Doc Number: FTP-00950

Version: B
Date First Published: July 6, 2017
Date Released: July 11, 2017
Audience: All Audiences

Troubleshooting UV Ink Curing Issues

Description: This document provides information and instructions for understanding and troubleshooting
UV ink-curing issues in the VUTEk® printer family. These guidelines are applicable to all UV
curing printer models.

Affected Printers: VUTEk h3, HS125 Pro, HS100 Pro, HSr Pro, VUTEk LX3 Pro (GS3LX),
GS3250LX Pro UltraDrop, GS3250LX Pro, GS3250LX, GS3250 Pro, GS3200 Pro, GS3250,
GS3200, GS3250 Pro-CP, GS3250 Pro-TF, GS2000LX Pro UltraDrop, GS2000LX Pro,
GS2000LX, GS2000, GS2000 Pro, GS2000 Pro-TF, GS2000 Pro-CP, H2000 UltraDrop,
QS2 Pro, QS3 Pro, QS3, QS2, GS5500LXr Pro UltraDrop, GS5250LXr Pro, GS5000r,
GS3250LXr Pro, GS3250r, H1625 LED, H1625-RS, H1625-SD

Copyright © 2018 Electronics for Imaging, Inc. All rights reserved.

The information contained in this document is confidential and proprietary to Electronics for Imaging, Inc (EFI). This information is provided only to authorized representatives of EFI and
EFI customers solely for the purpose of facilitating the use of EFI's products. No information contained herein may be disclosed to any unauthorized person for any purpose whatsoever
without the prior written consent of EFI. EFI makes no representations or warranties with respect to the contents of this document. Further, EFI reserves the right to revise or change this
publication and the products it describes without notice.
Field Technical Procedure

Troubleshooting UV Ink Curing Issues

This document provides information and instructions for understanding and troubleshooting UV ink-curing issues in the VUTEk® printer
family. These guidelines are applicable to all UV curing printer models.

Document Overview
1.0 Understanding Ink Curing
1.1 Factors that Affect UV Curing
1.2 Effects of Cure on Ink Drop Characteristics and on General Coating Attributes
2.0 Guidelines for Evaluating UV Ink Curing Issues
2.1 Situation-Specific Questions
2.2 Primary Checks
2.3 Troubleshooting
2.3.1 System Checks
2.3.2 Substrate
2.3.3 RIP
2.3.4 Ink
2.3.5 Lamps
2.3.6 Cutter
2.3.7 Adhesion Tests
2.3.8 Possible Improvements
2.3.9 If Issue is Still Unresolved
Revision History
7/6/2017 Rev. A • First revision
7/11/2017 Rev. B • In 2.2 Primary Checks updated Lamp Cure Energy values to Low: 40%, Medium: 60%,
High: 80%, Maximum: 100%

FTP-00950, Rev. B © Copyright 2017 | ELECTRONICS FOR IMAGING, INC. ALL RIGHTS RESERVED. Page 2
Field Technical Procedure

1.0 Understanding Ink Curing

In general, UV curable inks have oligomers and monomers that, when in contact with free radicals, will link together, forming a cross-
linked layer. The reaction is controlled by producing the free radicals where and when within the ink layer.
This is why the UV light curing system is critical to proper ink film production. The UV energy penetrates the wet ink layer to convert
photo initiators into the necessary free radicals. The quality, the amount and the timing of this energy determines many of the drop
characteristics.

1.1 Factors that Affect UV Curing

It is important to understand the factors that can affect UV curing.
Factor Effect
Temperature Higher temperature increases reaction rate
Oxygen Scavenges free radicals produced by the photo initiators and stops the cure process
Cure energy wavelength The specific UV energy must be matched to the photo initiator(s) of the ink
Cure energy amplitude The amount of usable energy will determine how many free radicals will be started
Photo initiator Absorbed specific UV energy and creates a free radical
Distance UV energy decreases by the inverse of the distance squared
Substrate Surface tension, texture and absorption are a few of the effects substrates can make

1.2 Effects of Cure on Ink Drop Characteristics and on General Coating Attributes
 Hardness
 Gloss
 Feel
 Spread
 Adhesion
 Flexibility
 Overall coating look and feel (texture)
 Detrimental effects on media

FTP-00950, Rev. B © Copyright 2017 | ELECTRONICS FOR IMAGING, INC. ALL RIGHTS RESERVED. Page 3
Field Technical Procedure

2.0 Guidelines for Evaluating UV Ink Curing Issues

These guidelines are applicable to all UV curing printer models, both Mercury Arc and LED Lamps.

2.1 Situation-Specific Questions

• Is this curing issue new, or has it come on gradually?
• Is the issue more noticeable in a specific color? Is it ink batch related? Which ink batch?
• Check curing effect on different substrates
• Have the Printer Settings or Environment changed? Example could be image, application, lamps, substrate, print settings, RIP,
process, environment conditions (temperature and humidity, particulate, machines emitting RFID interference), storage.

2.2 Primary Checks

• Perform a visible equipment check.
• Check printer Error Log for any Nitrogen, Lamp or Pressure related warnings.
• Record Current Cure Settings. (Typical printer settings: double, low, heavy smoothing)
o Lamp Shutter Mode:
 Single: Cures with the trailing lamp only
 Double: Cures with both lamps
 Post: Cures with the leading lamp only
o Cure Energy
 Low: 40%
 Medium: 60%
 High: 80%
 Maximum: 100%
 Custom: User-selectable percentage
o Smoothing:
 None
 Light
 Heavy

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Field Technical Procedure

 Print Gap should be 0.060 inch, unless using a specialized application, such as MEG (Material Edge Guide)
 Mode: Bidirectional or Unidirectional?
 DPI?
 How many layers? What are they?
 Carriage speed: Standard or Maximum?

2.3 Troubleshooting
2.3.1 System Checks
The performance characteristics of both vary between LED and Mercury Arc curing but a basic system check may define the complaint.
Start with confirming the system is to specification following these guidelines:

 Check main facility air quality is equal to or better than described in the Customer Advisory Bulleting, Compressed Air Quality
Specifications, https://inkjet.support.efi.com/doc.php?doc=975
 Check/adjust main air pressure to be stable and meets the minimum air pressure as described in the Printer Specifications
 Check/adjust Nitrogen regulator (90 PSI)
 Check/replace Nitrogen filter (3 months)

2.3.2 Substrate
As the customer, be sure the vendor has tested the substrate in question for compatibility and application intended. See CAB-00617,
Media Handling Best Practices https://inkjet.support.efi.com/doc.php?doc=3486
 What is the substrate? e.g. Coroplast , styrene or Lexan .
o Supplier’s name and address
o Product name and grade
o Product Data Sheet
o Is there a digital grade?
o Type of surface treatment (matt, gloss, corona treated)
o Dyne Level of surface (minimum 35 dynes/min, if a dyne pen test kit is available, use it to obtain actual values)
o Follow instructions online at https://inkjet.support.efi.com/doc.php?doc=3750.
o Watch the video on the Dyne Test Overview, also online at https://inkjet.support.efi.com/doc.php?doc=3749.

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Field Technical Procedure

o Thickness of media
o Storage (In-plant: cover sheet, ambient dust, temperature, humidity)
o Cleaning (Is substrate cleaned prior to printing? e.g. dry wiping or wiping with IPA)

2.3.3 RIP
 Which RIP program is being used?
 What is the total ink percentage? To get blacker blacks, printers have increased the 'Total Ink' (CMYK build to make the maximum
black) during the linearization-profiling process. (Some printers increase the total ink used such as CMYK black, which makes curing
more difficult.)

2.3.4 Ink
Be sure the proper ink for their printer and contract is being used, as well as recommended best ink set for the application and
substrate in question.

 What ink set is being used?

 What are the part numbers, batch numbers, and date of expiration of the inks?
 If the ink has been sitting unused for a long period, invert the container several times to assure homogenous mixture.

2.3.5 Lamps
 Assess the condition of the UV lamps:
o What is the age of the lamps? How many hours?
o Are the lamps clean? Refer to each printer Maintenance Guide for proper cleaning instructions;
o Review updated Cleaning LED Lamp Window instructions with technicians, https://inkjet.support.efi.com/doc.php?doc=2143.

2.3.6 Cutters
 Gather information on the cutter, manufacturer, type, model, etc.
 Automated Digital Cutters have a variety of blades, depth and speeds that can be optimized for clean cuts. Be sure blades are not dull.
 Guillotine cutters must have sharp blades and proper holding and cutting action. Using a CNC cutter with a router can chip the edges.
A CNC cutter with a blade works better. Also consult with the customer’s applications team.

FTP-00950, Rev. B © Copyright 2017 | ELECTRONICS FOR IMAGING, INC. ALL RIGHTS RESERVED. Page 6
Field Technical Procedure

2.3.7 Adhesion Tests

The EFI Ink Group performs testing on a variety of digital UV based substrates.

 Perform an ASTM scratch test immediately after printing, and again after 24 hours;
o Refer to Ink Adhesion Test Procedure, https://inkjet.support.efi.com/doc.php?doc=3779, for acceptable test methods.
 EFI’s outdoor warranty is written in terms of “normal sun exposure” for areas in the US north of 35.0° latitude and “extreme sun
exposure” in areas south of 35.0° N latitude.
 The calculated average correlation for 35.0° N latitude in the United States is approximately 1,550 hr in ISO 18930 / year.
 The ASTM- D3359-B adhesion test is the adopted test for EFI. This test has been conducted using a few grades of tape with various
tack and more aggressive grip.
Note: Fingernail tests are not very useful when determining Adhesion.

2.3.8 Possible Improvements

 Reduce film thickness: less ink means more curing energy per gram and makes it easier for the UV energy to penetrate to the bottom
of the ink layer
 Use reduced ink profiles (total ink limit)
 Wait 24 hours after printing before cutting
 Avoid cutting the image area
 Precut the substrate
 Use a third party adhesion promoter
 Corona treat the surface; some medias, like Coroplast, lose treatment over time. High initial treatments are needed to compensate for
this loss
 Choose media that is designed for digital printing whenever possible
 Try a different media manufacturer
 Post Cure (The head lays down the ink, but the following lamp is not on. This allows more dot spread time and reduced coating
thickness)

FTP-00950, Rev. B © Copyright 2017 | ELECTRONICS FOR IMAGING, INC. ALL RIGHTS RESERVED. Page 7
Field Technical Procedure

2.3.9 If Issue is Still Unresolved

 Review all troubleshooting items with Technical Support.
 Try alternative substrate material.
 Ship material to the EFI Demo Center to evaluate application on a known printer.
 Upload the Original, Ripped file, XFE, EPL and ICC to the appropriate EFI ftp site, ftp://inkjet.support.efi.com for a test trial at one of
the EFI Demo Centers or with the Applications Service Engineer.

FTP-00950, Rev. B © Copyright 2017 | ELECTRONICS FOR IMAGING, INC. ALL RIGHTS RESERVED. Page 8