Colorjet VERVE User manual

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VERVE LED
Foreword
This user manual is briefly describing the operational aspects of the VERVE LED (VLR 2513) machine. In
this document, the step-wise instructions for handling 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 user.
This manual serves as the reference tool which guides their customers how to use or operate the VERVE
LED (VLR 2513) 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
manual carefully and follow all the instructions.
Disclaimer
The information and instructions provided in this user 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
User Manual
1
VERVE LED (VLR 2513)

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Table of Contents
1. About Document.......................................................................................................................................4
Purpose .....................................................................................................................................................4
Intended Audience....................................................................................................................................4
2. Specifications ............................................................................................................................................4
3. Machine Overview ....................................................................................................................................5
4. Getting Familiar with Print Control Center Interface................................................................................6
Setting Carriage and Gantry Position........................................................................................................ 6
5. Getting Ready for Printing ........................................................................................................................7
Switch ON Procedure................................................................................................................................7
Loading Media.........................................................................................................................................10
Ink Filling .................................................................................................................................................12
6. Main Menu Description ..........................................................................................................................13
7. Print Control Center Operations.............................................................................................................14
Print Option Menu..................................................................................................................................14
White and Varnish Settings.................................................................................................................15
Layer Mode .........................................................................................................................................17
Task Select Menu....................................................................................................................................18
DPI and Passes ....................................................................................................................................19
Checking the Image Ink Color Volume................................................................................................20
Pre-process Varnish Setting................................................................................................................20
Operation Menu .....................................................................................................................................21
Opening an Image File ........................................................................................................................21
Print Position.......................................................................................................................................22
Checking Printing Status .....................................................................................................................22
Maintenance Menu.................................................................................................................................23
Feeding Password ...............................................................................................................................26
8. Head Height Adjustment.........................................................................................................................27
9. Machine Calibration................................................................................................................................29
10. Head Cleaning .......................................................................................................................................30
Head Blotting and Purging......................................................................................................................30
Head Spraying .........................................................................................................................................32

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11. Shutdown Procedure ............................................................................................................................33
12 . Maintenance ........................................................................................................................................35
Print Head Maintenance.........................................................................................................................35
Maintenance of Machine Motion Parts..................................................................................................35
Equipment Cleaning................................................................................................................................35
Power System Maintenance ...................................................................................................................35
Control System Maintenance .................................................................................................................35
Ink Supply System Maintenance.............................................................................................................35
13. Troubleshooting Guide .........................................................................................................................37
Printer Not Initializing.............................................................................................................................37
Printer Manager Not Showing “READY” .................................................................................................37
Print Stops in Between Printing..............................................................................................................37
Print Margin is Shifting or Junk Printing .................................................................................................37
Print is Blur (Not Sharp) ..........................................................................................................................37
Lines in Print............................................................................................................................................37
Print Not Dry ...........................................................................................................................................37
Head Not Firing .......................................................................................................................................37
A Color Ink Not Supply ............................................................................................................................38
UV Lamp Not Working ............................................................................................................................38
UV Ink is not Fully Cured.........................................................................................................................38

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1. About Document
Purpose
The purpose of this document is to guide and educate the targeted audience about the Printer and its
Printer Manager software so that they can easily and effectively handle as well as use it as per their
requirements. Additionally, this document also provides step-wise instructions for handling various
aspects of the printer and its related software with the help of graphical screens for easy and better
understanding. Moreover, the document also describes commonly encountered problems while working
with the printer and Printer Manager software with appropriate remedial actions.
Intended Audience
This document is meant for all the users who want to use the Printer for their printing business.
Sometimes, the targeted audience has little knowledge about the printer but in most of the cases,
targeted audience is much familiar with the terminologies of printer and printing business. Thus, this
document is designed to facilitate both types of users.
2. Specifications
VERVE LED VLR-2513
Printing Technology
Drop-on-demand, Piezo Electric Inkjet
Print Head
Industrial Grade Jetting Assemblies
No. of Print Heads
2 to 8
Media
Size
2.56m X 1.68m
Thickness
Maximum 100mm
Curing System
Dual UV LED Lamps
Printing Size
2.50 m X 1.22 m
Ink
Type
UV LED Curable Ink
System
Bulk Ink Refillable System
Colors
CMYK + W
Printing Resolution (DPI)
Maximum 1200 dpi
Distance Accuracy
Error of less than ±0.3 % of distance travelled, or
±0.3 mm, whichever is greater
Connectivity
High speed USB 2.0
Power Requirements
AC 220 V, 30 A, 50/60 Hz
Dimensions (Printer Only)
4700 x 2660 x 1520 mm (LxWxH)
Dimensions (With Packing)
4830 x 2280 x 1840 mm (LxWxH)
RIP Software
Onyx (Colorjet Edition)
Weight
N.W. 1762, G.W. 1962
Environmental
Power ON
Temperature: 18 to 28℃Humidity: 20 to 60%RH
(non-condensing)
Power OFF
Temperature: 5 to 40℃Humidity: 20 to 80%RH (non-
condensing)

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3. Machine Overview
The Machine Overview is shown in the image below:
Fig 1: Displaying the Machine View
Table 1: Different Parts of the Machine
1. Left UV Lamp
2. Negative Pressure ON/OFF Knob
3. Right UV Lamp
4. Print Bed
5. UV Lamp Control Button
6. LED
7. Emergency Button
8. Bed Vacuum ON/OFF Button
Right UV Lamp
Left UV Lamp
Print Bed
LED
Emergency Button
UV Lamp Control Button
Bed Vacuum
Control Knob
Bed Vacuum
ON/OFF Switch

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4. Getting Familiar with Print Control Center Interface
The Print Control Center interface is shown in the image below:
Fig 2: Displaying the ColorJet UV Print Control Center
The description of the Print Control Center is given as below:
•Control Menu: Consist of several menu or sub menu options viz. Print Option, Task Select,
Operation, Maintenance, Help and also provide variety of functions in well organize manner.
•Quick Access Buttons: Display frequently performed actions like Print, Stop, Flash, Purge, Home,
Left, Right, Stop, Forward and Back.
•Error Messages: Displays the system generated error messages.
Setting Carriage and Gantry Position
Carriage and Gantry can be moved using Left, Right, Forward and Back icon on the Quick Access Buttons.
The Left and Right buttons enable to set the carriage position. On the other hand, the Forward and Back
buttons enable to move gantry in the forward and reverse directions. The control buttons are shown in
the image below:
Fig 3: Displaying the Control Arrow Keys
Error Messages
Control Menu
Quick Access Buttons

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5. Getting Ready for Printing
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.
Step 6: Switch ON the Chiller unit, as shown below:
Fig 4: Switch ON UV Lamps
Step 7: Switch ON the printer from the main power and MCB, as shown below:
Fig 5: Switch On the Main Power Button

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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: Place the media on the Print Bed.
Step 10: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:
a. Carriage path must be obstacles free.
b. Ensure that Z height must be enough to move smoothly over the print bed.
Step 11: Switch ON the required vacuum chambers by moving the Vacuum Chamber knob, as shown
below:
Fig 6: Switch ON the Vacuum Chamber
Step 12: Press the Detect Media Height button to sense the media height (Refer to Fig 11).

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Step 13:Turn ON the ink valve of each color in anti-clock direction to open it, as shown below:
Fig 7: Displaying the Ink Valves
Step 14: Lift the carriage up by pressing the Lifter Back Zero button on the Carriage Lifter tab under the
Maintenance menu (Refer to Fig 11).
Step 15:Press the Purging button (Refer to Fig 11) and clean print heads using the tissue provided with
the printer.
Step 16: Bring down the carriage by pressing the Lifter Move to Print Height button (Refer to Fig 11)
Step 17: Perform Nozzle test.
Now, printer is ready for printing.

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Loading Media
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 8: Turning ON the Bed Vacuum Button
Step 3: Switch ON the required vacuum chambers by moving the Vacuum Chamber knob, as shown
below:
Fig 9: Switch ON the Vacuum Chamber
The classification of Vacuum Chamber on the Print Bed is shown as below:
Fig 10: Classification of Vacuum Chamber on the Print Bed

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Step 4: Set the head height using the Carriage Lifter tab, as shown below:
Fig 11: Detecting Head Height
To open the Carriage Lifter screen, click on the Maintenance menu and select the Carriage Lifter tab.
After this, perform the following steps to adjust the head height:
a. Enter the X Offset value in the Detector X-Offset to PrintPos field.
b. Enter the Y Offset value in the Detector Y-Offset to PrintPos field.
c. After providing offset details, click on the Apply button (Refer to Fig 11).
d. Place the media on the print bed.
e. Click on the Detect Media Height button to detect head height.
A detailed description of the head height adjustment is given in the Head Height Adjustment section.

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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 12: The Main Ink Tanks
Note: Main tanks are equipped with ink level sensor which beeps once the ink level goes down.
Step 3: Fix the sub ink tank connectors to the ink refilling pins in the Head Board.
Now, pumps start working and ink start moving in the ink pipes. The ink sub tanks are shown in the
below image:
Fig 13: 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.

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6. Main Menu Description
The Main Menu and its related commands are shown in the image below:
Fig 14: Displaying the Main Menu and Its Related Commands
The description of the Main Menu and its related commands is given as below:
•Maintainance Password: Enable to feed and update the Maintainance Password. This can only
be done by the service engine.
•Reset Origin: Enable to move the carriage to the Home (Zero Position).
•Parameter: Using this option, user can Load To Disk and BackUp To Load.
•Recent Print: Issue Print command of recently used files.
•Calibration: Perform all types of calibration directly by using this command.
•Data Unit: Enable to change data units like mm, inch, etc.

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7. Print Control Center Operations
Print Option Menu
On-clicking the Print Option button, the following image appears on the screen:
Fig 15: Displaying the Print Option Screen
The description of the Print Option screen is given as below:
•UV Plat Form Settings: Allow to enable or disable UV lamps like Lamp1 Left Work, Lamp1 Right
Work, and similarly for Lamp 2.
•Colorbar Option: Enable users to define the colorbar width, distance from image, distance
between colors and colobar position.
•White Color Settings: Using the above screen, user can make white color settings like Full, RIP
Color and more).
•Varnish Color Settings: Enable to define the volume of varnish color and its source (like Full, RIP
Data and Valid Image)
•Pass Feather Settings: Set feather mode (Even, Shade, and User) and feather level (Small, Normal
and Large).
•Miscellaneous Functions: User can also perform the following functions:
oMedia Advance speed
oSkip White
oColorbar follow image

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White and Varnish Settings
The White Color Settings are explained as below:
Fig 16: Displaying the White Color Settings
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.
•Invalid Image: White color is printed where CMYK color is not present in the selected image.
•RIP Color: White color is printed as per the RIP file.
The Varnish Color settings are shown in the image below:
Fig 17: Displaying the Varnish Color Settings

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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.
•Image Data: Varnish color is printed same as the percentage of CMYK color in the selected image.
After selecting the desired option for varnish color, select the varnish thickness and curing in the Varn
Thick and Varn Curing list boxes available on the Properties dialog box, as shown below:
To enable varnish printing (over color) and curing, desired passes must be selected rather than “with the
color” or “with the varnish”. This process is completed in three steps:
1. Color (With UV)
2. Varnish (Without UV)
3. Curing (Only UV No print)

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Layer Mode
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. The Lay Mode and its related options are shown in the image below:
Fig 18: Layer Mode and Its Related Options

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Task Select Menu
The Task Select button is shown in the image below:
Fig 19: Displaying the Task Select Screen
Follow these steps to open and print a file:
Step 1: After opening the Task Select screen, navigate to the location where the printable file is stored
(Refer to Fig. 18).
Step 2: Double-click on the image icon. The Properties dialog box appears, as shown below:
Fig 20: Displaying the Properties Dialog Box

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Description of different options in the Properties dialog box:
•Varnish: Defines the thickness of varnish color with respect to number of Pass.
•Varnish UV Curing: Set curing of varnish color with respect to number of Pass.
•Region: Enables to print the selected area of the image. When user select the Region check box,
the Region(mm) section gets high-lighted where user needs to specify the X axis, Y axis, height,
and Width of the area to print.
•Multi copy: Allows user to print multiple copies of the same image. When user select the Multi
Copy check box, the Multi (mm) section gets activated where user has to specify total count of
images in X axis and Y axis as well as horizontal and vertical distance between images.
•Ink Volume: Specify the ink requirements of each color to print the selected image.
•Dir Reverse (Material Direction): Specify the printing direction like forward or reverse. By default,
the carriage moves in the Forward direction but user can change it in the Reverse using the Dir
Reverse check box for some applications where print requires white over color.
•Mirror Print: Enables or disables mirror print.
•Speed: Defines printing speed like Low, Medium and High.
Step 3: Click on the Print button to print the selected file. Additionally, user can also make change as per
the requirements.
DPI and Passes
VerveLED DPI and passes are given as below:
DPI
Passes
600 x 600
4
600 x 900
6
600 x 1200
8