Installation Manual for Seiko Colorpainter 64s 100s HP Designjet 8000s 9000s 10000s

This “Bypass System” comprises a USB dongle, some electronic circuitry and ink bottle holders with connections to the printer’s ink supply. The circuitry is installed to the cartridge set, this functionally replacing the original cartridge in the printer system.
The USB dongle carries coding which, for each colour manages the changing quantities of LavaInk, enabling replacement and therefore continuous supply.

Bypass System Installation

1. What's need to install?
   
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   • 6 HP Empty Cartridges CMYKLcLm
   
   
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   • 6 Mother Boards
   
   
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   • 6 USB Chips CMYKLcLm
   
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   • HP Ink Holder System
   
   
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2. How to Modify HP Ink Cartridges?
   
   • Make Two Slots at Cartridge to Connect the Mother Board and USD Chip
   
   
   
   
   
   
   
   
   This Bypass System comprises for each colour, a modified ink cartridge containing an Adaptor (to the host printer) and a Mother Board with external USB socket; also an ink bottle holder with connections to the printer's ink supply.
   
   The electronic circuitry replaces the chip in the original ink cartridge and responds to the printer's control system. USB dongles carry coding which, for each colour activates the circuitry in the modified cartridge, in turn enabling replacement and therefore continuous supply of LavaInk. Note that the Mother Board is powered by its own on board battery with a life of about 2 years.
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3. Install Printer less than 1 year old or new, unused printer.
   
   • Build the Bypass System onto the standalone frames and fit the filters. Clean the stainless steel bottle holders, tubes and filters using Maintenance Fluid (MF) (white bottle). Check connections including Observation Window for leakage, correcting as necessary. Do NOT fit any ink bottles at this stage.
   • Remove the Rear Ink Cartridge Cover (Left & Right) to access the pump motors.
   
   
   
   • Disconnect the original ink tubes from the rear of the filter module.
   
   
   Note: Disconnect at this point only.
   
   • Position the Bypass System frames close to the printer. Ensure that the frame for K, Lc and Lm is positioned at the Rear-Right of the machine and the frame for C, M and Y is positioned at the rear-Left.
   
   
   • Connect the tubes from the Bypass System filters to the appropriate ink tubes on the machine. Re-fit the Rear Ink Cartridge Covers.
   
   
   • Take the Modified Cartridge Set (with USB ports) as supplied with the Bypass System.
   
   
   
   • Open the first of the Modified Cartridges (say Black), disconnect the cable from its Mother Board and connect to the matched (Black) Maintenance Mother Board. Then load the Maintenance code into this Mother Board using the (Black) Maintenance dongle as follows:
     • Insert the (Black) Maintenance USB dongle into the Mother Board.
       
     • If the dongle flashes twice, remove from the cartridge.
       
     
     The LED on the dongle can indicate two other conditions during the loading of the code:
     
     
     • If the LED flashes continuously this indicates that all the codes on this Maintenance USB dongle have been used and a new (Black) Maintenance dongle should be used.
     
     
     • If the light does not flash or light up at all, it is likely just a bad connection at the USB port. Re-seating the dongle will normally and quickly solve the problem. More rarely, the Mother Board battery (of about 2 years life) has expired and needs changing.
     
     With the Maintenance Mother Board still fitted, close the (Black) modified cartridge.
     
     Repeat the same procedure for the remaining modified cartridges, ensuring the correct colour maintenance boards are fitted into each, (ie substitute each colour for Black where specified).
     
     
   • Power on the printer and enter the Maintenance Mode (When the printer is OFFLINE, press Cancel, Shift, Cancel, Cancel and then enter the Password Left, Right, Shift, OK).
   • Fit the LavaInk CF bottles to the Bypass System.
   • Go to the PH MAIN menu and select CHARGE INK SYS. Carry out a CHARGE INK SYS ALL. Procedure. Allow the procedure to run until the display shows a time left of '15'. At this point, raise and lower the Front Cover. The machine display asks START THE CHARGE INK SYS ALL? Select YES to allow the procedure to begin again. This prevents any codes being written to the Maintenance Mother Boards and allows for a quicker procedure.
   • Repeat step J until 2 litres of CF has been used per colour. The Waste Bottle will need emptying during this part of the procedure! Observe it carefully and whenever it becomes almost full, remove, empty and replace it. Then restart the CHARGE INK SYS. ALL procedure again.
   • Remove the empty CF bottles and fit the LavaInk to the correct bottle holders on each of the Frames.
   
   
   • Carry out a CHARGE INK SYS ALL. Procedure. Allow the procedure to run until the display shows a time left of '15'. At this point, raise and lower the Front Cover and allow the procedure to begin again. This prevents any codes being written to the Maintenance Mother Boards and allows for a quicker procedure.
   • Repeat step M until 1 litre of ink has been used per colour. Ensure that the Waste Bottle is checked regularly as it will need emptying during this part of the procedure.
   • Replace the empty bottles with full bottles of each colour and allow the CHARGE INK SYS. ALL procedure to run until the display shows a 'time left' of 15. Raise and lower the Front Cover again; when the machine display asks START THE CHARGE INK SYS ALL? Select NO and put the machine ONLINE.
   • Remove the modified cartridges from the machine, open each in turn, remove the Maintenance Mother Boards and re-connect the Ink Motherboards. Now, close each modified cartridge and load with a code from the appropriate colour USB dongle; do not yet put them back into the machine.
   • The LED flashes twice to indicate that the motherboard has been loaded with the new code.
     
   • If the LED flashes continuously this indicates that all the codes on the USB dongle have been used and a new, matching colour USB dongle should be used.
     
     Finally, return all the modified cartridges to the machine, one by one, in the following order:
     
   • K, LM, LC
   • Y, M, C
   • If at any stage a modified cartridge is not recognised by the machine:
   • Remove the cartridge and re-insert.
   • Go to the PH.MAIN sub menu and select Wiper Cleaning. Carry out a clean of the wiper and surrounding area as normal, but using LavaInk MF. Also moisten the Wiper Sponge with LavaInk MF.
   
   • In the same menu, select Cap Cleaning. Clean the edges and upper surfaces of all six Capping Units with LavaInk MF.
   • Use the IQ Test to check the quality of the printing. If printing is poor quality, use the normal methods as detailed in the HP manuals to recover the print quality.
4. Install Printer more than 1 year old.
   
   • Test the condition of the printheads in the presence of (a) the User, (b) the Distributor/ LavaInk representative, as follows:
   • Carry out a Nozzle Test
   • Carry out an IQ print
   • Repeat the Nozzle test and compare with the previous results.
   • Record the results; for signatures of both parties.
     Note: This record to be kept by the Distributor and made available in the event of any future dispute.
   • Clean and refresh the printheads, as follows (step A - Flushing):
   • Remove all 6 printheads from the machine, noting each S/N and its present colour for record. Then, taking each printhead in turn,
   • Fill the syringe with 50 cc of CF, connect to the head inflow tube and flush through all nozzles. Carry out at least 3 times.
   • Remove the syringe, fill the head inflow tube with CF and close it off.
   • Clean and refresh the printheads, as follows (step B - Ultrasound):
   • Prepare the Ultrasound machine, pouring CF to a depth of about 5 mm (0.2”) into the tank.
   • Place the head(s) into the Ultrasound tank, so that the CF just covers the nozzles (ensuring that no fluid touches the electronic parts of the head),
   • Run the Ultrasound machine for at least 15 minutes
   • Run the Ultrasound machine for at least 15 minutes
   • Run the Printer System cleaning cycle using a Spare Printhead set.
   • Take 6 unserviceable printheads
   • Install these to the printer
   • Power ON the printer. Run procedure 3-A-O.
   • Return to procedure 4-E et seq
   • Remove, Replace (or clean) the Dampers.
   • Power OFF the machine and remove all dampers.
     Note: It is necessary to replace/clean the Dampers when the printer is more than one year old as a residue will have built up inside them which is very difficult to remove. There is a risk that when a new ink is introduced there could be a chemical reaction between the two inks. This could (a) cause damage to the printheads and/or (b) cause a blockage affecting the smooth flow of ink, in turn reducing print quality. It is STRONGLY RECOMMENDED TO REPLACE THE DAMPERS, rather than clean them!
   • If new dampers are to be used, GO directly to 8 (below) and install them now.
   • If existing dampers are to be retained, clean and refresh them, (step A - Flushing):
   • Fill the syringe with 50 cc of CF, connect to the damper inflow tube and flush through. Carry this out at least 3 times.
   • Clean and refresh the dampers, (step B - Ultrasound):
   • Prepare the Ultrasound machine, pouring sufficient CF into the tank to fully immerse the dampers.
   • Place the damper(s) into the Ultrasound tank, the CF covering and filling the whole body.
   • Run the Ultrasound machine for 15 minutes – at least 3 times, until the inside of the damper(s) are perfectly clean.
   • Using the syringe, evacuate all remaining CF from all dampers.
   • Reinstall all dampers to their respective position on the machine.
   • Ensure the connections of the damper are tight and there is no leakage.
   • Install new (or refreshed) Printheads to the Printer.
   • Power ON the Machine.
   • Go to the PH.MAIN menu and select CHARGE INK SYS. Carry out a CHARGE INK SYS ALL. procedure. Allow the procedure to run until the display shows a time left of '15'. Raise and lower the Front Cover again; when the machine display asks START THE CHARGE INK SYS ALL? Select NO and put the machine ONLINE.
   • Remove the modified cartridges from the machine, open each in turn, remove the Maintenance Mother Boards and re-connect the Ink Motherboards. Now, close each modified cartridge and load with a code from the appropriate colour USB dongle; do not yet put them back into the machine.
   • The LED flashes twice to indicate that the motherboard has been loaded with the new code.
   • If the LED flashes continuously this indicates that all the codes on the USB dongle have been used and a new, matching colour USB dongle should be used.
   
   Finally, return all the modified cartridges to the machine, one by one in the following order:
   
   • K, LM, LC
   • Y, M, C
   • If at any stage a modified cartridge is not recognised by the machine:
     Remove the cartridge and re-insert.
   • Go to the PH.MAIN sub menu and select Wiper Cleaning. Carry out a clean of the wiper and surrounding area as normal, but using LavaInk MF. Also moisten the Wiper Sponge with LavaInk MF.
   
   • In the same menu, select Cap Cleaning. Clean the edges and upper surfaces of all six Capping Units.
   
   
   
   • Use the IQ Test to check the quality of the printing. If poor quality is printing, use the normal methods as detailed in the HP manuals to recover the print quality.
   • Carry out the Printhead Alignment in accordance with the HP User Manual.
5. Ink Supply System
• There are two active parts to the LavaInk Bypass system, each linking with the host printer:
• The physical ink delivery circuit. This comprises for each colour, the bottle holder, connecting tubes and the renewable bottle of ink. It is a means only of supplying the ink in a continuous manner – subject to the replacement of an empty bottle with a full one. It has no communication with the printer‟s electronic control circuit. See also, the „bottle change procedure‟ below
• The coded electronic circuit. This comprises for each colour, a modified dry cartridge which replaces the original ink cartridge; it has a plug-in connector to the printer with internally, an adaptor connecting to an ink „mother board‟. The mother board has an exposed USB socket to receive a USB Dongle, which carries one or more codes. The coded Dongle, when required, provides a signal to the printer‟s master board, equivalent to a full, 1 litre cartridge. The mother board also satisfies the printer on the usage of one litre of ink, enabling printing to continue. See also, the „Use of Dongle procedure‟ below
• Bottle Change Procedure
• The operator must observe the usage of each colour ink, firstly as the level reduces in the upturned bottles – easily seen.
• Once the level reaches below the top edge of the bottle holder, the operator should make ready a new bottle of that colour.
• The ink level can then be watched through the Observation Window. When the level reaches the bottom edge of that window, the empty bottle can be safely and cleanly removed, without stopping the printer!
• The new bottle, with the cap removed, can then be upturned and placed smoothly into the bottle holder.
  
  Note. No action to load any coding from the matching USB Dongle is necessary at this stage, as this is not relevant to the ink change process.
• Use of the USB Dongle during Printing
  • USB Dongles are provided for each ink colour and cannot be used for any other colour. Each holds one code (or 6 codes), each code is for one litre of ink.
  • The printer will request an ink cartridge to be changed (as normal), when it appears from the ink pump data and or a signal from elsewhere in the system that a cartridge is close to empty.
  • When the display shows OPEN X INKCOVER – LOAD XX INK (where X is L/R and XX is the ink colour), use the following procedure:
    • Open the correct ink cover.
    • Remove the indicated, modified cartridge from the printer
    • Re-insert the modified cartridge
    • Close the cover and observe the printer Display
      If the message is the same, proceed as follows:
    • Re-open the correct ink cover.
    • Insert the matching colour USB Dongle into the correct modified cartridge. (Do not pull out cartridge!)
    • The USB dongle should flash twice (Condition A) indicating that the code has been loaded to the (modified cartridge) Mother Board.
    • Remove the USB dongle.
    • Close the cartridge cover.
  • If the LED on the USB Dongle does not flash twice, the code has not been successfully loaded to the Mother Board. In this case, there can be two other conditions which pertain, as follows:
    • Condition B: If the LED flashes only once, this indicates that the code is still valid but partially used. In this case, repeat C-iii. (above). If it fails repeatedly, then remove cartridge and insert/withdraw the USB Dongle while off the printer.
    • Condition C: If the LED flashes continuously this indicates that the one (or more codes) on the USB dongle has been used, or is corrupted. A new USB Dongle should then be used.
6. Daily Maintenance of the Machine with Bypass System
• Printer in Use
  The same procedures for daily maintenance should be carried out as for the original inks, but in addition it is strongly recommended that the following instructions are rigorously adhered to!
  
  • At the start of every day – working or not and before any print jobs, the following sequence must be carried out:
    • A STRONG CLEAN, to clean or recover the printhead. Then:
    • Clean the Wiper Blades using LavaInk MF.
    • Moisten the sponge using LavaInk MF.
    • Clean the Capping Units with LavaInk MF.
    • Dispose of the ink from the Waste Bottle.
    • Do not switch off the printer.
  • In a normal working day there will be two more STRONG CLEANS
    • At the beginning of the afternoon and again
    • In the evening, at the end of work before leaving the machine,
      (The Total number of STRONG CLEANS in a normal day therefore, is THREE.
  • The Seiko printer has a 'Fill Cap' function (which in the HP is called 'Wash Head') to introduce ink to the cap. This covers the printhead, thus keeping the nozzles moist. When the printer is not printing or in use, this function must be carried out immediately.
• Printer Out of Use
  • During periods when the printer is or may be out of use for 7 days or more, do the following:
    • At beginning. Carry out STRONG CLEAN. Wash the heads and Fill the Caps.
    • Every 7 days. Carry out STRONG CLEAN. Wash the heads and Fill the Caps.