Colorjet VerveLED VLR 2513 User manual

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Foreword
This installation guide is briefly describing the operational aspects of the VERVE LED (VLR 2513) 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 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 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
1.0
VERVE LED (VLR 2513)

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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. Preparation before Installation.................................................................................................................7
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
8. Input Power Checklist ...............................................................................................................................9
9. Installation of Print Control Centre.........................................................................................................10
Custom Software Settings.......................................................................................................................11
Enabling Administrator Mode.............................................................................................................11
Verifying Software Settings.................................................................................................................12
Print Head Configuration ....................................................................................................................13
Software Settings....................................................................................................................................14
Print Size .............................................................................................................................................14
Layer Mode .........................................................................................................................................17
DPI and Passes ....................................................................................................................................17
10. Switch ON Procedure............................................................................................................................18
11. Ink Filling ...............................................................................................................................................21
12. Head Installation...................................................................................................................................23
13. Negative Pressure Adjustment .............................................................................................................27
Understanding Negative Pressure ..........................................................................................................27
Negative Pressure Schematic..................................................................................................................27
Negative Pressure System Working........................................................................................................28
Negative Pressure Settings .....................................................................................................................29

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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................................................................................................................................40
Power System Maintenance ...................................................................................................................40
Control System Maintenance .................................................................................................................41
Mechanical System Maintenance...........................................................................................................41
Encoder System Maintenance ................................................................................................................41
Ink Supply System Maintenance.............................................................................................................42
Computer Maintenance..........................................................................................................................42
Using and Maintenance of Print Head....................................................................................................42
18. Troubleshooting....................................................................................................................................43
1. “Printer Not Initializing”......................................................................................................................43
2. “Print Control Centre Not Showing “Ready”.......................................................................................43
3. “Ink Not Filling”...................................................................................................................................44
4. “Ink Drop Formation”..........................................................................................................................44
5. “Head Nozzles Not Firing”...................................................................................................................44
6. “Print Stops In Between Printing”.......................................................................................................45
7. “Print Margin Is Shifting Or Junk Printing”..........................................................................................45
8. “Print Is Blur (Not Sharp)”...................................................................................................................45
9. “Lines In Print” ....................................................................................................................................46
10. “UV Lamp Not Working”...................................................................................................................46
11. “Negative pressure drop / not working” ..........................................................................................46
12. “Media not sticking to Bed”..............................................................................................................47
13. “Print not drying”..............................................................................................................................47
14. “UV Lamp Shutter Not Working”......................................................................................................47

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1. Site Layout
The Site Layout of the machine is shown in the image below:
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. Site Preparation
System Requirements
The System Requirements are given as follow:
Table 1: Recommended System Requirements
Requirements
Specifications
Operating System
Windows 7 (64 bit) or Windows 10 (64bit)
Processor
Intel Core i7
RAM
8 GB or More
Hard Disk
1TB
Solid State Disk (SSD)
128GB
USB Port
USB 2.0
Fig 1: Displaying the Site Layout of the Machine

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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)
•Multimeter (Carry by Engineer)
•Wire Cutter
•Nose plier
•Screw driver set
•Allen key set
•Taper Gauge
•Spanner
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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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
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:
•Total Power Consumption is 7KW.
•Machine needs single phase AC 220V, 30Amps (+ / - 10%), 50/60Hz.
•Uninterrupted power supplies (flicker free) should be provided as it has digital circuit.
•Exclusive Earthing should be required for printer and itshould not be shared withUPS and Building's
common Earth.
•Printer and computer must share same exclusive earthing.
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
Note: Ensure that the earth point for the Printer and PC should be same for the safety of interfaces.

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5. Preparation before Installation
To install the printer, you must follow the below mentioned instructions:
oPrepare the site as per the requirements like environmental temperature.
oConfigure PC as per the given system specification viz. RAM, operating system, processor, and
storage space.
oArrange the machine handling tools to avoid delays in unloading.
oInstall the Print Control Centre software by following all the instructions mentioned in the
Installation Guide.
oIf any damage in packaging is found, then immediately report the same to the dealer.
oDuring the installation, it is preferable that at least two operators are present for training, who
have proficient computer skills and printing experience.
oKeep the consumables like media and inks, ready in advance to avoid any delay in installation.
6. Handling Precautions
While handing the printer, the below mentioned instructions should strictly be followed:
•Printer
▪Follow all the safety and handling precautions
▪Avoid excess load on the printer
▪Don’t cover the ventilation area of the printer
▪Properly cover the printer while it is not in use
▪Assemble the printer in the specified site area with relevant temperature and humidity
▪Proper power cable fitting and port availability
•Print Head
▪Avoid losses due to Print Heads dry out situations
▪Clean Print Heads timely to avoid nozzle or any other blockage
▪Perform nozzle test every time while start printing
▪Appropriately calibrate the Print Head for high-quality printing
•Ink
▪Use recommended ink only
▪Don’t shake the ink bottle
▪Store ink in the mentioned site area to avoid dry or damage

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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. After packing, the weight gets increased up to 1962 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 from 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 5x38 mm screws from all the wooden plank side walls using the Nut Driver of 8mm
Bit.
Step 2: Gently remove the wooden top cover of the printer box including side walls.
Step 3: Carry out Chiller Unit and accessories box.
Step 4: Unpack the printer cover (bubble wrap).
Step 5: Lift the machine using Fork Lift and place it on an even place.

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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
•Don’t tilt the machine
•Don’t drop the machine
•Don’t climb or stack anything over the roof
8. Input Power Checklist
The input power checklist is given as below:
L –N
220 V
L –E
218V
N –E
2V

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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). The installation process gets started.
Step 4: Select the Setup Type as per the configuration from the Setup Type screen, as shown below:
Fig 4: Selecting a Setup Type

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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. Follow these steps to run the software
as an administrator:
Step 1: Right click on the Verve LED software icon available on the desktop. The list of options appears on
the screen, as shown below:
Fig 6: Displaying the Context Menu

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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.
Now, the Print Control Center Software runs as an administrator.
Verifying Software Settings
Note: Refer to the Readme files save in the CD and verify all the given parameter with the software values.
If not same then correct the value in the software.

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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.
Follow these steps to configure print head:
Step 1: Select the desired option as per ink from the Print Head Configuration list box.
Step 2: Click on the Load Configuration button.
Step 3: Click on the Apply button to apply the settings.
Now, print heads get configured.
To open the Print Control Center screen, double-click on the Print Control Center icon at desktop. The
Print Control Center screen appears as shown below:
Fig 9: Displaying the User Interface of Print Control Centre

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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
check box (Refer to Fig 10) and then specify the width and height of the image. Similarly, if you want to
print multiple copies of the same image then first select the Multi Copy check box and specify X Cnt and
Y Cnt values.
White and Varnish Settings
The White Color Settings are explained as below:
Fig 11: Displaying the White Color Settings

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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.
•After selecting the desired above-mentioned option for white color, select the printing direction
from the Properties dialog box (Refer to Fig 10).
•Forward: Color over white.
•Reverse: White over color.
For example, Reverse case is used while printing on glass.
The Varnish Color settings are shown in the image below:
Fig 12: 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:
Fig 13: Selecting Varnish Setting
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
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. The Lay Mode and its related
options are shown in the image below:
Fig 14: Layer Mode and Its Related Options
DPI and Passes
In Verve LED, DPI and passes are given as below:
DPI
Passes
600X600
4
600X900
6
600X1200
8

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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.
Step 6: Switch ON the Chiller unit, as shown below:
Fig 15: Switch ON UV Lamps
Step 7: Switch ON the printer from the main power and MCB, as shown below:
Fig 16: 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: 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 10: Switch ON the required vacuum chambers by moving the Vacuum Chamber knob, as shown
below:
Fig 17: Switch ON the Vacuum Chamber