colordyne 1600-c...this manual is intended solely for the use and information of colordyne...

Colordyne 1600-C

HIGH SPEED

COLOR LABEL

AND TAG PRINTER

OPERATOR

MANUAL

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.

ColordyneTM 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.

TABLE OF CONTENTS

i

Table of Contents SECTION 1 – Getting Acquainted 1

Front View 1 Rear View 2 Print Engine View 3 Ink Tank View 4 1600-U Unwinder/Roll Feeder (Optional) 5 1600-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

ii

NOTES

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SECTION 1 GETTING ACQUAINTED

1

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.


2

Rear View

1. ON/OFF LED Button – Use to turn power ON or OFF during idle time and

maintenance.

2. Print/Pause LED Button – Press to stop printing, press to restart printing. Press

switch to continue printing.

3. 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.

4. Adjustable Media Guide – Adjusts to hold the paper/media against the

Alignment Guides.


3

Print Engine View

1.

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.

2. Ink Revolver Couplings – Connect the ink hoses to the Printhead Cartridge.

The Printhead Latch extends and retracts the couplings from the Printhead.

3. Printhead Cartridge – Memjet

® Printhead produces an 8.5" wide full color

print area.

4. 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.


4

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).

4. Ink Waste Tray – Absorbs excess ink and drips that may occur during Printer

operation and maintenance. Release Tabs located on both sides.

5. Service Station Dock – The Service Station is located here. The Service Station

keeps the Printhead clean and hydrated during operation and maintenance cycles.


5

1600-U Unwinder/Roll Feeder (Optional)

1. Speed Control – Turn clockwise to speed up, counterclockwise to slow down.

2. AUTO/Manual Mode Switch – Use to set the Unwinder in Automatic or

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.

7. Label Tension Guide Shaft – Spring-loaded shaft controls starting and stopping

as tension is maintained or released by media.

8. 24V, 2.5A External Power Connector* – For connecting printers or equipment

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.

10. Alignment Notch – Fits over Alignment Screw on Printer to keep Printer and

Unwinder aligned.


6

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.

10. 24V, 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.


7

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.

CONTROL PANEL INDICATORS – NORMAL OPERATION

PRINTER

STATUS POWER (ON/OFF)

PRINT/RESUME (STOP/RESUME)

CANCEL/CUT (CANCEL JOB/CUT)

Power cord

plugged in. Control

Panel Power

Switch OFF.

BLUE LED OFF GREEN LED OFF RED LED OFF

Press to POWER UP

Printer.

Inactive Inactive

Unit Powered Up,

No Job Loaded.

BLUE LED ON GREEN LED OFF RED LED OFF

Press to POWER

DOWN Printer.

Inactive Inactive

Unit Powered Up,

No Job Loaded.

Loading Media.

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.


8

PRINTER




Job Submitted,

Printing

BLUE LED ON GREEN & RED LEDs flashing alternately ON/OFF

once/second.

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.

Press to PAUSE Job

temporarily. Printer

finishes printing label in

progress, then stops and

holds. Does not cap

Printhead.

Press to STOP media

feed indefinitely. Printer

finishes label in

progress, advances to

cutter, cuts, and retracts

to start position. Caps

Printhead.

Job Submitted,

Paused

Temporarily,

(Printhead not

capped)

BLUE LED ON GREEN LED flashing

ON/OFF once/second.

RED LED OFF

Press to POWER

DOWN Printer:

Press once: Printer

advances to cutter,

cuts, and retracts

media to start

position. Caps

Printhead.


Job.

Press again: Shuts

down Printer.

Press to RESUME/

START media feed from

the next label.

Press to CANCEL Job:

Press once: Printer

advances to cutter, cuts,

and retracts media to

start position. Caps

Printhead.


Job.

Job Submitted,

Paused Indefinitely,

(Printhead capped)

BLUE LED ON GREEN LED flashing

ON/OFF once/second.

RED LED OFF.

Press to POWER

DOWN Printer:


Job.

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 CANCEL Job.


9

PRINTER




Normal Operation:

Performing

Maintenance

Downloading a Job

Positioning Media

BLUE LED ON GREEN & RED LEDs flashing simultaneously

once/second.

Press to POWER

DOWN Printer:

Press to pause all

actions and return

components to start

positions.

Press to POWER

DOWN.

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 POWER (ON/OFF)


CANCEL/CUT (CANCEL JOB)

IDS- related

Errors

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.

Paper Path

Errors: (End of

roll, paper jam)

System initiated.

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.

Hardware

Errors: (Service

Module error,

door open,

Printhead latch

open, etc.)

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:

http://colordynetech.com/node/88

See also Troubleshooting Guide on page 56


10

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

Powered

ON/Connected to

Printer

Powered

ON/Connected to

Printer

Disabled. (Still cuts manually by

pressing 'CANCEL' button.)

Roll-to-Cut

Powered

ON/Connected to

Printer

Powered OFF or

Disconnected from

Printer

Enabled for automatic cutting

Fanfold

Powered OFF or

Disconnected from

Printer

Powered OFF or

Disconnected from

Printer

Enabled for automatic cutting

See Section 2 "Installing the Printer," "Loading Labels" for how to load Roll and Fanfold Labels

SECTION 2 INSTALLING THE PRINTER

11

SECTION 2 – Installing the Printer

Contents of Packaging

1. Colordyne 1600-C Printer

2. 1600-U Unwinder (Optional)

3. 1600-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.


12

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


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.


13

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 60°.

3. 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.


14

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.


15

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

http://www.colordynetech.com/node/88 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>.

http://www.colordynetech.com/node/88


16

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.


17

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.


18

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.


19

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






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.


20

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



end with scissors.

[B] Remove the






Electrical Contacts. DO


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.


21

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.



5. 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.


22

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.

3. [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.

CAUTION





23

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 lint-

free 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.


24

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].


25

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].


26

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.


27

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.


28

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.


29

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.

SECTION 3 OPERATING THE COLORDYNE 1600-C

30

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).


31

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.


32

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.


33

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.


34

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.


35

[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 self-

servicing 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.


36

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.


37

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.


38

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.

SECTION 4 MAINTENANCE

39

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.


40

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.


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.


41

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.


42

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

D5127-90 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







43

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


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.


44

4. Carefully remove the

Printhead Cartridge



end with scissors.

[B] Remove the






electrical contacts. DO


to touch the electrical

contacts.

[D] Remove protective


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.


45

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




7. 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.


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.


46

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


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.


47

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.


48

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.


49

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.


50

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.

CAUTION




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.

B

Unlatch the Print Engine Clamshell

A

Raise the Print Engine Clamshell B


51

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.


52

[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.)


53

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



54

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


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.


55

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.

SECTION 5 TROUBLESHOOTING

56

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.

Air and bubbles blocking Nozzles. 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.

Print shows regularly

missing or misdirected

nozzles or ink color mixing.

Debris on Printhead. 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


Replace the Printhead.

Ink mixing -- Mixed or

muddy colors.

Causes: Ink flooding, air in the

Printhead or a dirty Printhead.

Clean the Printhead using

one of the Cleaning Levels in





No print or crisp blocks of

missing drops.

Electrical failure or poor electrical

connection.

Reseat the Printhead.

Replace the Printhead.

System will not reprime ink

after replacing Printhead

Cartridge

Printhead nozzles dry.

Ink Tanks may be 1/3 full or less.




Replace Ink Tanks.

WARNING!

DO NOT REMOVE THE SIDE COVERS OF THE PRINTER! THERE ARE HIGH VOLTAGES PRESENT BEHIND THE COVERS!

SECTION 5 TROUBLESHOOTING

57

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.)

Wrong Interface settings.

Static electricity.

Dirty Media Sensor.

Check software or database

on PC.

Close the software, then

turn Printer OFF and ON.

Clean Media Sensor.

No communication Improper cabling / connector.

Unit not receiving power.

Use proper USB cable (see

Operator Manual.)

Check plug connections,

ON/OFF button and fuse on

side panel.

Print too light or missing

character dots

Clogged or dirty Printhead.

Running out of ink.

Check the Printhead.

Check Ink Tanks.

Blurry address

Image is not sharp. Clean Printhead using one

of the Cleaning Levels in


Clean the Printhead

manually using distilled

water and a wet, clean, lint-

free 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.

APPENDICES

58

Appendix A – Colordyne 1600-C Specifications

PRINT RESOLUTION Best: 1600 x 1600 DPI

Normal: 1600 x 800 DPI

PRINT SPEED High Quality Mode: 6" (15 cm)/second

Normal Quality Mode: 12" (30 cm)/second

UNWINDER/WINDER

SPEED 0-125 RPM

MAX. PRINT SIZE 8.5" (215.9 mm) W x Continuous

MEDIA TYPES Roll or Fanfold (Label, Tag, Paper, Envelope)

MEDIA SIZE Minimum: 2" (50.8 mm) W

Maximum: 9" (228 mm) W x Continuous

MEDIA THICKNESS Minimum: 3 points (0.1 mm)

Maximum: 12 points (0.3 mm)

ROLL SIZE (3" CORE)

(Opt. Unwinder/Winder)

ROLL-to-CUT Minimum: 2" W x 10" Dia. (50 mm x 254 mm)

Maximum: 9" W x 10" Dia. (228 mm x 254 mm)

ROLL-to-ROLL Minimum: 2" W x 500' (50 mm x 152 m)

Maximum: 8.5" W x 500' (215 mm x 152 m)

ROLL CORE SIZES Reversible Hub: 1.5" & 3" Dia. (38 mm x 76.2 mm)

MEDIA SENSING Label gap, notch, tick mark

INK Water-based ink. 5 individual 250 ml ink tanks (CMYKK)

PRINT CARTRIDGE One Memjet® Printhead (8.77"/222 mm Print Width)

INTERFACE USB and Ethernet

DIMENSIONS PRINTER: 21" W x 21" L x 11" H (53 cm x 53 cm x 27 cm)

UNWINDER/WINDER: 17" L x 9" W x 11" H (43 cm x 22 cm x 27 cm)

PRINTER WEIGHT 70 lbs. (31.8 kg)

All Specifications Subject To Change Without Notice

Appendix B – Supplies and Optional Hardware

Available from your Colordyne Distributor:

Supplies

Black Ink Tank

Cyan Ink Tank

Magenta Ink Tank

Yellow Ink Tank

Optional Hardware

1600-U Unwinder

1600-W Winder

INDEX

59

A Adjust Core Size 27

Adjusting Speed, Unwinder & Winder 28

Aligning Printer w/ Unwinder & Winder 24

Alignment Notch, Unwinder 5

Auto/Manual Switch 5

C Cancel/Cut Button 2, 7

Cartridge, Printhead 3

Choose Location 11

Clamshell Latches 3

Cleaning Ink Revolvers 52

Ink Tank Contacts 40

Print Engine 51

Printer 51

Printhead 42

Computer Connecting 14

Connecting Computer 14

Printer 14

Printer to Unwinder/Winder 26

Control Panel Cancel/Cut Button 2, 7

Power Button 2, 7

Print/Pause Button 2, 7

Cutting Blade Assembly 4

D Diagnostic Port 1

Diagnostics, Toolbox 36

Disposal, Ink Tanks 41

Dock Ink Tank 4

Service Station 4

E Envelope Printing Attachment 22

External Power Connector 5, 6

F Fanfold Labels 29

Front Cover 1

Fuse Main 1

Unwinder 5

Winder 6

G General Tab, Printer Driver 30

H Head Media Guide 22

Hub Assembly Adjust Core Size 27

Unwinder 5

Winder 6

Hydrating Printhead 12, 20, 44

I Indicators, Control Panel 7

Ink Revolver Couplings 3

Ink Revolvers 52

Ink Tanks Cleaning Contacts 40

Disposal 41

Dock 4

Installing 17

Latches 4

Removing 55

Replacement 58

Replacing 39

Storage 41

Ink Usage, Toolbox 37

Ink Waste Tray 4, 49

Installing Ink Tanks 17

Printer 11

Printer Driver 15

Printhead 19

Interconnect Cord, Unwinder/Winder 5, 6

Interface Connection Unwinder 1

Winder 1

J Jams in Printer 50

L Label Roll Spindle 5, 6

Label Tension Guide Shaft 5, 6

Labels Fanfold 29

Loading 27

Roll-to-Cut 26, 28

Roll-to-Roll 24, 27

Latches Clamshell 3

Ink Tank 4

Printhead 3

Layout Tab 31

Location, Choose 11

M Main Fuse 1

Main Power Receptacle 1

Main Power Switch 1

Maintenance 39

Maintenance Schedule 61

Media Guide 2

Media Guide Ring 6

Media Tab, Printer Driver 32

Minimum Requirements, System 15

Misfeeds 50

Mode Switch, Unwinder 26

N Network

Configuration 37

Connection 1

O Optional Hardware 58

INDEX

60

P Power Button 2, 7

Power Connector, External 5, 6

Power Receptacle 1

Power Switch Main 1

Winder 6

Print Engine Cleaning 51

Ink Revolvers 52

Print/Pause Button 2, 7

Printer Aligning w/ Unwinder & Winder 24

Cleaning 51

Connecting 14

Connecting Unwinder/Winder 26

Control Panel 7

Default Printing Modes 10

Installing 11

Jams, Removing 50

Maintenance 39

Misfeeds 50

Operation 30

Optional Hardware 58

Setup 11

Shipping/Transporting 53

Specifications 58

Supplies 58

Toolbox 34

Troubleshooting 56, 57

Unpacking 11

Printer Driver General Tab 30

Installing 15

Layout Tab 31

Media Tab 32

Properties 30

Services Tab 33

Printer Port 1

Printer Toolbox Diagnostics 36

Ink Usage 37

Network Configuration 37

Service Menu 38

User Interface 34

Using 34

Printhead 3

Cleaning 42

Hydrating 12, 20, 44

Installing 19

Latch 3

Removing 53

Replacing 42

Troubleshooting 56

Printing Default Printer Modes 10

Fanfold Labels 29

Roll-to-Cut Labels 26

Roll-to-Roll Labels 24

R Remove/Replace

Envelope Attachment 22

Head Media Guide 22

Removing/Replacing Ink Tanks 39, 55

Ink Waste Tray 49

Printhead 42, 53

Service Station 46, 54

Service Station TransportTab 13

Shipping Tape 13

Roll Labels 24, 26, 27

Roll-to-Cut Labels 28

S Schedule, Maintenance 61

Service Menu, Toolbox 38

Service Port 1

Service Station Dock 4

Removing 54

Removing Transport Tab 13

Replacing 46

Services Tab, Printer Driver 33

Setup Change Core Size 27

Printer 11

Shipping or Transporting Printer 53

Shipping Tape, Removing 13

Specifications, Printer 58

Speed Adjust, Unwinder & Winder 28

Speed Control Unwinder 5, 28

Winder 6, 28

Spindle Lock 5, 6

Storage, Ink Tanks 41

Supplies 58

System Requirements, Minimum 15

T Toolbox, Using the 34

Top Cover 1

Troubleshooting 56

Printer 57

Printhead 56

U Unpacking Printer 11

Unwinder 5

Aligning w/Printer 24

Alignment Notch 5

Auto/Manual Switch 26

USB Port 1

User Interface, Toolbox 34

W Winder 6

Aligning w/ Printer 24

PRINTER MAINTENANCE SCHEDULE General, periodic maintenance is needed to keep the Printer in good working order. Many tasks can be

performed by operators with basic supplies, no special tools needed. Other tasks should only be performed

by trained service personnel. NOTE: High volume usage may require more frequent maintenance.

Maintenance Supplies & Equipment: Flashlight, small telescoping mirror, hard-bristled toothbrush or

equivalent, powder-free nitrile gloves, protective clothing and eyewear, small flathead screwdriver,

tweezers, vacuum with wand, deionized distilled water, Super Lube 21030 synthetic grease (or equivalent),

Loctite 38650 copper anti-seize (or equivalent), can of compressed air, foam or lint-free cotton swabs, lint-

free wipes, disposable shop towels.

COMPONENTS/TASKS MAINTENANCE TYPE

DAILY BI-WEEKLY MONTHLY YEARLY AS NEEDED

PERFORMED BY OPERATOR

Printhead (Manual Wiping) WIPE

Ink Revolver Couplings and Connections: Inspection/Cleaning

EVERY

PRINTHEAD REMOVAL

Residue and Debris Removal CLEAN CLEAN CLEAN CLEAN CLEAN

Optical Sensors (Media Path)

CLEAN CLEAN CLEAN

Wiper Assembly: Inspection

INSPECT INSPECT INSPECT

Grit Rollers (Media Path) INSPECT CLEAN

Ink Tank Latches/Ink Bay INSPECT

Ink Tubing, Couplings, Components

INSPECT INSPECT

Ink Waste Tray INSPECT INSPECT REPLACE

Lift Motor Gear INSPECT INSPECT

PERFORMED BY SERVICE TECHNICIAN

Lubrication APPLY

Pen Driver PCA Contacts: Cleaning

EVERY

PRINTHEAD REMOVAL

Moving Parts/Motor TEST

Service Station Sled Assembly CLEAN

Wiper Assembly: Cleaning

CLEAN

WARNING! ALWAYS POWER DOWN THE PRINTER BEFORE CONNECTING OR DISCONNECTING ANY WIRING HARNESSES OR CABLE CONNECTIONS TO AVOID SERIOUS SHOCK OR INJURY.

CAUTION ALWAYS USE APPROPRIATE PERSONAL PROTECTION EQUIPMENT (PPE).

USE ELECTROSTATIC DISCHARGE (ESD) PROTECTION WHEN MAINTAINING EQUIPMENT.

DISPOSE OF ALL MAINTENANCE WASTE IN ACCORDANCE WITH LOCAL REGULATIONS.

NOTES

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colordyne 1600-c...this manual is intended solely for the use and information of colordyne...

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