Colordyne 1600-C HIGH SPEED COLOR LABEL AND TAG PRINTER OPERATOR MANUAL

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1 Colordyne 1600-C HIGH SPEED COLOR LABEL AND TAG PRINTER OPERATOR MANUAL

2 SAFETY PRECAUTIONS THIS EQUIPMENT PRESENTS NO PROBLEM WHEN USED PROPERLY. HOWEVER, CERTAIN SAFETY RULES SHOULD BE OBSERVED WHEN OPERATING THE COLORDYNE 1600-C LABEL PRINTER. BEFORE USING THE PRINTER, YOU SHOULD READ THIS MANUAL CAREFULLY AND FOLLOW THE RECOMMENDED PROCEDURES, SAFETY WARNINGS, AND INSTRUCTIONS: Keep hands, hair, and clothing clear of rollers and other moving parts. Avoid touching moving parts or materials while the machine is in use. Before clearing a jam, be sure machine mechanisms come to a stop. Always turn off the machine before making adjustments, cleaning the machine, or performing any maintenance covered in this manual. The power cord and power supply supplied with the machine should be plugged into a properly grounded, easily accessible wall outlet located near the machine. Failure to properly ground the machine can result in severe personal injury and/or fire. The power cord and wall plug is the primary means of disconnecting the machine from the power supply. DO NOT use an adapter plug on the line cord or wall outlet. DO NOT remove the ground pin from the line cord. DO NOT route the power cord over sharp edges or trap it between furniture. Avoid using wall outlets that are controlled by wall switches or shared with other equipment. Make sure there is no strain on the power cord caused by jamming between equipment, walls or furniture. DO NOT remove covers. Covers enclose hazardous parts that should only be accessed by a qualified service representative. Report any cover damage to your service representative. This machine requires periodic maintenance. Contact your authorized service representative for required service schedules. To prevent overheating, do not cover the vent openings. Use this equipment only for its intended purpose. In addition, follow any specific occupational safety and health standards for your workplace or area. This manual is intended solely for the use and information of Colordyne Technologies, LLC, its designated agents, customers, and their employees. The information in this guide was obtained from several different sources that are deemed reliable by all industry standards. To the best of our knowledge, that information is accurate in all respects. However, neither Colordyne Technologies, LLC nor any of its agents or employees shall be responsible for any inaccuracies contained herein. Colordyne TM is a registered trademark of Colordyne Technologies, LLC. Memjet is a registered trademark. All other trademarks are the property of their respective holders. All rights reserved. No part of this book may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording, or any information storage and retrieval system, without permission in writing from the publisher.

3 TABLE OF CONTENTS Table of Contents SECTION 1 Getting Acquainted 1 Front View 1 Rear View 2 Print Engine View 3 Ink Tank View U Unwinder/Roll Feeder (Optional) W Winder (Optional) 6 Control Panel Button/LED Indicators: 7 Printer Default Printing Modes 10 SECTION 2 Installing the Printer 11 Contents of Packaging 11 Choose a Location 11 Unpacking and Setup 11 Hydrating the Printhead Cartridge 12 Remove Service Station Transport Tab and Shipping Tape 13 Connecting the Colordyne 1600-C 14 Install the Printer Driver 15 Install the Ink Tanks 17 Install the Printhead Cartridge 19 Removing the Head Media Guide 22 Aligning Printer with 1600-U Unwinder and 1600-W Winder 24 Connecting the Printer to the Optional Unwinder and Winder 26 Loading Labels 27 SECTION 3 Operating the Colordyne 1600-C 30 Printer Driver Properties 30 Using the Printer Toolbox 34 SECTION 4 - Maintenance 39 Replacing the Ink Tanks 39 Cleaning Ink Tank Contacts 40 Cleaning/Replacing the Printhead Cartridge 42 Replacing the Service Station 46 Replacing the Ink Waste Tray 49 Removing Jams in the Printer 50 Cleaning 51 Shipping or Transporting the 1600-C Printer 53 SECTION 5 Troubleshooting Guide 56 The Memjet Printhead 56 The Printer 57 Appendices 58 Appendix A Colordyne 1600-C Specifications 58 Appendix B Supplies and Optional Hardware 58 Index 59 Printer Maintenance Schedule 62 i

4 NOTES ii

5 SECTION 1 GETTING ACQUAINTED SECTION 1 Getting Acquainted Front View 1. Top Cover Provides access to the Print Engine. 2. Front Cover Provides access to the Ink Tanks and Service Station. 3. Winder Interface Connection Winder Interface Cable plugs in here. 4. Service Port Provides advanced diagnostic access for service technicians. 5. Unwinder Interface Connection Unwinder Interface Cable plugs in here. 6. USB Port Connection Attach USB cable to the Printer here. 7. Network Connection Attach network cable here. 8. Main Power Switch, Receptacle and Fuse Receptacle: Power cord plugs in here. Switch: Turns main power ON/OFF. (Use Control Panel LED Power switch to turn machine OFF for cleaning and maintenance). Fuse: Protects the Printer s electronic circuits. 1

6 SECTION 1 GETTING ACQUAINTED Rear View ON/OFF LED Button Use to turn power ON or OFF during idle time and maintenance. Print/Pause LED Button Press to stop printing, press to restart printing. Press switch to continue printing. Cancel/Cut LED Button Press this switch to cancel the job being printed. Also activates the cutter to cut labels or roll at the point desired. Adjustable Media Guide Adjusts to hold the paper/media against the Alignment Guides. 2

7 SECTION 1 GETTING ACQUAINTED Print Engine View Printhead Latch When closed, connects the Ink Revolver Couplings with the Printhead Cartridge. When opened, retracts the Ink Couplings from the Printhead Cartridge and provides access to the Printhead Cartridge for cleaning and replacement. WARNING! Never attempt to open the Printhead Latch manually, severe damage will result. Use the Printhead Release function in the Toolbox utility on your PC. Ink Revolver Couplings Connect the ink hoses to the Printhead Cartridge. The Printhead Latch extends and retracts the couplings from the Printhead. Printhead Cartridge Memjet Printhead produces an 8.5" wide full color print area. Clamshell Latches Lift both latches at the same time to open the top half of the Print Engine. DO NOT open while the Printer is operating. DO NOT lift the assembly more than 60 degrees. DO NOT let the assembly drop, close it gently. 3

8 SECTION 1 GETTING ACQUAINTED Ink Tank View 1. Cutting Blade Assembly Cuts the media after each piece or at the end of a job. 2. Ink Tank Latches Hold Ink Tanks in place. 3. Ink Tank Dock Holds the 5 Ink Tanks. (Ink Tanks shown installed) Ink Waste Tray Absorbs excess ink and drips that may occur during Printer operation and maintenance. Release Tabs located on both sides. Service Station Dock The Service Station is located here. The Service Station keeps the Printhead clean and hydrated during operation and maintenance cycles. 4

9 SECTION 1 GETTING ACQUAINTED 1600-U Unwinder/Roll Feeder (Optional) 1. Speed Control Turn clockwise to speed up, counterclockwise to slow down. AUTO/Manual Mode Switch Use to set the Unwinder in Automatic or 2. Manual Mode. 3. Fuse Unwinder fuse is located here. 4. Hub Assembly Reversible to fit 1-1/2" and 3" cores. 5. Spindle Lock Holds the roll on the Spindle. 6. Label Roll Spindle Holds the Label Roll. Label Tension Guide Shaft Spring-loaded shaft controls starting and stopping 7. as tension is maintained or released by media. 24V, 2.5A External Power Connector* For connecting printers or equipment 8. other than the 1600-C. *Requires disconnecting wire from Unwinder circuit board and connecting wire from External Power Connector. 9. Unwinder Interconnect Cord Connects Feeder/Unwinder to Printer. Alignment Notch Fits over Alignment Screw on Printer to keep Printer and Unwinder aligned

10 SECTION 1 GETTING ACQUAINTED 1600-W Winder (Optional) 1. Speed Control Turn clockwise to speed up, counterclockwise to slow down. 2. ON/OFF Switch Use to turn power Winder ON or OFF. 3. Fuse Winder fuse is located here. 4. Hub Assembly Reversible to fit 1-1/2" and 3" cores. 5. Spindle Lock Holds the roll in place on the Spindle. 6. Label Roll Spindle Used to wind the Printed Labels around an empty core. 7. Label Tension Guide Shaft Spring-loaded shaft controls starting and stopping as tension is maintained or released by media. 8. Adjustable Media Guide Ring Slide to fit width of media exiting Printer. 9. Winder Interconnect Cord Connects Winder to Printer V, 2.5A External Power Connector* For connecting printers or equipment other than the 1600-C. *Requires disconnecting wire from Winder circuit board and connecting wire from External Power Connector. 6

11 SECTION 1 GETTING ACQUAINTED Control Panel Button/LED Indicators: The Control Panel has 3 buttons with LED indicators. POWER (ON/OFF) Turns Printer power ON and OFF. Turn off power for cleaning and maintenance. PRINT/PAUSE (PAUSE JOB/RESUME) Temporarily stops the Feed or Resumes Printing. Press to Pause Job Temporarily. Printer will finish printing media in progress, then stop and hold. Press to Resume Printing. Restart printing after a feed error (such as a media jam or running out of labels). CANCEL/CUT (CANCEL JOB) Stops a Job indefinitely. Cancels a Job. Cuts the media. Press to Stop Media Feeding. NOTE: Cancelled Jobs must be reloaded before printing can resume. Press to Cut the Roll. Once the job is finished, pressing this button advances the last printed label to the cutter, cuts the label and retracts the media to the start position. PRINTER STATUS Power cord plugged in. Control Panel Power Switch OFF. Unit Powered Up, No Job Loaded. Unit Powered Up, No Job Loaded. Loading Media. CONTROL PANEL INDICATORS NORMAL OPERATION POWER (ON/OFF) PRINT/RESUME (STOP/RESUME) CANCEL/CUT (CANCEL JOB/CUT) BLUE LED OFF GREEN LED OFF RED LED OFF Press to POWER UP Printer. Inactive Inactive BLUE LED ON GREEN LED OFF RED LED OFF Press to POWER DOWN Printer. Inactive Inactive BLUE LED ON GREEN LED OFF RED LED OFF Press to POWER DOWN Printer. Press once to feed media forward at 3 inches/second. Press and hold for 3 seconds to feed media backward at 3 inches/second. 7

12 SECTION 1 GETTING ACQUAINTED PRINTER STATUS Job Submitted, Printing Job Submitted, Paused Temporarily, (Printhead not capped) Job Submitted, Paused Indefinitely, (Printhead capped) POWER (ON/OFF) BLUE LED ON Press to POWER DOWN Printer: Press once: Printer finishes printing label in progress, advances to cutter, cuts, and retracts media to start position. Caps Printhead. Press again: Cancels Job. Press again: Shuts down Printer. BLUE LED ON Press to POWER DOWN Printer: Press once: Printer advances to cutter, cuts, and retracts media to start position. Caps Printhead. Press again: Cancels Job. Press again: Shuts down Printer. BLUE LED ON Press to POWER DOWN Printer: Press again: Cancels Job. PRINT/RESUME (STOP/RESUME) CANCEL/CUT (CANCEL JOB/CUT) GREEN & RED LEDs flashing alternately ON/OFF once/second. Press to PAUSE Job temporarily. Printer finishes printing label in progress, then stops and holds. Does not cap Printhead. GREEN LED flashing ON/OFF once/second. Press to RESUME/ START media feed from the next label. GREEN LED flashing ON/OFF once/second. Press to RESUME/ START media feed from the next label. Press and hold for 3 seconds or more to reload media (if needed). Press to STOP media feed indefinitely. Printer finishes label in progress, advances to cutter, cuts, and retracts to start position. Caps Printhead. RED LED OFF Press to CANCEL Job: Press once: Printer advances to cutter, cuts, and retracts media to start position. Caps Printhead. Press again: Cancels Job. RED LED OFF. Press to CANCEL Job. 8

13 SECTION 1 GETTING ACQUAINTED PRINTER STATUS Normal Operation: Performing Maintenance Downloading a Job Positioning Media POWER (ON/OFF) BLUE LED ON Press to POWER DOWN Printer: Press to pause all actions and return components to start positions. Press to POWER DOWN. PRINT/RESUME (STOP/RESUME) CANCEL/CUT (CANCEL JOB/CUT) GREEN & RED LEDs flashing simultaneously once/second. Inactive Inactive Normal Operation: Downloading Firmware Power Up Power Down BLUE, GREEN & RED LEDs flashing simultaneously once/second. Inactive Inactive Inactive PRINTER ERROR INDICATORS PROBLEM IDS- related Errors Paper Path Errors: (End of roll, paper jam) System initiated. Hardware Errors: (Service Module error, door open, Printhead latch open, etc.) POWER (ON/OFF) PRINT/RESUME (STOP/RESUME) CANCEL/CUT (CANCEL JOB) BLUE LED ON GREEN LED OFF RED LED ON ACTION: Press POWER to POWER DOWN. Check/clear error source. If OK, press PRINT to resume printing. If not fixed, press CANCEL to cancel the job. BLUE LED ON GREEN LED FLASHING RAPIDLY (About 3 times/second.) RED LED OFF ACTION: Press POWER to POWER DOWN. Fix problem, load new roll, clear jam. If OK, press PRINT to resume printing. BLUE LED ON GREEN LED OFF RED LED FLASHING RAPIDLY (About 3 times/second.) ACTION: Press POWER to POWER DOWN. Fix the problem. Press CANCEL to clear the error. For a color version of the Control Panel Indicators go to: See also Troubleshooting Guide on page 56 9

14 SECTION 1 GETTING ACQUAINTED Printer Default Printing Modes The Printer has three default Printing Modes "Roll-to-Roll", "Roll-to-Cut", and "FanFold". Depending on what is connected or disconnected from the Printer determines what mode the Printer will operate in and disables or enables the automatic function of the Cutter. NOTE: These defaults will override any presets built into the job being run. Before starting to print a job make sure the Printer, Unwinder and Winder are set up correctly for that particular job. PRINT MODE UNWINDER WINDER CUTTER Roll-to-Roll Roll-to-Cut Fanfold Powered ON/Connected to Printer Powered ON/Connected to Printer Powered OFF or Disconnected from Printer Powered ON/Connected to Printer Powered OFF or Disconnected from Printer Powered OFF or Disconnected from Printer Disabled. (Still cuts manually by pressing 'CANCEL' button.) Enabled for automatic cutting Enabled for automatic cutting See Section 2 "Installing the Printer," "Loading Labels" for how to load Roll and Fanfold Labels 10

15 SECTION 2 INSTALLING THE PRINTER SECTION 2 Installing the Printer Contents of Packaging 1. Colordyne 1600-C Printer U Unwinder (Optional) W Winder (Optional) 4. Ink Tanks Cyan, Magenta, Yellow, Black, Black 5. Printhead 6. Adjustable Media Guide 7. AC Power Cord 8. USB Cable 9. Operator Manual 10. Driver Software CD Before using the Colordyne 1600-C Labeler the following must be done: Choose a location for the Printer (plus the optional 1600-U Unwinder and 1600-W Winder if used) Unpack the Printer (plus the optional 1600-U Unwinder and 1600-W Winder if used) Remove the Transport Tab from the Service Station, remove Shipping Tape Plug in the Printer and connect it to the computer Install the Printer Driver Install the Ink Tanks Install the Printhead Align the Printer with the 1600-U Unwinder and 1600-W Winder (If used) Connect the 1600-U Unwinder and 1600-W Winder to the Printer (If used) Load Labels (Roll or Fanfold) and Set Up the Feed on the Printer Choose a Location The Colordyne 1600-C should be placed on a sturdy level worktable or cabinet at least 9 inches from any walls. The surface should be large enough to accommodate the 1600-C, and 1600-U Unwinder and 1600-W Winder if used, in a line together. Protect the Printer and optional Unwinder/Winder from excessive heat, dust, and moisture. Avoid placing it in direct sunlight. Unpacking and Setup Remove the Printer, and optional 1600-U Unwinder and 1600-W Winder if used, and all parts from cartons. Remove all packing tape. 11

16 SECTION 2 INSTALLING THE PRINTER Hydrating the Printhead Cartridge Before you begin assembling the Label Printer, it is a good idea to hydrate the Printhead Cartridge. CAUTION Use electrostatic discharge (ESD) protection when handling. Hold the Printhead Cartridge by the handles ONLY. DO NOT touch the ink couplings, nozzle surface or electrical contacts. DO NOT unpack the Printhead Cartridge until the Printer is ready for installation. Once unwrapped, delay in installing the Printhead can compromise print quality due to dehydration. DO NOT place an unwrapped Printhead on any surface before installing. Protect the Printhead from scratches, dust, fibers, dirt and other contaminants at all times. 1. Carefully remove the Printhead Cartridge from the foil packaging. [A] Tear at notch or cut end with scissors. [B] Remove the protective plastic cover. Hold the Printhead by the handle and unclip the cover from the Printhead. [C] Remove protective strip from the Printhead Electrical Contacts. DO NOT allow removed strip to touch the electrical contacts. [D] Remove protective strip from the Printhead Nozzles. Hold the Printhead by the handle with one hand. Pull the strip tab with the other hand and slowly peel the strip from the Printhead. DO NOT pull the strip at any angle less than 45 with the Printhead surface. DO NOT allow removed strip to touch the Printhead Nozzles. 2. Pour just enough distilled water into the orange plastic cover you removed in Step 1B to moisten the bottom strip inside. Carefully reinstall the Printhead back into the plastic cover. Set the Printhead aside for installation later. This rehydrates Printhead and allows easier priming once it is installed in the Printer. 12

17 SECTION 2 INSTALLING THE PRINTER Remove Service Station Transport Tab and Shipping Tape 1. Open the Top Cover. 2. Release the two latches (one on either side of the Print Engine). Open the top half of the Clamshell by lifting both levers at the same time. CAUTION OPERATE AND HOLD ONTO BOTH LATCHES WHEN OPENING AND CLOSING THE CLAMSHELL COVER TO PREVENT DAMAGE. DO NOT ALLOW THE CLAMSHELL TO DROP BY ITSELF WHEN CLOSING. TO PREVENT DAMAGE TO THE INK LINES, A STOP LIMITS RAISING THE CLAMSHELL MORE THAN Pull up on the two red tabs to remove the cardboard Transport Tab [A] from the Service Station. 4. Remove the tape [B] securing the Head Media Guide. (If necessary, wipe off any tape residue from the Head Media Guide surface [C].) 5. Carefully close and relatch the Upper Clamshell. Then close the Top Cover. 13

18 SECTION 2 INSTALLING THE PRINTER Connecting the Colordyne 1600-C Plugging in the Printer Connect the power cord to the receptacle [1] on the non-operator side of the Label Printer. The internal power supply in the Printer is rated 115 to 240VAC, 50/60 Hz. CAUTION DO NOT USE AN ADAPTER PLUG OR EXTENSION CORD TO CONNECT THE LABEL PRINTER TO THE WALL RECEPTACLE. DO NOT USE OUTLETS CONTROLLED BY WALL SWITCHES. DO NOT USE AN OUTLET THAT SHARES THE SAME CIRCUIT WITH LARGE ELECTRICAL MACHINES OR APPLIANCES. Connecting to the Computer The Label Printer connects to the computer through the USB port [3]. A Network port [2] is provided when operating in a network environment. The Unwinder Interconnect port [4] is located just below the USB port. Turning Power ON and OFF Powering Up Printer: 1. Press the Main Power Switch on the Side Panel. 2. Press the Power Button on the Control Panel. Powering Down Printer: CAUTION WHENEVER POWERING DOWN UNIT, ALWAYS: 1. PRESS THE POWER BUTTON ON THE CONTROL PANEL. 2. WAIT FOR THE PRINTER TO STOP PROCESSING. 3. THEN PRESS THE MAIN POWER SWITCH ON THE SIDE PANEL. 14

19 SECTION 2 INSTALLING THE PRINTER Install the Printer Driver For the Printer software to operate properly check that the computer system meets these minimum requirements: Windows XP, Windows Vista, Windows 7. (Supports 32 and 64 bit systems) You must have administrative privileges on the system. Microsoft Internet Explorer 6.0 or higher. Java version 6 or higher USB 2.0 port (ports will be identified as USB2 or Enhanced in the Device Manager.) Microsoft.NET Framework 3.5 installed (Even if you have a higher version installed, version 3.5 must also be installed.) IMPORTANT: Before installing the Printer software (Toolbox and Driver), you should temporarily disable all antivirus programs and firewalls. In addition, you must be logged onto the system with full administrative privileges (admin rights). NOTE: If installing over USB, do not plug in the USB cable until prompted. 1. Make sure the Printer is plugged in and turned OFF. Disconnect the USB connection if you have plugged it in already. Install the disk supplied with the Printer in your CD drive or go to to download the latest driver. When the Driver Window opens, click Install Printer Software to start. 2. The License Agreement window opens. Carefully read the End User Agreement. If you agree to the terms, check I accept then click Next>. 15

20 SECTION 2 INSTALLING THE PRINTER 3. After a few moments the Printer Connections window opens. Click Configure to print using USB. Then click Next>. 4. The software will start installing the Printer Software. 5. The Connect Device Now window opens. Switch the Printer ON and connect the USB cable. Don t click on either button in the window. The software will then finish installing. 6. The Finished software installation window opens. Do not print a test page since Printer is not set up yet. Do not check the Print Test Page. You can also set the printer to be the default printer. To complete the process you must reboot the computer. Click Reboot. 16

21 SECTION 2 INSTALLING THE PRINTER Install the Ink Tanks The Printer uses a single Printhead Cartridge and five Ink Tanks (two Black, one Cyan, one Magenta, and one Yellow). Install the Ink Tanks as follows: 1. Open the Printer Toolbox. Go to All Programs, open the Colordyne Folder and open the Toolbox. On the Opening Screen you will see System Status information in the upper left corner. Note that the Ink Tank levels are all empty. 2. Open the Front Cover (hinged at bottom). Open the three Latches [A]. 3. Remove the new Tank(s) from packaging. 4. Slide the new Ink Tanks (label up) into their appropriate color slots [B]. Close the three Ink Tank Latches. INSTALLATION TIP: Make sure the Ink Tanks seat properly. Insert the Tank into the appropriate Ink Station, then pull the Ink Tank back about an inch and push forward firmly to insure that the Ink Nozzles penetrate the seals on the Tanks. 17

22 SECTION 2 INSTALLING THE PRINTER 5. Watch the Toolbox screen on your computer; you will see the ink colors fill in as the Tanks are installed. If the ink color does not fill in after a few seconds, reinstall the Tank. 6. Close the three Latches. Close the Front Cover. WARNING! The ink in the Ink Tanks may be harmful if swallowed. Keep new and used Ink Tanks out of reach of children. Discard empty Ink Tanks immediately. 18

23 SECTION 2 INSTALLING THE PRINTER Install the Printhead Cartridge The Printhead Cartridge is a delicate precision device. Handle with extreme care to avoid damage and issues that could degrade print quality. CAUTION Use electrostatic discharge (ESD) protection when handling. Hold the Printhead Cartridge by the handles ONLY. DO NOT touch the ink couplings, nozzle surface or electrical contacts. DO NOT unpack the Printhead Cartridge until the Printer is ready for installation. Once unwrapped, delay in installing the Printhead can compromise print quality due to dehydration. DO NOT place an unwrapped Printhead on any surface before installing. Protect the Printhead from scratches, dust, fibers, dirt and other contaminants at all times. 1. With the Printer power ON, open the Top Cover. The Printhead Latch [1] should be already opened. NOTE: If Latch is closed, open using the Printhead Release buttons in the Printer Driver Services Tab or in the Toolbox. NOTE: Remove the Cap Protectors on the Ink Nozzles [2]. Be sure to open the Latch fully to retract the Ink Nozzles. CAUTION DO NOT PRY OR MANUALLY LIFT THE PRINTHEAD LATCH OR THE LATCH MAY BREAK. ONLY OPEN THE LATCH USING THE PRINTHEAD RELEASE COMMANDS IN THE SERVICES TAB OR PRINTER TOOLBOX. 19

24 SECTION 2 INSTALLING THE PRINTER 2. Take the Printhead Cartridge you hydrated and set aside earlier, remove the orange cover and proceed to Step 3. Otherwise, follow the Steps below: Carefully remove the Printhead Cartridge from the foil packaging. [A] Tear at notch or cut end with scissors. [B] Remove the protective plastic cover. Hold the Printhead by the handle and unclip the cover from the Printhead. [C] Remove protective strip from the Printhead Electrical Contacts. DO NOT allow removed strip to touch the electrical contacts. [D] Remove protective strip from the Printhead Nozzles. Hold the Printhead by the handle with one hand. Pull the strip tab with the other hand and slowly peel the strip from the Printhead. DO NOT pull the strip at any angle less than 45 with the Printhead surface. DO NOT allow removed strip to touch the Printhead Nozzles. IMPORTANT! Pour just enough distilled water into the orange plastic cover you removed in Step 2B to moisten the bottom strip. Carefully reinstall the Printhead back into the plastic cover. Set the Printhead aside for 15 to 20 minutes. This rehydrates Printhead and allows easier priming once it is installed in the Printer. WARNING! TO AVOID ELECTRICAL SHOCK OR SHORTING: Before installing Printhead, make sure nozzles are hydrated and contacts are DRY! 3. Carefully insert the Cartridge into the compartment at an angle [1], with the Printhead surface facing down and the Ink Nozzles facing the Ink Hoses. Once it is seated, gently tilt the Cartridge back until it snaps into an upright position [2]. DO NOT FORCE the Cartridge into position. 20

25 SECTION 2 INSTALLING THE PRINTER 4. Wet the Printhead Surface. This ensures that the Printhead will prime correctly. Open the Top Cover. Release and lift up the two latches at the same time to raise the Printhead Clamshell. Moisten the Printhead nozzles using distilled water and a damp, lint-free cloth, wiping end to end. (Gray strip located below orange strip.) Close and relatch the Printhead Clamshell. CAUTION OPERATE AND HOLD ONTO BOTH LATCHES WHEN OPENING AND CLOSING THE PRINTHEAD CLAMSHELL TO PREVENT DAMAGE. DO NOT ALLOW THE CLAMSHELL TO DROP BY ITSELF WHEN CLOSING. TO PREVENT DAMAGE TO THE INK LINES, A STOP LIMITS RAISING THE CLAMSHELL MORE THAN Close the Printhead Latch [1]. The Printer will run a start-up routine and prime ink into the Printhead. This may take a few minutes. Make sure that ink is flowing through the hoses. 6. Watch the Toolbox screen on your computer again. Notice that some of the information is in red. As the Printer circulates ink and primes the system these fields should all turn black. 7. When the Printer stops processing and all the fields in System Status are black, the Printer is ready for use. Close the Top Cover. NOTE: The Printer may take up to 12 minutes to set itself up during initial startup. This is normal. The machine will emit a number of chirps, whirrs and other noises as it circulates ink and runs systems. 21

26 SECTION 2 INSTALLING THE PRINTER Removing the Head Media Guide You can remove the Head Media Guide if you are primarily printing on thin, flat stock (that is, not printing large batches of envelopes) and are encountering print quality issues. The attachment is used to flatten the envelope flap for better print consistency. 1. Open the Top Cover 2. Open the Printhead Clamshell. CAUTION OPERATE AND HOLD ONTO BOTH LATCHES WHEN OPENING AND CLOSING THE PRINTHEAD CLAMSHELL TO PREVENT DAMAGE. DO NOT ALLOW THE CLAMSHELL TO DROP BY ITSELF WHEN CLOSING. TO PREVENT DAMAGE TO THE INK LINES, A STOP LIMITS RAISING THE CLAMSHELL MORE THAN [A] & [B] Slide the Envelope Printing Attachment to the left and pull down on the Head Media Guide to release it from the metal support. [C] Remove the Guide from the Printer. Save for later use. 22

27 SECTION 2 INSTALLING THE PRINTER 4. Carefully pull out the right-hand Spacer (smaller) in the hole in the Service Station Platen [A]. 5. Carefully pull out the left-hand Spacer (larger) in the hole on the left end of the Service Station Platen [B]. 6. Wipe the Printhead Nozzles end to end using distilled water and a damp lintfree cloth. Close and relatch the Printhead Clamshell. Close Top Cover. NOTE: When removing the Head Media Guide or servicing or replacing the Service Station, DO NOT discard the 2 Spacers, remove and save with Guide for reuse. 23

28 SECTION 2 INSTALLING THE PRINTER Aligning Printer with 1600-U Unwinder and 1600-W Winder Roll-to-Roll Label Printing Make sure the Unwinder and Winder are properly connected to the Printer and turned ON, this will disable automatic function of the Cutter. (Cutter can still be operated manually by pressing the CANCEL button). Proper alignment of the Unwinder, Printer and Winder is critical to operation of the Label Printer. Position the Printer on a sturdy, stable level work surface with enough room to place the Unwinder and Winder at either end. Position the Unwinder: 1. Fit square notch cut into the base of the Unwinder [A] over the pin located along the base of the feed end of the Printer [B]. 2. Make sure base of Unwinder and base of Label Printer are flush [C]. 24

29 SECTION 2 INSTALLING THE PRINTER Position the Winder: 1. Open the Ink Tank Door. Note the notch cut in the top edge of the Door [A]. 2. With the Door open, position the corner of the Winder flush with the top edge of the Door so the corner is centered in the notch [B]. 3. Close the Ink Tank Door. Winder is aligned and positioned at the correct distance from the Label Printer [C]. 25

30 SECTION 2 INSTALLING THE PRINTER Roll-to-Cut Label Printing Make sure the Unwinder is properly connected to the Printer and turned ON. The Winder should be turned OFF or disconnected to enable automatic operation of the Cutter. Proper alignment of the Unwinder and Printer is critical to operation of the Label Printer. Position the Printer on a sturdy, stable level work surface with enough room to place the Unwinder at the feed end of the Printer. See "Position the Unwinder" Steps 1-2 above. Connecting the Printer to the Optional Unwinder and Winder CAUTION MAKE SURE THAT THE PRINTER IS TURNED OFF BEFORE CONNECTING THE UNWINDER AND WINDER. Connecting to the 1600-U Unwinder: Connect one interconnect cable into the 7-pin connector port on the Printer [1] located just below the USB port. Connecting to the 1600-W Winder: Connect the other 7-pin interconnect cable into the 7-pin connector port located on the exit end of Printer's non-operator side panel [1]. Unwinder Mode Switch The Unwinder has a Mode Switch for Auto or Manual operation. When used with the Colordyne 1600C, the Unwinder can be left in the Auto position. Auto Unwinder is OFF. Unwinder is controlled by the Printer (or other external device) thru the interface cable. Allows easy roll loading since the Unwinder will not start turning when the Drive Press Roller is lifted, only when the Printer is running a job. Manual Unwinder is always ON. When the Drive Press Roller is balanced (in the center position of its arc), the unit is OFF. If tension from the media increases (Roller raises), the unit turns clockwise to relieve the tension. If tension from the media decreases (Roller drops), the unit turns counterclockwise to increase the tension. This is useful if using the Unwinder with a non-interface external device. 26

31 SECTION 2 INSTALLING THE PRINTER Loading Labels Roll-to-Roll Printing IMPORTANT! Make sure the Unwinder and Winder are connected to the Printer. This will ensure that the automatic cut function of the Cutter is disabled. (Cutter can still be engaged manually by pressing the Cancel button). The Colordyne 1600-C Printer is equipped with one Adjustable Side Media Guide. Make sure the Unwinder is set to Auto and Winder (if used) is turned OFF and that both are connected to the Printer via the appropriate ports. 1. Adjust Core Size (Unwinder and Winder): The Unwinder and Winder can fit 1-1/2" or 3" cores using the reversible Hub Assembly. To change core sizes, proceed as follows. [A] Carefully remove the retaining-clip holding the Hub Assembly in place. [B] Slide the Hub Assembly off the Shaft. NOTE: Do not lose the key in the slot in the Shaft. Each side of the Hub fits a different size core. (Larger side fits 3" cores; smaller side fits 1-1/2" cores.) [C] Turn the Hub so the desired core size is facing out. Slide the Hub Assembly back into place over the key in the Shaft. [D] Reinstall the retaining-clip into the groove cut in the Shaft. 2. Load Label Roll: [A] Slide Roll onto Unwinder Shaft, labels facing up with the Roll End facing the Printer. [B] Slide the Roll Lock onto the Unwinder Shaft until the 4 pins fit into the roll core. [C] Pull the roll leader under the Drive Press Roller, under the crossbar, raise the Brush Assembly and push leader to entry of Print Engine. Lower the Brush Assembly. [D] Align the side edge of the roll with the two alignment pins on the Printer and feed the roll end into the Print Engine. [E] Slide the Adjustable Side Guide until it just touches the labels. Tighten the locking knob on the Adjustable Side Guide. 27

32 SECTION 2 INSTALLING THE PRINTER 3. Press the Print Button momentarily and the Printer will align and pull in the labels. Hold the Print Button down to feed the labels through the Printer until you have enough leader to attach it to the Winder. 4. [A] Adjust Winder to hold core size of roll being used. Load an empty core on the Winder Spindle. Slide the Spindle Lock on the shaft until the 4 pins fit into the roll core. [B] Take the leader end and pull it end under the Drive Press Roller on the Winder. [C] Tape or glue the roll end (label side up) to the top side of the empty core. NOTE: Make sure the edge is secured straight on the core for proper winding. [D] Slide Adjustable Media Ring Guide on the Drive Press Roller Shaft to the edge of the media. Adjusting Speed on 1600-U Unwinder and 1600-W Winder For proper media feeding and printing, you will have to adjust the speed on the Unwinder and Winder depending Printer speed selected and on the type of media and job you are running. To speed up the Unwinder and Winder turn the Speed Control clockwise. To slow the speed, turn the Control counterclockwise. CAUTION SETTING UNWINDER SPEED TOO HIGH CAN CAUSE THE MEDIA TO HESITATE AS IT UNWINDS AND AFFECT PRINT REGISTRATION. Roll-to-Cut Labels IMPORTANT! Winder must be turned OFF or disconnected from the Printer and moved out of the way. This will ensure that the automatic cut function of the Cutter is enabled. Load the Label Roll on the Unwinder and Printer using Steps 1-2 in "Roll-to-Roll Printing" above. Then press the Print button momentarily so the Printer will align and pull in the labels. 28

33 SECTION 2 INSTALLING THE PRINTER Fanfold Labels IMPORTANT! Make sure both the Unwinder and Winder are turned OFF or disconnected from the Printer and moved out of the way. This will ensure that the automatic cut function on the Cutter is enabled. Loading Fanfold Labels: 1. Place Fanfold Labels label-side up next to the feed end of the Printer. 2. Feed the Labels the under the Brush and into the Printer, aligning the left-side edge with the alignment pins on the Printer. Feed the Label end into the Print Engine. 3. Slide the Adjustable Side Guide so it just touches the right-side edge of the labels. 4. Press the Print Button momentarily and the Printer will align and pull in the labels. Hold the Print Button down to feed the labels through the Printer. 29

34 SECTION 3 OPERATING THE COLORDYNE 1600-C SECTION 3 Operating the Colordyne 1600-C Once the Printer Driver is installed on your computer and the Printhead is primed, you are ready to start printing. Set up your job and send it to the Printer. The Printer will start and print. The Printer Driver that you installed on your computer in Section 2 should be set as the default driver. It will then be accessible through your applications such as Microsoft Word. Other types of applications and database management software will work in a similar manner when using this Driver. This Section further assumes that you have set up the feed and the Printer is connected to your computer. Printer Driver Properties The Printer Driver for the Colordyne 1600-C works the same as any other Printer Driver for Windows. It does have some enhancements to help you maximize the ability of the Printer to print variable addressed pieces quickly and efficiently. Windows XP, Vista, Windows 7: Once the job is set up, click Print. The window on the right will open. Make sure the M Series Driver is the selected Printer. Clicking on Properties opens the Properties window. General Tab The General tab lets you select: Orientation Portrait (Default), Landscape, Rotate 180 and Mirrored. Page Buffering Allows the entire print job to load before printing starts. Copies Lets you choose the number of copies to be printed. Media Allows you to adjust the Printer for the media being used for a job. Type: Choose type of media to be used. Size: Set a different size media than the document was originally designed for. The document is automatically resized to fit the new media. Overspray: Checking this box allows printing to the edge of the media (borderless). 30

35 SECTION 3 OPERATING THE COLORDYNE 1600-C You can also create and save a Custom Size to suit your needs. NOTE: Do not exceed maximum media size for the Printer. Source: Set where the media is coming from (Main Tray, Roll Feed, etc.) Color Selection Set printing for Color or Monochrome. Print Speed Determines print quality. Select Normal or Best. Normal is 1600 x 800 dpi, checking the Half Speed box slows printing for higher quality on glossy stock. Best setting is 1600 x 1600 dpi, for use when high quality images are required. My Print Settings Save and access saved presets for jobs. Layout Tab Layout allows you change how the document prints without changing the original document. Resizing Lets you specify the Original Size or Custom Resize: lets you resize the original as a % of normal size. The Printer will print the document in the size you selected regardless of the size of the paper selected. Print on: lets you specify the particular size of paper that you want to print on regardless of the size of the original document. Checking Scale to Fit automatically resizes the document to fit on the new page size. Printing Adjustments Allows you to make minor positioning changes to the print area in relation to the media if needed. NOTE: Only works on jobs using less than the full print area (less than 8.5" wide). Watermark Prints a light background watermark in the paper while printing the original document. When this option is selected the First page only option prints the watermark on the first page, but not subsequent pages, unchecking prints the watermark on all pages. The Custom button lets you create a new watermark or edit an existing watermark, including font selection, color, size and printing angle. My Print Settings Access your saved custom print settings for various jobs. 31

36 SECTION 3 OPERATING THE COLORDYNE 1600-C Media Tab Media allows you make adjustments as to how the job prints or is cut without changing the original document. Position Adjustment Allows you to make minor positioning changes to the image position in relation to the media if needed. You can set Horizontal or Vertical Offsets in Inches, Millimeters or Pixels. NOTE Only works on jobs using less than the full print area (less than 8.5" wide). Media Layout Select type of roll media you are using for a particular job. Page Cutting Set (Job Cut) or (Sheets per cut) or Use Printer Setting for each. My Print Settings Access your custom print settings for various jobs that you uploaded through the Media Profile Upload in the Toolbox. 32

37 SECTION 3 OPERATING THE COLORDYNE 1600-C Services Tab Services allows you to: Clean Printheads Clicking this button opens another screen that gives you three cleaning levels to choose from: Quick Circulates ink, wipes and cleans the Printhead Cartridge. Normal Runs cleaning and wiping routine twice for better flushing and cleaning. Full Runs the cleaning routine multiple times for the most thorough flushing and cleaning of the Printhead. Wipe Printhead Wipes and cleans excess ink from the Printhead Cartridge. Print Configuration Page Prints out the current configuration of the Printer including current Firmware Version, Network Connection, Printer Serial Number and more. Print Colorbar Page Prints type and color bands to check print quality. Print Diagnostic Page Shows basic Printer information, memory, Network Settings, Event Log and RAM partitions. Printhead Release Deprimes the ink from the system and opens the Printhead Cover for removing/installing the Printhead Cartridge. System Deprime Drains the ink in the lines back into the Ink Tanks before servicing the Printhead Cartridge or prepping the Printer for storage or transport. Other Services If you are connected to the Internet you can also Order Supplies and Get Support with Printer questions. 33

38 SECTION 3 OPERATING THE COLORDYNE 1600-C Using the Printer Toolbox Once the Printer Driver is installed you have access to the Printer Toolbox. The Toolbox lets you monitor ink usage, perform diagnostic checks, print reports and run maintenance tasks on the Printer from your computer. To open the Toolbox: Click Start from the Windows taskbar, go to All Programs, open the Colordyne folder, then click on Toolbox. When the User Interface window opens you will find a series of Menu Options you can click on at the lower left of the screen. You can check the Printer Status in the upper left part of the screen. User Interface [A] Screen Buttons: Let you perform maintenance and operating tasks. You can use the screen buttons to Clear Errors, Pause/Resume, Cancel a Job, Reset the Job Counter, and Reset the Page Counter. You can also: Circulate Ink Purges air from the lines and primes the system after replacing the Ink Tanks or Printhead Cartridge. Wipe Printhead Activates the Service Station to wipe the Printhead. Cleaning Buttons: Provide 3 levels of cleaning for the Printhead Cartridge. These work the same way as the 3 Maintenance Level Buttons in the Printer Driver: Quick Clean Printhead Circulates ink, wipes and cleans the Printhead Cartridge. Normal Clean Printhead Runs cleaning and wiping routine twice for better flushing and cleaning. Full Clean Printhead Runs the cleaning routine multiple times for the most thorough flushing and cleaning of the Printhead. 34

39 SECTION 3 OPERATING THE COLORDYNE 1600-C [B] Basic Printer Settings Lets you adjust automated service and cleaning intervals, adjust the feeder speed for a job and adjust the Printer for pre-printed media. KWS Setting (Keep Web Spitting) Keeps Printhead hydrated while running a job. Select from 3 settings: None, Light (default), Heavy, to determine how much ink will spit from the Printhead Nozzles. Set in conjunction with Mid Job Servicing which determines the frequency of the Printer stopping for selfservicing during a job. Mid Job Servicing Sets the frequency of automatic maintenance cycles run during a job after a set amount of media is run. Settings are: Default (14m), Level 4 (100m), Level 3 (250m), Level 2 (375m), Level 1 (500m) and Off (. NOTE: Changing the setting from Default may cause print quality issues and reduce Printhead life. Ignore Exit Sensor Checking this box turns the Exit Sensor OFF. The Sensor may not see the trailing edge of a piece of pre-printed media if the back of that media is dark or black. (Example: adding addresses to a pre-printed postcard.) This may fool the Sensor into thinking a jam has occurred. Turning the Sensor OFF prevents these false jams from stopping the job. [C] These buttons control functions that require the machine to be out of service for extended periods of time while they are being performed. Eject Service Station Releases the Service Station for removal for cleaning, repair or replacement. Install Service Station Pulls the Service Station back into place after cleaning, repair or replacement. Release the Printhead Performs the same task as the Cover Release button on the Printer. Pumps the ink back into the Ink Tanks and opens the Printhead Cover to remove/install the Printhead Cartridge. System Deprime Pumps the ink back into the Ink Tanks prior to replacing the Printhead Cartridge or transporting the Printer. Shutdown the Printer Turns the Printer OFF from your computer. 35

40 SECTION 3 OPERATING THE COLORDYNE 1600-C D] Display Language Selects the language the Printer will operate in. Diagnostics From this screen you can see the current status of your Printer. You can also: Print Sample Page Prints type and color bands to check print quality. Print Configuration Page Shows the current configuration of the Printer including Firmware Version, Network Connection, Printer Serial Number and more. Print Diagnostic Page Shows basic printer information, memory, Network Settings, Event Log and RAM partitions. Print Demo Page Prints a 4-color sheet. Print Color Bars Page Shows how well Printhead is printing. 36

41 SECTION 3 OPERATING THE COLORDYNE 1600-C Ink Usage Allows you to monitor the estimated amount of ink left in each of the five Ink Tanks. You can monitor ink use and consumption and schedule Tank changes (saving down-time during a print run.) NOTE Ink Usage only works when you start with a new Tank and leave it in the Printer. Ink Estimation Mode Checking this box lets you predetermine how much ink a given job may use prior to printing. This can be useful for determining per piece costs. The job is sent to the Printer and loads, but does not print. Once the job is loaded, the chart shows the amount of ink (by color) that the job will use. NOTE: The estimating process will take as long as the job would take to print (i.e., if the job would take 1 hour to print, the estimate will take 1 hour to display.) Network Configuration Permits you to view, enter or change settings to connect the Printer to your network. Network Connection Set Up: 1. The Printer is still connected to the computer via the USB cable. To connect the Printer to a network, open the Toolbox. On the User Interface page, click Network Config. This will open the Printer Toolbox Home page. 37

42 SECTION 3 OPERATING THE COLORDYNE 1600-C 2. The Network Configuration page opens. Your IT person can choose the Network Settings to enter the correct settings for your network. 3. Connect Ethernet cable to Network Port on Rear Panel of Printer. Service Menu For authorized personnel only. Provides access to more advanced Printer control and maintenance menus. 38

43 SECTION 4 MAINTENANCE SECTION 4 - Maintenance This section covers how to care for the Ink Tanks, Printhead Cartridge, Service Station, clear paper jams and replace the Sheet Separators. Replacing the Ink Tanks Replace the Ink Tanks when the ink runs out. 1. Open the Printer Toolbox. Go to All Programs, open the Colordyne Folder and open the Toolbox. On the opening screen you will see System Status information in the upper left corner. You can see which Ink Tank Levels are low or empty. 2. Power down the Printer. 3. Open the Front Cover (hinged at bottom). Open the three Latches [A] and pull the Ink Tank(s) out of the Printer. 4. Remove the new Tank(s) from packaging. 5. Slide the new Tank (label up) into its appropriate color slot [B]. INSTALLATION TIP: Make sure the Ink Tanks seat properly. Insert the Tank into the appropriate Ink Station, then pull the Tank back about an inch and push forward firmly to insure that the Ink Nozzles penetrate the seals on the Ink Tanks. 39

44 SECTION 4 MAINTENANCE 6. Power up the Printer. Open the Printer Toolbox. 7. Watch the Toolbox screen on your computer; you will see the ink colors fill in as the Ink Tanks are installed. If the ink color does not fill in after a few seconds, reinstall the Tank. 8. Prime the system by running the Circulate Ink routine from the User Interface window in the Toolbox. 9. Watch the Toolbox screen on your computer again. Notice that some of the information is in red. As the Printer circulates ink and primes the system these fields should all turn black. 10. When the Printer stops processing and all the fields in System Status are black, the Printer is ready for use. 11. Close the Front Cover. WARNING! The ink in the Ink Tanks may be harmful if swallowed. Keep new and used Ink Tanks out of reach of children. Discard empty Ink Tanks immediately. Cleaning Ink Tank Contacts When reinstalling or replacing Ink Tanks, the Ink Level indicator in the Toolbox may not refresh. This may be due to a dirty Ink Tank Level Prism and/or QA Chip contacts on that Ink Tank(s). You can clean the contacts as follows: 1. Power down the Printer. 40

45 SECTION 4 MAINTENANCE 2. Open the Front Cover, release the Ink Tank Latch(es) [A] required and remove the Ink Tank(s) [B] with Levels that did not refresh. 3. Clean the Ink Level Prism [A] and QA Chip contacts [B] with a clean, dry, lint-free cloth. NOTE: You can dampen the cloth with distilled water to wipe the Prism, but DO NOT get the QA Chip contacts wet. 4. Reinstall the Ink Tank(s) (label up), close the Ink Tank Latch(es). 5. Power up the Printer. Open the Printer Toolbox and click the "Circulate Ink" button. INSTALLATION TIP: Make sure the Ink Tanks seat properly. Insert the Tank into the appropriate Ink Station, then pull the Tank back about an inch and push forward firmly to insure that the Ink Nozzles penetrate the seals on the Ink Tanks. 6. Close the Front Cover. Storage New Ink Tanks should be stored in their original packaging and kept away from heat. Opened Ink Tanks should remain in the Printer. Disposal The Ink Tank may be disposed of in a normal manner. Clean up spills with soap and water. Abrasive soap is effective in cleaning ink off your hands. 41

46 SECTION 4 MAINTENANCE Cleaning/Replacing the Printhead Cartridge Cleaning The Printhead in the Colordyne 1600-C Printer is cleaned automatically each time the machine is turned on or when the Quick Clean Printheads routine is performed by the operator. This can be found under the Service Tab, Clean Printheads button in the Printer Driver or in the Printer Toolbox. Normal Clean Printheads and Full Clean Printheads can be used to more thoroughly clean or clear the Printhead. If running the Clean Printheads doesn t help improve print quality, the Printhead Cartridge can be cleaned manually. 1. Open the Top Cover. 2. Release and lift up the two latches (one on each side of the Printhead Assembly) at the same time to raise the Printhead Clamshell. 3. Moisten the Printhead nozzles using deionized/distilled water (reference ASTM D Type E-II Electronic Grade Water) and a damp, lint-free cloth, wiping end to end. (Gray strip located below orange strip.) Take care not to damage the copper contacts, the metal plate, or the gold Printhead surface. 4. Close and relatch the Printhead Clamshell. Generally, when the ink supply is adequate and the print quality remains poor, or when the automated cleaning processes or manually cleaning the Printhead has not helped the image quality, the Printhead should be replaced. CAUTION Use electrostatic discharge (ESD) protection when handling. Hold the Printhead Cartridge by the handles ONLY. DO NOT touch the ink couplings, nozzle surface or electrical contacts. DO NOT unpack the Printhead Cartridge until the Printer is ready for installation. Once unwrapped, delay in installing the Printhead can compromise print quality due to dehydration. DO NOT place an unwrapped Printhead on any surface before installing. Protect the Printhead from scratches, dust, fibers, dirt and other contaminants at all times. 42

47 SECTION 4 MAINTENANCE Replacing the Printhead Cartridge 1. Open the Printer Toolbox. Go to All Programs, open the Printer Folder and open the Toolbox. On the Opening Screen you will see information about the System Status in the upper left corner. 2. Open the Top Cover. Open the Printhead Latch [1] using the Printhead Release button in the Printer Driver Services Tab or in the Toolbox. The Printer pumps any ink in the system back into the Ink Tanks. Then the Printhead Latch pops open. CAUTION DO NOT PRY OR MANUALLY LIFT THE PRINTHEAD LATCH OR THE LATCH MAY BREAK. ONLY OPEN THE LATCH USING THE PRINTHEAD RELEASE COMMANDS IN THE SERVICES TAB OR PRINTER TOOLBOX. 3. Make sure the Printhead Latch is fully opened to retract the ink lines. Remove the used Printhead Cartridge by tilting it toward the ink lines [2], then carefully lifting it out of the Printhead Compartment. 43

48 SECTION 4 MAINTENANCE 4. Carefully remove the Printhead Cartridge from the foil packaging. [A] Tear at notch or cut end with scissors. [B] Remove the protective plastic cover. Hold the Printhead by the handle and unclip the cover from the Printhead. [C] Remove protective strip from the Printhead electrical contacts. DO NOT allow removed strip to touch the electrical contacts. [D] Remove protective strip from the Printhead Nozzles. Hold the Printhead by the handle with one hand. Pull the strip tab with the other hand and slowly peel the strip from the Printhead. DO NOT pull the strip at any angle less than 45 with the Printhead surface. DO NOT allow removed strip to touch the Printhead Nozzles. NOTE: Keep foil packaging to store/dispose of old Printhead Cartridge. IMPORTANT! Pour just enough distilled water into the orange plastic cover you removed in Step 4B to moisten the bottom strip. Carefully reinstall the Printhead back into the plastic cover. Set the Printhead aside for 15 to 20 minutes. This rehydrates Printhead and allows easier priming once it is installed in the Printer. WARNING! TO AVOID ELECTRICAL SHOCK OR SHORTING: Before installing Printhead, make sure nozzles are hydrated and contacts are DRY! 5. Carefully insert the Cartridge into the compartment at an angle [1], with the Printhead surface facing down and the Ink Nozzles facing the Ink Hoses. Once it is seated, gently tilt the Cartridge back until it snaps into an upright position [2]. DO NOT FORCE the Cartridge into position. 44

49 SECTION 4 MAINTENANCE 6. Wet the Printhead Surface. This ensures that the Printhead will prime correctly. Open the Top Cover. Release and lift up the two latches at the same time to raise the Printhead Clamshell. Moisten the Printhead nozzles using distilled water and a damp, lint-free cloth, wiping end to end. (Gray strip located below orange strip.) Close and relatch the Printhead Clamshell. CAUTION OPERATE AND HOLD ONTO BOTH LATCHES WHEN OPENING AND CLOSING THE PRINTHEAD CLAMSHELL TO PREVENT DAMAGE. DO NOT ALLOW THE CLAMSHELL TO DROP BY ITSELF WHEN CLOSING. TO PREVENT DAMAGE TO THE INK LINES, A STOP LIMITS RAISING THE CLAMSHELL MORE THAN Close the Printhead Latch [1]. The Printer will automatically run a start-up routine and prime the ink into the Printhead. This may take a few minutes. Make sure that ink is flowing through the hoses. If air bubbles appear you may have to tap the lines or run the Circulate Ink routine to clear them. 8. Watch the Toolbox screen on your computer again. Notice that some of the information is in red. As the Printer circulates ink and primes the system these fields should all turn black. 9. When the Printer stops processing and all the fields in System Status are black, the Printer is ready for use. Close the Top Cover. IMPORTANT CHECK INK TANKS. PRINTER MAY NOT FULLY REPRIME IF TANKS ARE LESS THAN 1/3 FULL. NOTE: The Printer may take up to 12 minutes to set itself up during initial startup. This is normal. The machine will emit a number of chirps, whirrs and other noises as it circulates ink and runs systems. 45

50 SECTION 4 MAINTENANCE Replacing the Service Station The Service Station is designed provide a long service life. However, should it need to be replaced, follow these steps. The Service Station is located above the Ink Tank Station. 1. Open the Front Cover (hinged at bottom). Open the Top Cover. Release the two latches and open the Clamshell Cover. The Service Station will not fully eject with the Cover Closed. 2. Open the Printer Toolbox. In the User Interface window, press the Eject Service Station button. Once the Printer pushes the Service Station out, turn the Printer OFF. TURN PRINTER POWER OFF. CAUTION WHENEVER POWERING DOWN UNIT, ALWAYS: 1. PRESS THE POWER BUTTON ON THE CONTROL PANEL. 2. WAIT FOR THE PRINTER TO STOP PROCESSING. 3. THEN PRESS THE MAIN POWER SWITCH ON THE REAR PANEL. 46

51 SECTION 4 MAINTENANCE 3. Slide the Service Station out of the Service Station Dock. NOTE: Do not pull Station all the way out until you disconnect the Ribbon Cable. NOTE: It is a good idea to place an absorbent towel under the Service Station as you remove it to prevent any drips or leaks. 4. Disconnect the Ribbon Cable. Slide the Latch open on the Service Station Circuit Board to release the Ribbon Cable. Remove the Service Station. 5. Carefully unwrap the new Service Station. NOTE: Loose parts may fall out. Keep Roller side facing up when removing packaging. CAUTION MAKE SURE THE LATCHES ON THE WIPER ROLLER ARE FULLY LOCKED BEFORE INSTALLING THE SERVICE STATION. 47

52 SECTION 4 MAINTENANCE 6. Slide the Latch open on the Service Station Circuit Board. 7. [1] Plug the Ribbon Connector (blue side up) into the space under the Latch. [2] Close the Latch. 8. [1] Slide the Service Station into the Service Station Dock until it touches the bar. Align with tracks along sides and Guide on Service Station dock floor. [2] Look down through the Top Cover to make sure Service Station is aligned with the bar. IMPORTANT! Service Station must be perfectly aligned with bar to prevent misalignment and operating problems. 48

53 SECTION 4 MAINTENANCE 9. GENTLY push the Service Station while turning the large Gear on right side of Print Engine clockwise. Gear should engage gear on Service Station Roller and pull it in. Once the Service Station starts moving, stop turning the gear. Powering up the unit will pull the Service Station the rest of the way in. NOTE: Make sure the wick hanging below the Service Station is inside the plastic trough inside the Ink Tank Station to prevent ink seepage. NOTE: Service Station should operate smoothly. If it binds or makes irregular noises, reinstall the Service Station. Lubricate Side Tracks and Guide if necessary. 10. Close the Clamshell Cover. Replace the Exit Roller Door and Close the Front Cover. CAUTION OPERATE AND HOLD ONTO BOTH LATCHES WHEN OPENING AND CLOSING THE CLAMSHELL COVER TO PREVENT DAMAGE. DO NOT ALLOW THE CLAMSHELL TO DROP BY ITSELF WHEN CLOSING. Replacing the Ink Waste Tray The Ink Waste Tray soaks up any excess ink that may drip from the Print Engine during operation. After a period of time it may become saturated and need replacement. 1. Open Ink Tank Door. 2. Push in on the Tabs to release the Ink Waste Tray and remove it from unit. 3. Replace with a new Ink Waste Tray. 49

54 SECTION 4 MAINTENANCE Removing Jams in the Printer Clearing a jam depends on where the jam occurred. Print Engine Area: Open the Top Cover. Release and lift up the two latches [A] (one on each side of the Printhead Clamshell) at the same time to raise the Printhead Clamshell [B]. Clear the jam, then carefully lower and relatch the Printhead Clamshell. Close the Top Cover. B A Unlatch the Print Engine Clamshell CAUTION OPERATE AND HOLD ONTO BOTH LATCHES WHEN OPENING AND CLOSING THE PRINTHEAD CLAMSHELL TO PREVENT DAMAGE. DO NOT ALLOW THE CLAMSHELL TO DROP BY ITSELF WHEN CLOSING. TO PREVENT DAMAGE TO THE INK LINES, A STOP LIMITS RAISING THE CLAMSHELL MORE THAN 60. B Raise the Print Engine Clamshell Misfeeds To correct misfeeds: Roll Feed Unwinder/Winder may be moving too fast or slow for the job being printed. Readjust the Speed Controls on the Unwinder and Winder. Fanfold Straighten stack. 50

55 SECTION 4 MAINTENANCE Cleaning WARNING! THE PRINTER IS A PRECISION MACHINE. CLEAN REGULARLY TO INSURE MANY YEARS OF SERVICE. BEFORE PERFORMING ANY MAINTENANCE, DISCONNECT THE MACHINE FROM ITS POWER SOURCE! DO NOT REMOVE SIDE COVERS! HIGH VOLTAGES PRESENT. Clean the Printer regularly to remove accumulated paper dust and ink. Depending on the types of media that are run, paper dust may accumulate inside the Printer and on the Transport. 1. Turn the Printer OFF and unplug it from the power receptacle. Then open or remove the Covers. 2. Interior: Use a vacuum with a soft brush attachment or a can of compressed air to help loosen dust particles. NOTE: Be careful around ink tray and capping station in the Print Engine area as accumulated ink may splash onto other parts of the Printer. Take care not to damage the PC Boards or electrical wiring. 3. Exterior: Wipe clean with a lint-free cloth using any standard nonabrasive household cleaner that does not contain plastic-harming solvents. CAUTION NEVER SPRAY OR POUR CLEANERS DIRECTLY ON OR INTO THE PRINTER. EXCESS LIQUID COULD HARM ELECTRONIC PARTS. DAMPEN A LINT-FREE CLOTH WITH THE CLEANER AND APPLY IT TO THE PARTS TO BE CLEANED. Print Engine Areas in the Print Engine can become glazed with a buildup of dust, paper lint and accumulated ink and have to be cleaned regularly. Open the Top Cover. Open the Clamshell Assembly by releasing the two latches. Use a vacuum to pick up any loose debris. NOTE: Be careful around Ink Tray and Capping Station in the Print Engine area as accumulated ink may splash onto other parts of the Printer. Take care not to damage the PC Boards or electrical wiring. CAUTION USE ONLY DEIONIZED/DISTILLED WATER TO CLEAN PRINT ENGINE COMPONENTS. AVOID CONTAMINATING THE PRINTHEAD WITH CLEANERS, LUBRICANTS OR OTHER CHEMICALS. 51

56 SECTION 4 MAINTENANCE [A] Grit Rollers: Clean as needed by moistening a small hard-bristled brush or toothbrush with distilled water. DO NOT use anything other than distilled water to clean the Rollers. [B] Media Sensors: Paper lint and dust may build up on the Media Sensors. Use a can of compressed air or a damp (not wet) foam or lint-free cotton swab to gently swab the Sensors. Take care not to drip water into the Circuit Boards. Use a clean, dry swab to dab surfaces dry. Remember to wipe the clear panel over the Sensor Receiver in the upper Printhead Assembly (see inset). [C] Capping Station Seal and Squeegee. Clean as needed with distilled water on a damp, lint-free cloth. Be careful not to splash or drip ink on other parts of the Printer. [D] Printing Platen. Wipe with distilled water on a damp, lint-free cloth. Pat dry with a lint-free cloth. Cleaning the Ink Revolver Couplings 1. First Deprime the system and remove the Printhead Cartridge. 2. Moisten a foam swab in distilled water. 3. Insert the swab into one of the ink channels and rotate the swab to clean the chamber. 4. Use a new swab for each of the remaining ink channels until all 10 openings are clean. (5 on each side.) 52

57 SECTION 4 MAINTENANCE Shipping or Transporting the 1600-C Printer If you have to ship or transport the Printer for any reason, the unit will have to be prepared. Once the Printer is prepared, carefully package the Printer, Printhead Cartridge, Service Station and Ink Tanks in their original packaging. Deprime the System 1. This forces all of the ink to return to the Ink Tanks. You can do this by accessing the Toolbox User Interface Screen and pressing System Deprime or by using the Service Tab in the Printer Driver and pressing System Deprime. Remove the Printhead Cartridge 1. Open the Top Cover. Open the Printhead Latch [1] using the Printhead Release button in the Printer Driver Services Tab or in the Toolbox. The Printer pumps any ink in the system back into the Ink Tanks. Then the Printhead Latch pops open. CAUTION DO NOT PRY OR MANUALLY LIFT THE PRINTHEAD LATCH OR THE LATCH MAY BREAK. ONLY OPEN THE LATCH USING THE PRINTHEAD RELEASE COMMANDS IN THE SERVICES TAB OR PRINTER TOOLBOX. 53

58 SECTION 4 MAINTENANCE 2. Make sure the Printhead Latch is fully opened to retract the ink lines. Remove the Printhead Cartridge by tilting it toward the ink lines [2], then carefully lift it out of the Printhead Compartment. 3. Carefully pack the Printhead Cartridge using the original packaging. Remove the Service Station 1. Open the Ink Tank Cover (hinged at bottom). Open the Top Cover. Release the two latches and open the Clamshell Cover. The Service Station will not fully eject with the Cover Closed. 2. Open the Printer Toolbox. In the User Interface window, press the Eject Service Station button. Once the Printer pushes the Service Station out, turn the Printer OFF. TURN PRINTER POWER OFF. CAUTION WHENEVER POWERING DOWN UNIT, ALWAYS: 1. PRESS THE POWER BUTTON ON THE CONTROL PANEL. 2. WAIT FOR THE PRINTER TO STOP PROCESSING. 3. THEN PRESS THE MAIN POWER SWITCH ON THE REAR PANEL. 54

59 SECTION 4 MAINTENANCE 3. Slide the Service Station out of the Service Station port. NOTE: Do not pull Station all the way out until you disconnect the Ribbon Cable. NOTE: It is a good idea to place an absorbent towel under the Service Station as you remove it to prevent any drips or leaks. 4. Disconnect the Ribbon Cable. Slide the Latch open on the Maintenance Station Circuit Board to release the Ribbon Cable. Remove the Service Station. Remove the Ink Tanks 1. Open the Front Cover (hinged at bottom). Unlatch the three Locks [A] and pull the Ink Tank(s) out of the Printer. 2. Carefully package the Ink Tanks in the original packaging. IMPORTANT: Make sure the ink seals on the Ink Tanks are facing up and covered with absorbent wipes to prevent leaks and spills. 3. Pack the Ink Tank bays with absorbent towels to catch any ink drips or spills. 55

60 SECTION 5 TROUBLESHOOTING SECTION 5 Troubleshooting Guide The following Troubleshooting Guides are provided to assist you in solving any problems that might occur with the Colordyne 1600-C Label Printer. We have tried to make them as complete as possible. The best advice we can offer is to make sure that the system is set up properly, plugged in, and that it has an adequate supply of ink before attempting to troubleshoot any problem. The Memjet Printhead CONDITION PROBLEM SOLUTION Missing parts of letters or text. Print shows regularly missing or misdirected nozzles or ink color mixing. Ink mixing -- Mixed or muddy colors. No print or crisp blocks of missing drops. System will not reprime ink after replacing Printhead Cartridge Air and bubbles blocking Nozzles. Debris on Printhead. Causes: Ink flooding, air in the Printhead or a dirty Printhead. Electrical failure or poor electrical connection. Printhead nozzles dry. Ink Tanks may be 1/3 full or less. Clean the Printhead using recirculation, priming or cycles of depriming and priming found in the Driver or Toolbox. Rehydrate the Printhead using distilled water and a wet, clean, lint-free cloth. Bubbles often disappear with Printer use. Perform the startup routine. Clean the Printhead using one of the Cleaning Levels in the Driver or Toolbox. Wipe the Printhead manually with distilled water and a wet, clean, lint-free cloth. Replace the Printhead. Clean the Printhead using one of the Cleaning Levels in the Driver or Toolbox. Wipe the Printhead manually with distilled water and a wet, clean, lint-free cloth. Reseat the Printhead. Replace the Printhead. Wipe the Printhead manually with distilled water and a wet, clean, lint-free cloth. Replace Ink Tanks. WARNING! DO NOT REMOVE THE SIDE COVERS OF THE PRINTER! THERE ARE HIGH VOLTAGES PRESENT BEHIND THE COVERS! 56

61 SECTION 5 TROUBLESHOOTING The Printer CONDITION PROBLEM SOLUTION Ink Tank installed, no Ink Level indication in Toolbox Ink Tank contacts dirty, preventing Printer/Ink Tank communication. Remove Ink Tank(s). Clean prism and QA Chip contacts, see Maintenance, Cleaning Ink Tank Contacts. Extra lines; losing data Database problem. Check data in database program. Improper output (address information out of order, misfeeding, etc.) No communication Print too light or missing character dots Wrong Interface settings. Static electricity. Dirty Media Sensor. Improper cabling / connector. Unit not receiving power. Clogged or dirty Printhead. Running out of ink. Check software or database on PC. Close the software, then turn Printer OFF and ON. Clean Media Sensor. Use proper USB cable (see Operator Manual.) Check plug connections, ON/OFF button and fuse on side panel. Check the Printhead. Check Ink Tanks. Blurry address Image is not sharp. Clean Printhead using one of the Cleaning Levels in the Driver or Toolbox. Clean the Printhead manually using distilled water and a wet, clean, lintfree cloth. Feeding problems Misfeeds. Adjust the Speed on Unwinder and Winder. Job is sent to print but does not print. Printer not turned ON. Printer not connected to computer. Media Sensor is covered in Print Engine. Check that Printer is ON. Connect printer cable to computer and resend the job. Open Print Engine and remove media. 57

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