PRE-INSTALLATION GUIDE

For Kodak Prosper S-Series Imprinting System

This working document details the preparation stages necessary to make the installation of
your Kodak PROSPER S-SERIES Imprinting System a smooth process.

Printing System Installation Time Line

Physical Installation Plan

Key Items To Consider

Printing System Specifications

System Overview Packed Dimensions Unpacking

Power Operational Space Requirements

Environmental Requirements for Paper and Fluids

Ordering Fluids and Consumables

Preventive maintenance

Getting HELP

PROSPER S-Series Pre-Installation Guide 05/11/2011

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TABLE OF CONTENTS

WHAT IS THE STREAM CIJ TECHNOLOGY? ...................................................................... 3

PROSPER S-SERIES IMPRINTING SYSTEM INSTALLATION TIME LINE.......................... 4
Phase I Preliminary planning ........................................................................................... 4
Phase II Finalization of Plans........................................................................................... 4
Phase III Pre-installation Check off .................................................................................. 4
Phase IV Physical Installation .......................................................................................... 4
Phase V System Validation.............................................................................................. 4
PHYSICAL INSTALLATION PLAN KEY DATES ................................................................. 5
PROSPER S-SERIES IMPRINTING SYSTEM SPECIFICATIONS........................................ 7
PRINTHEAD SPECIFICATIONS ........................................................................................ 7
SYSTEM OVERVIEW ............................................................................................................ 8
PACKED DIMENSIONS ......................................................................................................... 8
UNPACKING THE SHIPPING CONTAINERS ..................................................................... 10
POWER REQUIREMENTS .................................................................................................. 11
Prosper S-SERIES Print Station Power: ........................................................................... 11
DC3800 Print Carriage:..................................................................................................... 11
REQUIREMENTS FOR EQUIPMENT AND OPERATION ................................................... 12
SPACE REQUIREMENTS ................................................................................................ 12
FLUIDS ORDERING ............................................................................................................ 14
MAINTENANCE AND REPAIR ......................................................................................... 14
PREVENTIVE MAINTENANCE ........................................................................................ 15
CONSUMABLE LIST FOR PROSPER S-SERIES ............................................................... 16
SAFETY REQUIREMENTS.................................................................................................. 17
GETTING HELP ................................................................................................................... 18
DC3800 INSTALLATION DRAWINGS ............................................................................... 188

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WHAT IS THE STREAM CIJ TECHNOLOGY?

The STREAM technology uses a continuous inkjet (CIJ) stream capable of running at high
speed and high resolution and is suitable for a wide range of applications. Unlike
conventional CIJ technology, the new technology uses no electrostatics. It introduces a new
principle, based on thermal 'pinch-off' of continuously jetted fluid streams.
By applying a regular pulse to heaters surrounding each nozzle orifice, the ink is stimulated
into breaking into fine droplets. Ink drops not required are deflected away from the substrate
by airflow and re-circulated to the ink supply. Drop size and 'pinch off' is regulated by the
time between heat pulses. This capability provides higher print speeds and printhead life
many times greater than existing drop on demand (DOD) technologies.

PROSPER S-SERIES Imprinting System contains:

PROSPER S-SERIES contains:

S-SERIES print station

S-SERIES print station

Umbilical

Umbilical

Printhead

Printhead

DC3800 Printhead Carriage if ordered

Controller

Controller
DC3800

DC3800

Print
Station

Controller

"Typical PROSPER S-SERIES Imprinting System".

System Configuration
Note: The PROSPER S-SERIES Imprinting System can be ordered in several configurations to meet the
customers needs.

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PROSPER S-SERIES IMPRINTING SYSTEM INSTALLATION TIME LINE

Phase I Preliminary planning
Typically, shortly after a formal acceptance of the order by Kodak, the following events
occur:

Preliminary physical Installation requirements.

A pre-site visit is performed to review the installation facility.

The Kodak Technical Solutions Specialist contacts the local Kodak field service
organization and provides the overall support requirements for the site and sets up an
introductory meeting with the customers site coordinator.

The customer site coordinator introduces the person who is responsible for the
physical installation at the site to the Kodak Technical Solutions Specialist and
Installation Leader.

The workflow support plan identifying connectivity methods and initial applications is
approved.

The test plan for validating the installation is discussed.

Installations with near line finishing Kodak Technical Solutions Specialist will
coordinate a meeting with the customer's Site coordinator. There should be a meeting
with all the participants.

Phase II Finalization of Plans

Typically, 8 weeks prior to delivery of equipment the following events occur:

Planning process is reviewed and modified as necessary and then approved.

An operator training plan is presented for review.

Operators are identified and scheduled for training.

Phase III Pre-installation Check off

Typically, 4 weeks prior to delivery of equipment: The following event(s) will occur

The Site Service support plan is presented by the Kodak System Solutions Engineer.

Phase IV Physical Installation

Physical installation of the equipment takes place at the date agreeable to both Kodak and
the customer.
Phase V System Validation
Validation of Prosper S Series operation

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PHYSICAL INSTALLATION PLAN KEY DATES

Item

Responsibility

Projected
Due Date

Date
Completed

What date printer is scheduled to be on site?

The printer installation - start date?
The printer installation - physical completion date?
Is a staggered delivery required?

Yes

No

Are there special dock requirements?

Yes

No

Is offsite uncrating required?

Yes

No

Is there a forklift onsite?

Yes

No

Is the equipment uncrated and placed?

Yes

No

Has the customer been told that its their responsibility for the removal
of crates?

Yes

No

Has operator training been scheduled?

Yes

No

Has ordering supplies procedure been covered?

Yes

No

Has the customer been Informed that they need isolated power for the
equipment, or a UPS?

Yes

No

Has the returning parts procedure been covered?

Yes

No

Review with customer the consumables that will need to be ordered

(ink, fluids)

6080010-01

KODAK VERSAMARK FD8600

BLACK INK - 20 LITER

Yes

No

6080011-01

KODAK VERSAMARK FR8601

REPLENISHER FLUID - 20 LITER

Yes

No

6080012-01

KODAK VERSAMARK FF8602

STORAGE FLUID - 20 LITER

Yes

No

6080010-02

KODAK VERSAMARK FD8600

BLACK INK - 208 LITER

Yes

No

6080011-02

KODAK VERSAMARK FR8601

REPLENISHER FLUID - 208 LITER

Yes

No

6080012-02

KODAK VERSAMARK FF8602

STORAGE FLUID - 208 LITER

Yes

No

NOTES:________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________

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KEY ITEMS TO CONSIDER

Installation requirements

Responsibility

Has the printer location been determined?

Yes

No

Does the customer have other equipment that has to be moved?

Yes

No

Is there suitable access to the building and clearance / access to the

point of installation? Has it been verified?

Yes

No

Will professional riggers be required?

Yes

No

Yes

No

Yes

No

Yes

No

Yes

No

Has the customer been informed of the type of electrical attachment

and ground fault protection to be used?

Yes

No

Has the site environment (temperature / humidity) been validated?

Yes

No

Is there adequate ventilation to meet required operating parameters?

Yes

No

Is the site environment reasonably dust free?

Yes

No

Are compressed air requirements met if needed? (DC3800 Carriage)

Yes

No

Yes

No

Yes

No

Is there sufficient storage space for supplies / parts?

Yes

No

Is the storage area secure?

Yes

No

Yes

No

Yes

No

Yes

No

Yes

No

Yes

No

Yes

No

Yes

No

Yes

No

Does the Kodak floor plan include sufficient space to run production
and also maintain the system?
Does the customer have a forklift with a minimum capacity of 4400 lb
rating?
Will a forklift and operator be available to move the modules to the
installation location?
Has the customer been informed that they will need to install all the
power drops for the electrical wiring?

Have all MSDS and waste disposal requirements been reviewed with
the customer?
Suggest to the customer that a vacuum cleaner with attachment tools
should be purchased for the removal of dust from the printing system
due to paper?

Projected
Due Date

Date
Completed

Application requirements
Have the applications been Identify that will need to be changed or
converted for migration to the new printer?
Prepare a detailed plan for converting and testing application that will
be used with the printer.

Additional considerations
Has the customer been informed that the power connectors need to
be 20A for our equipment? (See Power Requirements pg 11.)

List any other relevant observations pertaining to the preparation of the site:

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PROSPER S-SERIES IMPRINTING SYSTEM SPECIFICATIONS

New CIJ Technology

Each print station supports 1 or 2 Jetting Modules 4.16 inches or 105.7 mm wide
Resolution 600 DPI across the print
swath (PH)
Incorporation of Smart Card technology
Ink: pigment ink (to come) or dye based
Minimal Operator Jetting Module
Maintenance

PRINTHEAD SPECIFICATIONS
TYPE/MODEL
JETTING MODULE

PRINT WIDTH
4.16 (105.7 mm)

PROSPER S-Series Pre-Installation Guide 05/11/2011

SPEED
25 - 1000 fpm
(7.62 to 305 mpm)

RESOLUTION (DPI)
600 x 600

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SYSTEM OVERVIEW
The Kodak PROSPER S-SERIES Imprinting System offers laser quality printing at inkjet
cost.
The PROSPER S-SERIES includes:

Four-S-SERIES PIC boxes with Jetting Modules (4.16-inch, 600-dpi, 1000-fpm,

monochrome printheads)

DC3800 Printhead Carriage, which are connected by the printhead interfaces

Prosper S-SERIES Print Stations connect by Ethernet to a System Controller.

The printhead creates the printed image by depositing or withholding an ink drop from 2,496
printable jets across the 4.16-inch width.
Four printheads allows printing up to 16.64 inches (42.26 cm) wide. The stitching can be
mechanical, electronic, or both mechanical and electronic. Stitching results from positioning
the printheads correctly in line with each other and routing data correctly to each printhead.

PACKED DIMENSIONS
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Components
DC3800 Print Carriage
PROSPER Imprinting
System includes:
PROSPER /S-SERIES
Print Station

Width

Depth

Height

Weight

Qty

Part

See attachments at the end of this document for the mount sizes.

35.63
inches
(90.5 cm)

45.28
inches
(115 cm)

42.91
inches
(109 cm)

531 lbs
(241.4 kg)
NOTE 2

CS410 System
Controller

36 inches
(92 cm)

32 inches
(82 cm)

40 inches
(102 cm)

400 lbs
(182 kg)

CD132 Data Station

36 inches
(92 cm)

32 inches
(82 cm)

40 inches
(102 cm)

400 lbs
(182 kg)
Total
800 lbs

NOTE3

8
NOTE1

0200900

1- (PIC 1 4)
1 (PIC 1 4)
2 -(PIC 5 8 )
2 (PIC 5 8 )
3- (PIC 9 12)
4 -(PIC 13-16)

CS300 System
Controller

NOTE1

Carriages (1 per tower) capable of accepting up to 8 PIC box/jetting modules.

Print Station supports up to 2 PIC Box 35.63 inches (90.5 cm)

NOTE2

Weight is for dual channel Print Station

NOTE3

CS410 and up to two CD132 are contained in one cabinet an auxiliary data station cabinet is required for
more than two CD132s.

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UNPACKING THE SHIPPING CONTAINERS

All equipment is shipped in a container or on one or more pallets, and should contain the following
parts.
NOTE: Please inspect all packaged materials carefully so that small parts are not thrown away.
Report any shortage or damaged parts.
The print carriage crate contains:

DC3800 Printhead carriage (rail, mounts and support brace)

2 4 PIC buckets on 2 rails.
Flexible umbilical track
Hardware and flexible conduit for air conditioning ducts.
Misc. Hardware

The following components are shipped palletized:

S-SERIES Print Station cabinet

PIC boxes max of (2)
Boxed cables and umbilicals max of (2)
Boxed documents, accessories and installation kit (1)
Ramp for rolling print station off the pallet (1)
CS410 Controller

These tasks require two (2) persons. Having at least three persons will significantly reduce the time
required for completion.
The following tools are required for these procedures:

Forklift truck, capacity 2000kg (4400 lbs) or higher

Box cutter or utility knife
Hex head (Allen) wrench set, 1-12mm
Open end wrench set, 6-24 mm
Power drill / driver with TORX bits
Pry bar / wrecking bar, medium (730 X 18 mm or Equivalent)
Dollies
Machine level / Laser level
Lift Straps

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POWER REQUIREMENTS
Note: Power drops should be located within 5 ft. (1.5 m) of the center of each component. Conduit
must be secured to the system or structure.
**** The complete Prosper S-SERIES imprinting system MUST had an isolated power supply (or a
UPS to power the equipment if there is a power outage).

Prosper S-SERIES Print Station Power:

200-240VAC (single phase); 50-60Hz; 10A @ 230VAC (each unit)
Electrical connector plug on the input power cable:
Locking Plug, Industrial
NEMA Configuration = L6-20P

DC3800 Print Carriage:

230 VAC, 50 - 60 Hz, 10A (for each automated adjustment version)
No power drop needed for the manual adjustment version

CS410 System Controller:

200-240VAC (single phase); 50-60Hz; 14A
Electrical connector plug on the input power cable:
Locking Plug, Industrial
NEMA Configuration = L6-20P

Installing the CS410 System Controller

Before you install a CS410 system controller, check these site conditions.

Verify that there is a dedicated grounded electrical outlet within 5 ft (1.5m) from the Prosper SSERIES imprinting system.
Make sure the facilitys network personnel will be available at the time of installation.
Verify the facility network administrator is available for the network connectivity and the network is
functioning before installing the controller.
Verify the system controller location will have a temperature range of 68-104F (20-40C).

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REQUIREMENTS FOR EQUIPMENT AND OPERATION

Ambient Temperature and Relative Humidity (RH):
Operating: ..................................................................................... 68 to 104F (20 to 40C) @ 30 to 60% RH
Best for Printing ....................................................................................... 77 to 95F (25 to 35C) @ 50 % RH
Miscellaneous
Audible Noise ................................................................................................................. less than <78dB (A)
Water Supply Requirements ................................................................................................... None required
Incoming Compressed Air ................................................................... 80 psi (DC3800 pivoting print rollers)
System Operating Speed ........................................................................ 25 to 1000 FPM (7.6 to 305 MPM)
Paper Weight .......................................................................................................................... 55 160 gr/m2

SPACE REQUIREMENTS
As you plan your physical layout consider this:

Install the printer away from the main traffic pattern.

Allow space for operators and service representatives to perform their tasks. This space should not extend
into walkways.

Install the printer in a location that is convenient for the operator. For example, consider whether the
planned location is close to printer supply storage areas and to output distribution areas.

Allow space for waste tank and ink containers.

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ENVIRONMENTAL REQUIREMENTS FOR PAPER AND FLUIDS

Storage Requirements for Paper
The temperature and humidity content of paper has an impact on the quality of the final printed product.
o

Optimal paper storage values are 55 to 80 Fahrenheit at 45 to 55% RH (non condensing). For best overall
results, store paper in an area where temperature and humidity are similar to that of the environment of the
print room. Prolonged exposure of paper to relative humidity greater than 65% or at temperature extremes can
reduce print quality and cause the finished paper to curl.
Paper should be moved to the printing location and left wrapped at least 24 hours before use so it can
acclimate* to the environmental conditions of the room. Once the temperature of the paper is close to that of
the print room the paper can be unwrapped to better adjust to the conditions of the room. A longer period of
time may be necessary if the storage conditions of the paper are more than 10 degrees F from that of the print
room.
* Acclimation is a process where the temperature of paper closely matches the temperature of the room so that the transfer
of moisture is limited.

When Storing Papers

Always keep paper off the floor and away from heaters and walls

Always make sure reels and packs are stacked correctly.

Always try to keep control of temperature and humidity - THIS IS CRITICAL!

Never turn heating off at night in cold or damp environmental conditions.

If you have large opening doors, fit a draft screen around the door to reduce effects of the cold damp air.

Examples of Paper Storage

Examples of Paper Handling

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INK AND FLUID HANDLING / STORAGE

Wear protective equipment such as gloves and safety goggles. Use in well-ventilated areas. Avoid contact
with skin, eyes and clothing. Avoid rough handling or dropping. Wash hands thoroughly after handling.
Protect against light. Keep container tightly closed and away from incompatible substances such as acids or
oxidizing agents.
DISPOSAL CONSIDERATIONS
Treatment, storage, transportation and disposal must be in accordance with applicable federal, state/provincial,
and local regulations. Do not disposal of ink waste into the surface water or sanitary sewer system.

FLUIDS ORDERING
Kodak Global Customer Service at 1-800-472-4839. The Kodak Global Customer Service hours of operation
are Monday-Friday 8am-6pm EST. E-mail Orders can also be submitted anytime to
US-GDT-Customer@kodak.com. Orders placed by e-mail will be processed on the next business day.
Please provide the purchase order number, shipping method, quantity of items requested, fluid description, and
part number when placing orders
Below are some of the items youll need for your Prosper printing system.
Part Number
6080010-01
6080011-01
6080012-01
6080010-02
6080011-02
6080012-02
Part Number
6085001-01
6085001-02
6085002-01
6085002-02
6085003-01
6085003-02
6085004-01
6085004-02
6085005-01
6085005-02
6085006-01
6085006-02

Description Dye Inks only

KODAK FD8600 BLACK INK - 20 LITER
KODAK FR8601 REPLENISHER FLUID - 20 LITER
KODAK FF8602 STORAGE FLUID - 20 LITER
KODAK FD8600 BLACK INK - 208 LITER
KODAK FR8601 REPLENISHER FLUID - 208 LITER
KODAK FF8602 STORAGE FLUID - 208 LITER
Description Process Color Inks
Cyan 20L
Cyan 208L
Magenta 20L
Magenta 208L
Black 20L
Black 208L
Yellow 20L
Yellow 208L
Process Replenisher 20L
Process Replenisher 208L
Process Storage 20L
Process Storage 208L

MAINTENANCE AND REPAIR

If you have a Global Service Support maintenance agreement, a Primary Site Field Engineer should have been
assigned to your location. The primary site engineers should be responsible for:

Scheduling Kodak GCG Field Engineer work assignments

Management of the parts depot
Part logistics (ordering, returns)
Preventive Maintenance (PM) scheduling
Initiating escalations as appropriate

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PREVENTIVE MAINTENANCE
Before your printing system is installed you should receive a copy of your Service Support Plan, which is
tailored to your printing system and configuration at your site. The service plan will contain a copy of all the
operator maintenance responsibilities for the Kodak Prosper S-SERIES imprinting system.
This schedule is broken down into daily, weekly, monthly and so on maintenance task that the operator will
perform.
If youve purchased a maintenance agreement we can provide you with a list of maintenance tasks the Kodak
Field Service Engineer will be performing and how often.
The Kodak Primary Site Field Engineer will provide you with a schedule for preventative maintenance (PM).
The schedule will be based upon a 12 month period. The PM schedule will define the time required to complete
each PM intervention.
Kodak will work cooperatively with you to establish the available and agreed upon dates and times for each
scheduled Preventive Maintenance activity.
Operator and Service Maintenance schedules are made specifically to fit the Customer printing system
configuration.

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CONSUMABLE LIST FOR PROSPER S-SERIES

The following is a brief list of part numbers for the Prosper S-SERIES consumables you might need to keep on
hand, depending on your printing system configuration.

CONSUMABLES
PART NUMBER

DESCRIPTION

0205919

NITRILE GLOVES CLASS 10 (50 PAIR LARGE)

0205949

SWAB-TX761 (100 PK)

0204647

SPEC WIPE 9X9 QTY (100 PACK)

0205642

BOTTLE DISPENSING (ML-250)

0173306

FILTER AIR, PRINTHEAD

0203750

FILTER HEPA, PIC

0203749

FILTER INK (QTY 2)

0203805

FILTER VACUUM BLEED (QTY 5)

0203444

FILTER VALVE, VAC FRESH AIR (FRU)

0203798

FILTER ASSY-STORAGE FLUID (FRU)

0206087

FILTER DOOR, RIGHT SIDE

0191188

FILTER KIT VACUUM PUMP (FRU)

0178612

FILTER, AIR - PRINT STATION (FRU)

0188043

FILTER-IN-LINE (QTY 10)

0205524

FILTER MIST (FRU)

0196080

FILTER BYPASS, 50U+.017 ORIFICE (QTY 2)

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SAFETY REQUIREMENTS
Safety requirements are covered in the Kodak Prosper S-SERIES imprinting system manuals. All areas of
concern are labeled.
Example of safety labels.

LOCKOUT - TAGOUT INFORMATION

The purpose of lockout/tagout of equipment is to prevent inadvertent startup and/or release of stored energy
(electrical, mechanical, hydraulic, chemical, thermal, or pneumatic) that could cause injury to personnel.
Logout/Tagout procedures are governed in the United States by OSHA Standard 29 CFR 1910.147. This
standard provides the basis for local work instructions and requirements.
At a minimum, equipment should be locked out and tagged during the following operations:

Installation of equipment

Set up of equipment

Inspections of equipment that requires internal access to equipment or exposure to

dangerous conditions

Adjustments of equipment that requires internal access to equipment or exposure to

dangerous conditions

Cleanings of equipment that requires internal access to equipment or exposure to

dangerous conditions

Lubrication of equipment that requires internal access to equipment or exposure to

dangerous conditions

Removal of jams that requires internal access to equipment or exposure to dangerous

Conditions

Modification of equipment

Repair of equipment

Refer to local work instructions for specific guidelines and information.

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GETTING HELP
Customer Service

Phone: 800-472-4839 or 937-259-3739

Place Orders 08:00 -18:00 M-F Eastern
Obtain RMAs 08:00 -18:00 M-F Eastern
Request On-Site Service 24x7x365
Technical Support 24x7x365
Fax Orders: 937-259-3808
Email Orders: US-GDT-Customer@kodak.com
Email Tech Support: US-GDT-Techsupport@kodak.com
Web Site: http://www.graphics.kodak.com

Dispatch / Ordering / Technical Support

1.800.472.4839
www.graphics.kodak.com

Magnets and
stickers can be
ordered from
Customer
Service by
calling the 800
number.

Order Processing: US-GDT-Customer@kodak.com

Customer Support: US-GDT-Techsupport@kodak.com
06-28-2007

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