Category Archives: Printing

Printing with an emphasis on the HP DesignJet dye printer

HP Designjet printer head cleaning and repair

Two years of use

3/3/2011: For a comprehensive update to what follows, click here. I have also extensively annotated one of the illustrations below and provided a click-through to an HP print quality document which helps with diagnosis of printing problems.

This article is of use solely to those using or contemplating purchase of one of the Hewlett Packard 30/90/130 DesignJet dye ink printers. Actually, even if you do not have one but enjoy pithy comments, read on in any case, as it gives me a chance to unload on a brilliant engineering company that couldn’t organize a drink-fest in a brewery when it comes to diagnostic information.

It is now two years since I placed the HP Designjet 90 printer in service, and I remain delighted with this device. Sure, it only uses six ink cartridges compared to eight or twelve found in more recent printers, but there’s no arguing with the quality of the prints this fine machine makes.

I’m on my second or third set of print cartridges (depending on color) and when reprinting one of my pictures I ran into a snag.

Here’s the problem:

Doubly irritating as I had just wasted a 24″ x 18″ piece of paper – I had set the job to print while taking a shower and this is what rewarded my return. I thought it might be a glitch in Aperture 2.0 so I printed from Photoshop CS2 and everything was pink, so suspicion fell on the printer.

The DesignJet series of printer (30, 90, 130) include a useful status panel telling you about ink levels:

The vertical black bars denote ink level and the symbols that look like a felt-tip pen tell you about the status of the print heads – one head per ink color. If one of these is blinking it means the head is faulty and needs replacement. Or not – read on. They don’t cost too much in the US – $35 – but it’s not the sort of thing you stock as a spare if you, like me, are an amateur low volume printer.

However, the status screen on my DJ90 showed all the ink levels were fine and none of the ‘felt tips’ was blinking, so I checked the HP web site. Now HP, you must know, is an engineering company which means they have one of the worst web sites imaginable. It wouldn’t do for great engineers to write clear instructions now, would it, (real men do not need instructions and God help women) and the HP Systems Maintenance Utility resolutely refuses to run on my MacBook. Eventually I came across HP’s printer head cleaning instructions and applied these rigorously.

First, open the printer ink cartridge flap then open the cover for the printer heads when they have ceased moving. Pull the power cord now, then remove all the heads. They are color coded so no mix-up is possible. I believe they are actually identical but, once loaded with dye, you don’t want to switch these!

Using a coffee filter (these are lint free) and distilled water (not dirty tap water) wipe each head.

You want to keep wiping with a moist (not wet) filter until you get two clean ink streaks from the base of the head – the part that goes down into the well. That denotes good dye flow. You can see the twin tracks from the Magenta head in the picture above. Then wipe the contacts on the rearward facing (when in the printer) part of the head.

Next, wipe the receptor contacts in the printer as shown below.

A lot of gunk comes out. I would guess I have made one hundred 13″x19″ and thirty 18″x24″ prints since I bought the printer, to give you an idea of the use it has had. I was actually surprised to have this failure as HP keeps the heads warm even when the printer is off (as long as it’s plugged into the mains) and I have not had any of the repeat clogging that I experienced with the Epson 1270. This is important as I tend to print in batches and with this last print run the printer remained idle for three months. (I was working for the US Government, filling out income tax returns and sending them 50% of my 2007 income the better to feed the losers who increasingly dominate our once free country, hence the inactivity).

A first print test showed a repeat of the problem (the print was as sharp as can be) but after a second cleaning the problem persisted. Additionally, I got three blinking head errors second time around, but removal and reinsertion of the relevant heads fixed the problem.

Don’t make my mistake and let the ink dry on your fingers. I couldn’t get it off with isopropyl alcohol and had to resort to an abrasive Scotch pad. I now have no fingerprints, a status that equips me for a life of crime. Maybe I should run for Congress?

Head alignment and diagnostics

OK, so despite manual cleaning of the heads I was still having the ‘pink part way through the print’ issue.

Once Apple’s OS X Tiger (10.4.x) was introduced HP failed to properly update its System Maintenance Utility for Mac OS X, meaning that when you fire it up you will get an error message. (But see ‘Follow up’, below). Don’t even think of calling HP for help. First, they will charge you for fixing their errors and second, the chances of finding someone who has the answer is slim to none. Don’t believe me – check their chat board. A lot of unhappy Apple users there. Maybe HP hasn’t heard that creative people use Apple computers?

However, you can do everything that’s needed using the three buttons on the control panel by referring to this document. Though it says it’s for the 100, 110, 120 and 130 printers, it also works fine with the 90 model I have. And I’ll bet it works for the 30 model, too, as the 30/90/130 range share the same ink cartridges and print heads. Too bad HP does not know about it!

Using this document you can run usage and information reports, clean the print heads (in addition to the technique illustrated above), lock the heads for transport, align the print heads and – wait for it – switch off that piercing end-of-job buzzer which has irritated me from day one of ownership.

So by holding the Power button down and pressing the OK button thrice, I aligned the heads. Then, holding the Power button down I pressed the Cancel button twice to force a ‘Soft’ Printhead Recovery (HP speak for flushing the heads). Sure enough, the printout disclosed that the Light Cyan head was not performing properly (the color bars were either discontinuous or completely missing and came with a big black ‘X’ at the bottom right on the all three pages of the report). So I ran the ‘Hard’ Printhead Recovery cycle by pressing both the Cancel and OK buttons sequentially twice while holding the Power button down. Now all was well. You are looking for a cyan check (UK: tick) mark on the bottom right of the report and continuous tone in the test patterns. You can run these reports on regular 8.5″ x 11″ letter size paper – save your photo paper for pictures. The process takes several minutes, so be patient.

In case some yo-yo at HP deletes it, here’s what you need to know for future use:

The ink use report is far more accurate than the one provided by the LCD status bars on the front panel of the printer.

Mine is not a network-capable version so the last choice is inapplicable.

Interpreting test print results is addressed in this very poorly written document on HP’s site. Have patience – they use some of the slowest servers in the world and the page takes a while to appear. That’s when their servers are not down, which seems to be much of the time.

Yes, I do have an engineering degree and, no, I do not have dirty fingernails (just dirty fingers after this job), facial hair or an inability to communicate clearly. Let’s leave the last three to HP’s engineers.

Follow-up:

Well, my ‘repair’ lasted a couple of prints then the problem resurfaced. I determined the Light Cyan head was at fault and ordered a replacement. Now all is well. No thanks to HP and it’s poorly documented diagnostics. Hopefully this will help others using this fine printer who run into problems.

To run color test prints run the HP Designjet System Maintenance utility going to Calibrate Color->Image Quality on the web page that will load (if you are lucky; if not, reboot and try again).

Here are the ‘Before’ and ‘After’ test prints – the second after installing a new Light Cyan print head. As you can see, light cyan is largely missing in cell D3 and the Green has trended to yellow in cell C3, leading me to conclude that the Light Cyan head is at fault. Not that you can divine that from HP’s on line ‘diagnostic’ illustration.

Before – faulty Light Cyan cartridge diagnosed. Plus head alignment is needed.

After – faulty Light Cyan cartridge replaced. Head alignment still needed.

HP says to align heads after any printhead change; in practice, run the above report first and if you see problems in the areas annotated, above, run the printhead alignment routine then. No point in running it if not needed. In the above picture, the white vertical line in the big color chart and the magenta shading in cell B2 indicate that head alignment is needed.

Had cell D1 been flaky, I would have replaced the Light Magenta head. The other cells and their respective error conditions are addressed in HP’s referenced diagnostic document, which largely seems to forget about its six head printers. I don’t know but I would bet that the 100, 110 and 120 models they reference use four heads and inks.

Once the new LC head was in place the printer ground away for a good five minutes before being ready to print, with the hour glass displayed on the LCD screen on the front panel.

Here is a later illustration from HP’s web site which is a bit clearer:

There’s also a print quality manual which you can download by clicking the image below:

Click to download

Making Systems Maintenance work on a Mac:

I finally got the HP System Maintenance Utility to run on my MacBook. I first erased all the HP files in MacBook->Library->HP and in User->Library->HP, downloaded the utility and reinstalled it. If your Mac fails to respond to this approach the hard key method described above is every bit as good and a lot less frustrating as you are not confronted with HP’s constant page errors caused by mistakes in their code. The only thing that will not work is the firmware upgrade, but then we Mac users are just so much scum to the brilliant engineers at HP, no?

After changing the print head it is necessary to run the HP System Maintenance->Calibrate Color utility for each type of paper you propose using. If you cannot get the HP System Maintenance Utility to run you are out of luck. I did this for HP Premium Plus Photo Satin Best (bi-directional printing) and for HP Premium Plus Photo Satin Best Maximum Detail (mono-directional printing – slower). HP Premium Plus Photo Satin is the only paper I use in this printer as it looks great when mounted and has a slight sheen which allows retention of a decent contrast range without the specular reflections of glossy paper. The utility uses the HP’s built-in spectrometer to maximize color accuracy by comparing a test print to what it ideally should be – a feature generally found on printers costing several times as much – like the new, and very costly, Z3100 series. Each calibration run takes some 10-12 minutes and you must not mess with the printer while it is doing this. You must use test sheets (letter size) of the paper you are calibrating the printer for something, amazingly, that HP’s on-screen instructions never mention.

Conclusion:

Suffice it to say that all ended well, and the 18″ x 24″ annual birthday snap of our son is ready for mounting and framing, after a 24 hour drying period to let the inks firm up nicely. Oh! and one other thing – it was printed out of Lightroom, Aperture being softwara non grata in the Pindelski household.

Despite HP’s lousy diagnostic instructions I still remain over the moon delighted with the DesignJet 90 printer.

Update – 4/2009:

Another head gave out – the banding in cells C2, D1 and D2 pointing to a faulty Light Magenta printhead. It’s nice to have HP’s good diagnostic tools, even if the instructions are so poor.

Here’s the full troubleshooting table for printheads in case you cannot access the web-based utility offered by HP:

HP DesignJet 90 ink use

Frugality is thy name.

I did some arithmetic to show just how inexpensive ink and paper are when it comes to a large exhibition print using the DJ90 here.

Well, it’s coming up on my first anniversary of ownership of the HP DesignJet 90 printer and it finally came time to replace one of the ink cartridges as the Light Magenta indicator started blinking, showing the ink was about to run out. Replacement is literally a 10 second afffair – pull the old, plug in the new.

An appropriate time to point out that the DesignJet should never be unplugged from the mains; even when switched off with the front panel push-button, the DJ keeps the ink cartridges warm to prevent clogging. The front panel light attests to the fact the printer is getting power and the warmth of the ink cartridge area confirms the clever warming feature, something sorely needed on my older Epson 1270 which would clog up if not used for a month or so. I just came back to the DJ after six weeks of not using it and the first print was as perfect as any other. Why HP doesn’t shout about this feature from the rooftops beats me, but then it’s always been a company more about engineering than marketing.

Here are the ink meters right after replacing that Light Magenta cartridge:

My best estimate is that over the past year I have made twenty 18″ x 24″ prints and fifty 13″ x 19″ ones, before that first cartridge gave up the ghost. As the picture shows, the other cartridges are between 1/2 and completely full. Do the math and that works out at less per square inch than those great instant 6″ x 4″ prints from the local drug store at 19 cents each. And you get fade resistant inks into the bargain – suffice it to say that Wilhelm’s test say 82 years or something silly, meaning I won’t care when these start fading! Wilhelm Research is the leader in testing ink longevity.

HP seems to be continuing with the dye ink based DJ series, even though the new pigment ink based DesignJet Z series with built-in colorimeters would appear to be their latest thing. The Z series uses pigment inks. Pigments rest on the surface of the paper like paint on a wall, whereas dyes need a porous medium as they are absorbed, like stain on wood, meaning that the paper you use with the DJ90 has to be suitable for dye based inks – not all papers are absorbent.

I have read tests on the Z series which suggest that there is nothing to choose between dyes and pigments (heretofore dyes were generally regarded as superior for color fidelity) though I have not seen Z prints for myself. Given the target user market for the new Z printers – professionals – I doubt that HP would supercede the DJ dye printers with something inferior. These are very costly printers and not something you would really want to use for small prints.

Anyway, after almost a year the honeymoon with the Hewlett Packard DesignJet 90 printer continues untroubled – no breakdowns, no lockups, no cryptic messages. Should these ever get remaindered and you like big prints, do consider one if you can make the space for it at home. That’s with a Mac, of course. I can’t see how any Windows user could write objectively about up time given that he or she is busy rebooting most of the time….

HP ink costs

The old HP 12C helps out.

In my piece on framing Really Big Prints I guessed at the cost of ink used by that frugal beast, the Hewlett Packard DesignJet 90 printer.

Well, in the HP engineering spirit, I whipped out the old 12C and set to work.

Checking the ink levels on the printer showed the following:

Yellow 3/4 full
Black Full
Magenta 3/4
Cyan 3/4
Light Magenta 1/2
Light Cyan 1/2

Now as the level in each cartridge is reported in one quarter steps, I averaged 3/4 full to mean 5/8 full (i.e. half way between 3/4 and 1/2) and so on, making for ink use aggregating 2.5 cartridges.

Production?

13 18″ x 24″ prints and 27 13″ x 19″ prints, or 12,285 sq. in.

With cartridges averaging $35 (the prices differ, strangely, according to color), that works out to $87.50 in ink, or $1.75 for a 13″ x 19″ and $3.07 for an 18″ x 24″.

So my $4 ink cost-per-print estimate in that earlier journal entry was a tad high. You can make an 18″ x 24″ print with the HP DesignJet, paper included, for the price of a hamburger-and-fries at the local fast food joint.

The HP DesignJet dye-based series of printers (30, 90, 130) are frugal, indeed, when it comes to ink use. I cannot express how pleased I am with this large printer and, in truth, rather regret not having bought the 24″ carriage model, though how I would handle mounting and framing 24″ x 36″ monsters in 32″ x 42″ frames boggles the mind.

Mounting Really Big Prints

Some practical hints.

Every year, a couple of months before Christmas, I invite a few friends to select a couple of prints from a small web presentation, asking that they elect 13″ x 19″ or, now that I have the HP DJ90, 18″ x 24″.

So as this year’s print ‘orders’ came in, I thought it might be instructive to share my technique with readers. Those who see obvious errors are encouraged to set me on the straight and narrow and those contemplating the self-abuse that is print mounting might like to see what they are letting themselves in for.

First, I should point out that I do not accept the apologia proferred by many for ‘hinge mounting’ where a print is held to a backing board with a few pieces of tape at the top in the purported interest of archival permanence. The moment the humidity changes, the print cockles and you have a throw away print. It’s just another excuse to cut corners masquerading as technique. Don’t believe them when they tell you ‘curators insist on this’. Sheer Rot. I have prints which I dry mounted thirty years ago (using a domestic iron, no less), before we knew about acid free this and pH neutral that, and they remain perfect and unfaded. So when people tell you dry mounting is no friend of permanence, look elsewhere.

Key dimensions:

I typically mount both 13″ x 19″ and 18″ x 24″ prints on 22″ x 28″ boards. The HP DJ90 and 130 leave a 1/4″ border top, left (long side) and right (long side), with a bottom border of 9/16″ (short side). For the HP Designjet 90/130, after allowing another 1/8″ for safety,the mat openings are as follows:

  • 13″ x 19″: Opening is 12 3/8″ x 18 1/16″
  • 18″ x 24″: Opening is 17 3/8″ x 23 1/16″

These openings will leave 1/16th of an inch of printed image to work with on all sides, for alignment purposes. Matboard & more will custom cut these for you. Stock mats which come with 12 1/2″ x 18 1/2″ and with 17 1/2″ x 23 1/2″ openings will not work, leaving white borders on the matted print.

Archival issues:

My goal is a print which will outlive me and here’s what is involved:

1 – A printer with fade free inks. The DJ90 uses dyes, others use pigments. Both are great. Most modern ink jet printing inks are fade free. Look for them when making your printer selection. Older designs will fade in as little as a year in bright light.

2 – Cotton gloves. Yes, I do advocate delegating the drudge of routine printing – meaning anything under 8″ x 10″ – but when it comes to show prints I am not about to let the clerk at the framing store, who has just feasted on a Big Mac, cheese and fries, get his hands on my print. Grease is the last thing I need. Not to mention that ten of these will pay for that overpriced Seal press. The cotton gloves are used from the moment the printing paper is removed from the box all the way through final placement of the mounted print in a protective glassine bag for shipping. Cheap insurance.

3 – Acid free mounting board. I use the 3/16″ thickness – it costs little more than the 1/8″ and is more robust.

4 – Acid free mats cut by Redimat. Their machine cutter is incredibly accurate. As Apple’s Aperture leaves a 1/2″ border around the print with the DJ90, my 18″ x 24″ prints get a 16 7/8″ x 22 7/8″ cut out, while the 13″ x 19″ ones use 11 7/8″ x 17 7/8″. That way I have 1/8″ to play with when positioning the print on the mounting board. Color? Anything your heart desires. I mostly use black. Simple. No distractions.

5 – Seal Bienfang RC Colormount tissue. This seals at 185F and is intended for RC paper. Its low sealing temperature is ideal for ink jet prints. Go much over 210F and these start to fry.

6 – A Seal mounting press.

7 – A Seal tacking iron to tack the mounting tissue to the print and the print + tissue to the mounting board.

8 – 3M two-sided adhesive tape to attach the mat to the mounted print.

9 – Release paper for tacking and heating in the press

10 – Bert the Border Terrier to keep me company. These are very hard to find and, in my opinion, essential.

Strict cleanliness throughout this process is key. Any dirt or grit and your print is shot.

The tissue is precut using a sharp knife and a granite counter.

The Seal tacking iron, set just below ‘Med’ and no higher, is warmed up.

Using a small piece of release paper betweeen the mounting tissue and the back of the print, the tissue is tacked to the print – count for 10 seconds – remember those darkroom days? “Elephant One, Elephant Two, Elephant Three….”

Hold the tacked part down for a couple of seconds to cool.

Get one mounting board and one mat – the latter will be used as a positioning template.

Having positioned the print + tissue on the board using the mat (the mounting board and mat must have identical outside dimensions), tack the print to the board, protecting the print with the release paper:

Once more, hold the heated area for a few seconds to ensure a good ‘tack’.

The print is now tacked to the board.

Heat the press to 170F.

Place the print + board in a folded over piece of release paper.

The press must be adjusted so that reasonable hand pressure on the lever closes it. Too much and you will have creases in any print that needs multiple passes. In my press, an 18″ x 24″ print needs four passes. This is where you put the Border Terrier in play.

The red light indicates the press is on, and the orange light to the left will extinguish once the set temperature is reached. Once the orange light goes off you are at the set temperature. I do not bother to preheat the print or board to get rid of moisture as both are stored in a dry, heated home.

Each heating cycle must be for at least 90 seconds – pull out that 60 year old Kodak analog timer, the one you can read from across the room. Overdoing it is not a problem – I sometimes let it run 4-5 minutes while I do something else, but if you are in a hurry, less than 90 seconds is a no-no.

My press makes its home in the wine cellar, but yours does not have to.

Once the heating process is complete, pull out the Scotch 3M double sided tape dispenser. Do not economize by using something cheap.

Place two inch strips in the center of the board on all four sides of the print between the print edge and board edge. Now place the mat on the print, aligned edge to edge, and press down on these four points. The goal is to lightly glue the mat to the board – the framing process will ensure the two stay together.

Do yourself justice – sign the bloody thing. Wilting violets …. wilt. I use a white ink pen from the art store.

Sticking with the cotton gloves, insert the ‘sandwich’ into an acid free, sealable, glassine sleeve for storage and transit.

Stand back and admire your work.

Finally, pray the post office does not bend your prints in transit.

Framing is addressed here.

HP DesignJet Z photo printer

Brought to you despite the Board of Directors.

If you have been following the financial news recently, you could be excused for thinking the Board of Hewlett Packard couldn’t organize a booze-up in a brewery. Depsite the twits in the corner office, the great engineers at HP continue to make innovative products. The most recent announcement is the HP DesignJet Z photo printer.

Long time readers of this journal will know how pleased I am with my HP DesignJet 90, which will make up to 18″ wide prints using fade-resistant inks. Having made some forty 13″ x 19″ and 18″ x 24″ prints in aggregate over the past six months on mine, ink levels remain astonishingly high – if those meters are linear this has to be one of the most economical printers available. Three cartridges are still showing full, the other three three-quarters full. Print quality is as good as it gets.

The new floor standing DesignJet Z comes in 24″ and 44″ widths and is focused on extreme color accuracy, courtesy of a built-in Gretag/Macbeth/X-rite spectrophotometer to automate paper profiling and ICC profile generation. I use an external version of the X-Rite to profile my screen and then adjust the ICC profile manually for the paper used with HP’s provided tools, as I explained in my review. Well, now the need for tortuous manual ICC paper profiling is gone. You can get some idea of HP’s target market by looking at the picture above – that looks like a photograph of a Tissot painting in the printer on the left.

These are not cheap. The base 24″ model will sell for $3,400, compared to $1,300 for the six ink 24″ DJ130. The price of the new printer compares favorably with that of the 24″ Epson 7800 at $3,000. The new DesignJet will come in eight or twelve (!) ink models, so you can see how totally focused HP is on color fidelity. As a point of reference, my six ink DJ90 goes to 18″ wide and sells for $1,050. This will be a great machine to fool all those Label Drinkers. Just tell them the print was made using traditional darkroom techniques, just like Ansel Adams used.

Which just goes to show that no matter how disfunctional your Board of Directors may be, you can’t kee a good engineer down.