Colorjet Neptune User manual

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Foreword
This installation guide is briefly describing the operational aspects of the NEPTUNE 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 NEPTUNE
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
1.1
NEPTUNE
June 2019

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Table of Contents
1. Site Layout.................................................................................................................................................3
2. Site Requirements.....................................................................................................................................3
Hardware Requirements...........................................................................................................................3
Supporting Software.................................................................................................................................4
Site Requirements.....................................................................................................................................4
Power Requirements ................................................................................................................................4
Proper Earthing.........................................................................................................................................5
Environmental Requirements...................................................................................................................5
3. Safety Requirements.................................................................................................................................6
4. Preparation before Installation.................................................................................................................6
5. Handling Precautions................................................................................. Error! Bookmark not defined.
6. Unpacking the Printer...............................................................................................................................7
7. Assembling the Printer..............................................................................................................................8
8. Ink Filling .................................................................................................................................................11
9. Head Installation.....................................................................................................................................13
10. Installing the Printer Manager..............................................................................................................17
Printer Manager Settings........................................................................................................................23
Printer Settings ...................................................................................................................................23
Head Voltage Settings.........................................................................................................................25
11. Head Alignment ....................................................................................................................................27
Calibration Wizard ..............................................................................................................................27
Step Calibration...................................................................................................................................29
Mechanical Checks..............................................................................................................................30
Horizontal Calibration.........................................................................................................................32
12. Do’s and Don’t.......................................................................................................................................34
13. Maintenance.........................................................................................................................................35
Print Head Maintenance.........................................................................................................................35
Head Purging...........................................................................................................................................35
Head Spraying .........................................................................................................................................37
14. Troubleshooting Guide .........................................................................................................................38
15. Error Handling.......................................................................................................................................42

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1. Site Layout
The Site Layout of the machine is shown as below:
Fig 1: Displaying the Site Layout
Machine Dimension (LxWxH): 4500 x 1000 x1400 mm
2. Site Requirements
Hardware Requirements
Table 1: The Hardware Requirements are given as below:
Parts
Specifications
Operating System
Windows 7/10
Processor
Intel Dual core
RAM
2 GB or greater
HDD
Enhanced IDE 360 GB
Video Resolution
1024x768 16-bit Color
USB Port
USB 2 ports Minimum (2.0)
Internal PCI Slot
1 for Interface card
CD Drive
CD Rom R/W Drive

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Supporting Software
Table 2: List of Supporting Software
Parts
Software
Operation system
Windows 7/10
Driver of print card
Provide by ColorJet CD
Operating Software of printer
Provide by ColorJet CD
Site Requirements
The site requirements are given as below:
•Dimension of printer: LxWxH 4500 x 1000 x 1400 MM
•Minimum working area requirement: LxWxH 5500 x 2500 x 3000 MM
•Avoid using carpet on floor as it can generate electrostatic charge and can accumulate dust.
•There should be ample space to load and unload the media as well as ink.
•The machine should be installed in a room which is air conditioned and is dust free and adequate
ventilation is available in the room. It is also important that adequate space should be available
around the machine for easy operation and maintenance.
Power Requirements
The machine needs the following power connections.
•Uninterrupted Power supply of 220V (+ / - 10%), 50Hz (+ / - 2 %)
•The power requirement will be as follows:
Machine 700W
PC 500 W
Heater Pre 1000 W
Heater Post 1000 W
It is recommended that 5 KW UPS be installed for the machine, alternatively one may go in for a 2 KW
UPS and let the Heaters run on RAW 220 Volts.

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Proper Earthing
The quality of printouts will depend on the earth connection provided to the machine. During printing,
the media generates lot of static charge that can affect the placement of dots and also excessive charge
may damage the print heads which would be a very expensive damage.
It is recommended that a separate earth connection should be provided to the machine and the earth
resistance should be in the range of 4-5 ohms. The distance of the PC from the machine should not be
more than 2 -3 feet.
Note: It should be ensured that the earth point for the Printer and the PC is same this is important for the
safety of the interfaces.
The Earth Connection for the system should be shown in the drawing:
Environmental Requirements
The printer should be installed in a clean, dust-free environment, with temperature and relative
humidity range which are given as below:
•Power ON: Temperature : 18 to 280C
Humidity : 20 to 60%RH (Non-condensing)
•Power OFF: Temperature: 5 to 400C
Humidity : 20 to 80%RH (Non-condensing)
Fig 2: Displaying the Earth Connection
Neutral
Line
Separate
Earth
Earth
Line
Neutral
Uninterrupted
Power Supply
Distribution
Board
PC
Printer
Schematic Connection of Power
Monitor

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3. Safety Requirements
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.
Ink storage must be strictly in compliance with local fire regulations for the use and storage of
combustibles.
Ventilation
In order to prevent the danger caused by volatile gas accumulation, the storage room must have sufficient
ventilation.
Note: Solvent gas specific gravity is greater than the air, it would accumulate near the floor. Installation
work in the vicinity of electrical equipment must confirm the GB/T standards, national electrical regulation
requirements for level II sites, and installation by a corresponding qualification of the professional electrical
contractor.
Software Errors
While using the Printer Manager software, it is possible that some errors may occur. In such case, all the
errors or system messages will be displayed on the Error Information area. Read the error message and try
to resolve it. If you are not able to resolve the issue, please contact us or call at our customer care number
for more assistance.
4. Preparation before Installation
To install the printer, you must follow the below mentioned instructions for better use and long life of the
printer:
•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.
•Arrange the machine handling tools to avoid delays like a forklift.
•Install the Printer Manager software by following all the instructions mentioned in the Installation
Guide.
•If any damage in packaging is founded, then immediately report the same to the dealer.
•During the installation, it is preferable that at least two operators are present for training, who have
proficient computer skills and printing experience.
•Keep the consumables like media and inks ready in advance to avoid any delay in installation.
•While assembling, check the labels on the box "right and left" and “front and rear”.

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6. Unpacking the Printer
This is advisable that please open the printer box in the presence of a service engineer. If any damage is
found in the box, kindly report the same to the dealer with their respective picture.
The Neptune machine is packed into two iron pallets. One pallet is used for packing the upper body of the
machine and other for cabinets.
The upper body of the machine is packed into the below iron pallet:
Fig 3: Iron Pallet for Upper Body of the Machine
The machine’s cabinets are packed into the below pallet:
Fig 4: Iron Pallet for Machine Cabinet
Gently, remove the top frames of both pallets and then, lift up the machine from both corners with the
help of at least two people and assemble the machine by following the steps given in the “Assembling the
Printer” section.
Top Frame
Top Frame

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7. Assembling the Printer
Assembling of the printer is done in the presence of a service engineer. The total weight of the printer
with stand is 300 KG (Approximate). For the safety concerns, the assembling process requires at least 6
persons.
Follow these steps to assemble the printer:
Step 1: Remove the packing of both cabinets of the machine and place them in an even platform.
Step 2: Fix all the four levelers into both ends of the machine, as shown below:
Fig 5: Fixing the Machine Levelers
Step 3: Tight all the Allen Bolts of M10 x 20 with M10 Washer to fix the Truss at both cabinets (8 Allen Bolts
on each cabinet), as shown below:
Fig 6: Fixing the Truss
Note: Don’t fully tighten the Truss screws.
Levelers

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Step 4: Place the Center Jack on the Truss to ensure the direction.
Step 5: Tight all the Allen Bolts of M6 x 16 with M6 Washer to fix the Center Jack, as shown below:
Fig 7: Fixing Center Jack
Step 6: Prepare the media supply rollers with supply pipe pins.
Step 7: Unscrew the bearing holders from the cabinets and insert the media pipes to right end, as shown
below:
Step 8: Insert and fix the Spur Gears, as shown below:
Fig 8: Fixing the Spur Gears
Step 9: Install the Media Motor again.
Step 10: Carefully lift the upper body of the printer and place on the stand so that its screw holes align.

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Step 11: Tight all the Allen Bolts of M8 x 16 with M8 Washer (8 Allen Bolts each side), as shown below:
Fig 9: Placing Upper Body of the Machine
Step 12: After fixing the upper body of the machine, fix the Fan Housing and tight all the Allen Bolt of M
10 x 20.
Step 13: Tight all the Truss screws to fix it.
Now, the Neptune Machine gets assembled and the front view of the machine is shown as below:
Fig 10: An Assembled Neptune Machine

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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: 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:
Fig 11: Filling Ink in Main Ink Tank
Step 3: Fix the sub ink tank connectors to the ink refilling pins in the Head Board, as shown below:
Fig 12: Connecting Sub Ink Tank Connectors

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Ink gets filled in the Sub tanks as shown below:
Fig 13: Refilling Ink in Sub Tanks

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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.
Note: Don’t apply much pressure on Print Head while handling it.
Follow these steps to install the Print Head:
Step 1: Remove the Ink Inlet caps gently to avoid damage to the Print Head.
Step 2: Fix the Air Releasing and Ink Sub Tank pipes on the Ink Inlet Tube, as shown below:
Fig 14: Fixing Air and Ink Sub Tank Pipes
Step 3: Remove the Nozzle Cap from the Print Head (Refer to Fig 14).
Note: Don’t put the Print Head (nozzle facing) on the rough or dusty surface.
Step 4: Mount the Print Head in the slot on the Head Plate.
Step 5: Fix both screws (4x16 mm screws) gently on the Print Head, as shown below:
Fig 15: Fixing the Head Screws
Ink Sub Tank Pipe
Air Pipe
Nozzle Cap

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Step 6: Fix the Ink Sub Tank pipe into the other end, as shown below:
Fig 16: Connecting the Ink Sub Tank Pipe
Step 7: Remove the cap of the Air Releasing Pipe (Refer to Fig 16).
Step 8: Hold the pipe down and press the Purging button of a particular color, as shown below:
Fig 17: Displaying the Air Releasing Pipe and Purging Button
Note: Carefully perform the above step to avoid the chances of ink spilling.
Additionally, perform the same action for all colors and release ink up to 5ml.
Step 9: Simultaneous, release the purging button and cap the Air Releasing Pipe.
Purging Button

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Step 10: Insert one end of the head cable on the top of the Print Head by following the arrow mark, as
shown in the image below:
Fig 18: Inserting the Head Cable on the Top of Print Head
Note: While inserting the head cable, the machine must be Switch OFF.
Step 11: Similarly, insert the second end of the head cable on the Head Board, as shown below:
Fig 19: Inserting Head Cable to the Head Board
To verify the head cable orientation, please carefully view the highlight area on the above image.
Step 12: Check whether the Waste Bottle is attached or not.
Step 13: Perform the Head Purging for all colors.
Arrow Mark

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Step 14: Perform the Head Blotting to gently clean the Print Head. The Head Blotting is shown in the image
below:
Fig 20: Displaying the Head Blotting
Step 15: Perform the Nozzle Test to check the nozzle status of all the Print Heads.
Now, the Print Head gets installed.

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10. 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:
•DotNet framework
•USB Driver
Let’s discuss the installation process in details.
Follow these steps to install the Printer Manager software:
Step 1: Verify whether DotNet framework is installed in your computer system or not. If not, then first
install the framework using the CD or download the installer from the below mentioned link:
http://www.microsoft.com/en-in/download/details.aspx?id=17718 and follow the instructions appear on
the screen.
Step 2: Copy and paste the Printer Manager software from the CD to the secure location.
Step 3: Double-click on the Printer Manager Software (.exe file) icon, as shown below:
Fig 21: Starting the Printer Manager Installation

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On-clicking the Printer Manager icon, the Startup screen appears, as shown below:
Fig 22: 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. In case, if it is not
properly installed, then the status is Offline. To open the Printer Manager, click on the Printer Manager
icon. The Printer Manager window appears on the screen, as shown below:
Fig 23: Displaying the Printer Manager Window

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Note: USB driver is automatically installed with the Printer Manager software. If not, then follow the
below given steps.
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 24: Selecting the Manage Option
Step 6: Select the Device Manager option from the Computer Management window (Refer to Fig 25). The
Device Manager and its related options get expanded on the middle pane of the Computer Management
window, as shown below:
Fig 25: Displaying the Device Manager Screen