Colorjet METRO KONICA HEAD Installation And Troubleshoot Manual
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Colorjet METRO KONICA HEAD Installation And Troubleshoot Manual

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  • Page 1 KONICA HEAD...
  • Page 2 Disclaimer The information and instructions provided in this manual have been checked for accuracy, uniqueness, and reliability. ColorJet group reserves all the rights to modify and revise this manual as per the company requirements without any prior notice. “No part of this document shall be reproduced or used by externals without prior permission of the ColorJet group”.

  • Page 3: Table Of Contents

    Table of Contents 1. Site Layout ..............................4 Machine Dimensions ..........................5 Room Dimensions ............................. 5 2. Safety Precautions ............................ 6 Emergency Stop Button ..........................6 Precautions for Use ........................... 6 Precautions for Fabric Use ........................6 Precautions for Ink Use ..........................7 3.
  • Page 4 7. Head Installation ............................. 30 8. Installation of Printer Manager ....................... 33 Printer Manager Settings ........................37 Head Temperature Settings ........................ 39 Save to Printer ............................. 41 9. Head Alignment ............................42 Calibration Wizard ..........................42 Mechanical Checks ..........................43 Vertical Check ............................

  • Page 5: Site Layout

    1. Site Layout The Site Layout of the printer is shown as below: Fig 1: Displaying the Site Layout METRO (Konica Head) Page | 4...

  • Page 6: Machine Dimensions

    Machine Dimensions Dimension, weight and other details are given as below: Printer • Gross Weight: 4738 Kg • Net Weight: 4300 Kg • Printer Dimensions (L x W x H): 5300 x 1840 x 2450 MM • Packing Dimensions (L x W x H): 5520 x 2160 x 2533 MM •...

  • Page 7: Safety Precautions

    2. Safety Precautions Emergency Stop Button Sometimes, it may possible that machine behaves unusually. In such situations, immediately press the Emergency Stop button and shut off the machine using the main power button. Try to resolve the problem and after confirming it’s safe to restart, gain start the machine and resume operations. The Emergency Stop button is shown in the image below: Fig 2: Displaying the Emergency Stop Button Precautions for Use...

  • Page 8: Precautions For Ink Use

    • Do not wet the fabric. • Keep the box or bag that came with the fabric. They can be used for storage. • Store fabric in a cool and dry place. Avoid direct sunlight. • When storing a fabric roll, use the bag that came with it. Put the roll into the bag and store in a horizontal position.

  • Page 9: Safety Requirements

    3. Safety Requirements Power Requirements • Printer o Print Engine: Total Wattage: 5500Watts @ 220Volts AC 50Hz, Sinewave ▪ Uninterrupted power supplies (flicker free) should be provided as it has digital circuit. ▪ Safety: 32A MCB must be used to Power this Inlet. o Belt Dryer: Total Wattage: 4000Watts @ 220Volts AC 50Hz, Sinewave ▪...

  • Page 10: Installing Accessories

    4. Installing Accessories Levelling the Machine In METRO, total number of levellers are twelve from which eight levellers are used in both cabinets (left and right) and four levellers are in the main machine. The Main Machine Leveller is shown in the image below: Fig 3: Displaying the Main Machine Leveller The Cabinet Leveller is shown in the image below: Fig 4: Displaying the Cabinet Leveller...

  • Page 11: Led Light

    LED Light In METRO, LED lights are already fixed and service engineer needs to connect the connector, as shown below: Fig 5: Displaying the LED Connector Tower Light Follow these steps to place the tower light: Step 1: Place the tower light in the given space, as shown below: Fig 6: Fixing the Tower Light METRO (Konica Head) Page | 10...

  • Page 12: Water Tank And Washing Tub

    Step 2: Tight the screws to fix the tower light, as shown below: Fig 7: Fixing the Screws Step 3: Fix the Tower Light Connector to make the connection, as shown below: Fig 8: Fixing the Tower Light Connector Now, the Tower Light is fixed. Water Tank and Washing Tub Follow these steps to place the water tank and water tub: Step 1: Place the Water Tank to the back side of the machine.
  • Page 13 Connecting the Water Inlet pipes to the motor, as shown below: Fig 9: Connecting the Water Inlet Pipes Connecting the Water Outlet Pipe to the Water Tank, as shown below: Fig 10: Connecting the Water Outlets METRO (Konica Head) Page | 12...
  • Page 14 Step 3: Connect the Water Tank Inlet pipe to the Jetting Nozzle Pump using the Tightening Clamp, as shown below: Fig 11: Connecting Water Tub Inlet Pipe to the Jetting Nozzle Pump Step 4: Similarly connect the Water Outlet pipes to the Washing Tub from both sides, as shown below: Fig 12: Connecting the Water Outlet Pipes Step 5: Fill the tank with 3/4 of water.

  • Page 15: Ink Tank

    Ink Tank Follow these steps to connect ink tanks: Step 1: Unlock the Ink Knobs of each color in the below shown direction: Unlock Ink Knob Fig 13: Unlocking the Ink Knob Step 2: Connect the Ink Inlet Pipe to the Fitting Connectors, as shown below: Fig 14: Connecting the Ink Inlet Pipe to the Fitting Connectors METRO (Konica Head) Page | 14...

  • Page 16: Adjusting The Conveyor Belt Tensioning

    Adjusting the Conveyor Belt Tensioning Follow these steps to adjust Conveyor Belt tensioning: Step 1: Tighten the adjustment rings on the right and left sides of the belt in the rear, using a pair of pliers. Step 2: Make sure that tighten the rings on the right and left sides with the same torque. Step 3: Mark any two points vertically at a measuring span of 1000mm in the Belt.

  • Page 17: Setting Belt Speed

    Using the BELT MOTION screen, you can perform the following actions: • SPEED: Set the speed of the Conveyor Belt. • AUTO REV: Auto move the belt in the reverse direction. • AUTO FWD: Auto move the belt in the forward direction. •...

  • Page 18: Belt Shifting Control

    Belt shifting control Below procedure explains about the Conveyor Belt shifting control. • Belt shifting can be controlled ‘on the fly’ as well as when print is stopped. • To control the position of Adjust Roller, turn the Toggle switch into FWD/REV direction (The Toggle Switch is available backside of the HMI) as per the requirements.

  • Page 19: Setting Washing Unit

    Setting Washing Unit To set the position of washing tub, select the TUB DOWN icon from the WASHING SYSTEM screen. The WASHING SYSTEM screen appears, as shown below: Fig 18: Displaying the WASHING UNIT Screen After setting the tub position, switch ON the brush, belt dryer, jetting pump, print dryer. Using the WASHING TUB screen, you can perform the following actions: •...

  • Page 20: Stages Of Glue (Adhesive) Process

    • Solvtek: This is used either to dilute the adhesives, or to complete removal of the all adhesive layers. The following are the two main reasons for removing all the glue layers:- o When the thickness of the adhesive layer goes on increasing due to multiple coat of the Perma.

  • Page 21: Glue Process Preparation

    NOT RECOMMENDED • Aromatic • Benzene • Toluene • Xylene • Aliphatic • Hexane • Cyclohexane • Ketone • Acetone • Methyl ethyl ketone (MEK) • Chlorinated hydrocarbon • Methyl chloride • (Mono) chlorbenzene • Chloroform • Trichloroethane • Trichloroethylene •...
  • Page 22 Step 4: Put masking PVC tape on both edges of the Conveyor Belt, by simultaneously moving the belt through HMI in slow speed. Fig 20: Using Masking Tape Step 5: Put on gloves, goggles, and face mask for safety Fig 21: Using Safety Precautions Step 6: Keep ready the following items: - •...

  • Page 23: Glue Coating Procedure

    Glue Coating Procedure Note: Extreme care to be taken during the glue process, any negligence may render the coat unsuitable for use, and complete process may be required to be repeated. 3 persons will be required for this process. Follow these steps to start the glue coating process: Step 1: Put the Press Roller down.
  • Page 24 Step 7: When glue below the Press Roller seems to be diminishing at some areas, and becoming of higher viscosity and uneven, person standing in front, should start spraying the cleaner liquid continuously till the end. Fig 24: Spraying the Cleaner Liquid Step 8: Later the cleaner liquid spraying should be done throughout the belt, until the remaining glue appears to be deactivated, due to mixing of cleaner liquid.

  • Page 25: Glue Removing Preparation

    Glue Removing Preparation Prepare and ready the following below mention things before removing glue: • Prepare proper ventilators. • Wear proper safety armament to prevent from touching glue and cleaner. • Put cover sheets on under belt, printer front and rear to protect them from dropped glue and cleaner.
  • Page 26 Step 3: Pour cleaner liquid (Solvtek) onto wipe clothes. Fig 26: Pouring Cleaner Liquid Step 4: Wait 5 minutes to dissolve glue. Step 5: Wipe dissolved glue and cleaner by wipe clothes. Step 6: After wiping out the part, turn the belt and repeat wiping until wipe out over all. Fig 27: Wiping the Glue Step 7: Spray or pour purified water onto the belt.
  • Page 27 Step 9: After clean up the part, turn belt and repeat cleaning until clean up over all. Remove cover sheet which covers washing unit. Step 10: Finally, remove remained cover sheets, and keep the belt dry. Fig 29: Removing the Cover Sheet METRO (Konica Head) Page | 26...

  • Page 28: Loading The Fabric

    5. Loading the Fabric Follow these steps to load the fabric: Step 1: Run the Supply Motor in the manual. Step 2: Stop the Supply Motor when the unlock position of Safety Chuk and Shaft get matched, as shown below: Unlock Position Unlock Position Fig 30: Displaying the Unlock Position...
  • Page 29 Step 6: Load the media as per the path given below: Fig 32: Displaying the Fabric Path Now, the fabric is loaded. METRO (Konica Head) Page | 28...

  • Page 30: Filling Ink

    6. Filling Ink To refill ink, remove the Main Ink Tank cap and refill ink as per the color sticker. The Main Ink Tank is shown in the image below: Main Tank Cap Fig 33: Displaying the Main Ink Tank Points need to remember: •...

  • Page 31: Head Installation

    7. Head Installation Use this section, if Print Head is not installed in the printer. The installation of Print Heads is to be done only by a service engineer. If the Print Head is not installed correctly, it can affect the printing quality. Note: Don’t apply much pressure on while handling it.
  • Page 32 Step 6: Connect Head Inlet pipe to the Y Connector. Step 7: Connect refill connections to the head board (Refer to Fig 36). Step 8: Remove the cap of the Air Releasing Pipe (Refer to Fig 36). Step 9: Hold the pipe down and press the Purging button of a particular color. Note: Carefully perform the above steps to avoid the chances of ink spilling.
  • Page 33 Step 13: Check whether the Waste Bottle is attached or not. Step 14: Perform the Head Purging for all colors. Step 15: Perform the Head Blotting to gently clean the Print Head. Step 16: Perform the Nozzle Test to check the nozzle status of all the Print Heads. Now, print heads get installated.

  • Page 34: Installation Of Printer Manager

    8. Installation of Printer Manager Before installing the Printer Manager software, please confirm that the DotNet Framework is available in your system. If it is not installed, then first install it. With the Printer Manager, you need to install the following: •...
  • Page 35 The Select Installation Folder window appears as shown below: Fig 39: The Select Installation Folder Window Step 3: Click on the Browse button to navigate to the location where you want to store all the setup files and then click on the Next button to move to the next step of installation (Refer to Fig 39). The Confirm Installation window appears.
  • Page 36 Now, the installation of Printer Manager is completed and the Installation Complete window appears on the screen, as shown below: Fig 40: The Installation Complete Window Step 7: Click on the Close button to close the window and complete the installation process (Refer to Fig 40).
  • Page 37 The Printer Manager window appears as shown below: Fig 41: Displaying the User Interface of Printer Manager METRO (Konica Head) Page | 36...

  • Page 38: Printer Manager Settings

    Printer Manager Settings This option enables users to update the default settings of the printer viz. Print, Move, Preference, and Calibration. To open the Setting window, click on the Main MenuSettingEdit path. The Setting window appears on the screen, as shown in the image below: Fig 42: Displaying the Setting Window Describing the different sections of the Setting window, as given below: •...
  • Page 39 o Width: Set width of the color bar. o Placement: Enable or disable the color bar and its placement viz. left, right, or both. o Height same with image: If enabled, the height of the color bar is same as the image height.

  • Page 40: Head Temperature Settings

    The Preference tab is shown in the image below: Fig 44: Displaying the Preference Tab Using the Preference tab, the measuring unit can be set or changed. Head Temperature Settings Follow these steps to update the head voltage: Step 1: Click on the Main MenuToolsReal Setting path, as shown in the image below: Fig 45: Selecting the Real Setting Option The Temperature window appears on the screen.
  • Page 41 Step 2: Enter the head and nozzle temperture values of each color Print Head under the Temperature and Voltage section, as shown below: Fig 46: Setting the Base Voltage Value Step 3: After specifying the head voltage, click on the Apply To Board button and then, on the Ok button to apply the settings (Refer to Fig 46).

  • Page 42: Save To Printer

    Save to Printer After making the desire changes in the printer settings, save these settings into the printer for future usage. To save the settings to the printer, click on the Main MenuSettingSave To Printer path, as shown below: Fig 47: Selecting the Save To Printer Option On clicking the Save To Printer option, all the previously made settings get saved on the Main Board.

  • Page 43: Head Alignment

    9. Head Alignment Calibration Wizard Print Heads should be calibrated to ensure good printing quality. To open the Calibration Wizard, click on the Main MenuToolsCalibration Wizard path, as shown below: Fig 48: Selecting the Calibration Wizard Option This should bring up the Calibration Wizard, as shown below: Fig 49: Displaying the Calibration Wizard Based on the above figure, the list of mechanical checks appears and as per these checks, Print Heads need to be adjusted with the help of tools provided.

  • Page 44: Mechanical Checks

    When you press the Next button, you are redirected to the Calibration Wizard, as shown in the below image: Fig 50: Displaying the Printer Calibration Options Let’s discuss each test and their result one by one in the upcoming section. Mechanical Checks Accurate mechanical alignment is the key for achieving good print quality.

  • Page 45: Vertical Check

    When there is angular error in a head’s placement, the line formed by a particular Print Head will appear broken, as shown in the image below: Fig 52: Defect in Angle Check Let’s discus the next vertical check. Vertical Check The vertical alignment test is performed to check the vertical alignment of all heads with reference to the Magenta head.
  • Page 46 Samples of Good and Bad Vertical Alignment Test Result is shown in the below figure: Fig 54: The Good and Bad Vertical Alignment Test Result When a Print Head is aligned with the reference Print Head (Magenta), then in the test print this would be evident by perfectly aligned vertical nozzle lines.

  • Page 47: Horizontal Calibration

    Step 5: Before check the vertical alignment for the H1 Heads, check and verify the vertical alignment of the H1 Magenta (base color) with respect to H0 Magenta. Step 6: If Step 5 is OK then perform vertical alignment for H1 Heads. Step 7: Now, perform Step 3 –...

  • Page 48: Step Calibration

    Left to Right and Right to Left Calibrations Left to Right Calibration is performed to achieve dot placement accuracy of all colors (Black, Cyan, and Yellow) with respect to Magenta during the carriage’s left to right print sweep. Similarly, Right to Left calibration is used to achieve dot placement accuracy during the carriage’s right to left sweep.
  • Page 49 The Step Calibration result image is shown as below: Fig 57: Displaying the Output of the Step Calibration From the above figure, you get the accurate step adjust correction value. The correction value is either positive or negative. If the value is positive, then add it in the current step adjust value for the Print Head calibration.

  • Page 50: Save To Printer

    Save to Printer After making the desire changes in the printer settings, save these settings into the printer for future usage. To save the settings to the printer, click on the Main MenuSettingSave To Printer path, as shown below: Fig 59: Selecting the Save To Printer Option On clicking the Save To Printer option, all the previously made settings get saved on the Main Board.

  • Page 51: Head Cleaning

    10. Head Cleaning Print Head is a delicate part which needs to be cleaned as per the recommended methods to have long life and to ensure consistent print quality. Below sections give recommended steps to clean the Print Heads. Head Blotting Head blotting refers to the process in which the head surface area is cleaned for better printing result and quality.

  • Page 52: Setting Wiping And Capping Height

    • Capping Enable: Enable the auto capping functionality. • Auto Capping Time: Define the auto capping time. When the printer is ideal for the define time then auto capping process gets started and capped the capping station with the head plate. Setting Wiping and Capping Height Using the Setting window, user can set the wipping and capping height by updating values in the Z Clean Pos and Z Wet Pos list boxes, as shown below:...

  • Page 53: Head Spraying

    Head Spraying Head spraying should be performed only when small percentage of nozzles are blocked. This method is used to avoid mixing of colors. When heads are sprayed all the nozzles are actuated at a high rate which helps in opening up dry nozzles of the printer. To perform head spraying, click on the Spray button available under the Quick Access Toolbar, as shown below: Fig 64: Displaying the Spray Button METRO (Konica Head)

  • Page 54: Do's And Don't

    11. Do’s and Don’t Do’s 1. Keep the room dust free and maintain the temperature between 25°C and 28°C 2. Use the Sponge Roller which is dipped and squeezed in fresh RO water 3. Clean the head sponge wiper after every wiping 4.
  • Page 55 a. Without making the tub down b. Without closing the finger valve 12. Don’t leave the Print Heads without capped and pulling the sponge tray 13. Don’t move the carriage over the Capping Station when printer is OFF and capping is in UP position 14.

  • Page 56: Maintenance

    12. Maintenance Print Head Maintenance Print Head is an important and delicate part of the printer. Thus, it must be handled with care to ensure the long life of the Print Heads. For Print Head maintenance, the following instructions should be taken care: •...

  • Page 57: Belt Shifting Control

    a) Wait for the completion of the current printing process. If the print command repeats, then immediately stop giving the next print command for printing. b) Takeout the fabric, lower down the tub, and run glue cycle in reverse direction with the 70% speed.

  • Page 58: Weekly Maintenance

    • Press roller and fabric guiding rollers should be wiped daily to remove the ink stains. Precautions: • While Print engine off and capping elevated, never move the carriage over the capping station • Always pour distill water in the Capping tray to avoid germs Weekly Maintenance Washing Tub Maintenance Washing Tub is an integral part of the Printer.

  • Page 59: Monthly Maintenance

    Computer Storage Management: • Remove unwanted files from your computer to maintain a minimum of 10GB free space in hard disk. • Remove unwanted programs and old ripped files from the computer to improve the speed of printing. Monthly Maintenance •...

  • Page 60: Troubleshooting Guide

    13. Troubleshooting Guide Error Name Reasons Remedial Actions Printer Not 1. No Power Supply to Case 1: No Power Supply to Head Board Initializing/Ini Head Board (beep can a) Check 24 V power supply output and tialization be heard) replace the Power Supply Incomplete b) Check the 24 V Power Supply on Head Board connector, if there is no power,...
  • Page 61 Printer 1. USB Cable is Loosely Case 1: Tighten the USB cable. Manager Not Connected Showing Printer “Ready” 2. USB Cable is Faulty Case 2: Replace the USB cable, if faulty. 3. Printer not Initialized Case 3: Please refer to the “PRINTER NOT INITIALIZING”...
  • Page 62 4. Ink stored unfavorable environment Case 5: Feed the Head Voltage value as 5. Head voltage is not mentioned in the Print Head. properly fed in Printer Case 6: Correct the step calibration using the Manager Step Calibration section. 6. Improper step calibration Case 7: Perform the following actions as per the...
  • Page 63 3. 24 V Input is not getting Case 3: Check 24VDC Voltage at SSR when PID supply to SSR shows replay ON. And at same time check 220VAC In Out terminal and replace SSR, if required. 4. Improper settings in PID Case 4: Perform the following actions as per the or faulty requirements:...
  • Page 64 3. Regulator is set at Low Case 3: Check the regulator settings and rotate and Take-Up regulator the knob to ON it. Additionally, if regulator is not working not working, replace it. Complete 1. Head voltage is not fed Case 1: Fed Head Voltage in Printer Manager. Head Not in Printer Manager Firing...
  • Page 65 3. Washing tub is not engaged properly Case 3: Check the following: 1. Check Actuator proper elevation (refer to the Washing Tub Not Engaging Properly section) 2. Actuator blot is not aligned properly, align it. 4. Glue dryer is not Case 4: Refer to the Heater Not Working section.
  • Page 67 For Any Query Please Contact Us www.colorjetgroup.com Call us on +91-120-4548195 Email on info@colorjetgroup.com For Ink Enquiry:- sales@colorjetgroup.com...

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