-on 1-6 

roll end sensor 1-5 

run fast, on operator display 1-22 

run slow 1-7 

run slow, on operator display 1-22, 1-23 

send mail 4-6 

set lever 1-16 

shaft down-n-up 1-6 

skew adjust 1-16 

skip, on operator display 1-23 

speed fpm, on operator display 1-21 

speed mpm, on operator display 1-21 

stand-by temp, on operator display 1-27 

start, on operator display 1-29 

stop 1-12 

stop button, behind interlocked OS door 1-12 

stop button, hidden 1-12, 1-22, 4-1 

stop machine 1-6 

stop, on operator display 1-23, 1-29 

taper setting 1-36 

temperature gauge 1-4 

tension controller 1-7 

tension meter 1-36 

tension setting 1-36 

turnbar 2, on operator display 1-25 

turnbar M, on operator display 1-25 

turnbar S, on operator display 1-25 

VST state, on operator display 1-21 

web break sensor 1-8 

web break, on operator display 1-21 

web guide 1-12 

web guide controller 1-7 

web guide sensor 1-8, 1-11 

web guide sensor position 1-8 

web tension infeed 1-13 

web tension outfeed 1-13 

web weight g/m 2 , on operator display 1-24 

web weight, on operator display 1-24 

web, on operator display 1-20, 1-27 

Corrected temp, on operator display 1-27 

Correlation, page 1-19, 2-48–2-51, 3-29–3-30 

sensor positioning 2-51–2-52 

Cover 

open error 4-11 

up/down 1-12, 1-17, 1-18 

Cue sensor 1-11, 1-12, 1-17 

adjusting sensitivity 3-19–3-21 

position 1-13, 1-17, 1-18 

positioning 2-30–2-32 

D 

D unit 

dryer cover error 4-11 

slide cover error 4-11 

step cover error 4-10 

Daily maintenance 5-2 


Index 

Dancer tension controller 1-37 

Data 

recovering 2-47 

reprinting 2-47 

Data, how to print 2-42–2-43 

Data, how to set up 2-35–2-41 

DC 300 

operator information 1-37 

setting cue delay 3-26–3-27 

Detection of roll end, setting 2-58–2-59 

Diameter maximum error 4-5 

Display descriptions 1-19–1-32 

D-Outfeed 



d-outfeed M, on operator display 1-25 

d-outfeed S, on operator display 1-25 

Drum 

[number] heater break error 4-12 

GS temp, on operator display 1-27 


OS temp, on operator display 1-27 

overheat error 4-11 


Dryer 

changing temperature 2-34–2-35 

error 4-6 

error screen 1-30, 4-11–4-12 

on operator display 1-20, 1-21 

screen 1-26–1-28 

status, on operator display 1-27 

webbing 2-17–2-18 

DT9000 


DT9000 Series Print Station 


Duplex print jobs 2-18, 3-5 

register front-to-back 2-46 

E 

Emergency stop 1-6, 1-18 

recovery from 2-52 

Enter, on operator display 1-26 

Error 


screen 1-29–1-30, 4-5–4-6 

Errors 

[printhead number] motor error 4-15 

A unit OS1 cover 4-10 

A unit OS2 cover 4-10 

A unit step cover 4-10 

air [number] heater break 4-11 

air overheat 4-11 

air press. down 4-11 

APR cover open 4-6 

APR error 4-6 

APU 4-5 

APU cover open 4-5 

arm GS cover 4-9, 4-16 

arm OS cover 4-9, 4-16 

arm up-down 4-7, 4-16 

blower error 4-12 

C unit cover 4-10 

checking for presence 2-52 

compen cover 4-10 

compen motor 4-8 

compressor 4-7 

cover open 4-11 

D unit dryer cover 4-11 

D unit slide cover 4-11 

D unit step cover 4-10 

diameter maximum 4-5 

drum [number] heater break 4-12 

drum overheat 4-11 

dryer error 4-6 

gripper roll 4-6, 4-8 

GS limit error 4-14 

GS limit error do lateral zero positioning 4-14 

GS over limit 4-14 

GS over limit error 4-14 

GS1 cover 4-8, 4-9, 4-16 

GS2 cover 4-8, 4-16 

hit to cover 4-18 

IJP cover open 4-6 

interlock off 4-7, 4-17 

interlock on 4-7, 4-16 

jog over speed 4-7 

lateral motor error 4-12 

lateral zero positioning not possible during machine 

running 4-13 

lateral zero positioning start 4-15 

lateral zero positioning stop 4-15 

motor [number] 4-6 

neglect break 4-12 

OS limit error 4-13 

OS limit error do latel zero positioning 4-14 

OS limit error do lateral zero positioning 4-13 

OS over limit 4-13 

overheatung is unusual the breaker of a heater is turned 

off 4-17 

paper end 4-5 

PLC battery low 4-17 

print error 4-5 

process unit oil pump error 4-17 

punch blower 4-7 

punch cover 4-9 

punch reguration 4-7 

punch screw 4-7 

remove catchpan or service tool 4-18 

reset 4-12, 4-15 

rewinder invertor 4-17 

rewinder invertor fan 4-17 

send mail 4-15 

servo battery low 4-17 

slide cover 4-8, 4-9, 4-10, 4-16 

slitter motor 4-17 

tension off 4-17 

upper cover 4-8, 4-9, 4-15 

upper cover closed 4-17 

warning 




lateral zero positioning not possible during machine 

running 4-13 




Index 

F 




web break 4-5 

Fast stop, on operator display 1-22 

G 

Getting started 

overview of operating 2-1 

Gripper 

adjusting rollers 2-14–2-15 

air pressure 1-37 

gripper on-off 1-37 

gripper roll error 4-6 

pressure 1-17, 1-18 

roll error 4-8 

wheel off-on 1-13, 1-17, 1-18 

GS 

GS limit error 4-14 

GS over limit error 4-14 


GS1 cover error 4-8, 4-9, 4-16 

GS2 cover error 4-8, 4-16 

H 

Height 

height adjust knob, printhead 1-16 

of printhead 2-26–2-27 

Home, on operator display 1-28 

Hours indicator 1-4 

How to ... 

adjust cue sensitivity 3-19–3-21 

adjust gripper rollers 2-14–2-15 

adjust web guide 2-12–2-13 

align web guide. Refer to the manufacturer documents. 

bypass sheeter-stacker unit 2-20 

change dryer temperature 2-34–2-35 

change printing speed 2-53 

change web weight 2-22 

check for errors 2-52 

configure page correlation 2-48–2-51, 3-29–3-30 

identify printheads 3-2–3-6 

jog 2-14 

load paper rolls 2-4–2-7, 2-8–2-10 

move printhead to print position 2-25 

move printhead to service position 2-24 

number printheads 3-2–3-6 

overview of procedures 2-1 

position cue sensor 2-30–2-32 

position page correlation sensor 2-51–2-52 

position web break sensor 2-32–2-34 

position web guide sensors. Refer to the manufacturer 

documents. 

print job 2-42–2-43 

print test pages 2-41–2-42 

recover from emergency stop 2-52 

recover from stops 2-52 

select printing speed 2-53 

select roll end detection 2-58–2-59 

select web direction 2-22 

select web weight 2-22 

set cue delay at the controller 3-22–3-27 

set printhead height 2-26–2-27 

set printhead position 2-43–2-45, 2-45–2-46, 3-22– 

3-27 

set printhead registration 2-43–2-45, 2-45–2-46, 3- 

22–3-27 

set printhead skew 2-28–2-29 

set speed compensation 3-27–3-29 

set up print job 2-35–2-41 

set web tension 2-23–2-24, 3-16–3-17 

turn off printing system 2-53–2-57 

turn on printing system 2-3 

unload paper rolls 2-4–2-7, 2-8–2-10 

web dryer 2-17–2-18 

web duplex job 2-18 

web print towers 2-15–2-19 

web printing system 2-4–2-24 

web rewind unit 2-20–2-21 

web spacer unit 2-13 

web turnbar 2-19 

web two-up job 2-18 

web unwind unit 2-10–2-13 

zero printheads 3-17–3-18 

I 

IJP cover 

open error 4-6 

screen 1-30, 4-10–4-11 

Image 

image data, on operator display 1-21 

image test, on operator display 1-21 

Inch / mm, on operator display 1-29 

Infeed 1, on operator display 1-25 

Infeed S, on operator display 1-25 

Ink, order of printing 3-2 

Interlock 

off error 4-7, 4-17 

on error 4-7, 4-16 

J 

Job speed buttons, on operator display 1-21 

Jobs 

duplex 2-18, 3-5 

duplex process color 3-5 

how to print 2-42–2-43 

how to set up 2-35–2-41 

process color 3-2 

two-up 2-18 

two-up duplex process color 3-6 

two-up process color 3-5 

Jog 

button 1-12 

button on unwind, print tower and rewind 1-6 

key 1-18 


over speed error 4-7 

Jogging web 2-14 

K 

Keypad 



Index 

L 

Lateral 

lateral motor error 4-12 

lateral zero positioning start error 4-15 

lateral zero positioning stop error 4-15 

motor error 4-12 


Lift arms 

air pressure 1-37 

rewind 1-35 

unwind 1-5 

M 

Main 


switch 1-3 

switch (compressor) 1-4 

Main screen 

print tower D 1-19–1-22 

Maintenance 

annual operator 5-11 

daily operator 5-2 

monthly operator 5-2–5-9 

quarterly operator 5-9–5-11 

weekly operator 5-2 

Mandrel 1-5 

lateral adjust 1-8 

MAPZ 


pull, on operator display 1-25 

Monthly maintenance 5-2–5-9 

Motor [number] error 4-6 

N 

Neglect break error 4-12 

Nip roller. See Gripper rollers 

Normal stop, on operator display 1-21 

O 

Off, on operator display 1-27 

On, on operator display 1-27 

Operator 

annual maintenance 5-11 

daily maintenance 5-2 

display, at print tower D 1-19–1-32 

key 1-18 

monthly maintenance 5-2–5-9 

quarterly maintenance 5-9–5-11 

weekly maintenance 5-2 

Option 1, on operator display 1-25 

Option 2, on operator display 1-25 

OS 

limit error 4-13 


over limit error 4-13 

Outfeed 1, on operator display 1-25 

Outfeed 2, on operator display 1-25 

Outfeed M, on operator display 1-25 

Outfeed S, on operator display 1-25 

Overheatung is unusual the breaker of a heater is turned off 

4-17 

P 

Page 

page correlation 2-48–2-51, 3-29–3-30 

page correlation sensor 2-51–2-52 

Page correlation 1-19 

Paper end 

paper end error 4-5 

Paper, loading and unloading 2-4–2-7, 2-8–2-10 

PLC battery low 4-17 

Positioning 

cue sensor 2-30–2-32 

web break sensor 2-32–2-34 

Power switch 

200-V 1-2 

400-V 1-2 

main (transformer) 1-3 

Print error 4-5 

Print jobs 

duplex 2-18, 3-5 

duplex process color 3-5 

order of printing colors 3-2 

printing test pages 2-41–2-42 

printing the job 2-42–2-43 

process color 3-2 

setting up the job 2-35–2-41 

two-up 2-18 

two-up duplex process color 3-6 

two-up process color 3-5 

Print position 2-25 

defined 1-15 

Print tower 

A, control descriptions 1-11–1-16 

B, control descriptions 1-16–1-17 

C, control descriptions 1-16–1-17 

D, control descriptions 1-17–1-19 

monthly maintenance 5-5 

webbing 2-15–2-19 

Printhead 

angle 1-16 

height adjust knob 1-16 

identities 1-16, 3-2–3-6 

identity in controller 3-2–3-6 

identity in PSI 3-2–3-6 

moving to print position 2-25 

moving to service position 2-24 

number in printing system 3-2–3-6 


printhead lateral error screen 1-31, 4-14–4-15 

printhead limit error screens 4-12–4-14 

set lever 1-16 

setting height 2-26–2-27 

setting position 2-43–2-45, 2-45–2-46, 3-22–3-27 

setting registration 2-43–2-45, 2-45–2-46, 3-22–3-27 

setting skew 2-28–2-29 

skew adjust 1-16 

tilt 1-16 

zeroing 3-17–3-18 

Printhead Sequence buttons 

All Off 2-54 


Index 

printheads 

shutting down all connected printheads 2-56, 2-57 

Printing system 

turning off 2-53–2-57 

turning on 2-3 

Process color print jobs 3-2, 3-5 

order of printing colors 3-2 

Process unit oil pump error 4-17 

PSI 


Pull ratio 


pull ratio screen 1-24–1-26 

Punch 


punch blower error 4-7 

punch cover error 4-9 

punch reguration error 4-7 

punch screw error 4-7 

Q 

Quarterly maintenance 5-9–5-11 

R 

Ready 

button 1-6, 1-12 


Recovering 

from emergency stop 2-52 

from error stops 2-52 

Recovering data 2-47 

Registration 

data 2-43–2-45 

of duplexed sides 2-46 


printhead 2-43–2-46, 3-22–3-27 


print tower D 1-28–1-29 

Reprinting data 2-47 

Reset error 4-12, 4-15 

Return, on operator display 1-28 

Rewind unit 

control descriptions 1-35–1-37 


procedures 2-59 

webbing 2-20–2-21 

Rewinder 

invertor error 4-17 

invertor fan error 4-17 

rewinder shaft down-n-up 1-37 

rewinder tension on-off 1-36 

rewinder tension under-over 1-36 

Roll end 

detection, setting 2-58–2-59 

off-on 1-6 

sensor 1-5 

Rolls, paper loading and unloading 2-4–2-7, 2-8–2-10 

Run fast 

does not operate 4-1 


Run slow 

button 1-7 

does not operate 1-7, 4-1 


S 

Screens 

APR cover 4-15–4-16 

APR error 1-32, 4-16–4-17 

APU cover 4-8–4-10 

APU cover screen 1-31 

APU error 1-31, 4-7–4-8 

APU screen 1-22–1-23 

descriptions, at print tower D 1-19–1-32 

dryer error 4-11–4-12 

dryer error screen 1-30 

dryer screen 1-26–1-28 

error screen 1-29–1-30, 4-5–4-6 

IJP cover 4-10–4-11 

IJP cover screen 1-30 

main screen, print tower D 1-19–1-22 

printhead lateral error 4-14–4-15 

printhead lateral error screen 1-31 

printhead limit error 4-12–4-14 

pull ratio screen 1-24–1-26 

registration screen, print tower D 1-28–1-29 

web screen 1-23–1-24 

screens 

Sleep Mode 2-54 

Selecting ... 

print speed 2-53 

web direction 2-22 

web weight 2-22 

Send mail 4-6 

error 4-15 

Sequence text field 

SHUTDOWNPRG sequence 2-56, 2-57 

sequences 

SHUTDOWNPRG 2-56, 2-57 

Service position 2-24 

Servo 

servo battery low 4-17 

Set 

printhead set lever 1-16 

Setting 

printhead height 2-26–2-27 

printhead registration 2-43–2-45, 2-45–2-46, 3-22– 

3-27 

printhead skew 2-28–2-29 

web tension 2-23–2-24, 3-16–3-17 

Shaft 

down-n-up 1-6 

unwind 1-5 

Sheeter-stacker unit 

bypass while webbing system 2-20 

shutdown 

all connected printheads 2-56, 2-57 

SHUTDOWNPRG sequence 2-56, 2-57 

Shutting down printing system 2-53–2-57 


Index 

Skew 

adjust knob 1-16 

of printhead 2-28–2-29 

Skip 


Sleep Mode button 2-54 

Sleep Mode screen 2-54 

Slide cover error 4-8, 4-9, 4-10, 4-16 

Slitter 

slitter motor error 4-17 

Spacer unit 


webbing 2-13 

Speed 

selecting and changing 2-53 

speed compensation 3-27–3-29 

speed fpm, on operator display 1-21 

speed mpm, on operator display 1-21 

Stand-by 


Start 


Starting 

printing system 2-3 

Status, checking 2-52 

Stop 

behind interlocked OS door 1-12 

button 1-12 

emerg. reset 1-18 

hidden 1-12, 1-22, 4-1 

machine button 1-6 


recovering from emergency stop 2-52 

recovery 2-52 

Subsystem bar buttons 

Sleep Mode 2-54 

Summary screen buttons 

All Off 2-56, 2-57 

Switching on printing system 2-3 

Synchronization. See Page correlation. 1-19 

T 

Taper setting 1-36 

Temperature 

changing of dryer 2-34–2-35 

gauge 1-4 

Tension 

controller 1-7 

setting web 2-23–2-24, 3-16–3-17 

tension meter 1-36 

tension off error 4-17 

tension setting 1-36 

Test pages, how to print 2-41–2-42 

Test pattern, how to print 2-41–2-42 

Transformer, description 1-3 

Turnbar 

turn-bar 2, on operator display 1-25 

turn-bar M, on operator display 1-25 

turn-bar S, on operator display 1-25 

webbing 2-19 

Turning off printing system 2-53–2-57 

Turning on printing system 2-3 

Two-up print jobs 2-18 

U 

Unwind unit 

control descriptions 1-4–1-9 


procedures 2-58–2-59 

Upper cover error 4-8, 4-9, 4-15 

V 

VST state, on operator display 1-21 

W 

Wakeup Date drop-down list 2-55 

Warning 




Lateral zero positioning not possible during machine 

running 4-13 






Warnings, checking for presence 2-52 

Web 

changing weight 2-22 

direction 2-22 

loading and unloading 2-4–2-7, 2-8–2-10 


tension 2-23–2-24, 3-16–3-17 

web screen 1-23–1-24 

Web break 

error 4-5 


sensor 1-8 

sensor positioning 2-32–2-34 

Web cleaner 


Web guide 1-12 

adjustment 2-12–2-13 

alignment. Refer to the manufacturer documents. 

controller 1-7 

positioning sensors. Refer to the manufacturer 

documents. 

sensor 1-8, 1-11 

sensor position button 1-8 

Web tension 

infeed 1-13 

outfeed 1-13 

Web weight 

changing 2-22 

g/m 2 , on operator display 1-24 


Webbing 

dryer 2-17–2-18 

one-up, duplex two-color over two-color 3-3 


Index 

one-up, process color 2-16 

printing system 2-4–2-24 

rewind unit 2-20–2-21 

sheeter-stacker unit bypassed 2-20 

turnbar 2-19 

two-up, two-color 2-16, 3-4, 3-5 

unwind unit 2-10–2-13 

Weekly maintenance 5-2 

Z 

Zeroing printheads 3-17–3-18 


0114304-602 

0114304-603 

© Kodak

Operator's Guide - Kodak

You also want an ePaper? Increase the reach of your titles

Delete template?

Save as template?