Colorjet Vulcan Series User manual

Foreword
This installation guide is briefly describing the operational aspects of the VULCAN 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 VULCAN 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
VULCAN

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VULCAN
Table of Contents
1. Site Layout....................................................................................................................................................4
2. Site Preparation............................................................................................................................................4
System Requirements ..................................................................................................................................4
Supporting Software Requirements .............................................................................................................5
Tool 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
Getting the Printer Ready.............................................................................................................................9
8. Ink Filling ....................................................................................................................................................11
9. Head Installation ........................................................................................................................................13
10. Head Alignment........................................................................................................................................18
11. LED UV Lamp Height Adjustment .............................................................................................................20
12. Installing the Printer Manager..................................................................................................................21
Printer Manager Settings ...........................................................................................................................26
Printer Settings.......................................................................................................................................26
Head Temperature Settings....................................................................................................................29
Save to Printer........................................................................................................................................30
13. Head Calibration.......................................................................................................................................31
Calibration Wizard..................................................................................................................................31
Step Calibration......................................................................................................................................33
Mechanical Checks .................................................................................................................................34
Horizontal Calibration ............................................................................................................................36
14. Media Loading..........................................................................................................................................38
15. Maintenance ............................................................................................................................................41
Machine Maintenance ...............................................................................................................................41
Equipment Cleaning ...................................................................................................................................41
Power System Maintenance.......................................................................................................................41

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Control System Maintenance .....................................................................................................................42
Mechanical System Maintenance...............................................................................................................42
Encoder System Maintenance....................................................................................................................42
Ink Supply System Maintenance.................................................................................................................43
Computer Maintenance .............................................................................................................................43
Using and Maintenance of Print Head........................................................................................................43
16. Troubleshooting .......................................................................................................................................44
1. “Printer Not Initializing” .........................................................................................................................44
2. “Printer Manager Not Showing “Ready” ................................................................................................44
3. “Ink Not Filling” ......................................................................................................................................45
4. “Ink Drop Formation” .............................................................................................................................45
5. “Head Nozzles Not Firing” ......................................................................................................................45
6. “Print Stops In Between Printing” ..........................................................................................................46
7. “Print Margin Is Shifting Or Junk Printing” .............................................................................................46
8. “Print Is Blur (Not Sharp)” ......................................................................................................................46
9. “Lines In Print”........................................................................................................................................47
10. “UV Lamp Not Working”.......................................................................................................................47
11. “Negative pressure drop / not working” ..............................................................................................47
12. “Media not sticking to Bed” .................................................................................................................48
13. “Print not drying” .................................................................................................................................48
14. “UV Lamp Shutter Not Working”..........................................................................................................48

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1. Site Layout
The Site Layout of the machine is shown in the image below:
2. Site Preparation
System Requirements
The System Requirements are given as follow:
Table 1: Recommended System Requirements
Requirements
Specifications
Operating System
Windows 10 Professional (64 bits)
Processor
i7 Processor Quad Core
RAM
16 GB or More
Hard Disk
HDD/SSD
USB Port
USB 3.0/3.1
Front View
Back View
Main Power
Button
1.5 M
1.5 M
1.5 M 1.5 M
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
•Wire Cutter
•Nose plier
•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 : 35 to 80%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 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:
•Print Engine: Total Wattage: 5500Watts @ 220Volts AC 50Hz, Sinewave
•Uninterrupted power supplies (flicker free) should be provided as it has digital circuit.
•32A 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 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:
•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.
6. Handling Precautions
While handing the printer, the below mentioned instructions should strictly be followed:
•Printer
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
•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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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
•Adjustable Spanner of 24mm
Unloading the Machine
The total weight of the machine with stand is 2550 Kgs. After packing, the weight gets increased up to 2850
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.
Now, the machine is unpacked and ready for installation process.
Caution:
Don’t move or unload the machine before ensuring that the place where the machine is landed, is even or
level.

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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
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. The Carriage lock is shown in the image below:
Fig 2: Showing Carriage Lock and It's Placement
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.
Fix Screws

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Step 8: Level the machine using the inside and outside levelers. The Machine Levelers are shown as follow:
Fig 3: Displaying the Inside and Outside Levelers
Step 9: Connect the chiller unit
Step 10:Switch on the printer and wait for the complete initialization of it.
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.

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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: Switch ON the printer.
Step 2: Fill recommended ink in each main ink tank as per the color stickers, as shown below:
Fig 4: 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, as shown below:
Fig 5: Connecting Sub Ink Tank Connectors

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Now, pumps start working and ink start moving in the ink pipes. The ink sub tanks are shown in the below
image:
Fig 6: 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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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.
The following print head is used in the VULCAN machine:
Fig 7: Displaying the Print Head
Note: Don’t apply much pressure on Print Head while handling it.
Follow these steps to install the Print Head:
Step 1: Unscrew the M4 Allen Screws from both sides of the print head to remove the head cap, as shown
below:
Fig 8: Unscrew the M4 Allen Screws

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Now, the head cap gets removed, as shown below:
Fig 9: Removing the Head Cap
Step 2: Unscrew the screws available on the carriage plate and remove the cover, as shown below:
Fig 10: Removing the Cover on the Carriage Plate
Step 3: Mount the print head on the head plate.
Step 4: Tight the M4 Allen screws to fix the print head on the head plate (Refer to Fig 11).

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Step 5: Fix all the Head Aligners viz. front and back sides, as shown below:
Front Side
Back Side
Fig 12: Fixing Back Side Aligners
Fix Push Fitting Connectors (both sides)
Fix Aligner
Fig 11: Fixing Front Side Head Aligners

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Step 6: Fix the Head Tensioner Strip for aligning head left and right, as shown below:
Fig 13: Fixing the Head Tensioner and Push Fitting Connectors
Step 7: Insert one end of the head cable on the top of the Print Head and gently press it to fix, as shown in
the image below:
Fig 14: Inserting the Head Cable
Step 8: Similarly, insert the second end of the head cable on the Head Board and gently lock the head cable
with the Head Board.
To verify the head cable orientation, please carefully view the image as shown above.

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Step 9: Insert one end of the power cable on the top of the Print Head and gently press it to fix, as shown in
the image below:
Fig 15: Fixing the Power Cable
Step 10: Similarly, insert the second end of the power cable on the Power Supply Board and gently lock the
cable with the Power Supply Board.
Step 11: Perform the Head Purging for all colors. First, Switch OFF the Negative Pressure knobs of all color.
After that, Switch ON the Negative Pressure knob of the selected color and press the Cleaning button.
Similarly, perform this action for each color.
Step 12: Perform the Head Blotting to gently clean the Print Head.
Step 13: 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. Head Alignment
The following aligners are used for aligning head:
Fig 16: Displaying Front and Back Sides Aligners
Steps to align head
To align head in upward or downward direction, tight the Push Fitting Connectorsfrom front or back side as
per requirements:
Fig 17: Aligning Head in Upward or Downward Direction
Push Fitting Connectors

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To align head in left or right direction, tight the Head Tensioning Strip screw as per requirements:
Fig 18: Aligning Head in Left or Right Direction
Head Tensioning Strip Screw