UG-14-0007

OPERATION MANUAL
Rev.9
Released

7200z SERIES
OPERATION MANUAL

Direct Color Systems®

www.DirectColorSystems.com
REVISION 9
1
1.1
Contents
Revision Changes ................................... 1
4.3.2 Preparing Media ............................24
Vacuum Table Attachment ............27
1.2 DISCLAIMER OF WARRANTY ................... 1 4.3.4 Adhesion Promoter ........................28
1.3 Notices ................................................... 1 4.4 Registering the Thickness of the Media 31
1.4 Restriction in Use ................................... 1 4.5 Extended Functions ............................. 32
1.5 About Usable Ink .................................... 2 4.5.1 UV Light Intensity ..........................32
1.6 On This Operation Manual ..................... 2 4.6 Print Home .......................................... 32
1.7 Machine Specifications .......................... 2 4.7 Sending Print Data ............................... 32
1.8 Safety Precautions ................................. 3 5 MAINTENANCE ............................ 33
1.8.1 Symbols............................................3
5.1 Maintenance ....................................... 34
1.8.2 Warning for Use ..............................4
5.1.1 Precautions for Maintenance ........34
2 BEFORE USE .................................. 5 5.1.2 About the Maintenance Kit............34
2.1 Installing the Machine ............................ 6 5.2 Daily Maintenance Tasks ..................... 35
2.1.1 Caution for Installation ....................6 5.3 Weekly Maintenance Tasks ................. 35
2.1.2 Where to Install the Machine ..........7 5.4 Uncapping the Print Head .................... 36
2.1.3 Working Environment ......................8 5.5 Maintenance: Ink & Waste .................. 38
2.1.4 Moving the Machine........................8 5.5.1 Run the Ink Maintenance Routine 38
3 Control Panels ............................... 9 5.5.2 Empty the Ink Waste Bottle & Reset
the Counter 38
3.1 Control Panel Overview ....................... 10 5.6 Maintenance: Print Head ..................... 39
3.2 Main Control Panel .............................. 11 5.6.1 Nozzle Tests ...................................39
3.2.1 Home Screen Functions .................11 5.6.2 Print Head Automatic Cleaning
3.2.2 Home Screen Indicators .................12 Functions 39
3.2.3 Ink Level Screen .............................13 5.6.3 Wiping the Print Head ...................39
3.2.4 Maintenance Panel ........................16 5.7 Maintenance: Capping Station ............. 40
3.2.5 Carriage .........................................16 5.7.1 Capping Station Life .......................40
3.2.6 Capping Station .............................16 5.7.2 Cap Cleaning ..................................40
3.2.7 EMERGENCY STOP BUTTONS .........17 5.7.3 Wiper & Ink Discharge Pad Cleaning
3.3 Connecting Cables ................................ 18 41
3.3.1 Connecting the Power Supply Cable 5.8 Maintenance: X-Axis ............................ 42
18 5.8.1 Main Shaft Maintenance ...............42
3.3.2 Connecting USB Interface Cable ....18 5.8.2 Guide Shaft Maintenance ..............43
3.4 Filling the Ink System ........................... 19 5.8.3 Encoder Strip Cleaning ...................44
3.4.1 Ink Tank Setup ...............................19 5.9 Maintenance: UV Lamps ...................... 45
3.4.2 Assembling the Ink Refill Kit...........19 5.9.1 UV Lamp Lens Cleaning .................45
3.4.3 Filling the Ink Tanks .......................20 5.9.2 UV Lamp Filter Replacing...............45
4 BASIC OPERATIONS ..................... 21 6 Troubleshooting .......................... 46
4.1 Workflow ............................................. 22 6.1 Media Error ......................................... 47
4.2 Turning the Printer ON/OFF ................. 23 6.2 Ink Error............................................... 47
4.2.1 Turning the Printer ON ..................23 6.3 Critical/Restart Error............................ 48
4.2.2 Turning the Printer OFF .................23 6.4 Error Codes .......................................... 48
4.3 Placing Media....................................... 24
4.3.1 Origin (X and Y Start Position) .......24
4.3.3

1
1.1 Revision Changes
Date Section Description REV
2/9/17 5.1.1 Added steps for users with Device Package 2.0 or higher. E
Updated Main Control Panel Instructions for new revision
9/12/17 3.2 F
firmware
11/1/17 Added IRF6-T Ink Set information G
Added information for Printer Firmware Version 2.2
3.2
4/30/18 Added Automatic Carriage Uncap Instruction for Printer H
5.4
Firmware Version 2.2
3/27/20 5.7 Updated to reflect capping station design changes I

1.2 DISCLAIMER OF WARRANTY

NO WARRANTY OF ANY IND IS MADE WITH REGARD TO THIS MATERIAL, INCLUDING, BUT NOT
LIMITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESSOR A PARTICULAR
PURPOSE.

1.3 Notices
THE INFORMATION IN THIS DOCUMENT IS SUBJECT TO CHANGE WITHOUT NOTCE.
No liability is assumed for errors contained herein or for incidental damages in connection with
the furnishing, performance, or use of this material.
This document contains proprietary information which is protected by copyright. All right are
reserved. No part of this document may be photocopied, reproduced, or translated without prior
written consent.

1.4 Restriction in Use

This machine is dangerous as it has high-speed moving parts, emits UV irradiation and uses ink
that requires proper safety equipment. Use of this machine is limited to the user who
understands the dangers completely.
Only users who have received proper training should operate the machine.

1
1.5 About Usable Ink
Usable ink for this machine is UV LED IR2, UV LED IRF4, UV LED IRF6 and UV LED IRF6-T (White)
ink ONLY.
Store ink in the original brown or black tightly sealed bottles, at 65-85°F (18-27°C) and out of
direct sunlight. Ink should always be kept away from heat, sparks, and flames. The shelf life of
the UV LED Inks is 12 months from the Date of Manufacture (D.O.M) when stored in a factory
sealed container under prescribed conditions.
Filling bottles should also be kept out of direct sunlight and within the prescribed conditions
above.

1.6 On This Operation Manual

• This Operation manual describes the operations and maintenance for UV inkjet printer
7200z Series
• Read this Operation manual carefully and understand it thoroughly to operate the printer.
• This manual has been carefully prepared for easy understanding, however, please do not
hesitate to contact a Direct Color Systems representative in your area if you have any inquiry
or Technical Support at 1-860-829-1027 or Email techsuport@directcolorsystems.com.
• The latest manual can be downloaded from www.DirectColorSystems.com

1.7 Machine Specifications

On-demand inkjet (Micro Piezo) 10-channel print head w/360
Image Processing
nozzles/inch/channel
Draft: 360x360 / Text & Graphics: 360x720 / Production: 720x720, 720x1440 /
Resolutions
Quality: 1080x1440, 1440x1440, 2880x1440, 2880x2880
Ink Drop Size (Min/Max) 3.5 picoliters / 21.8 picoliters
Ink Colors Yellow, Magenta, Cyan, Black, 4x White, 2x Clear
Ink Delivery System Bulk Ink System. User refillable 300mL Tanks
29.7m2/hr // 320 ft2/hr – Draft Mode
Print Speed
19m2/hr // 205ft2/hr – Text & Graphics Modes
Y-Axis Accuracy ± 0.038mm // ± 0.0015”
Print Direction Uni- and Bi-Directional
Max Printable Area 600mm x 1,200mm // 23.80” x 48”
Max Substrate Size 660mm x 1,270mm // 26.00” x 50.00”. Larger may be printed. 3 sides open.
Z-Axis 7200z15: 0cm to 15cm // 7200z30: 0cm to 30cm
Interface Hi-speed USB 2.0
UV Curing System Two individually controlled, air-cooled, UV LED Lamps

2
Operating System Windows 7 (32 & 64bit), Windows 8 (32 & 64bit), Windows 10 (32 & 64bit)
PC Requirements CPU of > 3GHz, 8GB RAM, 100GB Free Hard Disk Space, 4 available USB Ports
Power Source 100-240 VAC, 50-60 Hz, 20A auto-switching
Operating Temperature 18°C - 27°C (60°F - 80°F)
Humidity Non-Condensing 20% - 80%
EasyCyl 7200; EasyRoll 7200, Vacuum Table, ADA/Braille Module, Pallet Shuttle
Optional Accessories
System, Automated URL design
Weight Approx. 635kg //1,400lbs
Dimensions Depth 2,337mm // 92” x Height 1626mm // 64” x Width 1,575mm // 62”
Warranty Printer 1-year limited warranty
RIP Color Byte RIP 10

1.8 Safety Precautions

1.8.1 Symbols
Symbols are used throughout this manual to ensure safe operation and for
prevention of damage to the machine.

Meaning
Failure to observe the instructions given with this symbol can result injuries
to personnel. Be sure to read it carefully and use it properly.

Failure to observe the instructions given with this symbol can result in
damage to equipment or property.

Important notes in use of this machine are given with this symbol.
Understand the notes thoroughly to operate the machine properly.

Eye protection must be worn to carry out these instructions. Failure to do

so could cause harm to personnel.

Gloves must be worn to carry out these instructions. Failure to do so could

cause harm to personnel.

Proceed with CAUTION, specifically take precaution of hazardous voltage.

Carry out the instructions in this section with the UV LAMPS OFF. Failure to
do this could cause damage to personnel and/or printer components.

3
 1.8.2 Warning for Use
WARNING
• Read all guidelines before operating this printer.
• Avoid physical contact with the printer’s Gantry, Table and Carriage Unit while printer is
in operation.
• Keep hair, jewelry or loose clothing away from the moving parts of the printer.
Do Not Repair without Permission
• Do not attempt to repair this machine
without prior DCS authorization. Unless
specified in this guide, only qualified
service personnel should attempt any
disassembly, repair or access to internal
components.
Abnormal Event Occurs
• If the device is used under an abnormal
condition the device could producessmoke,
fire or electric shocks. Turn OFF thepower
switch immediately and detach the plug
from the receptacle.
Adhesion Promoter
• Adhesion Promoter should not be •
used in an enclosed area without
adequate ventilation. RESPIRATORY
PROTECTION: If exposure can
exceed the PEL/TLV, use only
NIOSH/MSHA approved air-
purifying or supplied air respirator
operated in a positive pressure
mode per the NIOSH/OSHA 1981
occupational health guidelines for
chemical hazards.
Handling of Ink
• Always wear goggles and gloves
when handling ink.
• Keep all inks, solvents and
lubricants out of the reach of
children.
• Use only approved cleaning
agents and solvents.
• Keep inks in a cool, dark and dry
location.
• Inks must be used and stored in
opaque containers only.
• For prolonged exposure to ink,
Butyl Black or Ethylene Vinyl
Alcohol Copolymer laminated
gloves are recommended.
Pallet Jack Required
Machine should be lifted with a palletjack
or fork lift only. Do not attempt to lift
machine.
4
2 BEFORE USE

5
2.1 Installing the Machine

2.1.1 Caution for Installation

CAUTION
A place exposed to direct A place where temperature or
On an inclined surface
sunlight humidity varies significantly
• Use The machine ONLY under
the following environmental
conditions
• Operating Environment:
18°C - 27°C (65°F - 80°F)
20% - 80% Humidity

A place exposed to direct air flow

A place that vibrates Around a place where fire is used
from an air conditioner or the like

A place with a lot of dust A place where chemicals are near

6
2.1.2 Where to Install the Machine
Set up the restriction area within the range indicated below. Note that this is the
minimum space required. More space may be desired for operating the machine.

7
2.1.3 Working Environment
To ensure reliable printing, operate the machine within the specifications listed
below.
Operating Temperature: 18°C to 27°C // 65°F to 80°F
Humidity: Non-Condensing 20%-80%

2.1.4 Moving the Machine

The printer will be calibrated to perform optimally in the location in which it is
installed. Any change to this location will require re-calibration and possibly a visit
from a service technician.
Contact a Direct Color Systems representative before moving the machine.

8
3 Control Panels

9
3.1 Control Panel Overview
The machine has two different control panels. The Main Control Panel is located on the
pendent holder located in the front of the machine. The Maintenance Control Panel is
located under the Main Print Engine Cover.
While these two control panels are responsible for different functions, there is some
overlap. Users should only use the Maintenance Panel when instructed to do so.

10
3.2 Main Control Panel

3.2.1 Home Screen Functions

11
3.2.2 Home Screen Indicators

12
3.2.3 Ink Level Screen
Displays current ink level for each tank and provides white ink circulation pump
control.

13
3.2.3.1 UV Intensity Screen
The UV lights can be controlled from this screen. Here you can change intensity
and/or enable or disable the lights individually.

3.2.3.2 Diagnostic Screen

PH Position (x0.01mm)
Note: If upgrading Firmware in the field, the Factory Default of 000 will be set. If
the printer was manufactured with Firmware Version 2.2, this Print Home
Position will be set specifically for the machine and should only be changed if
recommended by a DCS Representative.
This feature allows the user to adjust the Print Home Start Position by +/- 0.01mm
increments to a maximum of +/- 6.99mm to create Print Home starts positions in
the range of 4.86mm to 18.84mm distance measured from the y-axis 0-position
sensor. Any change added to the Print Home position setting is stored in the 7200z
EE Memory and will remain the new setting until the user changes this value again.

Open 7900 Ink Doors:

Allows for service of ink chips.

Pwr7900 Maint Mode:

Allows the user to select if they want to run the printer in Maintenance Mode or
Normal Mode. Once this is SET, the Print Engine needs to be restarted. When the

14
LED is lit, the Print Engine will start in Maintenance Mode. When the LED is not lit,
the Print Engine will start in Normal Mode.
Note: While it is possible to Print in Maintenance Mode, it is recommended that
the user still prints in Normal Mode.

Open 7900 Capping Sta:

If the Print Engine is powered on in Maintenance Mode (see previous section),
pressing this button will automatically release the Print Carriage from the Capping
Station. Pressing the button again will automatically lock the Print Carriage on the
Capping Station. This can be used when performing maintenance on the printer.

Z Position (x0.01mm):
Displays the current table distance to the Locked Height Setting if the Locked
Height Setting is Enabled.

Y Position (x0.01mm)
Displays the current gantry position the Y-Axis 0 position sensor.

E Status | Y Status | IO Status

Reports any Error Conditions that might exist. Pressing the Reset button will
attempt to clear any Status Error conditions.
Note: If the ERROR will not clear after the RESET button is pressed, this may be
due to a hard failure and service may be required to fix machine and clear the
Error. Certain error types, when cleared by pressing RESET will cause the Y-Axis
or UV Lamp motor to re-home as part of attempting to clear the Error condition.

15
3.2.4 Maintenance Panel

Located behind the main cover, the Maintenance Panel should only be used if
instructed to do so. The panel is used to execute maintenance, service and
calibration operations as well as provides error code information. See the
Troubleshooting Section for more information.

3.2.5 Carriage
The carriage is equipped with the print head and two UV Lamps.
This component moves at high speeds. All operation of the printer should be done
with the Front/Main Cover ON.

3.2.6 Capping Station

The capping station consists of ink caps, the wiper for cleaning the print head and
the ink discharge pad.
The ink caps prevent the nozzles from drying up in the head when the printer is
sitting idle.
The wiper cleans the nozzles for each channel on the print head.
The ink discharge pad collects ink when the print head exercises the nozzles during
print head maintenance.

16
3.2.7 EMERGENCY STOP BUTTONS
There are two EMERGENCY STOPS on the machine. One EMERGENCY STOP is
located on the end of the gantry cover. The other EMERGENCY STOP is located on
the Main Control Panel Pendent.
When stopping the machine for safety reasons, push down on the button.

When you press the emergency stop button and the machine
stops, be sure to follow the procedure below.

(1) Turn off the main power supply and then remove (resolve)
the cause.

(2) After checking that the machine is now safe to operate, pull
the emergency button upward (or rotate) to release.

(3) Turn on the main power supply.

17
3.3 Connecting Cables

3.3.1 Connecting the Power Supply Cable

You are not allowed to install the printer by yourself. Please contact a Direct Color
Systems representative to install the machine.
Ensure that a wall outlet is available near the power supply entry.
The power supply specifications of this machine are as follows:
Auto-Switching (100-120VAC 20A // 210-240VAC 10A) 50-60Hz

3.3.1.1 Power Cable Specifications

The machine ships with the following power cable
Length
Cable Length (ft) 10
Cable Length (m) 3.05
Connections
Connector A NEMA 5-20P
Connector B IEC-320-C19
Number of Connectors 2
Other
Construction 3 x 12 AWG Copper Conductors

A NEMA 5-20P to Desired Connector can be used to plug the

machine into a wall outlet. If you wish to purchase a new cable,
ensure it meets the requirements listed above.

3.3.2 Connecting USB Interface Cable

The printer communicates with the through USB connection only.
Use the provided 6’ USB cable to connect the printer to the computer.

18
3.4 Filling the Ink System

3.4.1 Ink Tank Setup

There are ten ink tanks located on the top of the gantry. In normal operation and
when referred to in this manual, the tanks are viewed from the back of the
machine.
The tanks are organized to match the channels on the print head, when the print
head is viewed from the front of the machine.
From left to right the tanks are ordered and labeled as follows; White 1, White 2,
Clear 1, Yellow, Magenta, Cyan, Black, Clear 2, White 3 and White 4.

3.4.2 Assembling the Ink Refill Kit

The Refill Kit (PT-REFILL) contains 6 Fill Straws, 6 Valve Assemblies and 6 Empty
500mL Ink Bottles.

(1) Insert the straw into the valve assembly. Press down firmly until it locks.

(2) Fill the Empty Ink Bottle with the same color ink that is on the label.

(3) Insert the valve assembly into the now full ink bottle and tighten.

Valve Assembly

CLOSED OPEN

19
3.4.3 Filling the Ink Tanks
Safety Glasses and gloves should be used whenever filling or draining ink tanks.
For prolonged exposure, Butyl Black or Ethylene Vinyl Alcohol Copolymer
laminated gloves should be worn.
BEFORE FILLING ANY INK TANK, ENSURE IT IS THE CORRECT INK TYPE FOR THE
MACHINE. IRF6-T USERS WILL WANT TO BE POSITIVE THEY ARE FILLING UP THEIR
WHITE INK TANK WITH IRF6-T INK ONLY.

(4) First Time Only: Remove the tank plug with a 7/16” wrench.

(5) First Time Only: Install a breather cap into each tank with the same 7/16”
wrench.

(6) First Time Only: Remove the yellow shipping caps and replace with the color
coded caps.

(7) Re-locate the Main Control Panel Pendent so it can be visible during filling.

(8) Turn OFF the White Ink Circulation System.

(9) Navigate to the Ink Levels Screen.

(10) Remove the ink cap on the fill tube.

(11) Open the valve on the refill bottle.

(12) Place the end of the refill bottle into the neck of the fill tube. Squeeze the
refill bottle firmly to dispense ink.
If the tank was on LOW you will hear a short beep when the LOW light turns off.
Stop filling the tank when the green FULL light is ON or when you hear a Long beep.

20
4 BASIC OPERATIONS

21
4.1 Workflow

1 Turn Main Power ON 4.2

Turn Print Engine Power ON Error!

2 Reference source not found.

3 Place Media 4.3

4 Register Thickness of Media 4.4

5 Extended Functions 4.5

6 Print Home 4.6

7 Send Print Data 4.7

22
4.2 Turning the Printer ON/OFF

4.2.1 Turning the Printer ON

4.2.1.1 Main Power - ON

Flip the Main Power Switch to the UP position to turn ON Main Power.

The Main Status Indicator will flash while the machine is doing a self-
diagnostic. When the Main Status Indicator is Solid the Print Engine can
be turned ON.

4.2.1.2 Print Engine - ON

Wait for the Main Status Indicator to be Solid then press the Power
Button on the Main Control Panel to turn the Print Engine ON.

A solid Print Engine Indicator light on the Main Control Panel indicates that
the Print Engine is ON and READY.

4.2.2 Turning the Printer OFF

4.2.2.1 Print Engine - OFF

The Print Engine will begin its power down routine. When the Print Engine Status
Indicator goes blank it is safe to turn off the Main Power.

4.2.2.2 Main Power - OFF

Flip the main power switch to the DOWN position to turn OFF Main Power.

Always Turn OFF Print Engine Power before turning OFF Main
Power. Main Power should always be left ON, unless otherwise
instructed. If the Main Power is OFF, the White Ink Circulation
System cannot run and may cause permanent damage to the
machine.

23
4.3 Placing Media

4.3.1 Origin (X and Y Start Position)

Print Start is located near the bottom right corner of the media table when
standing in front of the machine looking down. Print Start and the edges of the
table are not the same. The X-Axis and Y-Axis Start Points are determined by
printing registration marks. The edges of the table should not be used as start
points.

4.3.2 Preparing Media

TACKY MAT CUSTOM JIG VACUUM TABLE

• Easy to install. • Design • Ideal for flat, thin

• Simple to clean. considerations. pieces of material.
• Good for trial and • Easy to load and • Best option when
error testing with unload multiple printing ADA/Braille
new products products quickly. or Texture.
before a custom jig • More consistent • Harder to align
can be made. image placement on objects accurately.
• Not recommended products. • Least likely to
to hold down large • Low likelihood of experience head rubs
flat sheet stock. head rubs or crashes or crashes due to flat
• Head rubs and due to consistent hold down.
strikes more likely materials.
due to holding down
products
adequately.

24
4.3.2.1 Using the Tacky Mat
A 24in by 48in tacky mat ships standard with all machines unless requested
otherwise by the customer.
The tacky mat is made of a silicone material and is double-sided. The mat will
collect dust, debris and excess ink and therefore should be kept clean. Clean the
mat with isopropyl alcohol or similar cleaning agents.
To accurately place objects on the tacky mat, you can first print an outline of the
object directly to the mat. Because UV Ink does not permanently adhere to
silicone, this outline can be cleaned after the job is complete.

4.3.2.2 Using & Designing Jigs

Jigs ensure that object placement remains consistent from print to print. Also, jigs
make it easy to remove and replace many objects quickly. Below are a few
guidelines to consider before designing a jig.
GUIDELINES FOR CREATING JIGS
• Design jigs out of non-reflective material.
• Jigs should cover the blank space of the table to prevent reflection from
the UV Lights.

For greatest accuracy, design the jig to have at least two pins that can fit into the
bushings on the Media Table. See figure below. For best results, make one pin
round and the other a diamond.

25
26
4.3.3 Vacuum Table Attachment

4.3.3.1 Installing the Vacuum Table

To install the vacuum table, lower the Media Table to the lowest point.
Place the Vacuum Table onto the Media Table, lining up the two pins with the two
bushings.

4.3.3.2 Using the Vacuum Table

There are three zones. To activate and deactivate zones, use the levers on the side
of the machine.
The zones are shown in the figure below. Zone 3 is when Zone 1 and 2 are on at
the same time.

27
All OFF ZONE 3 ZONE 2 ZONE 1

If, within the absorption area, there are suction holes not closed by the media,
close the suction holes by placing a thin sheet of material such as paper, film or
tape. Ensure the material is thinner than the media.

4.3.3.3 Bypass Valve

The bypass valve is used to keep the Vacuum Pump cool during operation. Open
the valve to let air enter the pump and cool it down.

4.3.3.4 Foot Switch

Use the foot switch to turn ON or OFF the vacuum pump.

4.3.4 Adhesion Promoter

Some materials require the use of an adhesion promoter which helps strengthen
the bond between the ink and the substrate. There are various promoters outlined
below, each having its own recommended use. Please note that these are
recommendations only. All substrates should be tested for image receptivity,
adhesion and durability, with final acceptance and suitability determined by the
customer.

4.3.4.1 Low-Odor Adhesion Promoter

This is Direct Color Systems proprietary adhesion promoter and therefore can be
purchased through Direct Color Systems directly. Reference Part # PT-K-0004.

28
USES

COATED COATED COATED

ACRYLIC RUBBER
METAL WOOD PLASTIC

4.3.4.2 Bohle Adhesion Promoter

Direct Color Systems does not sell this adhesion promoter directly. It can be
purchased through Bohle. Reference Part# BO 5209488 (3.5 fl. Oz.) or BO
5209489 (35.27 fl. Oz.).
USES

GLASS STAINLESS COATED UNCOATED

CERAMIC
STEEL METAL METAL

4.3.4.3 Applying the Low-Odor Adhesion Promoter

• Use a lint free cloth and wipe the promoter on the substrate (typically
only where the print is going to be). You do not need to dry the
promoter after but be sure there is a thin even coat.
• The shorter the time between applying the promoter and printing, the
better. However, some prints still exhibit good adhesion after the
promoter sat for a few hours.
• Sometimes, this promoter may damage the surface of the substrate,
29
most often acrylic. If this happens, dilute the promoter by mixing in

30
 99% Isopropyl Alcohol. 70 parts IPA to 30 parts Promoter is the most
common mixture.

4.3.4.4 Applying the Bohle Promoter

• Use a lint free cloth and wipe the promoter on the substrate (typically
only where the print is going to be). You do not need to dry the
promoter after but be sure there is a thin even coat.
• The shorter the time between applying the promoter and printing, the
better. However, some prints still exhibit good adhesion after the
promoter sat for a few hours.
• Bohle dries much quicker than the Low-Odor Promoter so be careful
not to over apply as it will only waste the promoter and will most likely
not increase adhesion.

31
4.4 Registering the Thickness of the Media
Head height is set by an LED beam located on the back of the gantry.
After the media is installed, use the up arrow until the media breaks the LED beam.
Once the beam is broken, the table will step back down a small amount and the
head height will be set.

Due to the location of the LED sensors, materials placed within

the first 9 in (228mm) will not be sensed. Place the material
further down the table to set the correct head height and ten
move it back to its proper location for printing.

32
4.5 Extended Functions

4.5.1 UV Light Intensity

UV Light Intensity is changed for many different reasons. By default, both UV
Lamps should be ON and at 100% Output.
To change the intensity, use the buttons above and below the intensity, 100 being
maximum output.
The UV lights can also be disabled and enabled from this screen. Press either the
UV Light #1 or UV Light #2 icon to disable. Press the icon again to enable the UV
Light.

4.6 Print Home

Before sending a print job to the printer, the gantry must always be in Print Home.
This is indicated by the LED indicator light on the Print Home icon.
If Print Home is not selected before sending a print job, the Maintenance Panel
will show a 122F Error and will require a reboot of the system.
When in Print Home certain functions are locked out. To regain functionality or
exit Print Home press the Unlock button. The gantry is unlocked when the LED
indicator light turns OFF.

4.7 Sending Print Data

Refer to the Color Byte Software Guide for more information on sending print data.

33
5 MAINTENANCE

34
5.1 Maintenance
Maintain the machine regularly or as necessary so that its accuracy will be maintained and the
life of components will be prolonged.

5.1.1 Precautions for Maintenance

• Be sure to wear protective glasses whenever performing maintenance.
• Be sure to wear protective gloves whenever performing maintenance.
• To ensure stable ink jetting, it is necessary for the print head to be capped
and locked onto the capping station. Minimize the amount of time the
print head is exposed.
• Perform all maintenance with both UV Lamps OFF.

5.1.2 About the Maintenance Kit

Items in the maintenance kits
Item Description
Gloves Used when performing all maintenance procedures.
IPA Wipes Individually packaged isopropyl alcohol wipes for cleaning.
Swabs For cleaning Capping Station Components.
Lubricant MPT-12 Precision Oiler.
Syringe Priming Syringe for Ink System.
For calibrating and checking the Print Head Height.
Print Head Height Gauge
Approximately 1mm (0.040”).
For calibrating and checking the UV Lamp Height.
UV Lamp Height Gauge
Approximately 1.5mm (0.060”).
Glass Scraper For cleaning the UV Lamp Lenses.
Purge Device For cleaning the Print Head Nozzles.
Drain Tube For draining Ink from the Ink Tanks.
Purge Tube For purging cleaning solution through the Ink System.

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5.2 Daily Maintenance Tasks
• Nozzle Tests

5.3 Weekly Maintenance Tasks

• Empty the Ink Waste Bottle & Reset Counter
• Inspect UV Lamps
• Clean Encoder Strip

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5.4 Uncapping the Print Head
Most of the maintenance tasks listed below require the print head to be
uncapped/unlocked from the capping station.
Automatically Uncapping the Print Head (Firmware Version 2.2 Only)
1. Bring the Gantry all the way to the front limit
2. Navigate to the Diagnostic Screen
3. Press SET next to PWR 7900 Maint. Mode
4. Navigate back to the Main Screen
5. Turn OFF ONLY the Print Engine (Green Power Button)
6. Turn ON the Print Engine
7. Navigate to the Diagnostic Screen
8. Press SET button for Open 7900 Capping Sta. – Wait while the 7200 completes
this sequence - LED indicator next to SET button is ON
9. Remove Front Cover
10. Perform Maintenance Task. Note: If the Print Engine is left unattended for an
extended period of time and goes into Sleep Mode – the machine will need to
be restarted as the Carriage Encoder Sensor will be shut-off and therefore the
carriage and UV Lamps will not be able to move freely across the X-Axis Shaft.
11. Lock the Capping Station by pressing SET button for Open 7900 Capping Sta.

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Manually Uncapping the Print Head
1. Bring the Gantry all the way to the front limit
2. Turn off the Main Power to the machine
3. Open the door to the electronics cabinet
4. Rotate the white gear shown below clockwise until the white tab is all the way
in the down position.

5. Hold the UV Light Bracket and carriage and slowly slide them away from the
capping station.

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5.5 Maintenance: Ink & Waste

5.5.1 Run the Ink Maintenance Routine

Note: There are different workflows for this maintenance task based on your
version of software.
Performing Ink Maintenance is critical to the operation of the machine. This
routine ensures that the ink channels are properly cleaned and the print head is
free of debris.
Failure to perform this function could result in printer down time or a required
visit from a Service Technician.

Device Package Version 2.0 or higher

When performing an Ink Waste routine is necessary, the RIP will display the Bulk
Ink Maintenance Dialog. Select OK and the print job will start. When the print job
ends, perform the Ink Maintenance Routine (Section 3.2.2.2)

Device Package Version 1.9 or lower

Perform this operation weekly. See Section Error! Reference source not found..
Performing Ink Maintenance is critical to the operation of the machine. This
routine ensures that the ink channels are properly cleaned and the print head is
free of debris.
Failure to perform this function could result in printer down time or a required
visit from a Service Technician.

5.5.2 Empty the Ink Waste Bottle & Reset the Counter
The Ink Waste Bottle (located on the outside of the gantry) should be emptied at
the beginning of each week. After the Ink Waste tank is emptied, clear the counter
(Print Engine Power must be off to reset the Waste Tank counter) Refer to Section
3.2.2.2.

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5.6 Maintenance: Print Head

5.6.1 Nozzle Tests

Nozzle Tests should be done multiple times a day to check that all the print head
nozzles are printing correctly.
This test is printed through the Color Byte RIP and prints a pattern for each of the
10 channels that consists of 360 individual lines.

If the nozzle test is missing sections (shown below) perform the Print Head
Automatic Cleaning Functions outlined in section 4.2.2. If these functions do not
bring back the nozzles, refer to Poor Nozzle Health section under Troubleshooting.

5.6.2 Print Head Automatic Cleaning Functions

5.6.2.1 Normal Head Clean

When a Normal Cleaning is activated, the printer cleans all 5 color pairs
(all 10 channels).

5.6.2.2 Power Head Clean

The purpose of a power cleaning cycle is to remove air from the negative
pressure dampers, or air from the print head side of the dampers.

5.6.3 Wiping the Print Head

With the print head exposed, use a clean IPA wipe and gently wipe the bottom of
the print head.
This procedure is most frequently used if the user has experienced a head rub or
excess build up is seen on or around the print head.

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 After wiping the print head, run a Normal Head Clean.

5.7 Maintenance: Capping Station

5.7.1 Capping Station Life

The life of the capping station will vary based on working environment, frequency
of maintenance and level of production. Typically, a capping station will need to
be replaced every 3 to 5 months.
One of the first signs of a failing capping station is deteriorating nozzle health. The
five caps, mentioned below, start to warp and therefore no longer seal the print
head properly, allowing air into the system.
As the machine is used repeatedly, the wiper, ink cap and ink tray become dirty
with ink, dust etc. Frequently cleaning the items below will help to improve the
longevity of the capping station.
The Capping Station functions as follows…
• Wiper: Wipes the ink off the surface of the print head
• Ink Cap: Prevents the print head nozzles from clogging due to dryness or
being exposed to UV Light.
• Ink Discharge Tray: Collects ink that is discharged from the print head
during operation, to exercise nozzles.

5.7.2 Cap Cleaning

Instructions
1. To expose the top of the Capping Station, follow the steps in Section 5.2 to
unlock the print head and move it away from the Capping Station.
2. Use a swab to clean the ink off the edges of the 5 caps.

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5.7.3 Wiper & Ink Discharge Tray Cleaning
Instructions
1. To expose the top of the Capping Station, follow the steps in Section 5.2 to
unlock the print head and move it away from the Capping Station.
2. Pull out the Wiper and Ink Discharge Tray with your fingers.

3. Use an IPA Wipe to clean the Ink off the Wiper Blade.

4. Use a cloth or paper towel to absorb ink from the discharge tray.

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5.8 Maintenance: X-Axis

5.8.1 Main Shaft Maintenance

Clean and Lubricate the Carriage Main Shaft as needed.

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5.8.2 Guide Shaft Maintenance
Clean and Lubricate the Carriage Guide shaft as needed.

44
5.8.3 Encoder Strip Cleaning
Clean the X-Axis Encoder Strip with an Isopropyl Alcohol Wipe or Lint Free Cloth
as needed.

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5.9 Maintenance: UV Lamps

5.9.1 UV Lamp Lens Cleaning

Inspect the UV Lamp Emitting windows frequently.
Note: Do not submerge the light source or spray any liquid directly onto the light
source.
Normal Cleaning
1. Follow the instructions in section 5.2 to uncap the print head.
2. Wipe down the glass with a dry paper towel to remove any uncured UV material.
3. Carefully scrape large debris off the window using the Glass Scrapper.
4. Use an IPA wipe to remove any remaining dust or debris left on the window
during the cleaning process.
Caution: Wear sharp resistant gloves.
Thorough Cleaning
If a more thorough cleaning is required, use a 1000 grit, very fine, aluminum oxide
abrasive pad to scrub any remaining material from the glass that the Glass
Scrapper could not remove. Repeat steps 2 through 5 after.

5.9.2 UV Lamp Filter Replacing

If the white filter on top of the UV Lamp gets dirty, replace it.

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6 Troubleshooting

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6.1 Media Error
A “Load Paper” Sequence is required if the Main Control Panels shows this error
state.
Remedy Instructions
1. Unlatch and Remove the Top Cover.
2. Press the Paper Release Button (Section 3.2.3).
3. Select OK, when the prompt asks about paper type.
Note: The 7200Z Model does not require a physical loading of paper. Therefore,
by executing this sequence the printer will confirm Y-Axis Positioning.
During the sequence, a selection of the “Paper” type is required. This “Paper” type
refers to the way in which the Y-Axis steps during printing. The correct “Paper”
setting for the 7200Z model is Premium Semigloss Photo Paper (250). This is the
highest quality setting for the printer.

6.2 Ink Error

Ink Maintenance or Ink Waste Reset is required if the Main Control Panel shows
this error state.
Remedy Instructions
1. Unlatch and Remove the Top Cover
2. Read the Error Message on the Maintenance Panel
3. If the message reads “No Ink Cartridge, Install Ink Cartridge” go to the Function
Menu on the Main Control Panel and perform the Ink Maintenance Reset.
Note: The 7200Z Model does not use cartridges. The Ink Levels are there for
reference on how much ink has been used. When the level reaches 25% the
maintenance routine will run to protect nozzle health and reset the level to 100%.
4. If the message reads “Replace Ink Maintenance Tank Soon” replace the Ink
Waste and Reset the Ink Waste Counter before the next print job.
5. If the message reads “Replace Ink Maintenance Tank” replace the Ink Waste
and Reset the Ink Waste Counter immediately.

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6.3 Critical/Restart Error
A restart of the printer is required.
Remedy Instructions
1. Turn OFF Print Engine Power
2. Turn OFF Main Power
3. Wait 20 Seconds and then Turn ON Main Power
4. Turn ON Print Engine Power.
If the critical/reset error shows again, remove the front cover and note the Error
Code. See the list of common Error Codes and Remedies below.
If the critical/reset error does not show again, there will most likely be a Media
Error. Refer to Section 6.1 to clear this error and continue production.

6.4 Error Codes

After a Critical/Reset Error, the Maintenance Control Panel will most often display an Error Code
or Error Reference. Below are the common error codes/references.

Error Code Common Cause Remedy

The Gantry was not in Print Home when the
122F Reboot the Print Engine.
print data was sent to the printer.

Uncap the Print Head (Section 5.4) and

Typically after maintenance is performed on
turn OFF the Main Power without
the wiper or cap. The assembly has gotten
1489/1439 powering down the Print Engine. Then
out of sync due to moving the parts by
turn ON the Main Power then the Print
hand.
Engine.

Remove the obstruction and check the

The carriage motion was interrupted, Print Head for damage. Perform
Paper Jam
commonly due to a head crash or strike. Maintenance on the Print Head if
necessary. Reboot the Printer.

One of the Emergency Stops was used while

3000 Reboot the Printer.
the Print Engine was still powered ON.

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