digit printers theory.book - Kodak

KODAK VERSAMARK DP5000 Series Printers 

Theory of Operation 

DP5120, DP5122, and DP5240 

Kodak Versamark, Inc.

KODAK VERSAMARK DP5000-Series Printers 


DP5120/DP5240/DP5122 Printers

FCC Compliance Statement 

This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to Part 15 of the FCC Rules. These 

limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. 

This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instruction manual, 

may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference, 

in which case the user will be required to correct the interference at his own expense. 

Note: Good quality, shielded (braided shielded) cables must be used for the RS-232-C and Centronics interfaces. 

Canadian EMI Compliance Statement 

Le présent appareil numérique n’émet pas de bruits radioélectriques dépassant les limites applicables aux appareils numériques de la classe A 

prescrites dans le Règlement sur le brouillage radioélectrique édicté par le ministère des Communications du Canada. 

This digital apparatus does not exceed the Class A limits for radio noise emissions from digital apparatus set out in the Radio Interference Regulations 

of the Canadian Department of Communications. 

EMI-CISPR 22/EN 55 022/CE Marking 

Warning: This is a Class A product. In a domestic environment, this product may cause radio interference in which case the user may be 

required to take adequate measures. 

KODAK VERSAMARK DP5000-Series Printers Theory of Operation, DP5120/DP5240/DP5122 Printers 

Part Number Media Revision Date Description ECN 

0113846-602 

0113846-603 

Print 

PDF 

001 04/01 Extracted from 0113851 and revised for the DP5122 Printer K44798 

© Eastman Kodak Company, March 4, 2005. All rights reserved. 

This document contains proprietary information of Kodak Versamark, Inc. or its licensors and is their exclusive property. It may not be 

reproduced without a written agreement from Kodak Versamark, Inc. No patent or other license is granted to this information. 

The software described in this document is furnished under a license agreement. The software may not be used or copied except as provided 

in the license agreement. 

Kodak Versamark, Inc. makes no warranty of any kind with regard to the contents of this document, including, but not limited to, the implied 

warranties of merchantability and fitness for a particular purpose. Kodak Versamark shall not be liable for any errors or for compensatory, 

incidental or consequential damages in connection with the furnishing, performance, or use of this document or the examples contained herein. 

Information concerning products not manufactured by Kodak Versamark, Inc. is provided without warranty or representation of any kind, and 

Kodak Versamark, Inc. will not be liable for any damages resulting from the use of such information. 

Kodak and Versamark are trademarks of Eastman Kodak Company. 

0113846-602 

0113846-603 03/2005 Printed in U.S.A.

Scope 

Theory of operation provides general, technical background for the following 

Kodak Versamark products: 

• DP5120 Printer and DS5120 Printing System 



This guide is part of the following service manual set: 

• Volume 1 (0113902-001) 

Theory of Operation (0113846) 

Service Guide (0113864) 

• Volume 2 (0113902-002) 

Illustrated Parts List (0113783) 

Service Diagrams (0113874) 

Installation Guide (0113847) 

The information in this guide is intended only for a Kodak Versamark field 

engineer, or a service technician trained by Kodak Versamark, Inc. 


iii

Scope 

Text Notations 

Text Notations 

This manual uses the following typographical conventions. 

This style 

Ready 

go 

ENTER 

[NEXT] 

Save 

File → Open 

ALT+F1 

ALT, TAB 

xx,yy 

jobfile.dat 

Refers to 

Text displayed by the software. 

Anything you type, exactly as it appears, whether referenced 

in text or at a prompt. 

Special keys on the keyboard, such as enter, alt, and 

spacebar. 

Buttons and lights on the printer operator panel. 

Software command buttons and sections of dialog boxes, 

such as group boxes, text boxes, and text fields. 

A menu and a specific menu command. 

Pressing more than one key at the same time. 

Pressing more than one key in sequence. 

Variable in error messages and text. 

File names. 

Safety Notations 

The following definitions indicate safety precautions to the operator. 

Note: Information that needs to be brought to the reader’s attention. 

Caution: A situation where a mistake could result in the destruction of data or system-type 

damage. 

! WARNING 

A potential hazard that could result in serious injury or death. 

! DANGER 

An imminent hazard that will result in serious injury or death. 

iv 

DP5000 Series Printers

Scope 

Service and Support 

Service and Support 

Technical equipment support is available 24 hours a day, 7 days a week. 

Software and applications support is available 8:00 a.m. to 5:00 p.m. EST/EDT, 

Monday through Friday. 

Call for telephone or on-site technical support; to order parts or supplies; 

to request documentation or product information. 

U.S.A., Canada, and 

worldwide 

Phone 

+1-800-472-4839 

+1-937-259-3739 

Fax 

+1-937-259-3808 

Europe +41-21-806-0404 +41-21-806-1920 

Asia/Pacific Rim +65-6744-6400 +65-6744-6700 

Japan +81-3-3256-2613 +81-3-3256-2616 

Updated service 

information 

Customer support 

http://www.kodakversamark.com 

customer@kodakversamark.com 


v

Contents 

Chapter 1. Overview 

Inkjet Printing Basics ......................................................................................... 1-1 

Pressure...................................................................................................... 1-1 

Stimulation .................................................................................................. 1-1 

Charge ........................................................................................................ 1-2 

Vacuum ....................................................................................................... 1-2 

Component Functions........................................................................................ 1-3 

Printhead Functions .................................................................................... 1-3 

Common Printing Sequence................................................................. 1-4 

Internal Differences............................................................................... 1-5 

Umbilical...................................................................................................... 1-5 

Fluid System ............................................................................................... 1-6 

Data System................................................................................................ 1-7 

Functionality and Reliability ............................................................................... 1-8 

General Guidelines ..................................................................................... 1-8 

Fluid System Guidelines.............................................................................. 1-8 

Chapter 2. Printer Functions 

Power Distribution.............................................................................................. 2-1 

Data System ...................................................................................................... 2-2 

Machine Control................................................................................................. 2-3 

Host Communication ......................................................................................... 2-4 

Startup......................................................................................................... 2-4 

Printing ........................................................................................................ 2-5 

Shutdown .................................................................................................... 2-6 

Chapter 3. Controller Functions 

System Overview............................................................................................... 3-1 

System Configuration.................................................................................. 3-1 

Software ...................................................................................................... 3-2 

Interfaces .................................................................................................... 3-3 

Controller Operation .......................................................................................... 3-4 

Data Source ................................................................................................ 3-5 

Tach and Cue.............................................................................................. 3-6 

Print Control ................................................................................................ 3-7 

Layout ......................................................................................................... 3-7 

Index 


vii

Figures 

Figures 

Figure 1.1 Printer components ..................................................................... 1-3 

Figure 1.2 Fluid system operation, DP5240 and DP5122 Printers............... 1-6 

Figure 1.3 Data system components, DP5240 and DP5122 Printers .......... 1-7 

Figure 2.1 Major printer sub-systems........................................................... 2-1 

Figure 2.2 Power distribution, printer ........................................................... 2-2 

Figure 2.3 Signal and data flow, data system .............................................. 2-3 

Figure 2.4 Signal flow, machine control sub-system .................................... 2-4 

Figure 2.5 Startup communications sequence, printer and host .................. 2-5 

Figure 3.1 Communications paths, system configuration............................. 3-5 

Tables 

Table 3.1 System configurations, DP5000-Series Printers ..................... 3-2 

Table 3.2 Interface functions, DP5000-Series Printers ........................... 3-4 

viii 


Chapter 1. 

Overview 

General knowledge of the following subjects is necessary to effectively 

troubleshoot and repair KODAK VERSAMARK DP5000-Series products: 

• Inkjet printing basics 

• Component functions 

• Functionality and reliability 

Inkjet Printing Basics 

Inkjet printing is the process of placing small drops of ink onto a printing 

surface in a pattern that produces an image. The type of inkjet printing 

used in the DP5000-Series is continuous-flow, binary, multiple-jet array 

imaging. Continuous inkjet printing requires the following four elementary 

forces: 

• Pressure 

• Stimulation 

• Charge 

• Vacuum 

How these forces interact in an inkjet printhead is best understood by 

“building” a printhead and describing how the major printhead 

components harness these forces to create a printed, inkjet image. 

Pressure 

Pressure is produced by the ink pump that moves ink from the ink tank 

(supply) to the drop generator in the printhead. Printhead pressure, also 

called “bar pressure,” is measured in pounds per square inch (psi). 

Pressure must be sufficient to force ink through the orifices to create 

filaments, but not excessive. Low pressure results in ink starvation at the 

printhead. Complete loss of pressure prevents printing because no ink is 

available to form jets. Excessive pressure can cause an internal leak or 

ink spill. Normal operating pressure is about 9.5 psi in the DP5120 and 

DP5122 Printers and about 19 psi in the DP5240 Printer. 

Stimulation 

Stimulation is produced in the printhead by mechanical action of the 

droplet generator. Piezoelectric crystals are bonded to the droplet 

generator and excited. The resulting sinusoidal wave form produces 

vibration communicated to the orifice plate. The vibration breaks up the 

ink filaments passing through the jets into uniform drops. 

Theory of Operation 1 - 1


Inkjet Printing Basics 

Stimulation is measured by frequency. The DP5120 and DP5122 Printers 

use a stimulation frequency of 50 kilohertz (kHz); this creates 50,000 ink 

drops per second at each jet. The DP5240 Printer uses 100 kHz 

stimulation frequency that creates 100,000 drops per second at each jet. 

The correct stimulation frequency setting, typically called the “stim” 

setting, is critical to proper printhead operation and must be determined 

for the printhead by test printing. To achieve the proper stim setting, 

phase and voltage are adjusted within a range called a “window.” 

Prolonged over-stimulation causes printhead short-circuits (shorts), print 

voids and eventually damage to the printhead electronics. Understimulation 

causes streakers, dark areas (ink saturation), and eventually 

printhead failure. Total stim failure prevents printing, as all jets stay in 

catch and no ink reaches the substrate. Stimulation failures are rare, but 

the usual cause is a bad resonator or crystal that requires replacing the 

printhead. 

Charge 

The DP5000-Series Printers use electrical charge to designate which 

droplets are to reach the printing surface. When they leave the orifice 

plate tunnels, the ink jets carry no electrical charge. As the jets fall toward 

the printing surface and break into drops, they pass close to the charge 

plate and catcher. The charge plate can have either a positive charge 

(+100 to +180 volts DC) or no charge. Formatted print data (a bit map) 

from the character generator controls the charge on the charge plate and 

determines the droplets to be used for printing. 

A positive charge on the charge plate induces a negative charge in the 

droplets as they break away from the jet. The negatively charged droplets 

are attracted by the positive charge plate. This attraction changes the 

trajectory of the droplets, causing them to hit the catcher. 

If the charge plate has no charge, the ink remains electrically neutral 

when it forms droplets. The neutral droplets fall past the charge plate and 

catcher and hit the printing surface. Total charge failure results in an ink 

dump, all jets printing constantly which quickly saturates the substrate. 

Excessive charge causes high-voltage shorts and prolonged high voltage 

can etch the charge leads and damage the printhead. 

The DP5120 charge plate contains 128 charge areas, one for each jet. 

The charge on each area can be changed quickly enough to selectively 

pass or deflect each of the 50,000 droplets passing it each second; thus, 

charge allows the DP5120 Printer to control 6,400,000 drops per second. 

The DP5240 and DP5122 charge plates contain 256 charge areas and 

passes or deflects each of the 100,000 droplets, allowing these printers to 

control 25,600,000 drops each second. 

Vacuum 

Vacuum recovers and recirculates deflected drops. Charged drops hit the 

catcher face as they fall past the charge plate. Vacuum draws the ink on 

the catcher back into the fluid system where it is returned to the ink tank. 

Vacuum also assists the fluid system in maintaining the ink supply. As ink 

is used, ink or replenisher is drawn from the appropriate bottle into the 

tank. Vacuum failure results in ink collecting in the printhead. Excess ink 

in the printhead housing will eventually result in leaks or shorts. 

1 - 2 DP5000 Series Printers


Component Functions 


The basic functions of the following printer sub-systems are described: 

• Printhead 

• Umbilical 

• Fluid system 

• Data system. 

The printer enclosure physically contains the fluid system and data 

system. The umbilical connects the printhead to the enclosure. See 

Figure 1.1. 

Figure 1.1 

Printer components 

Umbilical 

Printhead 

Data System 

Fluid System 

The controller PC, software, and interfaces are the major components of 

a printing system that contains a DP5000-Series Printer. Printing system 

functions are described in Chapter 3. 

Printhead Functions 

DP5000-Series Printers have the following printheads: 

• DH5120 Printhead 

This 120-jet array prints 1.06 inches (2.69 cm) wide with vertical 

resolution of 120 dots per inch (dpi) and horizontal resolution of 120 

or 240 dpi. 


This 240-jet array prints the same width as the DH5120, but at a 

vertical resolution of 240 dpi, and a horizontal resolution of 240 dpi or 

480 dpi. 


This 240-jet array prints 2.133 inches (5.42 cm) wide at the same 

resolutions as the DH5120. 

Note: Vertical resolution is along the print array. Horizontal resolution is in the 

direction of substrate movement. 

Operation is a combination of the following features of these printheads: 

• Common printing sequence 

• Internal differences 




Common Printing Sequence 

The following sequence shows how the four basic elements required for 

inkjet printing (shown in bold) are created by the major printhead 

components (shown in italic) to form a printed image. 

1. The core of the printhead is a rectangular metal block, the resonator, 

mounted on a rigid frame. The resonator has an internal cavity with a 

narrow opening in one side. This opening faces toward the printing 

surface, or substrate. 

2. The opening in the resonator is covered by an orifice plate made of 

thin, copper-plated nickel with a linear array of orifices. 

Higher resolution requires smaller dots, so orifices in the DH5120 and 

DH5122 plates are 1.85 ± 0.06 mils in diameter (46.9 ± 1.5µm) while 

those in the DH5240 plate are only 1.30 ± 0.04 mils (33.0 ± 1.0µm). 

3. Pressure applied by the printer fluid system fills the resonator cavity 

with ink and forces the ink out through the array. The escaping ink 

forms filaments, or thin streams, one for each orifice. The entire array 

produces a curtain of continuous ink jets that would “print” a solid 

band of ink on the substrate. 

The solid band equals the maximum print width, 1.065 inches for the 

DH5120 and DH5240, and 2.133 inches for the DH5122. 

4. To control how much ink hits the substrate, the jets are broken into 

drops by the vibration of the droplet generator. This component of the 

resonator vibrates when high-frequency voltage stimulates 

piezoelectric crystals bonded to its surface. 

5. Drops are formed at a rate equal to the stimulation frequency. The 

DH5120 Printhead operates at 50 kilohertz (kHz) and produces 

6,000,000 drops per second from its 120 jets. The DH5240 and 

DH5122 Printheads operate at 100 kHz and produce 25,600,000 

drops per second from their 256 jets. 

6. To determine which drops reach the substrate, the falling drops pass 

the face of a charge plate bonded with an electrical lead for each jet. 

When a positive charge of 100 to180 +VDC is applied to a lead, it 

induces a negative charge in the falling drop. Attraction to the charge 

plate diverts the charged drop enough to hit the catcher face instead 

of the substrate. The printer data system controls when each charge 

lead is energized. The sequence of charging determines the pattern 

of the bitmapped image printed on the substrate. Uncharged drops 

fall freely, hit the substrate and form the printed image. 

7. Charged drops are diverted enough to strike the catcher face and run 

down it. This ink is returned, or recirculated, by vacuum applied to 

the catcher. Vacuum and positive air pressure combine to keep the 

catcher and orifice plate free of accumulated ink. Excess ink can dry 

within the printhead, causing irregular drops, shorts, etching, and 

clogged jets. 


Internal Differences 



The following internal components and construction differences 

distinguish the current DH5240 and DH5122 Printheads from the original 

DH5120 and early DH5240 Printheads: 

• An ink condensation heater was added along with a new catcher 

valve, printhead air inlet valve, new vacuum servos and pump. 

• Printhead and ink tank temperature was increased. 

• New eyelid assembly, including the eyelid seal, eyelid solenoid, and 

the printhead assembly itself. 

• Within the printhead assembly, the top-port resonator of the DH5120 

and the front-port resonator of the early DH5120 have been replaced 

by a side-port resonator in the current DH5240 and DH5122. 

• Replacement of the tab buffer board used in the DH5120 by the 

printhead adapter board. 

All these changes enhance printhead reliability. The changes are 

reflected in changed state tables, and pressure and stimulation changes. 

To enhance printhead startup reliability, jet pressure was increased to 6 

psi, and 200% stim was introduced to clear crooked (misdirected) jets. 

Umbilical 

The flexible cord or hose containing the electrical and fluid lines for the 

printhead connects the printer enclosure and the printhead housing. The 

following lines pass through the umbilical: 

Printer Electrical 

• Inkjet control 

• AC high-voltage (HV) supply 

• Condensation heater 

Printhead Electrical 

• Charge driver 

• Eyelid solenoid and air ingestion 

• Eyelid heater 

Fluidics 

• Inlet (supply) 

• Outlet (cross-flush) 

• Catcher 

• Positive air 

The three umbilicals differ in that there is a condensation heater line in the 

DH5240 and DH5122 umbilicals, and the DH5122 umbilical also has 

larger diameter fluid lines. 




Fluid System 

The fluid system delivers ink and replenisher to the printhead, removes 

ink from the printhead using vacuum, and fills the printhead housing with 

positive air. The inkjet controller board (IJC) runs this sub-system and 

operates all the components that regulate the flow of fluids through the 

printer, from the ink supply through the umbilical to the printhead (see 

Figure 1.2). The operation of the IJC is described in detail in Chapter 2. 

Figure 1.2 

Fluid system operation, DP5240 and DP5122 Printers 

Fluid system Umbilical Printhead 

Air 

Positive air 

Catcher 

Vac 

Outlet (cross-flush) 

Inlet (supply) 

Condensation* 

Ink tank 

Resonator 

Drain 

Replenisher 

Internal 

ink 

supply 

External 

ink 

supply** 

Catcher 

Ink 

Ink 

Quick disconnect 

Pump 

Heater 

Filter 

Ink 

Air or vacuum 

Ink under vacuum 




Data System 

The data system consists of the circuit boards in the printer enclosure, 

internal and external cables, and related electronics in the printhead and 

umbilical (see Figure 1.3). The data system processes input data 

received from a controller or input device, converts that data into an 

image bit-map, and sends electrical signals to the printhead that control 

charging and form the inkjet image. The operation of the data system is 

described in detail in Chapter 2. 

Figure 1.3 

Data system components, DP5240 and DP5122 Printers 

Operator 

Panel 

7-Segment 

Display 

Printer enclosure 

K4K 

ETHERNET 

DS Main 

Data Output 

RS-232 Serial 

CENTRONICS 

Control I/O 

Tach & Cue 

Inkjet Controller 

Relay Output 

High-voltage AC 

Power Supply 

Filter 

AC Input 

Charge Driver 

Adapter 

Printhead housing 

Time Board 



Functionality and Reliability 

Functionality and Reliability 

The following sections relate printhead and fluid system reliability and 

functionality. The basic function of each sub-system relates directly to its 

potential as a source of printer or system problems. Use this information 

as an introduction to the troubleshooting procedures in the Service Guide. 

General Guidelines 

The following general guidelines apply to all DP5000-Series Printers: 

• Routine maintenance is the single most important factor in printer 

reliability. Consistent, proper routine maintenance will result in very 

high printer reliability. Most common problems that cause printer 

down time are solved by cleaning the printhead or changing filters. 

• The majority of printer problems not related to lack of routine 

maintenance are caused by job setup or data preparation errors. The 

fastest way to determine this is to print a test pattern. If the test 

pattern is okay, the printer is not the source of the problem. 

• Printer and controller hardware failures are the least likely cause of a 

problem and when they occur, the source of the problem is generally 

easy to determine using Jetscape diagnostics (see the Service 

Guide). 

• Reliability is enhanced by limiting startup and shutdown cycles. The 

more the printer runs, typically the better it performs. Idle periods 

longer than the average ink drying time increase the potential for 

problems because ink dries on the bottom of the printhead and even 

inside it. Thorough and consistent cleaning is especially critical for a 

printer that is used infrequently or intermittently. 

Fluid System Guidelines 

The following specific guidelines apply to all ink-related aspects of 

operation: 

• Cleaning is the most effective means of preventing problems. Dirty 

printheads will streak, drip, and eventually develop shorts, commonly 

exhibited as crooked jets. Actual printhead hardware failures are rare, 

and the most common problem, etching of charge leads or the orifice 

plate caused by prolonged contact with charged ink, is drastically 

reduced or eliminated by rigorous routine maintenance. The only 

serious problem that cannot be prevented by cleaning is resonator 

failure due to the strain imposed by constant, high-frequency 

stimulation, and it typically affects only printheads with a very high 

number of hours. 

• Check printed output for streakers and other defects diligently. Do not 

rely on error messages to call attention to a printhead problem. 

Frequent visual inspection will catch problems early when they are 

easily fixed and reduce down time. 

• Monitor ink concentration and change ink to avoid high concentration 

that will shift the phase window up and reduce print quality. Always 

perform a printhead clean before adjusting phase or voltage. 


Chapter 2. 

Printer Functions 

This guide divides the printer functions into the following four categories: 

• Power distribution 

• Machine control 

• Data system (DS) 

• Host (or system controller) communication 

These four functional categories relate directly to the three major subsystems 

of the printer (see Figure 2.1). 

Figure 2.1 

Major printer sub-systems 

Power 

distribution 

system 

Power 

Control 

Machine 

control 

Controls 

data 

Status 

Data 

system 

Commands 

data 

Status 

To 

system 

controller 

Power Distribution 

The power distribution system performs the following functions: 

• Provides filtered electrical power to all parts of the printer 

• Converts the line voltage to the levels of alternating current and direct 

current needed by various parts of the printer 

• Provides overload and short circuit protection 

• Provides hardware for controlled shutdown of the printer 

The basic components of the power distribution sub-system are shown in 

Figure 2.2. The circuit breaker switch on the rear of the printer allows 

external power to reach a transformer and the AC power relay. With the 

circuit breaker switch in the line on position, the printer can be turned on 

with one operator panel button. This button is a software-controlled, AC 

power relay. The ACHV low-voltage power supply supplies isolated +5V 

and +12V supplies for the secondary circuits, and an isolated supply to 

the catcher heater for sensing and control. The ACHV high-voltage DC 

power supply provides charge voltage for the printhead ranging from 5V 

to 180 VDC with a maximum current of 40mA. The DP5122 lacks the 

voltage selector switch present on the DP5120 and DP5240. 



Data System 

Figure 2.2 

Power distribution, printer 

+5, ±12, VDC 

Low voltage 

power supply 

To data system 

Primary 

120 VAC 

Safety extra 

low voltage 

+24 VDC 

+5, ±12, +24 VDC 

To inkjet controller 

100-240 VAC 

50-60 Hz 

AC line 

filter 

100-240 VAC 

Circuit 

breaker 

AC high 

voltage supply 

DH5120 and 

DH5240 only 

Voltage 

selector 

switch 

100-240 VAC 

Auto 

transformer 

Fan 

100-240 VAC 

120 VAC 

Primary 

120 VAC 

Fluid system AC 

Data System 

The data system consists of the following components: 

• Data system (DS) main board 

• DS output board 

• K4K board (optional) 

• Seven segment display 

The data system provides overall control of printer operation, including 

the following functions: 

• Receives print data and commands from the system controller 

• Formats print data 

• Generates character bitmaps 

• Transmits commands and formatted print data to the inkjet controller 

As shown in Figure 2.3, the data system also provides two-way 

communication between the operator and printer using the software 

installed on the system controller. 



Machine Control 

Figure 2.3 

Signal and data flow, data system 

7-segment 

display 

Data system 

status 

Data system 

Status/data 

Serial data 

Column 

requesters 

DS 

output 

Parallel data 

Control signals 

Status 

Data 

To 

system 

controller 

To inkjet 

controller 

Commands 

Status 

Safety extra 

low voltage 

Sort codes 

Base stop 

Tach/cue 

Document blank 

To 

control 

I/O 

Backplane 

K4K cue 

K4K document blank 

K4K 

Print data 

tach/cue 

K4K cue out 

Safety extra 

low voltage 

Control signals 

Machine Control 

Machine control consists of the following components: 

• Inkjet controller assembly 

• Printhead 

• Printer operator panel 

• Fluid system 

As shown in Figure 2.4, machine control performs the following functions: 

• Receives and interprets commands from the data system 

• Controls ink flow through the fluid system and printhead 

• Performs dot generation and printing 



Host Communication 

Figure 2.4 

Signal flow, machine control sub-system 

Print sync error 

Print done 

column request 

Formatted data 

Sweep available 

Commands 

Solenoids 

Sensors 

Inkjet 

controller 

Safety extra 

low voltage 

Display 

panel 

Status 

K4K cue 

K4K cue out 

Controls 

and data 

Status 

AC high voltage supply 

Safety extra 

low voltage 

Hazardous 

secondary 

Drive 

Feedback 

Solenoids 

Sensors 

Drive 

Feedback 

Status 

Status 

Printhead 

Printhead 

components 

Control/charge data 

Control/charge data 

Tab 

buffer 

Charge driver 

interface 

DH5240 

Hazardous 

secondary 

Charge driver 

DH5120 and DH5122 

Hazardous 

secondary 

Fluid system DC 


This section describes data, commands, and status signal flow between 

the printer and the host controller in the basic printer operating states. 

Startup 

Startup describes the normal method of putting the printer in a ready-toprint 

state and is normally interchangeable with power-up. 

Caution: To protect printer and printhead electronics, always follow the startup and 

shutdown procedures. 

When powered up, the Data System (DS) main and IJC assemblies 

perform power-on confidence (POC) tests. Figure 2.5 shows the main 

steps in this startup sequence. When the POC is successfully completed, 

the DS main assembly sends a command to the IJC assembly to bring 

the fluid system and printhead into a ready, but offline state, in which the 

fluid system is on but the eyelid is closed (shown as “normal operation” in 

the diagram). Lights on the operator panel indicate the printer is on and in 

standby. The process completes even if an error is detected. A fluid 




system error (detected by the IJC) lights the error indicator on the 

operator panel. Except for error IJ-40, the printer will attempt to complete 

the startup sequence and reach ready three times when a fluid system 

error is detected. A data system error lights the three lower-left panel 

lights. These lights remain lit after the startup sequence terminates. 

Figure 2.5 

Startup communications sequence, printer and host 

Host Data System Fluid System 

Power Power Power 

Power On 

Self Test 

All 

Pass? 

Power Up 

Diagnostics 

All 

Pass? 

Low-Level 

Diagnostics 

Start 

PC OS 

No 

No 

Check DS 

Ready 

Start 

Host SW 

Fast PH Up 

System 

Stop 

System 

Stop 

Serial communications begin 

Serial communications begin 

Power On 

Confidence 

Test 

Normal 

Operation 

Normal 

Operation 

Normal 

Operation 

Printing 

An open eyelid command puts the printer online, and allows the data 

system to accept commands from the system controller through the RS- 

232 interface. Commands are processed as received until an error is 

detected. Communication with the fluid system is over the RS-232 serial 

interface through the DS main board (J3) to the inkjet controller (J4). 

Data is received by the data system main over the CENTRONICS parallel or 

K4K parallel interface. The following critical signals control host and 

printer communication: 

• Initialize (INPUT PRIME) clears the data system input buffers and any 

pending documents 

• Select (SLCT) indicates to the host that the data system is ready to 

print 

• Error (/FAULT) alerts the host to a printer problem that may stop or 

prevent printing. 

The DS main assembly converts the data into bitmap images (print data) 

to be used for printing. The print data and formatting commands are then 

sent to the DS output board over the VME bus. The DS output board 

sends the data and commands to the IJC assembly. 




The IJC assembly counts tachs and cues to track the position of 

documents and produces a print enable signal at the correct time. The DS 

output board holds formatted data until the IJC assembly determines that 

the document is in the correct position for printing; the IJC assembly then 

sends the data to the charge driver in the DH5120 Printhead or to the 

charge driver interface in a DH5240 or DH5122 Printhead. The more 

advanced charge driver interface combines the charge driver and charge 

plate. Charging uses the formatted print data to control which leads 

deflect ink into the catcher. Undeflected drops form the image on the 

substrate. 

During printing, the DS main monitors systems, reports errors, and sends 

the start print and end of print signals to the DS output board. 

Shutdown 

Normal shutdown starts when the printer on button is pressed with the 

printer turned on. The IJC assembly software receives the power down 

command and relays it to the DS main. Normal shutdown requires that 

the circuit breaker remain in the line on position. 

If the printhead is ready when the shutdown starts, the IJC assembly 

evacuates fluid from the printhead to prevent ink residue from causing 

problems at the next startup. After evacuation, the IJC assembly waits 

three seconds, then turns off the AC power relay. 

Caution: The AC line filter, circuit breaker, and AC power relay control circuit are 

still connected to the AC mains. Turning off the circuit breaker 

disconnects the AC power relay control circuit from the AC mains. The 

line filter and one side of the circuit breaker are connected to the AC 

mains as long as the power cord is attached. 


Chapter 3. 

Controller Functions 

A controller combines with one or more printers to create a printing 

system. The terms controller, host controller, and system controller are 

interchangeable with regard to printer functions. This general description 

of controller functions is divided into the following sections: 

• System overview 

• Controller functions 

System Overview 

A printing system consists of the following major components: 

• Printer (DP5120/DP5240/DP5122) 

• Controller (PC with custom software) 

• Options (tape drive, multiple printer interface, K4K, ETHERNET) 

The following characteristics define how the printer is used in a printing 

system: 

• System configuration 

• Software 

• Interfaces 

System Configuration 

Communication between the printer and host data source provides the 

image data for printing and control signals needed for proper printer and 

host interaction. The DP5000-Series Printers can operate in the following 

types of configurations: 

• Printing system 

This is a stand-alone system with a controller dedicated to the 

DP5000-Series Printer. With the multiple printer interface option, a 

dedicated controller can send data to three printers. 

• K4K controller 

This is a system with a specialized controller, such as KODAK 

VERSAMARK 4000-Series binding line controller, that sends data to 

printers, but also controls other devices, often through a 

programmable logic controller (PLC). The number of printers is 

limited only by the capability of the controller; the practical limit for 

most applications is eight printers. 

• System controller 

This is a network system built around a system controller such as a 

KODAK VERSAMARK CS220 System Controller. The controller sends 

data to multiple printers and can have limited control over other 

devices. The practical limit for most applications is 8 printers, but a 

12-printer or even 16-printer system is possible. 




Note: This section describes only the printer-related aspects of controller 

operation. 

The following sections describe printer operation in a system 

configuration. All systems require the following three basic elements: 

• Software 

• Interfaces 

• Printer types 

Software 

Controller software controls system operation, but must be compatible 

with the printer software. Printer software comprises the following 

components: 

• Data system main board firmware and flash memory 

• Inkjet controller firmware 

Printer and controller software versions, compatibility between different 

components, and flash memory options are described in the Service 

Guide. 

Controller software defines both the printing system and the type of 

controller. Table 3.1 shows the various types of standard system 

configurations. 

Table 3.1 

System configurations, DP5000-Series Printers 

Printer Used / System Type 

Host Software DP5120 DP5240 DP5122 

Jetscape 

Mailscape 

DS5120 Printing System with 

Jetscape 


Mailscape 


Jetscape 


Mailscape 

Custom Not named 2 

DS5122 Printing System 1 

MPC3 or MPC4 DS6240 Printing System 3 

Binding Line 

4000-Series Binding Line Controller System 

1. The standard software includes both controller programs. Mailscape only is also available, but only Jetscape is not supported. 

2. Custom software and controller hardware is not described. The basic functions of most custom software applications are similar to 

Jetscape. 

3. This is any system that includes a KODAK VERSAMARK CS100, CS200, or CS220 System Controller. 

All configurations cannot be listed, as custom configurations can combine 

elements of more than one system, and such hybrid configurations 

cannot be described in general terms. 

Jetscape This controller software application comprises the following 

four programs: 

• Print Control 

• Control Panel 

• Diagnostics 

• Layout 

The first three programs are MS-DOS operating system programs. Print 

Control allows the operator to create, edit, save, and print job setups. 

Control Panel allows the operator to perform printer functions from the 

controller screen instead of the printer operator panel. Jetscape 




Diagnostics monitors both printer and controller operation and provides 

tests for determining the source of a printer or controller error. Tests can 

be selectively run on all the major components of the printer. Diagnostics 

supplements the power-on sequence tests that run automatically when 

the printer is turned on. Figure 2.5 shows the communications that occur 

during the start-up sequence. For a complete description of Jetscape 

diagnostics, see the Service Guide. 

Jetscape Layout is a MICROSOFT WINDOWS 3.1 operating system program 

with a GUI for creating, editing, and saving job setups for the DP5120 and 

DP5240. 

Jetscape is installed on a PC connected to the printer through its serial 

and parallel interfaces. To function correctly, Jetscape must be configured 

to operate with the printer connected to the host, and the job must be 

properly set up. 

Mailscape This printer control program provides the same basic 

functions as Jetscape Print Control, but in the MICROSOFT WINDOWS 98 

operating system environment. Jetscape Control Panel is still required 

with Mailscape to operate a DP5000-Series Printer from the controller 

screen. 

To function correctly, Mailscape must be configured to operate with the 

printer connected to the host, and the output module must be properly 

configured. Mailscape has built-in diagnostics that can be used to test an 

output module created for a DP5120 or DP5240 Printer. For the DP5122 

Printer, Jetscape Diagnostics must be used. 

Service Considerations From a service perspective, the basic 

guideline for understanding potential controller problems is to recognize 

that configuration and job setup errors are often mistaken for printer 

problems. Printing a test pattern is the easiest way to differentiate a host 

problem from a printer problem. If the test pattern is okay, the problem is 

not in the printer. If the problem is in the controller, first check the system 

configuration, then the job setup, and finally run diagnostics on the 

controller itself. 

For detailed descriptions of controller software, see the Jetscape Control 

Panel Operator’s Guide (0114083), Jetscape Print Control (0113817) 

Operator’s Guide (0113817), and the Mailscape Operator’s Guide 

(0114081). 

Interfaces 

The critical link in a printing system is a set of interfaces between the 

controller and all connected printers. The following basic interfaces are 

required for any system: 

• Data 

• Tach and cue 

• System control 

The data interface provides the image data for printing. Tach and cue time 

the movement of the substrate and start printing in coordination with 

substrate movement. System control provides, at minimum, a means of 

starting and stopping the movement of the substrate. 

Seven different connectors on the printer carry the three basic interfaces 

required for operation. Five of these connectors are multi-functional. 



Controller Operation 

Table 3.2 lists the functions of each interface. 

Table 3.2 

Interface functions, DP5000-Series Printers 

Interface Functions To From 

CENTRONICS 

Data / system control / tach and cue 

RS-232 serial 

System control / data / tach and cue 

- 

K4K 

Data / system control / cue for document count 

Host 

Control I/O System control / differential tach and cue I/O box / Host 

Tach and cue Tach and cue - Source Devices 

Relay output System control Controlled Device - 

ETHERNET Data / system control - Host 

The next section describes interface functions. For a detailed description 

of all interfaces and signals, see the Service Guide. 


The controller converts input data base records into documents in Native 

Input Command (NIC) or Inkjet Printer Data Stream (IJPDS) format, and if 

fonts are not loaded in memory at the printer, the controller downloads 

them to the printer along with the image data (documents). These basic 

functions can be broken down into the following operations: 

• Data source 

• Tach and cue 

• Print control 

• Layout 

These basic operations relate directly to the seven interface connections 

on the printer. Figure 3.1 diagrams the basic interconnections between 

printer, host, and other system components. 




Figure 3.1 

Communications paths, system configuration 

Coax ETHERNET 

Optional 

ETHERNET 

Printer 

K4K 

J1 

Host 

RS-232 Serial 

J1 

Optional 

K4K 

CENTRONICS 

J2 

J6 

J4 

Control I/O I/O 

J3 

DS Main 

(Data System) 

Inkjet Controller 

(Fluid System) 

Transport 

Tach & Cue 

J4 

J7 

Stacker 

P7 

I/O Box 

Relay Output 

ACHV 

Supply 

DS Output 

(Data System) 

J2 

J10 

Data Source 

The controller retrieves image data from its hard disk, the optional tape 

drive, or a network server and sends it to the printer over one of the 

following interfaces: 

Centronics The datapath CENTRONICS parallel interface is the most 

commonly used data connection. This 36-pin connector carries eight data 

lines (DATA 1-8) and the following control signals: 

• STROBE is active when DATA 1-8 are valid. 

• ACK goes active when a byte of data has been received. 

• BUSY goes active after STROBE goes inactive (indicating a byte 

received) and the FIFO goes full (4096 bytes loaded) to signal the 

host that the printer is unable to receive data. BUSY goes inactive 

when the FIFO reaches half full (2048 bytes loaded). BUSY also goes 

active if the printer goes offline and remains active until the printer is 

put back online. 

• SELECT goes active (high) when the printer is online and ready to 

receive data. It goes inactive (low) when the printer is taken offline. 

• INPUT PRIME goes active when the host clears the data system 

buffers including any pending documents. 

• FAULT goes active when a printer error condition exists. 




RS-232 Serial The serial interface is primarily the communications 

path between the host, data system, and fluid system, but it can be used 

as a data connection. The printer serial port is a standard EIA RS-232-C 

interface with an additional printer ready line (PR) and ground used to 

configure data terminal equipment (DTE). The serial interface can be the 

data input for the printer, but with a host controller, it is used for status 

information, with data input over the parallel interface. When connected to 

a controller, the port requires a null-modem cable. When it connects the 

printer to a modem, it requires a straight-through cable. In addition to 

eight data lines, the serial interface provides nine status signals and three 

grounds. 

K4K The optional, 50-pin K4K interface is a custom, parallel connection 

that provides differential, simultaneous transmission of status and image 

data with checksums to ensure data integrity. The K4K design was ported 

over from the Admark printer to allow DP5000-Series Printers to replace 

Admarks operating with binding line controllers (and in other applications 

using data transmission in Admark mode). With the DP5120 and DP5240, 

the K4K can use the Admark input format, but now the K4K is typically 

used the same as the CENTRONICS parallel port to receive standard NICformat 

data. 

To use K4K, the printer must have compatible software, optional 

hardware installed, and have the proper switches set on the DS main 

board. The optional hardware is the K4K board, cables, and back panel 

connector. 

In addition to 8 data bits, the K4K transmits 15 control signals and cue 

(input and output). Unlike the parallel interface, the K4K is capable of twoway 

simultaneous communication. 

Ethernet The optional ETHERNET interface provides a coaxial (Thinet, 

IOBase5) BNC connection for TCP/IP communication with a host, 

typically through a hub. 

To use ETHERNET, the printer must have compatible software, optional 

hardware installed, and have the proper switches set on the DS main 

board. The optional hardware is the ETHERNET transceiver and cable. 

Tach and Cue 

The printer must receive tach and cue to print, but the signal source 

varies depending on the system configuration. The printer can also output 

tach and cue to other devices. 

Tach and Cue Input tach and cue for the printer is carried over this 

dedicated 9-pin connection. If the printer is operating standalone, this 

connection goes directly to the tach encoder and cue sensor. If the printer 

is part of a system, this connection goes to the controller which provides 

processed tachs and cues. 

Control I/O Differential tach and cue inputs can be received through 

this connector. 

K4K Cue is carried on this interface to provide a document count for 

specialized applications. 




Print Control 

Controller software provides a means of creating a job setup, or modifying 

an existing setup. The job setup determines how the image data appears 

on the printed document. When job setup information is included in the 

data file, it is transmitted and processed along with the image data for the 

job. Once the setup is processed, only the information needed by each 

printer is transmitted along with the image data for printing. When this 

automatic setup function is not used, the operator must select a existing 

setup and use it to print the job, select and modify an existing setup, or 

create a new setup. 

All setups define how the image data is arranged on the document. Each 

part of the image data is assigned to a field, or position, on the document, 

given an orientation, and assigned other parameters such as fonts for 

text. 

Setup errors account for many problems mistaken for printer 

malfunctions. Incorrect setup can result in no visible image being printed, 

partially printed images, truncated images, or otherwise improperly 

formatted data. The simplest method of checking image data is to print a 

test pattern. If the test image is okay, the printer is functioning correctly, 

and the setup should be checked. If the setup is okay, the image data 

should be previewed to check the data file. 

Layout 

Jetscape includes a document layout utility that allows the operator to set 

up jobs using a WYSIWYG graphical user interface (GUI) common to all 

programs that run under the MICROSOFT WINDOWS operating system. 

Layout cannot be used with the DP5122 Printer. 


Index 

A 

adjustment, phase 1 - 2 

array 

creation of jets 1 - 4 

print 1 - 3 

automatic setup 3 - 7 

B 

bar pressure 1 - 1 

basic elements of inkjet printing 1 - 1 

binding line 

4000-Series controller 3 - 2 

system and controller 3 - 1 

C 

catcher 

action in recirculating ink 1 - 2 

function in printhead 1 - 2 

charge 

areas on printheads 1 - 2 

interaction with stimulation 1 - 1 

leads 1 - 4 

negative, on ink drops 1 - 2 

plate 1 - 2 

plate, function 1 - 2 

charge voltage 

controlling 2 - 6 

printing 1 - 2 

cleaning 

importance for reliability 1 - 8 

importance of operator maintenance 1 - 8 

computer 

controller PC 3 - 3 

system controller 2 - 2 

configuration 

errors 3 - 3 

Mailscape 3 - 3 

system 3 - 4 

Control Panel 

Jetscape 3 - 2 

program functions 3 - 2 

crystal 

cause of resonator failure 1 - 2 

piezoelectric 1 - 2 

cue 

interface 3 - 3 

theory of operation 2 - 6 

curtain of ink 1 - 4 

D 

dark defects, caused by under-stimulation 1 - 2 

data 

bit map conversion 2 - 5 

handling by printer 1 - 7 

data system 

components 2 - 2 

functions 2 - 2 

main board 2 - 5 

datapath, interfaces 3 - 3 

deflection See charge 

diagnostics 


program 3 - 3 

dots per inch See resolution 

droplets See drops 

drops 

creation by stimulation 1 - 2 

creation of 1 - 1 

number created per second 1 - 2 

DS main 

description 2 - 5 

function 2 - 5 


DS output board 

description 2 - 2 

function 2 - 5 

E 

electrical charge 

use in printing 1 - 2 

voltage and power source 2 - 1 

error 

charge related 1 - 2 

handling 2 - 6 

message viewing 2 - 5 

eyelid 

closing 2 - 4 

opening 2 - 5 

umbilical and signals 1 - 5 

F 

fields, printed images on document 3 - 7 

filaments 1 - 4 

fluid system 

communication 2 - 5 

guidelines for operator maintenance 1 - 8 

Theory of Operation

Index 

frequency 

measurement of stimulation 1 - 2 

stimulation 1 - 2 

functionality 1 - 8 

G 

general overview 1 - 1 

generation of characters (bit maps) 2 - 2 

GUI See Jetscape 

guide, operator’s 3 - 3 

guide, service 1 - 8, 3 - 2, 3 - 3 

guidelines for operator maintenance 1 - 8 

H 

heater, eyelid 1 - 5 

high voltage See charge 

horizontal resolution, print 1 - 3 

host 

communication 2 - 1 

system configuration 3 - 2 

I 

IJC assembly (board) 

error handling 2 - 5 

power on 2 - 5 

tach and cue 2 - 6 

image 

area, sizes 1 - 3 

building with inkjet printing 1 - 1 

errors caused by setup problems 3 - 7 

ink 

charged drops created 1 - 2 

curtain created by jet array 1 - 4 

droplets, formation of 1 - 1 

inlet 1 - 5 

maintaining ink level 1 - 2 

outlet 1 - 5 

recycling 1 - 2 

saturation 1 - 2 

supply and recirculation 1 - 2 

ink jet 

applying charge 1 - 2 

printing, basic elements 1 - 1 

printing, continuous 1 - 4 

inlet, ink 1 - 5 

J 

jets 

formation by charge 1 - 2 

number and arrangement 1 - 3 

Jetscape 


GUI interface 3 - 3 

job 

setup for printing, defined 3 - 3 

setup, with print control program 3 - 7 

K 

K4K 

assembly (board) 2 - 2 

option 3 - 1 

optional board in data system 2 - 2 

kHz. See kilohertz 

kilohertz 

differences between printheads 1 - 2 

stimulation measurement 1 - 2 

L 

layout 

controller function 3 - 4 

program 3 - 3 

M 

machine control 

components 2 - 3 


Mailscape 

configuration 3 - 3 

software configuration 3 - 2 

manuals 


service 3 - 4 

MICROSOFT WINDOWS operating system 3 - 3 

multiple 

printer option 3 - 1 

printers, system maximum 3 - 1 

N 

narrow format printing 1 - 3 

network 

printing system 3 - 1 

system configuration 3 - 1 

O 

operation, defined 1 - 3 

options 

flash memory 3 - 2 

printing system 3 - 1 

orifice plate 

function and relationship to pressure 1 - 1 

stimulation 1 - 1 

outlet, ink 1 - 5 

over-stimulation, effects 1 - 2 

P 

parallel 

connection between printer and controller 3 - 3 

interface control signals 2 - 5 

PC See computer 

piezoelectric action in printhead 1 - 2 

plate, charge 1 - 2 

POC test 2 - 5 

pounds per square inch (psi) 

in inkjet printing 1 - 1 

normal pressure in printhead during operation 1 - 1 

power distribution 

functions of 2 - 1 

system description 2 - 1 

power down 2 - 6 


Index 

pressure 

defined for inkjet printing 1 - 1 

measuring 1 - 1 

print 

array 1 - 3 

control 3 - 3 

job setup 3 - 7 

Print Control 

manual 3 - 3 

program functions 3 - 2 

print resolution 

options 1 - 3 

relationship to orifice diameter 1 - 4 

printer 

main functions 2 - 1 

maximum image area 1 - 3 

power distribution 2 - 1 

power down 2 - 6 

print speed 1 - 3 

resolution options 1 - 3 

sub-systems identified 1 - 3 

printhead 

clean 1 - 8 

operation 1 - 1 

printing 

basic elements 1 - 1 

function of electrical charge 1 - 2 

function of pressure 1 - 1 

system components identified 1 - 3 

tach and cue 2 - 6 


psi See pounds per square inch 

R 

reliability 1 - 8 

resolution 

number of jets 1 - 3 

options 1 - 3 

resonator 

description and function 1 - 4 

failure and printhead replacement 1 - 2 

S 

saturation See dark defects 

serial 

connection between printer and controller 3 - 3 

Jetscape interface 3 - 3 

seven segment display 2 - 2 

signals 

reference 3 - 4 

summary 3 - 4 

software documentation 3 - 3 

solenoid, eyelid 1 - 5 

stim setting See stimulation 

stimulation 

action in creating drops 1 - 2 

defined for inkjet printing 1 - 1 

failure 1 - 2 


streaker 

caused by under-stimulation 1 - 2 

print defect 1 - 8 

system 

controller 3 - 1 

operation 3 - 4 

T 

tach 


timing function 3 - 3 

tach and cue 

connections 3 - 6 

interface 3 - 3 

troubleshooting 1 - 8 

U 

under-stimulation, effects 1 - 2 

V 

vacuum 

general function in printing 1 - 2 

interaction with charge in printing 1 - 4 

removes ink from catcher 1 - 2 

system functions 1 - 2 

vertical resolution, print 1 - 3 

vibration See stimulation 

VME bus 2 - 5 

voids, caused by over-stimulation 1 - 2 

voltage 

charge 1 - 2 

controlling 2 - 6 

supply (high) 2 - 1 

supply (low) 2 - 1 

umbilical ACHV signal 1 - 5 

W 

width 

print array 1 - 4 

relationship to printhead resolution 1 - 3 

window, stimulation or phase 1 - 2 

WINDOWS See MICROSOFT WINDOWS operating system 

Theory of Operation

0113846-602 

0113846-603 

© Kodak Versamark, Inc.

digit printers theory.book - Kodak

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