Colorjet PoloTurbo User manual

POLO TURBO
Foreword
This installation guide is briefly describing the operational aspects of the POLO TURBO machine. In this
document, the step-wise instructions for installing 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 user.
This guide serves as the reference tool which guides the service engineer how to install the POLO TURBO 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 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”.
The reference table is shown in the below table:
Doc Type
Doc Code
Version
Machine Name
Date of Issue
Installation Manual
GXX12XXX01
1.0
POLO TURBO

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POLO TURBO
Table of Contents
1. Site Layout............................................................................................................................................................ 3
2. Site Preparation ................................................................................................................................................... 4
System Requirements.......................................................................................................................................... 4
Supporting Software Requirements .................................................................................................................... 4
Tool Requirements............................................................................................................................................... 4
Environmental Requirements.............................................................................................................................. 4
3. Safety Precautions ............................................................................................................................................... 5
4. Electric Requirements.......................................................................................................................................... 5
Proper Earth Connection ..................................................................................................................................... 5
5. Preparation before Installation............................................................................................................................ 6
6. Handling Precautions ........................................................................................................................................... 7
7. Unpacking and Unloading the Printer Box........................................................................................................... 8
Machine and Tool Requirements......................................................................................................................... 8
Unloading the Machine........................................................................................................................................ 8
Unpacking the Machine ....................................................................................................................................... 8
Getting the Printer Ready .................................................................................................................................... 9
8. Ink Filling ............................................................................................................................................................ 11
9. Head Installation................................................................................................................................................ 13
10. Head Height Adjustment.................................................................................................................................. 17
11. Installing the Printer Manager......................................................................................................................... 18
Printer Manager Settings................................................................................................................................... 23
Printer Settings .............................................................................................................................................. 23
Head Voltage Settings.................................................................................................................................... 25
Save to Printer................................................................................................................................................ 27
Ripping and Printing Software Installation ........................................................................................................ 27
12. Head Alignment ............................................................................................................................................... 28
Calibration Wizard ......................................................................................................................................... 29
Step Calibration.............................................................................................................................................. 32
Mechanical Checks......................................................................................................................................... 33
Horizontal Calibration.................................................................................................................................... 35
13. Do’s and Don’t.................................................................................................................................................. 38

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POLO TURBO
14. Maintenance .................................................................................................................................................... 39
Print Head Maintenance.................................................................................................................................... 39
15. Troubleshooting Guide .................................................................................................................................... 41
Printer Not Initializing/Initialization Incomplete ............................................................................................... 41
Printer Manager Not Showing “Ready”............................................................................................................. 44
Carriage Stops During Printing........................................................................................................................... 44
Print Margin Is Shifting Or Junk Printing............................................................................................................ 47
Print Is Blur (Not Sharp) ..................................................................................................................................... 49
Heater Not Working........................................................................................................................................... 50
Lines In Print....................................................................................................................................................... 50
Some Head Nozzles Not Firing........................................................................................................................... 53
Take-Up Not Working ........................................................................................................................................ 53
Media Supply Not Working in Auto/Manual ..................................................................................................... 54
Complete Head Not Firing.................................................................................................................................. 55
16. Error Handling.................................................................................................................................................. 56

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POLO TURBO
1. Site Layout
The Dimension of the Machine is shown in the image below:
Fig 1: Displaying the Machine Dimension

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2. Site Preparation
System Requirements
The System Requirements are given as follow:
Table 1: Recommended System Requirements
Requirements
Specifications
Operating System
Windows 7 and Windows 8
Processor
Intel I5
RAM
4 GB or More
HDD
SATA 500 GB
Video Resolution
1024x768 16 bit Color
USB Port
USB 2.0
Supporting Software Requirements
The Supporting Software Requirements are given as follow:
Table 2: Supporting Software Requirements
Requirements
Specifications
Printer Driver
Provided by ColorJet
Printer Software
Provided by ColorJet
RIP Software
Provided by ColorJet
Tool Requirements
The Tool Requirements for printer installation are given as follow:
Magnifying lens
Screw driver set
Allen key set
Taper Gauge
Spanner 24 mm
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)

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POLO TURBO
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. 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.
4. Electric Requirements
Before installing the printer, the below mentioned electrical requirements should be confirmed:
Printer requires a single phase power and a good dedicated ground connection
Ground resistance should be less than 10 Ω
Power supply range should be 220V voltage (± 10%) and AC 50Hz or 60Hz
Power outlets should be 32 AMPS
Proper Earth Connection
The trouble-free printing depends on the earth connection provided to the machine. In some cases, the media
generates static and excessive charges that can damage the Print Head as well as affect the placement of printing
dots. Thus, one should provide the proper earth connection before using the printer.
Precautions:
A separate earth connection should be provided to the machine
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: Ensure that the earth point for the Printer and PC should be same for the safety of interfaces.

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POLO TURBO
The Earth Connection for the system is shown in the image below:
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.
Arrange the machine handling tools to avoid delays in unloading.
Install the Printer Manager software by following all the instructions mentioned in the Installation Guide.
If any damage in packaging is found, 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 placing the machine, check the labels on the box "right and left" and “front and rear”.
UPS
Distribution
Board
COLORJET
Printer
Line
Neutral
Earth
Line
Neutral
PC
Earth
Fig 2: Displaying the Power Supply Diagram

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POLO TURBO
6. Handling Precautions
While handing the printer, the below mentioned instructions should strictly be followed:
Printer
oPay full attention to the box handling marks
oFollow all the safety and handling precautions
oAvoid excess load on the printer
oDon’t cover the ventilation area of the printer
oProperly cover the printer while it is not in use
oAssemble the printer in the specified site area with relevant temperature and humidity
oProper power cable fitting and port availability
oCarriage cover should be fixed while printing
Print Head
oAvoid losses due to Print Heads dry out situations
oClean Print Heads timely to avoid nozzle or any other blockage
oPerform nozzle test every time while start printing
oAppropriately calibrate the Print Head for high-quality printing
Ink
oUse recommended ink only
oDon’t shake the ink bottle
oStore ink in the mentioned site area to avoid dry or damage

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POLO TURBO
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
Spanner of 24mm
Unloading the Machine
The total weight of the machine with stand is 1500 Kgs. After packing, the weight gets increased up to 1650 Kgs
approximately.
Follow these steps to unload the machine:
Step 1: Tied the machine using ropes/slings for making a perfect balance for lifting.
Step 2: Unload the machine using the container or lorry.
Step 3: Machine should be kept on leveled and cleaned surface or floor.
Now, the machine gets unloaded.
Unpacking the Machine
Note: Packing may vary country to country.
Follow these steps to unpack the machine for wooden packing (Export):
Step 1: Remove the 5x38mm screws from all the wooden plank side walls using the Nut Driver of 8mm Bit.
Step 2: Remove the 6x80 mm (8nos) screws from the printer box using the 10mm Bit.
Step 3: Remove the top cover of the printer box.
Step 4: Remove the 6x80 mm screws from all side poles (8nos) using the 10mm Bit.
Step 5: Remove the 10x20 mm screws of open able stand offs (2nos at back side) from the base pallet using the
10mm Bit.
Follow these steps to unpack the machine for iron pallet (Domestic):
Step 6: Remove the U clamps (at 8 places) fixed between machine and pallet from four corners of the Truss
Bridge, using the 24mm Spanner.
Step 7: Lift the machine using fork lift and place it on the even or leveled floor.

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POLO TURBO
Now, the machine gets unpacked.
Caution:
Do not move or unload the machine before ensuring that the place where the machine is landed, is even or level.
Precautions:
Do not lift from the extreme ends of the machine
Do not tilt the machine
Do not drop the machine
Do not 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.
Step 2: Place the machine in an even place as per given Site Layout.
Step 3: Unwrap the machine and check the machine internal parts as well as accessories box.
Step 4: Open the Carriage Lock Brackets, as shown in the image below:
Fig 3: Displaying the Carriage Lock Bracket
Step 5: Move the carriage gently to check, if the carriage path is free from obstacles.
Step 6: Mount LCD monitor using the screws fixed at back side of the monitor.
Step 7: Connect computer system to the monitor and machine.
Carriage Lock
Bracket

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POLO TURBO
Step 8: Level the machine using the inside and outside levelers. The Machine Levelers are shown as follow:
Fig 4: Displaying the Inside and Outside Levelers
Step 9: Switch on the printer and wait for the complete initialization of it.
Step 10: Check and verify the settings of attached parts of the printer viz. Heater, Take Up, Supply, Fan,
Blowers, LED, etc. The Media Heating System settings are given as follow:
Pre-Heater and Post-Heater settings range for the preset temperature: 300 C to 600C
Dryer settings range for the preset temperature: 300 C to 600C
Step 11: Install the Printer Manager software and RIP software for printing. Please refer to the Installing the
Printer Manager section for more details.
Step 12: Issue a dry print command to check whether the printer works well.
Step 13: Fill ink in the main tank and sub tank. Please refer to the “Ink Filling” section to fill ink.
Step 14:Install the Print Head, please refer to the Head Installation section to install the Print Head.
Step 15: For test printing, perform the Nozzle Test and verify the result.
Now, the printer gets ready for use.
Out-Side Lever
In-Side Lever

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POLO TURBO
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 all the main tanks of each color, as shown below:
Fig 5: Displaying the Ink Tank
Step 3: Fix the sub ink tank connectors to the ink refilling pins on the Head Board, as shown below:
Fig 6: Displaying the Mapping with Head Board
Note: Please make sure that connectors are attached as per the above shown diagram to avoid the ink
overflow situation.
Connectors

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POLO TURBO
Now, pumps start working and ink start moving in the ink pipes. When the ink filled in the sub tanks, pumps get
automatically stopped. The ink sub tanks are shown in the below image:
Fig 7: Displaying the Ink Sub Tank
Note: Please make sure that the color sequence of filled ink is as per the above shown image. If ‘K’ is connected
to Head Board, then software shows pumping Black.

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POLO TURBO
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, as shown below:
Fig 8: Removing the Ink Inlet Caps
Step 2: Fix the Air Releasing pipe on one end of the Ink Inlet Tube, as shown below:
Fig 9: Fixing the Air Releasing Pipe
Step 3: Remove the Nozzle Cap from the Print Head (Refer to Fig 9).
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 (Refer to Fig 10).
Nozzle Cap
Air Releasing Pipe

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POLO TURBO
Step 5: Fix all the screws (3x16 mm screws) gently on the Print Head, as shown below:
Fig 10: Fixing the Head Screw
Step 6: Fix the Ink Sub Tank pipe into the other end of the Ink Inlet, as shown below:
Fig 11: Connecting the Ink Sub Tank Pipe
Step 7: Remove the cap of the Air Releasing Pipe (Refer to Fig 12).

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POLO TURBO
Step 8: Hold the pipe down and press the Purging button of a particular color, as shown below:
Fig 12: 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.
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 13: Inserting the Head Cable on the Top of Print Head
Note: While inserting the head cable, the machine must be Switch OFF.
Purging Button
Arrow Mark

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Step 11: Similarly, insert the second end of the head cable on the Head Board, as shown below:
`
Fig 14: 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.
Step 14: Perform the Head Blotting to gently clean the Print Head. The Head Blotting is shown in the image
below:
Fig 15: 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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POLO TURBO
10. Head Height Adjustment
In POLO TURBO, head height can be adjusted using the Head Height knob, as shown below:
Fig 16: Adjusting the Head Height
To adjust the head height, move the knob in clock-wise or anti-clockwise direction as per the requirements or
media thickness.