Colorjet Vulcan User manual

Foreword
This user manual is briefly describing the operational aspects of the VULCAN 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
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
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
VULCAN

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VULCAN
Table of Contents
1. About Document............................................................................................................................... 4
Purpose............................................................................................................................................. 4
Intended Audience............................................................................................................................ 4
2. Printer Specifications ........................................................................................................................ 5
3. Machine Overview ............................................................................................................................ 6
Front View ........................................................................................................................................ 6
Back View.......................................................................................................................................... 8
4. Getting Familiar with Printer Manager Interface .............................................................................. 9
5. Main Menu Options ........................................................................................................................ 10
Setting Menu .................................................................................................................................. 10
Tools Menu ..................................................................................................................................... 13
Help Menu ...................................................................................................................................... 14
6. Getting Ready for Printing .............................................................................................................. 15
Switch ON Procedure...................................................................................................................... 15
Loading Media ................................................................................................................................ 16
Ink Supply System ........................................................................................................................... 18
Ink Filling......................................................................................................................................... 19
7. Printing ........................................................................................................................................... 20
Nozzle Testing................................................................................................................................. 20
Print Head Calibration..................................................................................................................... 21
Opening the Calibration Wizard.................................................................................................. 21
Horizontal Calibration ................................................................................................................. 23
Step Calibration .......................................................................................................................... 25
Setting Print Origin.......................................................................................................................... 26
Setting Print Parameters................................................................................................................. 26
Adding Jobs..................................................................................................................................... 27
Editing Job....................................................................................................................................... 29
Ripping and Printing........................................................................................................................ 30
Pausing and Cancelling Printing ...................................................................................................... 30
UV Setting ....................................................................................................................................... 31
Feeding Time and Language Passwords.......................................................................................... 31
8. Switch OFF Procedure..................................................................................................................... 33
9. Head Cleaning ................................................................................................................................. 34
Head Wiping ................................................................................................................................... 34

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VULCAN
Head Purging................................................................................................................................... 35
Head Spraying................................................................................................................................. 35
10. Maintenance................................................................................................................................. 36
Environmental Maintenance .......................................................................................................... 36
Roller Maintenance......................................................................................................................... 36
UV Controller System Maintenance................................................................................................ 36
Print Head Maintenance ................................................................................................................. 36
Head Plate Maintenance................................................................................................................. 36
Air Pressure Maintenance............................................................................................................... 36
11. Troubleshooting Guide ................................................................................................................. 38
Printer Not Initializing..................................................................................................................... 38
Printer Manager Not Showing “READY”.......................................................................................... 38
Print Stops in Between Printing ...................................................................................................... 38
Print Margin is Shifting or Junk Printing.......................................................................................... 38
Print is Blur (Not Sharp) .................................................................................................................. 38
Lines in Print ................................................................................................................................... 38
Print Not Dryer................................................................................................................................ 38
Heaters Not Working ...................................................................................................................... 38
Head Not Firing............................................................................................................................... 39
A Color Ink Not Supply .................................................................................................................... 39
UV Lamp Not Working .................................................................................................................... 39
UV Ink is not Fully Cured ................................................................................................................. 39

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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.

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VULCAN
2. Printer Specifications
Table 1: The System Specifications of the VULCAN
VULCAN
Printing Technology
Drop-on-demand, Piezo Electric Inkjet
Print Heads
Industrial Grade Jetting Assemblies
No of Print Heads
4 and 7
Media
Width
3300 mm
Thickness
Maximum 10 mm with Liner
Roll Outer Diameter
Maximum 300 mm
Roll Weight
Maximum 150 kg
Core Diameter
2" & 3"
Type
Ceiling Film, Vinyl, Advertising Banner, PET,
Wall Paper, Fabric
Printing Width
Maximum 3200 mm
Inks
Type
UV Curable Ink
Colors
6 Colors (CMYK LC LM) + White
Printing Resolution (dots per inch)
Maximum up to 1800 dpi
Distance Accuracy
Error of less than ±0.3 % of distance traveled,
or ±0.3 mm, whichever is greater
Connectivity
High Speed USB 3.0
RIP Software
Onyx (ColorJet Edition)
Computer Requirements
Operating System : Windows 10 Professional
(64 bits)
Processor : i7 Processor Quad Core
RAM : 16 GB or greater
Hard Disk Drive : HDD/SDD
Video Resolution : 1024x768 16 Bit Color
USB Port : USB 3.0/3.1
Power Requirements
AC 230 V ±10%, 32 A, 50/60 Hz
Dimension (Printer Only)
5300 x 1080 x 1680 mm (LxWxH)
Dimension (With Packing)
5880 x 1220 x 1940 mm (LxWxH)
Weight (approx. with stand)
2550 Kgs N.W., 2850 Kgs G.W.
Environmental
Power On
Temperature: 180C to 280C
Humidity: 35 to 80%RH (Non-condensing)
Power OFF
Temperature: 50C to 400C
Humidity: 20 to 80%RH (Non-condensing)

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VULCAN
3. Machine Overview
Front View
The Front View of the machine is shown as below:
Fig 1: Displaying the Front View of the Machine
Table 2: Different Parts of the Machine
1. Carriage
2. Front Glass Door
3. Control Panel
4. Vacuum Pump Regulator
5. Take Up Regulator
6. Levelers
7. Chiller Unit
8. Take Up
9. Main Tank Ink Controller
10. Wheelers
11. Emergency Button
10
1
0
9
8
7
6
2
3
5
4
11

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The Control Panel is shown in the image below:
Fig 2: The Control Panel
Table 3: Different Parts and their Description
Power
Show whether the machine is ON or OFF
Front Roll
Enable/Disable the second roller
Pump
Switch ON/OFF the vacuum pump to control print bed vacuum.
Led Lighting Box
Enable/Disable the backlit effect
Potentiometer
Control the torque value so that media doesn’t slipped during printing

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Back View
The Back View of the machine is shown in the image below:
Fig 3: Displaying the Back View of the Machine
Different Parts of the Machine
1. Emergency Button
2. Supply Roller
3. Wheel
4. Leveler
5.
6.
7.
1
2
3
4
6
7
5

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VULCAN
4. Getting Familiar with Printer Manager Interface
The User Interface of the Printer Manager software is shown as below:
Fig 4: Displaying the User Manual of Printer Manager
The description of the Printer Manager window is given as below:
•Window Control: Use to minimize, resize or close the Printer Manager window.
•Main Menu: Consist of several sub menu options viz. Settings, Tools, and also provide variety
of functions in well organize manner.
•Quick Access Toolbar: Display frequently performed actions like Add Job, Delete Job, Print
Job, Pause or resume, Abort job, Check nozzle, Auto clean, Move left, Move right, Set print
origin, Move forward, Move backward, Move carriage to origin, and Edit job are available as
buttons on the Quick access toolbar.
•Job Information: Display the properties of the selected job like file name and path, Status,
Print Size, Print Area, DPI, Pass, and more.
•Job Preview: Show the job preview as well as print progress in this area.
•Job List: Displays the thumbnail preview of added jobs.
•Error message: Displays the system generated error messages.
0
Job List
Error Information
Main Menu
Quick Access Toolbar
Print Parameters
System Status
Job Information
Job Preview
Window Controls

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VULCAN
5. Main Menu Options
The Main Menu options are shown in the image below:
Fig 5: The Main Menu Options
Setting Menu
The Setting Menu options are shown in the image below:
Fig 6: The Setting Menu Options
•Save: Using this option, you can save the default settings of the machine. When you save the
settings, an .xml file will be created for further references.
•Load: Using this option, you can load the previous saved machine’s settings.
•Save To Printer: When you clicked on this option, all the current settings get saved in the
Main Board of the machine.
•Load From Printer: When you clicked on this option, the printer settings get saved from
Main Board to Printer Manager software.
•Edit: Using this option, you can edit the previously made settings of Printer. On clicking the
Edit option, the Setting window with Printer, Move, Preference, and Calibration tabs appears
on the screen.

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VULCAN
The Setting window with the Printer tab is shown in the below image:
Fig 7: Displaying the Setting Window
The Move tab is shown in the image below:
Fig 8: Displaying the Move Tab
The Preference Tab is shown in the image below:
Fig 9: Displaying the Preference Tab

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The Calibration tab is shown in the image below:
Fig 10: Displaying the Calibration Wizard
The Multilayer print tab is shown in the image below:
Fig 11: Displaying the Multilayer print

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VULCAN
Using the Multilayer Print functionality, operator can print in multi-layer pattern viz. Color-White-
Color, White-Color-White, and more. The Multilayer Print pattern is selected in the following way:
Fig 12: Selecting the Multi-Layer Print Pattern
Tools Menu
The Tools Menu options are shown in the image below:
Fig 13: The Tools Menu Option
•Update: This option enables to apply latest changes and updates in the machine. This option
supports .dat file format.
•Password: This option enables to feed the time and language passwords of the printer.
•DemoPage: This option displays the bi-direction check output to improve the bi-direction
printing capability.
•Calibration Wizard: Using this option, you can perform different types of calibration viz. Angle
Check, Vertical Check, Nozzle Check, and more. For more details, please read the “Calibration
Wizard”section carefully.
•HW Setting: This option enables to select the encoder type of the printer as per the
compatibility either linear or servo.
•Real Setting: This option enables to check and reset the temperature as well as voltage of
each Print Head.

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VULCAN
•Wave Form Setting: This option helps in controlling and setting the wave form of the printer
with respect to ink, Print Head type, and speed.
•Auto stop pump ink when time out: Enable or disable the pump automatically when time out
occurs.
Help Menu
The Help Menu is shown in the image below:
Fig 14: The Help Menu Option
•About: Enable to view the details about Printer Manager software viz. software version and
copyrights.

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VULCAN
6. Getting Ready for Printing
Switch ON Procedure
VULCAN machine must be ON. In any emergency situation, machine needs to shut down, then
operator has to follow the below mentioned steps to switch ON it:
Step 1: Maintain the room temperature.
Step 2: Switch ON the printer from the main power or board.
Step 3: Turn ON the Negative Pressure knob of each color, as shown below:
Fig 15: The Negative Pressure Knob
Step 4: Turn ON the UV Section, as shown below:
Fig 16: Switch ON the UV Section
Step 5: Turn ON the Chiller unit, as shown below:
Fig 17: Displaying the Chiller Unit
Step 6: Load the media by following all the steps mentioned in the “Loading Media”section.
Step 7: Finally, perform purging and then, nozzle test.
Now, the printer is ready for printing.

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VULCAN
Loading Media
Follow these steps to load the media on the machine:
Step 1: Check the media tensioning from front and back sides using the paper sheets, as shown in the
image below:
Fig 18: Verifying the Media Tensioning
Step 2: If media tensioning is not correct, then tight the tensioner skew, as shown below:
Fig 19: Adjusting the Tensioning
In case, operator needs to adjust the position of front or back roller, then press the Front Pressure
Roller or Back Pressure Roller button accordingly.

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The Front Pressure Roller button is shown in the image below:
Fig 20: Showing the Front Pressure Roller button
The Back-Pressure Roller button is shown in the image below:
Fig 21: Pressing the Back Pressure Roller Button
Step 3: Unwind the media roll and insert the media between the platform (rollers), as shown in the
image below:
Fig 22: Showing the Media Path
Step 4: Pull the enough media so that it reaches to the Take Up Roller.

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VULCAN
Note: While loading the media, make sure that media should be aligned or both sides need to be
matched properly.
Step 5: Paste the front edge of the media on the Core to wind correctly on it.
Now, media gets loaded into the machine.
Ink Supply System
The following are the features of VULCAN Ink System:
•Main ink tanks are equipped with ink level sensor which beeps once the ink level goes down.
•Sub ink tanks are equipped with heaters to maintain the temperature of inks.
•Float sensors are equipped in sub ink tanks to control the supply of inks in tanks.
•Overflow in sub ink tanks will pause the supply of inks and also software alerts the same.
The VULCAN Ink Supply System is explained through the below image:
2
M
Main Filter
Ink
Bottle
Ink Supply
Board
Control
Main Board
Control
Signal
Carriage Board
Pass Signal
Pump
Ink High Limit
Ink Low Limit
Fig 23: The Ink Supply System

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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 24: 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 25: 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.