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CHAPTER 4

MAXX 2 Care and Cleaning

The photographs below are close-up views of the printhead. The photograph on the left shows
the printhead mounted on the printhead carriage. The photograph on the right (printhead
removed from the MAXX 2 for identification purposes) shows the parts of the printhead.

End of the

printhead

Peel bar

Bead or print

element area

Peel bar

Bead or print
element

Green strip
between bead
and insulation

Black insulation

Circuit card

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Summary of Contents for 2

Page 1: ...GERBER MAXX 2 Owner s Guide ...

Page 2: ......

Page 3: ...re or reproduction of the article shown and the delivery of this document shall not constitute any right or license to do so Printed in USA GSP and EDGE are registered trademarks of Gerber Scientific Products Inc GERBER MAXX MAXX 2 MAXX READY OMEGA ThermApprove GerberTone GerberColor Spectratone ODYSSEY FasTrack Gerber FastFacts and Support First are trademarks of Gerber Scientific Products Inc Ad...

Page 4: ...tes 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 1284 1994 Compliant cables must be used with thi...

Page 5: ...Run continuous mode 15 Quick Start operation 15 Stopping and restarting jobs 15 Pausing jobs and restarting a job 16 Reprinting the last job 16 Queuing jobs at the MAXX 2 control panel 16 Displaying a list of jobs in the View Job Details 16 Displaying detailed information about each queued job 17 Re positioning a job in the queue 18 Deleting jobs from the queue 18 Adjusting the pull distance when ...

Page 6: ...g the recorded amount of foil in a cassette 34 Printing the job 34 Viewing foil and material information for the job 35 Printing test jobs 37 Chapter 6 Modifying MAXX 2 Print Settings 39 Printing the Pull Out or Pull Back Check prints 39 Modifying the Darkness Adjust setting 40 Modifying the Seam Adjust setting 41 Chapter 7 Understanding Messages 43 Status messages 43 Error Messages 46 Index 50 ...

Page 7: ...MAXX 2 foil cartridges and materials Extensive in house and field testing reveals cleanliness is an important factor impacting printing quality Printing Jobs describes in a step by step sequence how to print jobs on the MAXX 2 This chapter also includes a list of test jobs and their purpose Modifying MAXX 2 Print Settings explains Pull Check prints and details how to modify the Print Darkness and ...

Page 8: ... for hardware 860 644 6971 for software fax 860 648 8376 e mail gspservice gspinc com hardware or gsptech gspinc com software www gspinc com Additional sources of information are Gerber FastFacts provides answers to technical and service questions The telephone number is 860 648 8040 FastFacts are also available on the web site under Support If you are a Support First member use your toll free ass...

Page 9: ...re for 24 hours before printing Using MAXX READY material The MAXX prints only on GERBER MAXX READY materials Gerber specially developed GERBER MAXX READY materials for thermal printing and are the only materials recommended for use with the MAXX Gerber continues to qualify more substrates and foils on an on going basis For a list of currently qualified MAXX READY materials see www gspinc com Gerb...

Page 10: ...MAXX 2 material catching baskets which can leave impressions on the surface of the vinyl Store the vinyl standing on the end of the roll that will be opposite the edge sensors at the left side of the MAXX 2 Standing the roll on the end that will be used to align the vinyl can cause print quality problems To protect the material from the floor stand the roll on the plastic plug included with the or...

Page 11: ... front of the base A loop of material is automatically unrolled into the material catching basket to reduce drag on the material advance system magnet bars during printing Up to six foil cassettes can be mounted in the cassette rack The foil can be loaded and unloaded in the cassettes as required The control panel is the interface between the operator and the printer A message display provides inf...

Page 12: ... stored in an individual cassette bay The printhead carriage assembly During printing the supply and take up cassette pins pull the foil across the printhead The printhead is lowered by the Z axis lead screw and motor to press the printhead against the foil and material when printing The automatic cassette changer loads and unloads foil cassettes as required by the job design Take up pin Z axis le...

Page 13: ...ply roll The left roll hub is motor driven to provide a loop of material which reduces drag while the material advances through the printer When the loop is the correct size the motor is off Before loading the material lift the material tray up and lock it in the horizontal position On the left side of the tray is an alignment line There is another alignment line on the back of the table where the...

Page 14: ...he initializing sequence is complete and the display is Ready for Print job then press LOAD VINYL on the control panel CAUTION When performing the next step be certain that the vinyl slides between the magnet bars and on top of each bar s keeper plate If the vinyl goes under the keeper plate it will get damaged In order to keep the mag bars clean make certain that the leading edge of the vinyl is ...

Page 15: ...oil in the package is on two rolls a supply roll the larger roll and a take up roll the smaller roll There is a clear stiff leader at the start of the supply roll to make loading the foil easier The supply roll also contains a cassette reader button that monitors the amount of foil used the amount remaining on the roll and the foil color This information is sent to the control panel for display an...

Page 16: ... shown in the illustration The dull side of the foil will be facing away from the cassette body 5 Feed the take up roll through the trapezoidal window on the right side of the cassette and over the upper right roller bar 6 Slide the take up roll on the upper cassette shaft 7 Put the cover on the cassette and tighten the three screws in the order shown in the illustration Turn the screws 1 4 turn c...

Page 17: ...k To load the cassette in the cassette rack 1 Raise the transparent cassette rack cover 2 Tilt one of the cassette bays out and away from the front of the table 3 Lay the cassette in the bay as shown in the photo then push it toward the inside of the table until it touches the bay stops 4 Carefully lift the cassette bay so that it is vertical and the cassette is in the table area 5 Close the casse...

Page 18: ...obs Reprinting the last job Queuing jobs at the MAXX 2 control panel Control panel keys The illustration below shows the MAXX 2 control panel The keys and their functions are discussed in this chapter The control panel is the interface between the user and the printer The message display provides information and prompts while keys provide the ability to control the printer functions The control pa...

Page 19: ... online when a printing job is complete If more than one job is sent to the printer the next job starts automatically if a material change is not required Press this key when the RUN CONT indicator light is on to put the printer into the pause mode the light blinks RUN SINGLE In the RUN SINGLE mode the printer goes offline when a printing job is complete Press this key when the RUN SINGLE indicato...

Page 20: ...e function key corresponding to Units changes the display to Set English Units Set Metric Units Pressing the function key for one of the choices activates it Starting jobs Starting jobs is controlled by the RUN CONT and RUN SINGLE keys When you send a job to the printer from the GSPPlot program the lights over the two keys blink alternately Pressing either one of the keys starts the printing seque...

Page 21: ... initial job the Quick Start feature saves time by eliminating the substrate alignment and straightening procedure on subsequent jobs The operator must be present to ensure that the vinyl is properly loaded Take care when using Quick Start Do not use Quick Start if a job is longer than 5 feet 152 4 cm the operator is leaving the MAXX 2 unattended while printing multiple jobs of any length The QUIC...

Page 22: ...ay the last job you printed You can also use this feature to restart a job you aborted The display message is R Job waiting to print If you press the function key next to the R symbol the job automatically reprints In the run continuous mode only the last job in a sequence can be replayed Queuing jobs at the MAXX 2 control panel The Main menu item Job Queue allows you to display a list of all jobs...

Page 23: ...ption Job A Description Job B Description 3 Press DOWN or UP to scroll through the queue Displaying detailed information about each queued job Press the function key adjacent to any job listed in the queue and choose View Job Details to display the job information This display shows the queue position the job identification number which is assigned by GQMgr the job file name the first foil that pr...

Page 24: ... can delete a job from the queue by using the Remove Job From Queue command Deleting a job is not available for the replay job or if a job has already begun to print When you select Remove Job From Queue you must respond to a confirmation message before the job is marked for deletion When viewing the Job Queue from GQ Manager jobs removed from the queue are marked as aborted Even though a deleted ...

Page 25: ...istance entered The pull distance then resets to the default value of 16 inches and 16 inches 40 64 cm to 40 64 cm Updating the MAXX 2 firmware Occasionally GSP will update the firmware in your GERBER MAXX 2 to a new revision level Before updating the firmware using GQ Manager you must set the MAXX 2 to accept a system update Note Before installing the MAXX 2 firmware it is important to clean out ...

Page 26: ...up to the temp directory 8 Click Build XX mxb The firmware installs As the firmware is installing messages will automatically scroll through the Properties for Gerber MAXX dialog box When finished the following message is displayed MAXX FILES TRANSFERRED CYCLE POWER ON MAXX TO COMPLETE FIRMWARE UPDATE 9 After installing the new firmware and before sending a job to the MAXX 2 turn the MAXX 2 off fo...

Page 27: ...e recommended cleaning materials are rubber gloves strongly recommended pink ThermApprove printhead cleaning film Gerber part number P72966C ThermApprove printhead cleaning kit Gerber part number P66530B a clean lint free cloth 99 percent isopropyl alcohol tack cloth commercially available from most hardware stores glass cleaner 3 IN ONE machine oil Chemtronics Ultrajet 2000 or equivalent compress...

Page 28: ... with glass cleaner Pay special attention to the small slot between the top and bottom of the magnet bar Be careful to not get the cleaning cloth trapped under the magnet bar Check the magnet bars for pieces of vinyl that may have gotten stuck to them An additional way to clean the magnet bar and keeper plate is tilt the foil cassettes out to gain access to the magnet bar Remove the pins at each e...

Page 29: ...ved at step 3 and replace the material catching baskets Cleaning the platen CAUTION When cleaning the platen as described in the next paragraphs do not wipe or clean the black edge sensor notch with alcohol or cleaning solvents that will damage or change the paint color It is important to keep this area free of dust lint and dirt Moisten a clean lint free cloth with 99 percent isopropyl alcohol an...

Page 30: ... head wiper box you can move the printhead out of the way and park it On the MAXX 2 control panel press and hold the Quick Start key for five seconds The printhead moves to the left and stops and the display is Ready for print job After you load more cleaning film just send a job The printhead automatically relocates to the proper position before printing the job Cleaning the ways lead screw and b...

Page 31: ...a print made before the printhead was cleaned Note the raggedness at the start of the print and the visible seaming in the print The dirty printhead contributes to a ragged application of the foil to the vinyl Seaming is evident and caused by dirt at the extreme ends of the printhead In the close up view below the ragged start and seaming are clearly visible Seaming Ragged start ...

Page 32: ... the cleaning procedure performed according to the instructions in this document This should be ample evidence of the importance of cleaning the printhead especially the extreme ends The circles in these photographs show the exact same areas after cleaning the printhead and reprinting the job Note that the seams are now invisible and there is no ragged start to the printing ...

Page 33: ...metal chips on the cleaning film These small particles of dirt of metal chips can cause serious damage to the printhead Even though the MAXX 2 automatically cleans the printhead you should still manually clean the printhead every day See the following instructions Manually cleaning the printhead NOTE Because head cleaning is automatic the frequency of manual cleaning with the pink ThermApprove cle...

Page 34: ... the printhead mounted on the printhead carriage The photograph on the right printhead removed from the MAXX 2 for identification purposes shows the parts of the printhead End of the printhead Peel bar Bead or print element area Peel bar Bead or print element Green strip between bead and insulation Black insulation Circuit card ...

Page 35: ...e ends of the peel bar and printhead element Note If you are cleaning the printhead after a foil break visually inspect the printhead and elements very closely to make certain that foil has not fused to the printhead Extra cleaning may be required if fusing has taken place To manually clean the printhead CAUTION When cleaning the printhead it is very important that your fingers do not touch the pr...

Page 36: ...film for cleaning the cassette Do not use it again to clean the printhead 3 Using the pre moistened alcohol pad from the cleaning kit rub the peel bar printhead elements the green strip area between the bead and the insulation Do not clean the circuit card Rub the entire width all the way out to each edge approximately 10 strokes You may refresh the alcohol pad with 99 percent isopropyl alcohol if...

Page 37: ...queegee bar with the dull abrasive side of new or used pink cleaning film Be certain to rub the entire width of the squeegee bar all the way out to each edge As shown in the following photograph backcoat from the foil typically builds up at the far edges of the squeegee bar Use about one pound of pressure when rubbing and rub the width for approximately 10 strokes Left Squeegee Lower Squeegee Lowe...

Page 38: ...ver 3 If there is no foil in the cassette quickly spray the interior of the cassette with a compressed air ultra filtered non residue dust remover such as Chemtronics Ultrajet 2000 or equivalent Tip When cleaning the cassette with the alcohol it is a good time to wipe the MAXX 2 foil bay contact strips in the cassette rack and on the cassette to ensure good clean contact between the contact strips...

Page 39: ...es of type list box in the GSPPlot Open dialog box After you open a job in GSPPlot you can use all the features of the program to set up the job such as rotate panel and repeat for example To use the GSPPlot program refer to the GSPPlot Help system After the job is set up click on the print button to send the job to the MAXX 2 Determining the status of each bay The Bay Status display shows you the...

Page 40: ...es 4 Estimate the number of inches of foil you advanced then press DOWN to reduce the amount shown in the display Press ENTER to accept the new value Note If you accidentally decrease the value too much the UP key allows you to increase the amount back to the starting value but no greater Printing the job When the printer is ready for a job the display is Ready For Print Job and the lights above t...

Page 41: ...essing the function key opposite the Foil name of foil or Vinyl name of vinyl line in the display When viewing foil details the display shows the foils needed in the job the amount of foil loaded in the cassette and the amount of foil that is required for the job When viewing material details the display shows the design width of the job and the actual width and length of material required To view...

Page 42: ...ey next to a job This display is View Job Details Change Queue Position not displayed for a replay job or when there is only one job in the queue Remove Job From Queue not displayed for a replay job 3 Press the function key for View Job Details The display is Queue 2 Job Id 17 Job Description Process yellow GCP 706 if you press this function key you get a list of all the foils in the job Vinyl Whi...

Page 43: ...Red Used by an installation technician to check seam overlap on spot colors STARTUP RAW Process Yellow Process Black Used by a technician to check calibration of the MAXX 2 after installing a new printhead BREAK RAW Process Black Used by a technician to check calibration of the MAXX 2 after installing a new printhead LPISHP RAW Process Black Reference chart of available halftone types for shape fi...

Page 44: ... of the image is a four color photo to illustrate image details and range of color LPIPROCO RAW 4 color Process Example of the same four color image used in LPIPROC RAW after being optimized through GSPPlot The halftone type is Optimized GerberTone MAXX Top section of the image is a multicolor linear fill to illustrate color banding Bottom section of the image is a four color photo to illustrate i...

Page 45: ... Back Check prints must be printed on 225 white vinyl only Using a different substrate may provide erroneous results After printing the check prints contact Gerber Field Service for assistance To print the Pull Out or Pull Back Check prints 1 Load a roll of 225 white vinyl in the MAXX 2 2 Press MENU on the control panel The display is Bay Status Job Queue Setup Service 3 Press the function key for...

Page 46: ... for a specific substrate such as 225 you can print a Darkness Adjust Sample This print consists of a Process Yellow swipe overprinted with Process Black blocks at five different Darkness settings 4 2 0 2 and 4 Print this sample and use it as a reference to determine the optimal Darkness setting for that substrate Tip Depending on the job the change in Darkness may be subtle After altering setting...

Page 47: ...Seam Adjust setting If you notice that a print has gaps or obvious overlaps between swipes you can modify the Seam Adjust setting Any adjustments made to the settings are saved with the specific vinyl family and are used with all subsequent jobs that use the same vinyl Be sure to have the correct vinyl loaded in the MAXX 2 when printing To assist you in determining the correct setting for Seam Adj...

Page 48: ...the proper vinyl then press the corresponding function key The display is vinyl such as 225 Seam Adjust Darkness Adjust 2 Press the Seam Adjust function key The display is Print Seam Adjust Sample Change Seam Adjust 3 Press the Change Seam Adjust function key The display is Seam Adjust 0 less X more 4 Change the Seam Adjust setting to the overlap setting chosen when examining the Seam Adjust Sampl...

Page 49: ...s P A Message Type Comment Action A axis Failure P A May display at power up when A axis does not initialize properly Check for obstruction and press RUN CONT or RUN SINGLE to attempt to correct the failure Adjusting Vinyl I Appears after RUN CONT or RUN SINGLE is pressed and before printing starts Adjusting Voltage I May appear before a swipe as the MAXX 2 automatically adjusts voltage Busy Print...

Page 50: ...the foil in the cassette and then press RUN Foil Very Low Bay X P A Displayed prior to printing a swipe There is less than 0 1 of the length of a full roll of foil in the cassette Press RUN to continue or replace the foil in the cassette and then press RUN Foil Out Bay X P A The cassette in Bay X is out of foil The MAXX 2 is paused Replace the foil in the cassette and press RUN to continue Foil Br...

Page 51: ...erber Field Service Unload Any Bay to Proceed P A Appears if all bays have cassettes and there is also a cassette loaded on the printhead carriage Unload Cassette From Bay P A A cassette has been loaded in a bay from which the printhead carriage took a cassette Unprinted Jobs Found in Queue I Displayed at power up if unprinted jobs are in the job queue Version P p D d B b I Displays power up or wh...

Page 52: ...ed from the carriage Check the contacts on the cassettes and bays Change the foil in the cassette Can t Open Boost File This error may indicate a disk corruption problem Contact Gerber Field Service Can t Open Config File This error may indicate a disk corruption problem Contact Gerber Field Service Can t Open Job File This error may indicate a disk corruption problem Contact Gerber Field Service ...

Page 53: ...o F Contact Gerber Field Service DSP Y Positioning Error The Y axis motor has synched out resulting in Y axis position loss Contact Gerber Field Service DSP Z Positioning Error The Z axis motor has synched out resulting in Z axis position loss Contact Gerber Field Service Edge Tracking Error Check material for ragged or bent edges Replace vinyl If error still occurs there may be a bad sensor Conta...

Page 54: ...far to the left of the guide mark during a print job Check the vinyl edge for damage Replace vinyl If the error still occurs the vinyl sensors may be dirty Contact Gerber Field Service Material Twisted The material may not be perfectly straight The job pauses You can continue printing at your own risk or stop the job fix or replace the vinyl and reprint job Missing Fire Control Data Embedded fire ...

Page 55: ... contains more than 10200 lines of data The job is aborted Re render the job and re send it to the printer Vacuum System Fault Measured vacuum is less than the configured vacuum threshold Check the vacuum threshold and adjust if needed If error continues contact Gerber Field Service Workspace Error 1 A firmware error in which the workspace allocated for the PC operating system has overflowed Cycle...

Page 56: ...l cassettes See Cassettes Function keys 13 GQ Manager 16 19 Head wiper box filling 24 Information about jobs 17 Jobs deleting from queue 18 displaying details 17 displaying in queue 16 pausing 16 printing 33 34 queuing 16 repositioning in queue 18 reprinting 16 setting up and sending 33 starting 14 15 stopping 15 test 37 Lead screw cleaning 24 Load vinyl 13 Magnet bars 6 22 Main menu 13 14 Manual ...

Page 57: ...Seams in print 41 Sensor Strip 23 Slew material 19 Software 3 Squeegees 22 Starting jobs 14 15 Status messages 43 Stop key 13 Stopping jobs 15 Supply roll location 5 Support First 2 Telephone numbers 2 Temperature requirements 3 Test jobs 37 ThermApprove cleaning film 24 Tips defined 1 Up key 13 View Job Details 17 Vinyl care 3 cleaning 3 storage 4 unpunched 3 Warnings defined 1 Ways cleaning 24 W...

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