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Basic GelJet
Service master
Full training module
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Slide 1
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Objectives 1 2 3 4 5
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Slide 2
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Requirements 1 2 3 4 5
A GelJet machine.
Service manual.
Operation manual.
This presentation.
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Printing (Basic).
Colour (Basic).
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Module overview 1 2 3 4 5
1. Introduction
2. Detailed section descriptions
3. Image adjustments
4. Service procedures
5. Troubleshooting
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The below description about hyperlinks in this document only are applicable
when Powerpoint is in “Slide Show” view.
To go back to the above overview slide you can always click on the home
button.
Click on the the arrows on the bottom of the slide to go to the previous or
next slide.
or you can click on one of the the underlined chapter-names in the above
slide to “jump” to that chapter.
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1. Introduction
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Chapter overview 1 2 3 4 5
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Slide 9
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Alsace P1 / Provence P1
Provence P2W
Pegasus C1
Toscane G1 / Piemonte G1
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Chapter overview 1 2 3 4 5
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About ink 1 2 3 4 5
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About ink
The main components of ink nowadays can be divided into 3 groups: chemical base, colourant and
additives:
Chemical base.
¾ The chemical base is the carrier for the colourant and keeps the ink in a liquid state.
¾ The chemical base can be water, oil, alcohol, or other solvents.
Colourant.
¾ The colourant is the substance that gives colour to the ink.
¾ The colourant can be a dye or a pigment. Ink that uses dye as the colourant is called
dye-based ink. Ink that uses pigment as the colourant is called pigment-based ink.
¾ Dye-based ink.
•Dye is a chemical that fully dissolves in the chemical base. Generally dye-based
ink has a brighter colour than pigment-based ink, but because the dyes are
dissolved in the chemical base, they tend to soak into the paper, which makes the
ink less efficient and causing the ink to bleed into the paper.
¾ Pigment-based ink.
•A pigment does not dissolve in the chemical base. Pigment is a very fine powder of
solid colourant particles, dispersed throughout the chemical base. The pigment
particles do not soak into the paper together with the chemical base, they remain on
or between the fibers on the surface of the paper.
•Because pigment particles are larger than dye particles, pigment-based ink is
more durable and ultraviolet resistant. Also the pigment particles can be coated to
enhance the properties of the ink.
•The gel used in the GelJet technology is a pigment-base ink.
Additives.
¾ In addition to the chemical base and the colourant, ink also contains additives to give
the ink special properties. For example: additives that make the ink thicker or make the
ink dry faster. Each ink formula has a unique formula of additives.
Gel 1 2 3 4 5
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Gel.
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Carriage unit
Ink tubes
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The carriage unit moves across the paper from side to side.
The print-heads fire small drops of ink onto the paper.
The paper is fed below the print-heads in steps.
Ink is transported from the ink cartridges to the print-heads.
No fusing.
video
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Print-heads
Ink cartridges
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Ink cartridges 1 2 3 4 5
ID-chip
Ink bag
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Ink cartridges
The slide shows some ink cartridges from different GelJet machines. The different
ink cartridges differ in size, but are all based on the same principle. The following
applies to all GelJet ink cartridges:
A separate ink cartridge is used for each colour.
Installing/removing ink cartridges.
¾ Ink cartridges can easily be installed/removed by sliding them into/out
the ink supply unit on the front side of the machine. An ink cartridge
does not have to be shaken before it is installed.
Ink bag.
¾ Each ink cartridge holds an ink bag which contains the ink.
Ink valve.
¾ Ink leaves the ink cartridge through the ink valve. The ink supply pump,
on the back of the ink supply unit, sucks out the ink through a hollow
needle which penetrates the ink valve.
ID-chip.
¾ Most ink cartridges have an ID-chip that contains information about the
ink cartridge, such as: remaining amount of ink, used amount of ink,
installation date, etc.
Starter cartridges.
¾ Starter cartridges are available for some GelJet models. These
cartridges contain a smaller ink bag.
The ink supply pumps transport ink from the ink cartridges
to the print-head tanks.
A separate ink supply pump is used for each colour.
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Ink tube
Hollow needle
Piston
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Guide rod
Belt
Main-scan motor
Carriage unit
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Main-scan timing 1 2 3 4 5
Carriage unit
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Main-scan timing
To control the main-scan timing (timing of the carriage unit) a GelJet machine uses
the main-scan encoder sensor and the main-scan encoder strip:
Main-scan encoder sensor.
¾ The main-scan encoder sensor is a photo sensor mounted on the
carriage unit.
Main-scan encoder strip.
¾ The main-scan encoder strip is located near the guide rod of the
carriage unit and is threaded through the main-scan encoder sensor.
¾ The main-scan encoder strip is made of a transparent material and
contains very small vertical stripes.
When the carriage unit moves, the stripes on the main-scan encoder strip
interrupt the light of the main-scan encoder sensor. The machine uses the
signal from the main-scan encoder sensor to control the main-scan timing.
Paper registration 1 2 3 4 5
Paper
Carriage unit
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Paper registration
A paper registration sensor is used to detect the edges of the paper. The paper
registration sensor is used to set the printing start position and to prevent printing
outside the paper (on the paper transport belt).
Paper registration sensor.
¾ The paper registration sensor is mounted on the carriage unit.
¾ The paper registration sensor detects the leading edge of the paper, the
paper width and the trailing edge of the paper.
¾ Sometimes also a sensor at the entrance of the engine is used to detect
the trailing edge and/or the leading edge of the paper.
Envelope lever 1 2 3 4 5
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Envelope lever
The envelope lever mechanism lifts the print-heads slightly away from the surface of
the transport belt. This prevents the print-heads from touching the paper when
printing on thick paper or envelopes.
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2.6 Print-heads
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Print-heads overview 1 2 3 4 5
Print-
head
units Air
release
valve
Print-head
Wide print-head tank full-lever
Print-head / nozzles
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Print-heads overview
The left picture on the slide shows the carriage unit of the Provence P2W, which has
4 print-heads (CMYK). The right picture on the slide shows a single print-head unit.
The following items are the most essential parts of a print-head unit:
Print-head / nozzles.
¾ The print-head contains the nozzles. The nozzles are the ink ejection
devices that fire the ink onto the paper.
Wide print-heads
¾ The GelJet technology uses wide print-heads (about 33 mm on most
GelJet models). This is wider than those of competitor models. The
wide print-heads allow fast printing, because it requires fewer
movements of the print-heads to cover a complete page.
Print-head tank.
¾ The print-head tank is a small ink tank mounted on top of the print-head
and provides ink to the print-head.
Print-head tank full-lever.
¾ The print-head tank full-lever is mounted on the print-head tank and is
used to detect how much ink is left inside the print-head tank.
Sensor pins.
¾ The sensor pins are mounted on top of the print-head tank and monitor
the ink level in the print-head tank.
Air release valve.
¾ The air release valve is mounted on the print-head tank and is used to
release air from the print-head tank.
Printing resolution.
Print-head resolution (fixed).
Printing mode (variable).
Print-head 150dpi
300dpi
Nozzle
video
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Nozzles
The nozzles of the print-head are the ink ejection devices that fire the small drops of
ink onto the paper.
The slide shows a magnified picture of a GelJet print-head. The nozzles are
very small and cannot be seen with the naked eye.
Printing resolution
The printing resolution of a GelJet machine depends on the following:
Print-head resolution.
¾ The resolution of the print-head depends on the distance between the
nozzles. On most GelJet print-heads, the nozzles are arranged in two
arrays, each capable of printing 150 dpi. The two arrays are shifted
compared to each other, together they are capable of printing 300 dpi.
¾ The print-head resolution is fixed.
Printing mode.
¾ The printing mode sets in which way and in how many steps the image
is created.
¾ The printing mode is variable.
¾ More about printing modes will be explained later in this module.
Ink
Nozzle exit
Ink drop
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Nozzle exit
Ink drop
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M-Dot technology 1 2 3 4 5
Modulated-dot technology.
Allows a GelJet machine to combine ink drops to create more
variations in ink drop sizes.
1 2 3 4 5
Nozzle
A B C
A B
C
A
A+B
A+B+C
video
Paper
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M-Dot technology
In addition to creating different drop sizes, a GelJet machine can combine different
drops together to make one bigger drop. This is called M-Dot technology
(Modulated-Dot Technology).
M-Dot technology allows a GelJet machine to create more variations in drop
sizes.
The picture on the slide shows in 5 steps from left to right how three drops
(A, B, and C) are combined to one bigger drop (A+B+C). The drops are fired
in rapid succession. The last drops are ejected faster and stronger than the
first drops. The drops merge to one bigger drop before they hit the paper.
Bellow
1 2
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Print-head tank
full sensor
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Sensor pins.
Air release valve.
Ink out detection.
Sensor pins
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Sensor pins
Two sensor pins (1 pair for each tank) monitor the ink level in the print-head
tank. When the surface of the ink touches the sensor pins, a current flows
between the pins which indicates that the print-head tank is filled with ink.
When the sensor pins do not touch the surface of the ink, the current does
not flow which indicates that the ink level is low.
Air release valve
When the ink level is low, the air release valve is opened and the ink supply
pump starts pumping ink to the print-head tank.
The air release valve is located on the side of the print-head tank and can be
opened by a solenoid on the frame of the engine.
The air release valve enables air to escape from the print-head tank, allowing
more ink to enter the tank.
Ink out detection
The machine detects an ink out situation when the machine tries to refill the
print-head tank and the ink level stays below the sensor pins.
Carriage unit
Maintenance unit
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Maintenance unit
The maintenance unit is located below the carriage unit when the carriage
unit is in the home position.
The maintenance unit protects the print-heads when they are not used.
Also the maintenance unit cleans the print-heads with suction to keep the
print-heads in a good condition.
Pump
Wiper
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Slide 41
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Caps
The maintenance unit contains one cap for each print-head. The picture on the slide shows
the maintenance unit from the Pegasus C1 (5 print-heads).
The caps can move up and down.
The caps cover the print-heads when they are not used. This keeps the surface of the print-
heads moist, preventing the nozzles from drying and clogging.
One of the caps is attached to a pump. This cap can clean a print-head with suction.
Wiper
The wiper can wipe ink from a print-head. This is done after print-head cleaning.
The wiper can move up and down.
Maintenance motor
The maintenance motor drives the caps, the wiper and the pump.
Print-head cleaning
Print-head cleaning is done automatically at specified intervals during printing or after the
machine has been in standby-mode or switched off.
Print-head cleaning can also be activated manually. This can be done for maintenance
purposes, as described later in this module.
Print-head cleaning process overview:
1. The caps are lowered.
2. The carriage unit moves above the maintenance unit. The print-head that will be
cleaned is positioned above the cap that is attached to the pump.
3. The caps are raised.
4. The pump is activated, the print-head is cleaned with suction.
5. The caps are lowered. The wiper is raised.
6. The cleaned print-head moves across the wiper. The wiper removes remaining ink
from the cleaned print-head.
7. Removed ink goes to the ink collection tank below the maintenance unit.
Ink collection 1 2 3 4 5
Carriage unit
Maintenance unit
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Print-head flushing 1 2 3 4 5
Maintenance unit
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Print-head flushing
A GelJet machine flushes the nozzles of the print-heads at specified times. When
the nozzles are flushed, the nozzles eject some amount of ink to keep the nozzles
clear and in good condition.
Print-head flushing is done automatically at specified intervals during printing
or after the machine has been in standby-mode or switched off.
Print-head flushing can also be activated manually. This can be done for
maintenance purposes, as described later in this module.
The machine can flush the print-heads above the maintenance unit or above
the flushing unit. During printing, the machine flushes the print-heads above
the flushing unit.
¾ Flushing above the maintenance unit takes longer because only one
print-head can be flushed at a time (there is only one cap attached to a
pump). That is why the machine uses the flushing unit to flush the print-
heads during printing.
Flushing unit.
¾ The flushing unit is located on the other side of the paper transport belt,
opposite to the maintenance unit.
¾ The flushing unit consists of a closed ink collection tank with openings
in the top side (one for each print-head).
¾ On most GelJet models the flushing unit does not reach a full condition
within the life time of the machine and therefore does not have to be
emptied or replaced.
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Charge roller.
Charge control.
Carriage unit
Paper
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Sub-scan timing 1 2 3 4 5
Sub-scan motor
Sub-scan encoder disc
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Sub-scan timing
The sub-scan motor drives the paper transport belt through a belt. To control the
sub-scan timing (timing of the transport belt) a GelJet machine uses the sub-scan
encoder sensor and the sub-scan encoder disc.
Sub-scan encoder sensor.
¾ The sub-scan encoder sensor is a photo sensor mounted next to the
sub-scan encoder disc.
Sub-scan encoder disc.
¾ The sub-scan encoder disc is mounted on the shaft of the transport belt
drive roller. The edge of the sub-scan encoder disc goes through the
sub-scan encoder sensor.
¾ The sub-scan encoder disc is made of a transparent material and
contains very small stripes on the edge of the disc.
When the sub-scan encoder disc rotates, the stripes on the edge of the disc
interrupt the light of the sub-scan encoder sensor. The machine uses the
signal from the sub-scan encoder sensor to control the sub-scan timing.
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No additional notes.
The printing mode specifies in which way and in how many steps the
print-heads print the image.
The printing mode affects the printing resolution and the printing speed.
The printing mode is variable.
The following affects the printing mode:
Paper type setting.
Print quality setting.
Position of the envelope lever.
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Scan 1 2 3 4 5
1 scan
2 scans
4 scans
print- print
= heads = line = scan
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The printing mode specifies how much the paper is fed during printing.
If the paper feed steps are smaller, the dots on the paper are printed more
diffused throughout the image, resulting in a better image quality.
Paper feed example 1:
In this example the paper is fed 1 print-head width after each scan.
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Uni-directional printing 1 2 3 4 5
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Bi-directional printing 1 2 3 4 5
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Pass 1 2 3 4 5
‘Pass’ is used to explain in how many steps the image is created in main-
scan direction.
The examples below show how the dots on the paper are printed in 1 pass, 2
passes or 4 passes.
1 scan
1 pass:
2 passes:
4 passes:
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Interlace 1 2 3 4 5
1/1 interlace:
1/2 interlace:
1/4 interlace:
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1 scan
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Exercise 1 2 3 4 5
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3. Image adjustment
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Chapter overview 1 2 3 4 5
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Slide 64
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correct
NOT correct
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Slide 65
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Exercise 1 2 3 4 5
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Slide 66
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correct
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Slide 67
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Exercise 1 2 3 4 5
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Slide 68
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correct
NOT correct
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Slide 69
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Exercise 1 2 3 4 5
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Slide 70
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Slide 71
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Exercise 1 2 3 4 5
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Slide 72
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www.get-u-wice.com 1 2 3 4 5
4. Service procedures
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Slide 73
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4. Chapter overview 1 2 3 4 5
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Slide 74
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Slide 75
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No additional notes.
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Slide 77
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www.get-u-wice.com 1 2 3 4 5
5. Troubleshooting
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Slide 78
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5. Chapter overview 1 2 3 4 5
5.1 Smudging
5.2 Colour shifting
5.3 White lines
5.4 Dark lines
5.5 Paper from cold storage
5.6 White spots
5.7 Banding
5.8 Printing on OHP sheets
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Slide 79
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5.1 Smudging 1 2 3 4 5
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Slide 80
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Smudging
Smudging can be caused by the following:
The print-heads touch the surface of the paper while printing.
¾ Possible cause:
•Paper curling caused by a high ink coverage.
•Paper that is already curled, folded or damaged.
•Too thick paper.
¾ Work around:
•Use the envelope lever.
•Try to flatten paper that is curled.
•Do not use damaged paper.
There is ink on the paper transport belt.
¾ Work around:
•Clean the paper transport belt.
Versio n: 1.0.a
Slide 81
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Colour shifting
Colour shifting occurs when the timing between the print-heads is not correct,
causing shifted colours on the paper (CMYK).
Work around:
¾ Do the print-head gap adjustment procedure.
Versio n: 1.0.a
Slide 82
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Last upd ated o n 28- Nov- 06 Class ificati on: CONFIDENTIAL
White lines
White lines in main-scan direction can be caused by the following:
The paper feed timing is not correct, the paper feed value is too high,
causing gaps between the print lines.
¾ Work around:
•Do the paper feed adjustment procedure.
One or more nozzles are blocked.
¾ Work around:
•Do the nozzle block check. If the nozzle check pattern indicates that
one or more nozzles are blocked, most GelJet machines have an
option to initiate the print-head cleaning- or print-head flushing
operation.
Versio n: 1.0.a
Slide 83
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Last upd ated o n 28- Nov- 06 Class ificati on: CONFIDENTIAL
Dark lines
Dark lines in main-scan direction can be caused by the following:
The paper feed timing is not correct, the paper feed value is too low, causing
the print lines to overlap.
¾ Work around:
•Do the paper feed adjustment procedure.
Versio n: 1.0.a
Slide 84
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Slide 85
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Last upd ated o n 28- Nov- 06 Class ificati on: CONFIDENTIAL
White spots
When using a paper type that has a very low ink absorption rate (outside
recommended types), some areas on the paper surface can repel the ink, creating
white spots.
5.7 Banding 1 2 3 4 5
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Slide 86
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Banding
When a GelJet machine is printing in full-colour mode at 300dpi, each complete print
line is printed in one scan (1 pass, 1/1 interlace). This means that when the machine
is printing in bi-directional mode, each print line is printed in the opposite direction
compared to the previous print line. This also means that the colours (CMYK) of
each print line are transferred to the paper in opposite order compared to the
previous print line. This can cause banding in the image.
Work around:
¾ Change to uni-directional printing mode.
¾ Change to 600 dpi mode.
¾ Some GelJet machines use two Y and two M print-heads on each side
of the carriage unit to keep the colours in the same order in each
printing direction (banding is most visible with Y and M colours).
Versio n: 1.0.a
Slide 87
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www.get-u-wice.com 1 2 3 4 5
Basic GelJet
END
Versio n: 1.0.a
Slide 88
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