Colorjet Vulcan Series Installation And Troubleshoot Manual
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Colorjet Vulcan Series Installation And Troubleshoot Manual

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  • Page 2 Disclaimer The information and instructions provided in this installation 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 2. Site Preparation ............................4 System Requirements ..........................4 Supporting Software Requirements ......................5 Tool Requirements ............................5 Environmental Requirements........................5 3. Safety Precautions ............................6 4. Electric Requirements ..........................6 Proper Earth Connection ..........................6 5.
  • Page 4 Control System Maintenance ........................42 Mechanical System Maintenance ....................... 42 Encoder System Maintenance ........................42 Ink Supply System Maintenance......................... 43 Computer Maintenance ..........................43 Using and Maintenance of Print Head ......................43 16. Troubleshooting ............................44 1. “Printer Not Initializing” ......................... 44 2.

  • Page 5: Site Layout

    1. Site Layout The Site Layout of the machine is shown in the image below: Main Power Button 1.5 M Back View 1.5 M 1.5 M Front View 1.5 M Fig 1: Displaying the Site Layout of the Machine 2. Site Preparation System Requirements The System Requirements are given as follow: Table 1: Recommended System Requirements...

  • Page 6: Supporting Software Requirements

    Supporting Software Requirements The Supporting Software Requirements are given as follow: Table 2: Supporting Software Requirements Requirements Specifications Printer Software Provided by ColorJet RIP Software Provided by ColorJet Tool Requirements The Tool Requirements for printer installation are given as follow: •...

  • Page 7: Safety Precautions

    3. Safety Precautions Before operating the printer and Printer Manager software for the first time, please read the document carefully and follow all the usage instructions. While using the printer, kindly follow all the safety instructions which are given below: Fire Prevention Inks and solvents must be enclosed in a special storage cabinet for inflammable liquids or within a separate storage room and must be clearly identified to meet the professional requirements of safety regulations.

  • Page 8: Preparation Before Installation

    5. Preparation before Installation To install the printer, you must follow the below mentioned instructions: • Prepare the site as per the requirements like environmental temperature. • Configure PC as per the given system specification viz. RAM, operating system, processor, and storage space.

  • Page 9: Unpacking And Unloading The Printer Box

    7. Unpacking and Unloading the Printer Box Machine and Tool Requirements The Machine and Tool Requirements are shown as follow: • Fork lift • Crane • Heavy duty lifting belt/sling • Powered screw/nut driver • Nut driver of 8mm Bit •...

  • Page 10: Getting The Printer Ready

    Precautions: • Don’t lift from the extreme ends of the machine • Don’t tilt the machine • Don’t drop the machine • Don’t climb or stack anything over the roof Getting the Printer Ready Follow these steps to make the printer ready for use: Step 1: Verify the environmental requirements for the machine like room temperature and make the adjustment accordingly.
  • Page 11 Step 8: Level the machine using the inside and outside levelers. The Machine Levelers are shown as follow: Fig 3: Displaying the Inside and Outside Levelers Step 9: Connect the chiller unit Step 10: Switch on the printer and wait for the complete initialization of it. Step 11: Install the Printer Manager software and RIP software for printing.

  • Page 12: Ink Filling

    8. Ink Filling Please use the recommended ink in the printer for high printing quality and long life of print and Print Head. Follow these steps to fill ink in the printer: Step 1: Switch ON the printer. Step 2: Fill recommended ink in each main ink tank as per the color stickers, as shown below: Fig 4: The Main Ink Tanks Note: Main tanks are equipped with ink level sensor which beeps once the ink level goes down.
  • Page 13 Now, pumps start working and ink start moving in the ink pipes. The ink sub tanks are shown in the below image: Fig 6: The Sub Ink Tanks with Heaters The sub ink tanks are equipped with Heaters and float sensors to maintain the temperature of inks and indicate if ink level goes down.

  • Page 14: Head Installation

    9. 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. The following print head is used in the VULCAN machine: Fig 7: Displaying the Print Head Note: Don’t apply much pressure on...
  • Page 15 Now, the head cap gets removed, as shown below: Fig 9: Removing the Head Cap Step 2: Unscrew the screws available on the carriage plate and remove the cover, as shown below: Fig 10: Removing the Cover on the Carriage Plate Step 3: Mount the print head on the head plate.
  • Page 16 Step 5: Fix all the Head Aligners viz. front and back sides, as shown below: Front Side Fig 11: Fixing Front Side Head Aligners Back Side Fix Push Fitting Connectors (both sides) Fix Aligner Fig 12: Fixing Back Side Aligners VULCAN Page 15 of 50...
  • Page 17 Step 6: Fix the Head Tensioner Strip for aligning head left and right, as shown below: Fig 13: Fixing the Head Tensioner and Push Fitting Connectors Step 7: Insert one end of the head cable on the top of the Print Head and gently press it to fix, as shown in the image below: Fig 14: Inserting the Head Cable Step 8: Similarly, insert the second end of the head cable on the Head Board and gently lock the head cable...
  • Page 18 Step 9: Insert one end of the power cable on the top of the Print Head and gently press it to fix, as shown in the image below: Fig 15: Fixing the Power Cable Step 10: Similarly, insert the second end of the power cable on the Power Supply Board and gently lock the cable with the Power Supply Board.

  • Page 19: Head Alignment

    10. Head Alignment The following aligners are used for aligning head: Fig 16: Displaying Front and Back Sides Aligners Steps to align head To align head in upward or downward direction, tight the Push Fitting Connectorsfrom front or back side as per requirements: Fig 17: Aligning Head in Upward or Downward Direction Push Fitting Connectors...
  • Page 20 To align head in left or right direction, tight the Head Tensioning Strip screw as per requirements: Fig 18: Aligning Head in Left or Right Direction Head Tensioning Strip Screw VULCAN Page 19 of 50...

  • Page 21: Led Uv Lamp Height Adjustment

    11. LED UV Lamp Height Adjustment Loose all the screws shown in the image below and move up or down as per the requirements: Fig 19: Adjusting UV Lamp Height VULCAN Page 20 of 50...

  • Page 22: Installing The Printer Manager

    12. Installing the 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 23 On-clicking the Printer Manager icon, the Startup screen appears, as shown below: Fig 21: Starting the Installation Process Step 4: Click on the Next to confirm that you want to install the Printer Manager software and follow all the instructions appear on the screen. Now, the Printer Manager gets installed successfully and displayed the Ready status.
  • Page 24 Step 5: Open Device Manager, right-click on the My Computer icon and select the Manage option from the context menu, as shown below: Fig 23: Selecting the Manage Option Step 8: Select the Device Manager option from the Computer Management window (Refer to Fig 24). The Device Manager and its related options get expanded on the middle pane of the Computer Management window, as shown below: Fig 24: Displaying the Device Manager Screen...
  • Page 25 Step 11: Select the Update Driver Software option from the context menu, as shown below: Fig 25: Configuring the USB Driver The Update Driver Software window appears, as shown below: Fig 26: Displaying the Update Driver Software Window Step 12: Select the Browse my computer for driver software option from the Update Driver Software window (Refer to Fig 26).
  • Page 26 Step 13: Select the location where the driver software is stored by clicking on the Browse button, as shown below: Fig 27: Selecting the Driver Location Step 14: Click on the OK button to start the driver update process (Refer to Fig 27). The process gets started for updating the driver software and the process progress screen appears, as shown below: Fig 28: Displaying the Process Progress VULCAN...

  • Page 27: Printer Manager Settings

    Now, the driver updating process gets completed successfully, as shown below: Fig 29: Updating the Driver Successfully On completing the process, click on the Close button to close the process. Printer Manager Settings Printer Settings This option enables users to update the default settings of the printer viz. Print, Move, Preference, and Calibration.
  • Page 28 Describing the different sections of the Setting window, as given below: • Print setting o Auto skip white: Enable to auto skip the white space in the image during printing. o Step Time: Set time interval of the feed motor during printing. o Job Space: Set space between multiple jobs.
  • Page 29 The Preference tab is shown in the image below: Fig 32: Displaying the Preference Tab The Calibration tab is shown in the image below: Fig 33: Displaying the Calibration Wizard VULCAN Page 28 of 50...

  • Page 30: Head Temperature Settings

    The Multilayer print tab is shown in the image below: Fig 34: Displaying the Multilayer print 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 35: Selecting the Real Setting Option The Temperature window appears on the screen.

  • Page 31: Save To Printer

    Step 2: Enter the head and nozzle temperture values of each color Print Head under the Temperature and Voltage section, as shown below: Fig 36: 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 36).

  • Page 32: Head Calibration

    13. Head Calibration To improve and enhance the printing quality, you must carefully align the Print Head. The Print Head alignment process consists the following tests: • Mechanical Check: Includes Vertical Check and Angle Check • Software Calibration: Includes Horizontal Calibration viz. Left, Right, and Bi-direction. Calibration Wizard Print Heads should be calibrated to ensure good printing quality.
  • Page 33 This should bring up the Calibration Wizard, as shown below: Fig 39: 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. The list of mechanical checks are given as below: •...

  • Page 34: Step Calibration

    Step Calibration The printer step calibration is performed to verify and correct media feeding. The printer prints a complete image pass by pass. A pass is the horizontal carriage sweep perpendicular to the media movement. After each pass the printer moves the media forward for the next pass. This movement of media is called a step. The distance by which the media is moved is called the step size and it has to be accurate.

  • Page 35: Mechanical Checks

    Mechanical Checks Accurate mechanical alignment is the key for achieving good print quality. In case of misalignment, the Print Heads have to be adjusted manually using the provided tools and alignment should be re-verified iteratively until the Print Heads are perfectly aligned. Angle Check This test checks the mounting angle of all the Print Heads.
  • Page 36 Vertical Check The vertical alignment test is performed to check the vertical alignment of all heads with reference to the Magenta head. To execute vertical alignment test, click on the Vertical Check button on the Calibration Wizard. Samples of Good and Bad Vertical Alignment Test Result is shown in the image below: Fig 44: 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 37: Horizontal Calibration

    Horizontal Calibration Horizontal Calibration checks the bi-directional, left, and right alignment and corrects it by adding or subtracting the correction value from the default set value. It has to be performed for each print mode, whichever is required. Let’s discuss each type of horizontal test one by one. Bi-direction Calibration Bi-directional calibration is performed to achieve dot placement accuracy between the “Left to Right”...
  • Page 38 The Left Calibration Result is shown in the image below: Fig 46: The Horizontal Left Check The Right Calibration Result is shown in the image below: Fig 47: The Horizontal Right Check VULCAN Page 37 of 50...

  • Page 39: Media Loading

    14. Media Loading Follow these steps to load the media on the machine: Step 1: Check the media tensioning from front and back sides using the paper sheets, as shown in the image below: Fig 48: Verifying the Media Tensioning Step 2: If media tensioning is not correct, then tight the tensioner skew, as shown below: Fig 49: Adjusting the Tensioning In case, operator needs to adjust the position of front or back roller, then press the Front Pressure Roller or...
  • Page 40 The Front Pressure Roller button is shown in the image below: Fig 50: Showing the Front Pressure Roller button The Back-Pressure Roller button is shown in the image below: Fig 51: Pressing the Back Pressure Roller Button Step 3: Unwind the media roll and insert the media between the platform (rollers), as shown in the image below: Fig 52: Showing the Media Path VULCAN...
  • Page 41 Step 4: Pull the enough media so that it reaches to the Take Up Roller. Note: While loading the media, make sure that media should be aligned or both sides need to be matched properly. Step 5: Paste the front edge of the media on the Core to wind correctly on it. Now, media gets loaded into the machine.

  • Page 42: Maintenance

    15. Maintenance Machine Maintenance In order to keep the machine in a good working condition, one must regularly perform the following tasks: • Before printing, one should issue the nozzle test command to check print head’s nozzles status. In case, nozzles are blocked or test result is not good, then one should perform head cleaning process to clean print head’s nozzles (Refer to Head Cleaning section).

  • Page 43: Control System Maintenance

    Control System Maintenance Follow the below given instructions for control system maintenance: • Static Discharge o One must discharge electrostatic waste of the machine before touch the electronic components and parts of it. o Do not touch the pin connectors and welded joints on circuit boards and integrated circuit boards.

  • Page 44: Ink Supply System Maintenance

    Ink Supply System Maintenance Follow the below instruction for maintaining the ink supply system • Appearance Inspection o Check is there any leak between joint and ink tank, joint and valve seating. o Check is there any broken on ink tubes. •...

  • Page 45: Troubleshooting

    16. Troubleshooting 1. “Printer Not Initializing” Problematic Parts Reasons Correction Steps 1. Emergency Switch Switch is Pressed Release the Emergency Switch 2. 220V AC No power supply to the Head Check the Input/output Volt Board Check MCB and ON it, if not 3.

  • Page 46: Ink Not Filling

    3. “Ink Not Filling” Problematic Parts Reasons Correction Steps 1. Main Tank Main tank is empty Refill the Main Tank 2. Ink pump Ink pump is not working Replace the pump, if faulty Connectors are loose Tighten the connectors, if loosen 3.

  • Page 47: Print Stops In Between Printing

    6. “Print Stops In Between Printing” Problematic Parts Reasons Correction Steps 1. USB Cable Cable is loose Tighten the USB cable Cable is faulty Replace it, if faulty 4. File Size File size exceeded the limit Use compatible and small size images for printing 5.

  • Page 48: Lines In Print

    9. “Lines In Print” Problematic Parts Reasons Correction Steps 1. Head Nozzles Head nozzles are blocked Clean the Print Head 2. Feed Adjustments Incorrect feed steps Correct the feed steps using the Calibration Wizard 3. Head Alignment Head alignment is incorrect Refer to the Head Alignment section 4.

  • Page 49: Media Not Sticking To Bed

    12. “Media not sticking to Bed” Problematic Parts Reasons Correction Steps 1. Vacuum Pump Vacuum pump is not ON Switch ON the Vacuum Pump 2. Vacuum Settings Incorrect vacuum settings adjustment Correct vacuum settings 3. Run Button on the Run button is not pressed after After adjusting vacuum pump Vacuum Regulator settings...
  • Page 51 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 For Support:- support@colorjetgroup.com...

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