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Colorjet VerveLED VLR 2513 Installation And Troubleshoot Manual

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Summary of Contents for Colorjet VerveLED VLR 2513

  • 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 Environmental Requirements ........................5 3. Safety Precautions ............................ 6 4. Electric Requirements ..........................6 Proper Earth Connection .......................... 6 5.
  • Page 4 Setting Procedure – Negative Pressure Control Board ............... 30 Setting Procedure – Pressure Display Meter ..................30 14. Media Loading ............................31 15. Checking Status ............................. 32 16. Head Calibration and Alignment ......................34 17. Maintenance ............................40 Machine Maintenance ..........................40 Equipment Cleaning ..........................

  • Page 5: Site Layout

    1. Site Layout The Site Layout of the machine is shown in the image below: Fig 1: Displaying the Site Layout of the Machine Machine Dimension (L x W x H): 4700 x 2660 x 1520 mm Dimension with Packing (L x W x H): 4830 x 2280 x 1840 mm (LxWxH) 2.

  • Page 6: 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: • Magnifying lens (Carry by Engineer) •...

  • Page 7: Safety Precautions

    3. Safety Precautions Before operating the printer and Print Control Centre 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...

  • Page 8: Preparation Before Installation

    5. Preparation before Installation To install the printer, you must follow the below mentioned instructions: o Prepare the site as per the requirements like environmental temperature. o 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 ▪ Spanner Unloading the Machine The net weight of the machine is 1762 Kgs.

  • Page 10: Input Power Checklist

    Now, the machine is unpacked and ready for installation process. Fig 2: Unpacking the Machine Caution: Don’t move or unload the machine before ensuring that the place where the machine is landed, is even or level. Precautions: • Don’t lift from the extreme ends of the machine •...

  • Page 11: Installation Of Print Control Centre

    9. Installation of Print Control Centre Follow these steps to install the Print Control Center: Step 1: Insert CD in the CD drive. Step 2: Navigate the Setup file path to start the installation process, as shown below: Fig 3: Navigating the Setup File Path Step 3: Double click on the Setup icon (Refer to Fig 3).

  • Page 12: Custom Software Settings

    Now, the Print Control Center software is installed in your system and also a shortcut of it is created on the desktop, as shown below: Fig 5: Displaying the Desktop Icon Now, the print control center gets installed. Custom Software Settings Enabling Administrator Mode Please remember that software must be run as an administrator.

  • Page 13: Verifying Software Settings

    Step 2: Select the Properties option form the list. The Properties dialog box appears. Step 3: Select the Compatibility tab. Step 4: Select the “Run this program as an administrator” check box, as shown below: Fig 7: Displaying the Properties Dialog Box Step 5: Click the Apply button then OK.

  • Page 14: Print Head Configuration

    Print Head Configuration When we open the Print Control Center, 1190 error appears on the screen. To remove this error, the desired head configuration has to be selected. To select the head configuration settings, click on the Maintenance → Voltage path, the following screen appears as shown below: Fig 8: Setting the Print Head Configuration Note: Before setting print head configuration, service engineer has to provide the password in the user login screen.

  • Page 15: Software Settings

    Software Settings Print Size In Verve LED, total print size is 2500X1300 mm (WxH). To specify an image size, user needs to click on the Task Select menu and navigate the image file path. After this, double-click on the image. The Properties dialog box appears on the screen, as shown below: Fig 10: Setting the Print Size In the above image, user can print a particular region in the selected image simply by selecting the Region...
  • Page 16 Description of different options for the White Color printing: • No Print: No white color is printed. • Full: White will be printed completely all over the image. • Valid Image: White color is printed same as the percentage of CMYK color in the selected image. •...
  • Page 17 Description of different options for the Varnish Color printing: • No Print: No varnish color is printed. • RIP Data: Varnish color is printed as per the RIP file. • Flood: Varnish will be printed completely all over the image. •...

  • Page 18: Layer Mode

    Layer Mode Installation engineer needs to create all the required layers. Layer mode defines the sequence and depth of printing with respect to color, white and varnish. To increase the depth of ink layer, select the desire option from the available list. For example, if the layer mode C+W+V is selected. This means, the first layer of Color (CMYK) is printed, then White and Varnish is printed in the last.

  • Page 19: Switch On Procedure

    10. Switch ON Procedure Follow these steps to switch ON the printer: Step 1: Check and maintain the room temperature for smooth printing operations. Step 2: Check Ink Level. Step 3: Check Waste Ink Bottle. Step 4: Release the Emergency button, if pressed. Step 5: Check water level in the Chiller Unit and fill it, if required.
  • Page 20 Step 8: To initialize the machine, first open the Print Control Center and get it ready for use. Now, the machine starts initializing automatically. Firstly, the machine initializes the Z Axis, then the sequence is Y Axis→X Axis→ Again Z Axis. Step 9: Switch ON the Print Bed vacuum by pressing the Bed Vacuum button available on the front left side of the machine, as shown below: Note:...
  • Page 21 Step 11: Press the Detect Media Height button to sense the media height, as shown below: Fig 18: Setting Head Height Step 12: Lift the carriage up by pressing the Lifter Back Zero button on the Carriage Lifter tab under the Maintenance menu (Refer to Fig 18).

  • Page 22: Ink Filling

    11. 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: Open the left door of the printer to find out main tanks. Step 2: Fill recommended ink in main ink tank (as per the color sticker) as per the requirement, as shown below: 19:Displaying the Main Ink Tanks...
  • Page 23 Ink gets filled in the Sub tanks shown below: Fig 21: 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. Verve LED Page | 22...

  • Page 24: Head Installation

    12. 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 authorized 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 25 Step 4: Mount the Head I/O bracket near the sub tank of each color, as shown below: Fig 23: Mounting Head I/O Board Step 5: Remove the head cover. Step 6: Fix the Ink Inlet pipes as per the length required and disk filters, as shown below: Ink Filters Head Cable Connector Ink Inlet Pipes...
  • Page 26 Step 8: Fix all the screws front and back side on the Head Plate, as shown below: Head Alignment Screws Fig 24: Mounting Print Heads Step 9: Connect ink inlet pipes to the sub tanks (Refer to Fig 24). Step 10: Connect the Head cable connector to the Head I/O Board (Refer to Fig 24). Step 11: Connect one end of the head cable to the Head I/O board and another to the Head board in the given slot.
  • Page 27 In the above figure, you can view that the Yellow and Cyan color head cable is insert to Slot Number 3 on the Head Board. Similarly, Cyan and Black color cable is in the slot number 5. The Head Board (from the front side of the printer) is shown as below: Fig 26: Displaying the Head Board Note: Head cable connector pins are very delicate and tend to bend/peel off, care not to damage these...

  • Page 28: Negative Pressure Adjustment

    13. Negative Pressure Adjustment Understanding Negative Pressure Condition after purging: 1. Ink drops hold on the nozzle plate, neither drop nor sucked back (as shown in the image below). 2. This is perfect and ideal condition 3. Ink drop easily from the head Increase the negative pressure for eg.

  • Page 29: Negative Pressure System Working

    Negative Pressure System Working Pressure adjustment setting has to be done at two stages, first in the negative pressure control board and secondly in the pressure display meter mounted near this board. There are two display meters mounted in the machine. The first meter is available near the control board which displays the exact negative pressure value.

  • Page 30: Negative Pressure Settings

    Negative Pressure Settings Fig 29: Displaying the Negative Pressure Settings The Negative Pressure Control Board is shown in the image below: Fig 30: Displaying the Negative Pressure Control Board Verve LED Page | 29...

  • Page 31: Setting Procedure - Negative Pressure Control Board

    Setting Procedure – Negative Pressure Control Board Step 1: a) Enter setting mode→ Press “ESC”→Number “13.2” will flash, this is setting 1. b) Press “ESC” again→& number 23.33 will flash, this is setting 2 Setting 1: is for White Min set value Setting 2: is for White Max set value Setting 3: is for Color Min set value Setting 4: is for Color Max set value...

  • Page 32: Media Loading

    14. Media Loading Follow these steps to load the media on the machine: Follow these steps to load media: Step 1: Place the media on the Print Bed. Step 2: Switch ON the Print Bed vacuum by pressing the Bed Vacuum button available on the front side of the machine, as shown below: Fig 31: Turning ON the Bed Vacuum Button Step 3: Switch ON the required vacuum chambers by moving the Vacuum Chamber knob, as shown below:...

  • Page 33: Checking Status

    15. Checking Status Before giving the nozzle test, user needs to provide the printing parameters like print origin (X and Y), printing direction, and speed. To check the status of print head nozzles, click on the Status option under the Operation tab, as shown in the image below: Fig 34: Checking the Status of Head Nozzles The Media Thickness dialog box appears on the screen where user needs to set the media thickness, print head to media height, and lifter height.
  • Page 34 The Test Result is shown in the image below: Fig 36: Displaying the Test Result Note: In case of soft media, user needs to manually feed the value of media thickness, print head to media height, and lifter height by verifying it. Verve LED Page | 33...

  • Page 35: Head Calibration And Alignment

    16. Head Calibration and Alignment Accurate mechanical alignment is the key for achieving good print quality. In case of misalignment, the Print Heads have to be adjusted manually using tools and the alignment should be re-verified iteratively until the heads are perfectly aligned. Note: - Magnifying lens and torch is must to observe carefully the alignment patterns.
  • Page 36 Step 1: Printed Mechanical Check When you press the Next button, we redirect to the Mechanical check screen, as shown in the below images: Fig 39: Displaying the Mechanical Check Screen This test is done to check Vertical Alignment as well as Angle check. By clicking on the Print button, the Test Result appears on the screen, as shown below: Fig 40: Displaying the Mechanical Check Observe the above printed pattern for Vertical alignment of color to color (generally base color is Cyan).
  • Page 37 For Pass Step Calibration, click the Next button in the Calibration Wizard (Refer to Fig 39). The Pass Step Calibration screen appears as shown below: Fig 41: Displaying the Pass Step Calibration Screen Step 2: Pass Step Calibration Click on the Print button (Refer to Fig 41) and check the matching value, if the marked values don’t match, consider in between those values in the decimal (e.g.
  • Page 38 Step 5: Head Vertical Position Calibration (Y Offset) This is 2 stage of Vertical Alignment and is required to correct the vertical alignment precisely through software (in 2 decimal places). Click Print (Refer to Fig 45) and the printed result will be as shown in the below image (only Black in this case): Fig 43: Displaying the Vertical Alignment Test Result When a color is aligned with the reference head (cyan), then in the test print this would be evident by...
  • Page 39 For Color Offset, click twice to the Next to go to (Refer to Fig 41). The Color Offset screen appears as shown below: Fig 45: Displaying the Color Offset Close the Calibration Wizard by pressing the Close button Color Offset To check Color Offset, click on the Maintenance tab and select the Calibration tab.
  • Page 40 Firstly, check if Cyan(C) has 0 fed in its input field, make it zero before performing color offset (left right). Print color offset for ‘left to right’ selecting a speed. Observe the correct matching values and feed in the input field for each color. Mostly same values have to be entered in PH1(R) and PH1(L). Repeat the same for ‘Right to Left’.

  • Page 41: Maintenance

    17. 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 42: 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 Don’t touch the pin connectors and welded joints on circuit boards and integrated circuit boards.

  • Page 43: Ink Supply System Maintenance

    Ink Supply System Maintenance Follow the below instruction for maintaining the ink supply system • Appearance Inspection • Check for any leak between joints, ink tanks and valve seating. • Check for any cut on ink tubes. • Filter Replacement •...

  • Page 44: Troubleshooting

    18. 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 45: 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 46: 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 47: 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 48: 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 Correct vacuum settings adjustment 3. Run Button on the Vacuum Run button is not pressed after After adjusting vacuum pump Regulator...
  • Page 49 Verve LED Page | 48...

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