Colorjet METRO KONICA HEAD User manual

KONICA HEAD

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METRO (Konica Head)
Foreword
This installation guide is briefly describing the operational aspects of the METRO (Konica Head) machine.
In this document, the step-wise instructions for installing and operating the various aspects of the
machine with visual screens are provided for easy and better understanding. It also describes the error
messages encountered while working with the machine with appropriate remedial actions required to be
taken by the service engineer.
This guide refers as the reference tool which guides the service engineer how to install the METRO (Konica
Head) machine without anyone else assistance. The information provided in this document ensures its
uniqueness and language quality. For safe and proper use of the product, please read this document
carefully and follow all the instructions.
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”.
The reference table is shown in the below table:
Doc Type
Doc Code
Version
Machine Name
Date of Issue
Installation Manual
1.0
METRO (Konica Head)

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METRO (Konica Head)
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. Safety Requirements.................................................................................................................................8
Power Requirements ................................................................................................................................8
Water Supply Requirements.....................................................................................................................8
Computer Requirements ..........................................................................................................................8
Environment Requirements......................................................................................................................8
4. Installing Accessories ................................................................................................................................9
Levelling the Machine...............................................................................................................................9
LED Light..................................................................................................................................................10
Tower Light .............................................................................................................................................10
Water Tank and Washing Tub.................................................................................................................11
Ink Tank...................................................................................................................................................14
Adjusting the Conveyor Belt Tensioning.................................................................................................15
Controlling Belt Movement ....................................................................................................................15
Setting Belt Speed...................................................................................................................................16
Centering of Belt .................................................................................................................................16
Belt shifting control.............................................................................................................................17
Setting Washing Unit ..............................................................................................................................18
Glue Implementation..............................................................................................................................18
Stages of Glue (Adhesive) Process......................................................................................................19
Glue Process Preparation....................................................................................................................20
Glue Coating Procedure......................................................................................................................22
Glue Removing Preparation................................................................................................................24
5. Loading the Fabric...................................................................................................................................27
6. Filling Ink .................................................................................................................................................29

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METRO (Konica Head)
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 .........................................................................................................................................44
Horizontal Calibration.............................................................................................................................46
Step Calibration.......................................................................................................................................47
Save to Printer.........................................................................................................................................49
10. Head Cleaning .......................................................................................................................................50
Head Blotting ..........................................................................................................................................50
Setting Wiping and Capping Height ....................................................................................................51
Head Purging...........................................................................................................................................51
Head Spraying .........................................................................................................................................52
11. Do’s and Don’t.......................................................................................................................................53
12. Maintenance ........................................................................................................................................55
Print Head Maintenance.........................................................................................................................55
Belt Maintenance....................................................................................................................................55
Centering of Belt .................................................................................................................................55
Belt Shifting Control............................................................................................................................56
Glue Coating Layer..............................................................................................................................56
Environmental Maintenance ..................................................................................................................56
Daily Maintenance..................................................................................................................................56
Weekly Maintenance..............................................................................................................................57
Monthly Maintenance ............................................................................................................................58
13. Troubleshooting Guide .........................................................................................................................59

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

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METRO (Konica Head)
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
•CBM (Cubic Meter): 30.2
Dryer
•Gross Weight: 686 Kg
•Net Weight: 500 Kg
•Dryer Dimensions (L x W x H): 2560 x 1500 x 1350 MM
•Packing Dimensions (L x W x H): 2660x 1960 x 1770 MM
•CBM (Cubic Meter): 9.23
Feeder
•Gross Weight: 658 Kg
•Net Weight: 617 Kg
•Feeder Dimensions (L x W x H): 2350 x 800 x 1210 MM
•Packing Dimensions (L x W x H): 2560 x 960 x 1530 MM
•CBM (Cubic Meter): 3.76
Room Dimensions
Room Dimension (L x W x H): 8500 x 8000 x 3500 MM
Note: Door opening and ceiling height should be as per above dimensions.

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METRO (Konica Head)
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
Carefully read the instructions given below for the safe use of the machine. Neglecting them can damage
or malfunction the machine or lower down the print quality.
•Avoid direct wind coming from an air blower or air conditioner onto the machine. It can dry ink in
the printer head nozzles, clogging injection ports, lowering print quality, and more.
•Clean the print head, if the printer has not been used for more than a weak to avoid print head
nozzle blockage.
•Don’t apply more pressure while installing the main or sub ink tanks as it can cause ink leakage,
damage the machine, or contaminating the surroundings.
•Use the machine within the specified temperature and humidity range to avoid halt in operations.
•Use gloves while working with the internal parts of the machine to avoid damage.
Precautions for Fabric Use
Unprinted Fabric (Roll)
To keep the print result last in best conditions, carefully observe the following precautions during the
machine handling:
•Do not use the stain fabric.
•Do not scratch the printing side.
•Moisture transfer to fabric may negatively impact the print quality.
•Carefully hold the edges of the fabric roll. It is recommended to wear cotton gloves while loading
the fabric.
•Fabric surface may get wavy or curved by a sudden temperature and humidity change. When
setting the fabric into the machine, flatten the surface with hands without making any scratches
or stains.

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METRO (Konica Head)
•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.
•Remove the fabric roll from the printer after use. Rewind unused part and wrap the roll into the
bag that came with it for storage.
Printed Fabric (Roll)
Follow the instructions for the printed fabric, as given below:
•Do not rub or scratch the printed fabric.
•Do not touch the printed side of the fabric.
•Let the printed fabric dry completely without folding or piling up.
•Avoid direct sunlight
•When storing printed fabric, follow the instructions that came with fabric to avoid color change
Precautions for Ink Use
Ink Before Use
Carefully observe the following given instructions for storing ink:
•Store ink in a cool and dry place to avoid direct sunlight.
•Try to finish the opened ink bottle as soon as possible to avoid ink dry situation. If keeping the
opened ink out of necessity, tightly close the container to avoid contact of air.
Ink After Use (Waste Ink)
Printer's waste ink is industrial waste. Thus, it must be disposed according to regulations and local laws to
avoid the environment pollution. If there is any confusion, kindly ask operators for industrial waste
disposal to process waste ink.

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METRO (Konica Head)
3. Safety Requirements
Power Requirements
•Printer
oPrint 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.
oBelt Dryer: Total Wattage: 4000Watts @ 220Volts AC 50Hz, Sinewave
▪Continuous (5 Sec breaks acceptable in 60 Secs) power supplies required.
▪Safety: 20A MCB must be used to Power this Inlet.
•Dryer: Total Wattage: 8500Watts @ 220Volts AC 50Hz, Sinewave
oUninterrupted power supplies (flicker free) should be provided as it has digital circuit.
oSafety: 63A MCB must be used to Power this Inlet.
•Feeder: Total Wattage: 350Watts @ 220Volts AC 50Hz, Sinewave
oUninterrupted power supplies (flicker free) should be provided as it has digital circuit.
oSafety: 5A MCB must be used to Power this Inlet.
•Wire gauge should be at least 6sqm, recommended 8sqm.
•Exclusive Earthing should be required for printer and it should not be shared with UPS & Building's
common Earth.
•Printer and computer must share same exclusive earthing.
Water Supply Requirements
•60L normal tap water for circulation
•Hose pipe inlet diameter 20mm and total length is 18mtr
Computer Requirements
•Minimum requirement
oi5 processor (Quad Core)
o8GB RAM
o1TB HDD
•Recommended requirement
oi7 processor (Quad Core)
o8GB RAM
oWin7 Professional (64bit)
Environment Requirements
•Room temperature should be maintained in the range of 18-28 degree Celsius with humidity 35-
80% RH, Please Note: Printer is equipped with dryers, it may raise the room temperature –A 10%
additional load should be considered when designing the AC
•There should not be air draught in the room
•Closed dust-free room exclusive for Printer
oLight:
▪CRI 98%
▪LUX Min 200

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METRO (Konica Head)
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

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METRO (Konica Head)
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

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METRO (Konica Head)
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.
Step 2: Connect the Water Inlet and Drain pipes to the Water Tank.

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METRO (Konica Head)
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

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METRO (Konica Head)
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 3/4th of water.
Now, the Water Tank and Washing Tub is installed.

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METRO (Konica Head)
Ink Tank
Follow these steps to connect ink tanks:
Step 1: Unlock the Ink Knobs of each color in the below shown direction:
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
Unlock Ink Knob

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METRO (Konica Head)
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. Start tensioning the
belt by adjuster bolts thread by thread equally on both sides, till the length becomes 3mm (max) in excess
(i.e.,1003mm), as shown below:
Fig 15: Tightening the Conveyor Belt
Now, the Conveyor Belt tensioning gets adjusted.
Controlling Belt Movement
To control the belt motion, select the BELT MOVEMENT icon from the MAIN MENU screen. The BELT
MOVEMENT screen appears as shown below:
Fig 16: Displaying the BELT MOTION Screen

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METRO (Konica Head)
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.
•MANUAL REV: Manually move the belt in the reverse direction.
•MANUAL FWD: Manually move the belt in the forward direction.
Setting Belt Speed
To set the belt speed, select the SPEED icon from the BELT MOOVEMENT screen. The Numeric Keypad
appears on the BELT MOVEMENT screen, as shown below:
Fig 17: Setting the Belt Speed
Now, enter the belt speed in the Numeric Keypad and select the Enter button to set the belt speed.
Centering of Belt
Below section explains about centering of belt, when it has shifted towards edge of the roller:
•If the belt is shifting one side more than 5mm in 1 hour, do the following
oWait for the running print to be completed, if repeats are given, stop immediately after
the running image is completed, and prevent giving next command.
oTakeout the fabric, lower the tub and run glue cycle in reverse direction with 70% speed.
oWhen the belt is rotated reversely (without adjusting), further shifting is stopped and belt
starts moving in opposite direction. Closely monitor the process until it comes in the
center. Once belt has positioned centrally, glue cycle has to be stopped and shifting
control adjustment has to be done as mentioned further in next section.
•If the belt shifting has crossed 5mm outside the roller, print has be stopped immediately and belt
has to be repositioned in center by loosening the tensioner screws, else severe damage to belt
can happen. If you feel unconfident about doing so, please call the engineer.

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METRO (Konica Head)
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.
Case-I: Belt Shifted Towards Left
Case-2: Belt Shifted Towards Right

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METRO (Konica Head)
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:
•BRUSH OFF: Switch ON or OFF the brush unit.
•BELT DRYER: Switch ON or OFF the belt dryer.
•TAB DOWN: Move the washing tub in upward direction.
•JETTING PUMP: Switch ON or OFF the jetting pump of the machine.
•PRINT DRYER: Switch ON or OFF the print dryer.
Glue Implementation
Glue is composed of three different chemicals and two solvents.
Chemicals:
•Prima: It is used as a primitive coat, for smoothening the belt surface. This is to be done only when
the previous glue layers have been washed completely.
•Therma: It is used for an intermediate coat, for activating and deactivating the glue according to
the temperature variation.
•Perma: It is the final glue coat, to make the belt sticky for the fabric.
Solvent:
•Cleantek: This liquid solution is used for the renewing/refreshing the tackiness of the Perma
adhesive. In digital printing, the adhesive film must be even, thin and hard (to maintain accurate
distance in between print head and fabric). The Cleantek removes foreign elements, like dust and
micro fibers, from the top layer, hence enhancing the adhesion property of the Perma. If there is
no improvement using the Cleantek, it means it’s time for a coat of the Perma.

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METRO (Konica Head)
•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:-
oWhen the thickness of the adhesive layer goes on increasing due to multiple coat of the
Perma.
oWhen the glue layer feels smudgy or groovy (in terms of evenness).
Stages of Glue (Adhesive) Process
Stage 1: Prima coat
Stage 2: Therma coat
Stage 3: Perma coat
An interval of 4hrs is required for the glue to set and dry. After each glue coat, run the glue cycle for 50
minutes with glue heater ON. After final coat of Perma, printing can be started. The third stage is generally
a repetitive process, repetition depending on the frequency of printing hours. And when the glue coats
get uneven or once in 2-3 months, whole process has to be repeated after removing existing Glue layers.
Note: Average consumption for the Cleantek solvent is 500ml for one time.
Approximate consumption of chemicals for a year:
•Prima: Approx. 2 Ltrs
•Therma: Approx. 2 Ltrs
•Perma: Approx. 5 Ltrs
•Cleantek: Approx. 4 Ltrs
•Solvtek : Approx. 10 Ltrs
Note: Actual consumption depends on the work load, fabric type, and the maintenance. Generally, shelf
life for these chemicals is approx. 4 years.
Shelf life for this chemical are approx. 4 years. Some of the Glue are having these chemicals as base and
it harms the belt or adversely affects the life of the Printing Blanket (Conveyor Belt):
RECOMMENDED
•Alcohol
•Methyl alcohol
•Ethyl alcohol
•Isopropyl alcohol
•Ester
•Butyl acetate
•Ethyl acetate