Xerox CiPress 325 Reference guide

Xerox®CiPress™325 / 500 Production
Inkjet System
Customer Help Information
5.0 Software
August 2012

©2012 by Xerox Corporation. All rights reserved. XEROX®, XEROX® and Design, CiPress™
and FreeFlow® are trademarks of Xerox Corporation in the United States and/or other
countries.
BR3162

Table of Contents
1 CiPress™System.........................................................................................1-1
CiPress™Overview.................................................................................................................1-1
System Features....................................................................................................................1-1
System Configurations.......................................................................................................1-2
Speed Configurations.........................................................................................................1-3
System Components...........................................................................................................1-3
Infeed Module.........................................................................................................1-4
Right Marking Module..........................................................................................1-5
Left Marking Module.............................................................................................1-5
Outfeed Module......................................................................................................1-5
Attention Light......................................................................................................................1-6
Audible Alert..........................................................................................................................1-6
2 Power Management.................................................................................2-1
CiPress™System Power Overview..................................................................................2-1
CiPress™System Power On Procedure............................................................2-1
CiPress™System Power Off Procedure...........................................................2-3
CiPress™Printer Power Overview.....................................................................................2-4
Restarting the CiPress™Printer UI.....................................................................2-5
Restarting the CiPress™Printer...........................................................................2-5
CiPress™Touch Screen Power Troubleshooting............................................2-7
FreeFlow Print Server Power Overview.........................................................................2-8
Restarting the FreeFlow Print Server...............................................................2-9
FreeFlow Print Server Power Troubleshooting..........................................2-10
3 Web Setup....................................................................................................3-1
Web Setup Overview...........................................................................................................3-1
How to Set NVM ID 34063.................................................................................3-1
How to Restore NVM ID 34063 to the Default Value..............................3-1
4 Operating the CiPress™User Interface.............................................4-1
About the CiPress™User Interface.................................................................................4-1
CiPress™Views...........................................................................................................4-1
Command Button Bar...........................................................................................4-2
Common Printer Controls....................................................................................4-3
User Access Levels................................................................................................................4-4
Changing User Access Levels.............................................................................4-5
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Changing User Access Level Passwords.........................................................4-5
Resetting User Access Level Passwords..........................................................4-6
User Access Level Default Passwords..............................................................4-7
Multinational Support..........................................................................................4-7
Assigning Multinational Preferences to User Accounts.............4-8
Run View..................................................................................................................................4-8
Printer Name and Status...................................................................................4-10
Job ID and Job Name........................................................................................4-10
Status Areas...........................................................................................................4-10
CiPress™States..........................................................................................4-13
PPE States..................................................................................................4-14
Warning and Error Information........................................................4-14
Settings....................................................................................................................4-15
Paper Selection........................................................................................4-15
Overriding a Run View Paper Selection............................4-16
Application Selection............................................................................4-16
Overriding a Run View Application Selection.................4-16
Job Source Selection..............................................................................4-17
Changing the Job Source Selection...................................4-17
Online / Offline Selection....................................................................4-17
Print Line Selection.................................................................................4-18
Overriding a Run View Print Line Selection.....................4-18
Image Offset Setting (Optional)......................................................4-18
Resolution and Speed...........................................................................4-19
Setting Resolution - Speed Combinations.......................4-19
Ink Usage Estimation...........................................................................4-19
Estimating Ink Usage - Run View.......................................4-20
Check Pages / Enable............................................................................4-20
Setting the Number of Pages for a Check Page
Routine....................................................................................4-21
Printing a Check Pages Routine...........................................4-21
Advancing the Web...............................................................................4-21
Ready / Not Ready.................................................................................4-22
Definitions View.................................................................................................................4-22
Required Definitions...........................................................................................4-23
Standard Definition Controls..........................................................................4-24
Helpful Terms.........................................................................................................4-25
About Marks...........................................................................................................4-25
Mark Positioning.....................................................................................4-26
Paper Definition Tab...........................................................................................4-26
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Creating a New Paper Definition.....................................................4-27
Defining Properties and Pre-printed Marks.....................4-27
Editing a Paper Definition...................................................................4-31
Deleting a Paper Definition................................................................4-32
Deleting Multiple Paper Definitions................................................4-32
Application Definition Tab...............................................................................4-32
Additional Notes about Tandem (ROF) Marks............................4-33
Creating a New Application Definition..........................................4-34
Editing an Application Definition....................................................4-37
Deleting an Application Definition..................................................4-37
Color Patches in Job...............................................................................4-38
Full Frame Color Patches........................................................4-39
Partial Frame Color Patches..................................................4-39
Print Line Definition Tab....................................................................................4-39
Creating a Paper Path Definition.....................................................4-40
Removing a Device from a Print Line Definition........................4-43
Adding a Device for Print Line Selection.......................................4-44
Adding Marks for a Print Line Definition.........................4-45
Editing a Print Line Mark Definition..................................4-46
Deleting a Print Line Mark Definition...............................4-47
Editing a Print Line Definition...........................................................4-47
Deleting a Print Line Definition........................................................4-48
Consumables View............................................................................................................4-48
Consumables / HFSI............................................................................................4-49
Ink Usage Estimation.........................................................................................4-50
Estimating Ink Usage - Consumables View.................................4-50
Exporting the Ink Usage Estimate...................................................4-51
Administration View.........................................................................................................4-51
Call for Assistance Tab.......................................................................................4-53
Manually Submitting Call for Assistance Data...........................4-53
Meters Tab..............................................................................................................4-53
Test Patterns Tab..................................................................................................4-54
Software Tab..........................................................................................................4-55
System Information...............................................................................4-55
System Tab.............................................................................................................4-56
Importing and Exporting Definitions.............................................4-56
Importing Definitions..............................................................4-57
Exporting Definitions...............................................................4-57
Automatic Job End Eject.....................................................................4-58
Setting the Values for Automatic Job End Eject...........4-58
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Diagnostics View...............................................................................................................4-59
Intrusive Mode......................................................................................................4-62
Debug Logging Overview..................................................................................4-62
DC 106 Test Printing Overview.......................................................................4-62
DC 110 System Logs Overview.......................................................................4-62
How to Access DC 110 System Logs...............................................4-64
DC 131 NVM Overview......................................................................................4-64
DC 141 Head Setup Overview.........................................................................4-64
How to Run DC 141 Head Setup......................................................4-66
DC 142 Color Maintenance Overview..........................................................4-66
How to Run DC 142 Color Maintenance.......................................4-67
DC 610 Image Registration Overview.........................................................4-69
DC 965 Head Maintenance Overview.........................................................4-70
How to Run DC 965 Head Maintenance.......................................4-70
5 Problem Solving.........................................................................................5-1
Calibrating the Touch Screen..........................................................................................5-1
Thermal Controller General Checkout Procedure....................................................5-2
Web Registration Module Problem Solving...............................................................5-9
Activate Material Setup.....................................................................................5-12
Perform Material Setup for Primary (Upstream) CiPress™....................5-12
Perform Material Setup for Secondary (Downstream)
CiPress™...............................................................................................................5-12
Optimize Gain for Primary (Upstream) CiPress™......................................5-13
Optimize Gain for Secondary (Downstream) CiPress™...........................5-14
Image Quality Overview.................................................................................................5-14
Image Quality Defect Initial Actions...........................................................5-15
Image Quality Defect Diagnosis Section......................................5-15
Streak Defect Type Selection................................................5-16
Missing Jets Troubleshooting Procedure............5-18
Light or Dark Narrow Streaks..................................5-28
Light or Dark Wide Streaks......................................5-30
Color Non-uniformity (From a Single CiPress™
Printer).....................................................................................5-31
Poor Text / Line Quality or Spots.........................................5-33
Color-to-Color Misregistration..............................................5-34
Web Wrinkle or Damage........................................................5-37
Color Non-uniformity (From Two CiPress™
Printers)...................................................................................5-38
Ink Smudges or Smears..........................................................5-39
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Deletions (Images or colors).................................................5-42
Image Ghosting (Offset)........................................................5-43
Test Patterns................................................................................5-43
Test Patterns Section Overview..............................5-43
CharacterizeHeads_FullWidth_500fpm.............5-44
How to Print
CharacterizeHeads_FullWidth_500fpm.5-44
Cust_10Up_500fpm_23296...................................5-45
How to Print
Cust_10Up_500fpm_23296...............5-45
Uniformity_500fpm_23296....................................5-46
How to Print
Uniformity_500fpm_23296................5-46
PrintHeadReg_500fpm..............................................5-47
How to Set NVM ID 32345........................5-48
How to Print
PrintHeadReg_500fpm..........................5-48
How to Restore NVM ID 32345 to
the Default Value.....................................5-49
Fault Code Overview.........................................................................................................5-49
Image Quality Fault Code Problem Solving............................................................5-49
Print Head Fault Code Problem Solving....................................................................5-52
Web Fault Code Problem Solving................................................................................5-61
6 Cleaning........................................................................................................6-1
Cleaning the CiPress™Overview......................................................................................6-1
General Web Path Cleaning Tips......................................................................6-2
Before Cleaning Checklist....................................................................................6-3
Cleaning the Infeed Module..............................................................................6-3
Cleaning the Right Marking Module...............................................................6-3
Cleaning the Left Marking Module..................................................................6-5
Cleaning the Outfeed Module...........................................................................6-6
Cleaning the Exterior Printer Cover Doors....................................................6-7
Cleaning the Touch Screen.................................................................................6-7
Cleaning the FreeFlow Print Server Rack and CIP Enclosure.................6-8
7 Maintenance Tasks...................................................................................7-1
Print Head Replacement Overview................................................................................7-1
Print Head Replacement Prerequisites...........................................................7-1
How to Replace Print Heads from Left Marking Tower............................7-2
How to Replace Print Heads from Right Marking Tower.........................7-9
Maintenance Tasks (Animations)...............................................................................7-16
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Refilling the Waterless Ink Barrels.................................................................7-16
Emptying the Waste Ink Trays........................................................................7-16
Cleaning the Ink Drip Trays.............................................................................7-17
Replacing the Print Head Air Vent Filter.....................................................7-17
Replacing a Print Head......................................................................................7-17
Cleaning the Image Sensor Glass.................................................................7-17
Cleaning the Image Sensor Roll and Static Eliminator Brush............7-17
Replacing the Spreader Agent Metering Blade.......................................7-17
Replacing the Spreader Agent Application Roll.......................................7-17
Replacing the Spreader Agent Box...............................................................7-17
Cleaning the FreeFlow Print Server CIP Module Filters.........................7-17
Cleaning the Radiant Heater Area................................................................7-17
Servicing the Web Cleaner...............................................................................7-17
Cleaning the Web Path Sensors.....................................................................7-17
Cleaning the Web Guider Sensors.................................................................7-18
Cleaning the Print Box Unit (PBU) Backer Rolls.......................................7-18
Cleaning the Pre-Heat, Leveler, and Spreader Drums...........................7-18
Cleaning the Web Registration Sensors......................................................7-18
Cleaning the Infeed and Outfeed Module Rollers and Static
Eliminators.......................................................................................................7-18
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1
CiPress™System
CiPress™Overview
The Xerox®CiPress™Production Inkjet System is a four-color digital inkjet printer designed
for high speed continuous feed production. This system features waterless inkjet
technology that prints on either pinless or pinfed stock up to 20.5 inches wide.
System Features
Key features and technologies include:
DescriptionFeature
Waterless ink provides vibrant and stable image quality since the ink
remains on the surface of the paper. This patented ink does not
require pre-treated paper, water, or other agents, and does not need
special drying equipment. Because the ink is waterless, no curling
occurs in the paper and no evaporation occurs within the print heads.
Waterless ink technology
The drop on demand Print Heads are durable, heat resistant, and
customer replaceable, and the 880 jets per print head fire accurate
and consistent ink through the ejectors. The jets can be normalized
so all jets provide consistent performance between rolls. Print head
registration assures automated and accurate horizontal and roll
direction alignment which is controlled at the pixel level.
Print head technology
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DescriptionFeature
325 mode - Higher
productivity •325 feet per minute (100 meters per minute) print speed
•600 x 600 resolution
•1417 pages per mnute (US letter)
•Up to 7.8 million feet / 34 million impressions
500 mode - Higher quality •500 feet per minute (152 meters per minute) print speed
•600 x 400 resolution
•2180 pages per mnute (US letter)
•Up to 11.5 million feet / 50 million impressions
Output resolution is 600 x 400 dpi (cross process x process direction)
for excellent sharpness and uniformity. The image quality reflects
outstanding midtones, sharp text, pure neutrals, detailed shadows,
bright highlights, and excellent photo rendering.
Output resolution and
image quality
The ink delivery system uses a 35 gallon refillable drum for each
color that can be refilled or topped off while running jobs to prevent
interruptions in printing. The feeding system delivers ink through the
use of air pressure and vacuum tubing.
Ink delivery system
A patented double reflex printing process monitors the velocity,
acceleration, and tightness of the web. This keeps the paper moving
rapidly and smoothly through the system to preserve both
productivity and image quality.
Double reflex printing
process
Paper options consist of lightweight, uncoated, and untreated low
cost paper, 75 to 90 gsm. This includes Offset, Bond, Recycled,
Calendared, Ground wood, index, and mechanical fiber.
Low cost paper / Web
stock
A touch-sensitive screen provides touch control for all printer
operations such as setting up jobs, defining parameters, running
diagnostic routines, and troubleshooting.
Press interface touch
screen
Xerox FreeFlow Print Server enables continuous feed job processing
(RIPping) as well as job, queue, and color management.
Digital print server
The CiPress™integrates with third-party equipment, such as finishers,
unwinders, and roll feeders, to provide a complete solution. In
addition, the system manages print streams and file formats to
support a wide range of IPDS and PDL workflows including
transactional and variable data printing.
End-to-end solution
System Configurations
The CiPress™is configured at the time of the system installation. It can be configured
as a single print engine for 1-sided printing or as two print engines for 2-sided, or duplex,
printing.
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CiPress™System
(continued)

When two print engines are configured in tandem, the first print engine lays images on
one side of the paper while the second print engine lays images on the other side of the
paper. A turnbar, located between the print engines, flips the paper to enable the second
print engine to print on the second side of the web.
When a tandem configuration is used, the first print engine lays down marks on the
paper which are read by the second print engine. This process registers and aligns the
images on each side of the paper with each other.
Speed Configurations
Two speed configurations are available: CiPress™325 and CiPress™500.
The CiPress™325 runs only in 325 feet per minute (100 meters per minute) mode but is
upgradeable to the 500 speed mode via the purchase of a license.
The CiPress™500 includes both the 325 mode and the 500 mode. The CiPress™500 print
speed is 500 feet per minute (152 meters per minute).
All variable costs, such as print heads, ink, and meter rates, are the same for both speed
configurations.
System Components
The system is made up of a collection of components.
FunctionComponent
Located on the right front side of the system, the Infeed Module
accepts web stock from the unwinder and positions the paper for
entry into the Right Marking Module.
Infeed Module
The marking modules:Right Marking Module /
Left Marking Module •Control and maintain the web paper tension and velocity
•Set and maintain a consistent distance between the web and the
print heads
•Supply ink to the print heads and the paper
•Purge and clean the print heads to remove ink waste and clear
clogged jets
•Clean and heat the web before ink is applied (Right Marking
Module only)
•Cool the applied ink to a uniform temperature prior to spreading
(Left Marking Module only)
•Deliver the imaged paper to the Outfeed Module (Left Marking
Module only)
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CiPress™System

FunctionComponent
The Outfeed Module monitors the image for correct color-to-color
registration and missing image areas, heats and spreads the final
image, and exits the web to any third party finishing devices.
Outfeed Module
The left side of the Right Marking Module and the right side of the
Left Marking Module form an A-shaped frame that the web travels
over to receive ink from the print heads. The A Frame has 14 print
heads for each of the four color stations that spray ink onto the
surface of the paper.
A (Apex) Frame
This module, located at the rear of the machine behind the A Frame,
contains the power supplies, voltage lines, transformers, motor
controllers, and waste ink trays. The Electrical Module also contains
the environmental components that maintain a steady and correct
temperature in the A Frame.
Electrical Module
Xerox FreeFlow Print Server consists of multiple computers, two
network switches, and a Contone Image Processing (CIP) component
mounted on a rack next to the user interface. This server provides
RIP processing, job control, and job management for the CiPress™.
Print Server
The Touch Screen UI is located on the top of the Outfeed Module
and serves as the main control point for making or changing job and
system settings. Maintenance functions are also accessed from the
Touch Screen UI.
Touch Screen User
Interface (UI)
Four separate waterless ink barrels contain the inks for the CiPress™.
There is a barrel for each of the following ink colors: Cyan (C),
Magenta (M), Yellow (Y), and Black (K).
Dry Ink Barrels
Roll Feeders or Unwinders are used to load web stock to the CiPress™.Roll Feeder / Unwinder
The Thermal Controller provides the temperature-controlled water
to the heating and cooling drums within the CiPress™.
Thermal Controller
The Waste Ink Trays catch ink debris that accumulates from cleaning
the print heads. The trays are located on either side of the A Frame.
There are four trays on each side.
Waste Ink Trays
Infeed Module
The Infeed Module contains the following components:
DescriptionComponent
Provides coarse inboard-to-outboard registration of the paper
from the unwinder.
Web Edge Guide Assembly
Directs the web to the Right Marking Module and adjusts the
registration of the paper within +/- 0.1 mm. This results in
registration within approximately +/- 0.2 mm at the color
stations.
Web Registration Module
Provides coarse inboard-to-outboard registration of the paper
from the Outfeed Module in preparation for second-sided
printing. This assembly is for duplex printing on a single print
engine and is not currently used.
Duplex Web Edge Guide
Assembly
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CiPress™System
(continued)

DescriptionComponent
Located on top of the Infeed Module, alerts the operator
regarding faults, machine conditions, or low consumables.
Attention Light
Right Marking Module
The Right Marking Module contains the following components:
DescriptionComponent
Cleans the paper prior to the application of ink.Web Cleaner
Heats the paper in preparation for the application of ink.Web Heating Drum
Apply the ink to the paper.Print Heads
Set the position of the paper relative to the print heads as the
paper rides along on the rolls.
12 Backer Rolls
Purges old ink to the waste trays and then wipes and cleans
the print heads using wiper blades and other parts.
Print Head Cleaning Assembly
Left Marking Module
The Left Marking Module contains the following components:
DescriptionComponent
Cools and levels the temperature of the paper (no cool or hot
spots) in preparation for the Spreader.
Web Cooling Drum
Apply the ink to the paper.Print Heads
Set the position of the paper relative to the print heads as the
paper rides along on the rolls.
12 Backer Rolls
Purges old ink to the waste trays and then wipes and cleans
the print heads using wiper blades and other parts.
Print Head Cleaning Assembly
Outfeed Module
The Outfeed Module contains the following components:
DescriptionComponent
Reads the image on the web and provides input to the Image
Registration and Color Control system for image color
registration and possible missing image defects.
Image Sensor
Softens the ink so it can pass through the web.Radiant Heater
Applies heat and pressure to reduce the height of the image.
This makes the image more durable and resistant to abrasion.
Spreader
Returns the web to the Infeed Module.Bypass Transport
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CiPress™System
(continued)

Attention Light
The remote attention light provides operators with the status of general states of the
CiPress™. The light, visible from all directions, is designed to gain the attention of the
operator from a distance.
There is one attention light per CiPress™and the light has two color states:
•Red - Indicates the state of the local CiPress™.
State / ConditionAttention Light -
Red
The default state of the CiPress™red attention light.Off
The current CiPress™is in the Error state and needs immediate attention.Blinking
The current CiPress™is not in the Error state, and any HFSI or Consumable
in the current CiPress™is in the Due or Almost Due state. A steady red light
means something on the local CiPress™will need attention soon.
Steady
•Green - Indicates the state of the currently segmented print line.
State / ConditionAttention Light -
Green
The default state of the CiPress™green attention light.Off
Each of the PPEs in the currently segmented print line is either 1) in the
Soft Stop state with the web cycled up, or 2) in the Ready state, AND each
CiPress™in the currently segmented print line is in one of these states:
Steady
- Job Source = Online and Printer State = Ready, or
- Printer State = Ejecting, Preparing to Cycle Up, or Printing images and
then doing a managed stop
Note
The green attention light is on whenever the web is cycled up or will cycle
up without additional operator intervention when job data is available at
the CiPress™.
Audible Alert
Each CiPress™is equipped with an audible alert. The CiPress™will sound the alert under
the following conditions:
•When the operator presses any of the web advance control hard buttons prior to
moving the web, regardless of whether or not there is paper loaded in the CiPress™.
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CiPress™System

•When the operator selects any of the web advance CiPress™UI controls, such as Eject
Pages, prior to moving the web, regardless of whether or not there is paper loaded
in the CiPress™.
Note
If a printer or a print line condition exists that prevents the CiPress™from advancing
the web, the audible alert will not sound when the web advance controls are pressed
/ selected.
•Prior to the local CiPress™cycling up to print a job. Since each CiPress™has its own
alert, in a duplex system with two printers, there are two alerts and each will sound.
During intrusive diagnostics, the alert is always enabled. Upon exiting diagnostics, the
user setting is restored.
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CiPress™System

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CiPress™System

2
Power Management
CiPress™System Power Overview
This section provides the procedures required to power on and power off the CiPress™
System, defined as the CiPress™Printer, FreeFlow Print Server, and third-party
components.
These procedures provide instructions for the appropriate power on and power off
sequences of the CiPress™Printer and FreeFlow Print Server.
•CiPress™System Power On Procedure
•CiPress™System Power Off Procedure
CiPress™System Power On Procedure
See the CiPress™System Power Overview prior to performing this procedure.
Use this procedure when a CiPress™System is powered off.
1. Ensure that all third-party pre-processing and post-processing equipment is powered
on according to the manufacturer's instructions.
2. Switch the Power Supply Knife Switches for the Primary CiPress™Printer to the On
position. The Power Supply Knife Switches are located near the CiPress™Printer.
•United States: 480 VAC and 208 VAC
•Europe: 400 VAC and 200 VAC
Note
If performing this procedure as a part of a Printer System Restart, wait at least 60
seconds before switching the Power Supply Knife Switches back to the On position.
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1
Example of a 208 VAC Power Supply Knife Switch in the On position.
2
Example of a 480 VAC Power Supply Knife Switch in the On position.
3. Power on the Secondary CiPress™Printer if it exists using the instructions in the previous
step.
Important
Power on the Secondary or Downstream CiPress™Printer within two minutes of
powering on the Primary CiPress™Printer.
4. Wait until appears in the taskbar of the Primary
CiPress™Touch Screen.
Note
The CiPress™Touch Screen has no indicator light as to whether it is powered on or
powered off. See CiPress Touch Screen Power Troubleshooting if an image does not
appear on the Touch Screen within a short period of time.
5. Ensure that the FreeFlow Print Server display is powered on.
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Power Management

6. Power on the servers in the FreeFlow Print Server Rack by pressing the power button
on each unit.
The green colored power indicator light on each server goes from a state of slowly
flashing to a state of steady on.
CiPress™System Power Off Procedure
See the CiPress™System Power Overview prior to performing this procedure.
Use this procedure when a CiPress™System is powered on.
1. On the Primary CiPress™Printer UI, ensure that the current state is NOT READY.
2. Select Power > Shutdown.
A confirmation window displays.
3. Select Yes.
A pop-up window displays on the Secondary CiPress™Printer UI if a Tandem
Configuration is used.
4. If it exists, on the Secondary CiPress™Printer UI, select Shutdown > Yes from the
pop-up window.
5. Wait until the Touch Screen display(s) no longer show an image.
6. Switch the Power Supply Knife Switches to the Off position. The Knife Switches are
located nearby the Printer.
•United States: 480 VAC and 208 VAC
•Europe: 400 VAC and 200 VAC
Note
If performing this procedure as a part of a Printer System Restart, wait at least 60
seconds before switching the Power Supply Knife Switches back to the On position.
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Power Management

1
Example of a 208 VAC Power Supply Knife Switch in the On position.
2
Example of a 480 VAC Power Supply Knife Switch in the On position.
7. On the FreeFlow Print Server UI, select System > Shutdown.
The FreeFlow Print Server powers off. The green server power indicator lights on the
server rack go from a steady state to an intermittent state.
8. If desired, power off any third-party pre-processing and post-processing equipment
according to the manufacturer's instructions.
CiPress™Printer Power Overview
The procedures in this section should not need to be used while the CiPress™Printer or
related components, such as the Touch Screen, are operating normally. See CiPress™
System Power Overview for the standard power on and power off procedures.
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Power Management