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VERVE LED

16. Head Calibration and Alignment

To improve and enhance the printing quality, you must carefully align the Print Head. The Print Head
alignment process consists the following tests:

•

Mechanical Check

: Includes Vertical Check and Angle Check

•

Software Calibration

: Includes Horizontal Calibration Viz. Left, Right, and Bi-direction.

Calibration Wizard

Print Heads should be calibrated to ensure good printing quality. To open the

Calibration Wizard

,

click

on

the

Main Menu

→

Tools

→

Calibration Wizard

path, as shown below:

Fig 46: Selecting the Calibration Wizard Option

This should bring up the Calibration Wizard, as shown below:

Fig 47: Displaying the Calibration Wizard

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Содержание VerveLED VLY 2513

Страница 1: ......

Страница 2: ...t 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 m...

Страница 3: ...achine 9 Unpacking the Machine 9 8 Input Power Checklist 10 9 Software Installation 11 Printer Manager Installation 11 Disable Driver Signature Enforcement 15 Printer Manager Settings 18 Printer Settings 18 Head Temperature Settings 21 Save to Printer 22 10 Switch ON Procedure 23 11 Ink Filling 25 12 Head Installation 27 13 Negative Pressure Adjustment 32 Understanding Negative Pressure 32 Negativ...

Страница 4: ...ontrol System Maintenance 47 Mechanical System Maintenance 47 Encoder System Maintenance 47 Ink Supply System Maintenance 48 Computer Maintenance 48 Using and Maintenance of Print Head 48 18 Troubleshooting 49 1 Printer Not Initializing 49 2 Printer Manager Not Showing Ready 49 3 Ink Not Filling 50 4 Ink Drop Formation 50 5 Head Nozzles Not Firing 50 6 Print Stops In Between Printing 51 7 Print Ma...

Страница 5: ...Page 4 VERVE LED 12 Media not sticking to Bed 53 13 Print not drying 53 14 UV Lamp Shutter Not Working 53 ...

Страница 6: ...5030 x 2280 x 1890 mm 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 ...

Страница 7: ...nts 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 280 C Humidity 20 to 60 R...

Страница 8: ...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...

Страница 9: ...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 o Follow all the safety and handling precautions o Avoid excess load on the printer o Don t cover the ventilation area of the printer o Properly cover the printer while it is not in use o A...

Страница 10: ... 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 D...

Страница 11: ...e 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 ...

Страница 12: ...the secure location Step 2 Double click on the Printer Manager software exe file icon as shown below Fig 3 Starting the Printer Manager Installation On clicking the Printer Manager icon the Startup screen appears as shown below Fig 4 Starting the Installation Process Step 3 Click on the Next to confirm that you want to install the Printer Manager software and follow all the instructions appear on ...

Страница 13: ...elow Fig 5 Displaying the Printer Manager Window Note USB driver is automatically installed with the Printer Manager software If not then follow the below given steps Step 4 Open Device Manager right click on the My Computer icon and select the Manage option from the context menu as shown below Fig 6 Selecting the Manage Option Step 5 Select the Device Manager option from the Computer Management w...

Страница 14: ...r Screen Step 6 Select the Wide Format Printer option under Other devices and right clicked on it The context menu appears on the screen Refer to Fig 8 Step 7 Select the Update Driver Software option from the context menu as shown below Fig 8 Configuring the USB Driver The Update Driver Software window appears as shown below Fig 9 Displaying the Update Driver Software Window ...

Страница 15: ...electing the Driver Location Step 10 Click on the OK button to start the driver update process Refer to Fig 10 The process gets started for updating the driver software and the process progress screen appears On completing the process click on the Close button to close the process Note In case Window 10 operating system is installed in the user system then user must disable the driver signature en...

Страница 16: ...nd then click on the OK button A window appears by stating that you are about to be signed off and close the window by pressing the Close button Now the computer starts rebooting Step 3 Once your computer has rebooted select the Troubleshoot option from the window as shown below Fig 11 Selecting the Troubleshot Option The Troubleshoot window appears on the screen Step 4 Select the Advanced Options...

Страница 17: ...p 5 Select the Startup Settings option from the window as shown below Fig 13 Selecting the Startup Settings Option The Startup Settings window appears on the screen Step 6 Click on the Restart button to reboot your computer again as shown below Fig 14 Rebooting the System ...

Страница 18: ...all your unsigned drivers During the installation procedure Windows will inform you that can t verify the publisher of this driver software Just ignore the warning message and choose Install this driver software anyway to complete the installation Note After restarting the Driver Signature Enforcement will be automatically enabled again to prevent new drivers from being installed but Windows will ...

Страница 19: ...the type of feather effect and intensity percentage of the feather o Multiple Ink Enable to select the color depth of an image according to the passes The available options are Default Double and More Color Bar o Space Specify the distance of the color bar from the image o Width Set width of the color bar o Placement Enable or disable the color bar and its placement viz left right or both o Height...

Страница 20: ...e Print Pre spray Time option When enabled one can specify the duration if spray before issuing the Print command The Move tab is shown in the image below Fig 17 Displaying the Move Tab Using the Move tab the Y and Z Speeds can be updated as per the requirements The Preference tab is shown in the image below Fig 18 Displaying the Preference Tab ...

Страница 21: ...Page 20 VERVE LED The Calibration tab is shown in the image below Fig 19 Displaying the Calibration Wizard The Multilayer print tab is shown in the image below Fig 20 Displaying the Multilayer print ...

Страница 22: ...e Temperature and Voltage window appears on the screen Step 2 Enter the head and nozzle temperture values of each color Print Head under the Temperature and Voltage section as shown below Fig 22 Setting the Base Voltage Value Step 3 After specifying the head voltage click on the Apply To Board button and then on the Ok button to apply the settings Refer to Fig 22 Now the head and nozzle temperatur...

Страница 23: ...ave To Printer path as shown below Fig 23 Selecting the Save To Printer Option On clicking the Save To Printer option all the previously made settings get saved on the Main Board In case printer manager needs to reinstall then you can retrieve all the settings using the Load From Printer option Note In Setting the Save option is used for saving the previously made settings and created an xml file ...

Страница 24: ...in upward direction and then move toward Y Axis and X Axis Finally gantry comes back to the Home position If printer is successfully initialized then the following screen appears with the Ready message as shown below Fig 24 Printer Manager Software is Ready If service engine finds any problem during machine initialization or printer not initialize properly kindly refer to the Printer Not Initializ...

Страница 25: ...age 24 VERVE LED Step 7 Run the full 2500 1220 MM dry print command without Ink and Head to verify the functioning of the printer like XYZ axis sensors Limit Switch etc Now printer is ready for printing ...

Страница 26: ...er Step 1 Switch ON the printer Step 2 Fill recommended ink in each main ink tank as per the color stickers as shown below 26 Displaying 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 27 Connecting Sub Ink Tank Connectors ...

Страница 27: ...k start moving in the ink pipes The ink sub tanks are shown in the below image Fig 28 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 ...

Страница 28: ... is not installed correctly it can affect the printing quality The following print head is used in the machine Fig 29 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 30 Unscrew the M4 Allen Screws ...

Страница 29: ...Head Cap Step 2 Unscrew the screws available on the carriage plate and remove the cover as shown below Fig 31 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 32 ...

Страница 30: ...D Step 5 Fix all the Head Aligners viz front and back sides as shown below Front Side Back Side Fig 33 Fixing Back Side Aligners Fix Push Fitting Connectors both sides Fix Aligner Fig 32 Fixing Front Side Head Aligners ...

Страница 31: ...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 35 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 ...

Страница 32: ...ck 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 th...

Страница 33: ...own in the image below This is perfect and ideal condition II Ink drop easily from the head Increase the negative pressure for eg If 4 0 make it 4 1 III Ink drops disappear sucked up by the head Reduce the negative pressure For eg If 4 0 make it 3 9 This condition can clog nozzle on the running print Negative Pressure Schematic Fig 37 Displaying the Negative Pressure Schematic ...

Страница 34: ...ure value Similarly the second meter is placed on the carriage which helps in setting and displaying the maximum negative value set If a particular pressure value is set eg 3 0 the negative pressure pump will create vacuum and the negative air pressure will be stored in reservoir tank Whenever the pressure goes lower than 3 0 the negative pressure pump will be switched ON for the time period to ma...

Страница 35: ...ng the Negative Pressure Control Board Setting Procedure Negative Pressure Control Board Step 1 a Enter setting mode Press ESC Number 13 2 will flash this is setting 1 b Press ESC again number 23 33 will flash this is setting 2 Setting 1 is for White Min set value Setting 2 is for White Max set value Setting 3 is for Color Min set value Setting 4 is for Color Max set value ...

Страница 36: ...ADD button to adjust the numbers Step 4 Press the ENT button to save the setting Step 5 Press the ESC switch again to go to the next setting value Setting Procedure Pressure Display Meter Set 1 P Protection Value Press the SET button for one second and set the value 1 P with UP and DOWN button Note 2 P value should be bigger than current value Set 2 P Protection Value Press the SET button again it...

Страница 37: ... of the machine as shown below Fig 41 Turning ON the Bed Vacuum Button Step 3 Switch ON the required vacuum chambers by moving the Vacuum Chamber knob as shown below Fig 42 Switch ON the Vacuum Chamber The classification of Vacuum Chamber on the Print Bed is shown as below Fig 43 Classification of Vacuum Chamber on the Print Bed Step 4 Set the head height using the Measure paper width icon on the ...

Страница 38: ...romise the print quality by forming discolored horizontal streaks or bands The good and bad nozzle test results are shown in the image below Fig 44 Displaying the Good and Bad Nozzle Test Result To check the nozzle click on the Nozzle Test icon available on the Quick Access Toolbar as shown below Fig 45 Selecting the Check Nozzle Button In case of blockages refer to the Head Cleaning section to pe...

Страница 39: ...heck and Angle Check Software Calibration Includes Horizontal Calibration Viz Left Right and Bi direction Calibration Wizard Print Heads should be calibrated to ensure good printing quality To open the Calibration Wizard click on the Main Menu Tools Calibration Wizard path as shown below Fig 46 Selecting the Calibration Wizard Option This should bring up the Calibration Wizard as shown below Fig 4...

Страница 40: ...to be adjusted manually using the provided tools and alignment should be re verified iteratively until the Print Heads are perfectly aligned Angle Check This test checks the mounting angle of all the Print Heads Print Heads should be mounted at exactly 90 degrees to the carriage scan direction In the figure below when the Print Heads are mounted correctly at 90 degrees then an unbroken vertical st...

Страница 41: ...s Angle Alignment To align head in left or right direction tight the Head Tensioning Strip screw as per requirements Fig 51 Aligning Head in Left or Right Direction Note After correcting the Angle alignment issue the Print command using the RIP file and verify print with respect to its quality Head Tensioning Strip Screw ...

Страница 42: ...ion should be used to fine adjust the step size and has to be done for each desired pass The Step Calibration and its parameters are shown in the image below Fig 52 The Step Calibration Parameters First feed the Base Step Value as 95000 this is the approximate value and this need to be corrected by following the below steps Follow these steps to perform step calibration Step 1 Select the desired p...

Страница 43: ...nt Test Result When a Print Head is aligned with the reference Print Head Magenta then in the test print this would be evident by perfectly aligned vertical nozzle lines In case of vertically misaligned Print Head its nozzle lines would be either above or below the reference head s nozzle lines Similarly check for other colors Black Magenta and Yellow with the reference color Magenta Note During t...

Страница 44: ...ts it by adding or subtracting the correction value from the default set value It has to be performed for each print mode whichever is required Let s discuss each type of horizontal test one by one Bi direction Calibration Bi directional calibration is performed to achieve dot placement accuracy between the Left to Right and Right to Left print sweeps If the bi direction offset value is correct th...

Страница 45: ...performed to achieve dot placement accuracy of all colors Black Cyan and Yellow with respect to Magenta during the carriage s left to right print sweep Similarly Right to Left calibration is used to achieve dot placement accuracy during the carriage s right to left sweep When the position of the test head is correct then it would align perfectly with the reference color at 0 position indicating th...

Страница 46: ...Page 45 VERVE LED The Right Calibration Result is shown in the image below Fig 57 The Horizontal Right Check ...

Страница 47: ...e months the ink system should be thoroughly cleaned in order to keep good printing quality Equipment Cleaning Follow the below given instruction during the equipment cleaning process Avoid splashing liquid and dropping on in the circuit board or the power line Should clean the circuit boards using the low power hair dryer Sensitive devices like sensors and raster should be cleaning using the liqu...

Страница 48: ...oil to all the parts of the machine and the lubrication oil should with adhesion force between 30cst to 150cst Carefully install the print heads In case print heads are not properly installed then it may cause of head damage and bad printing results Check the tightness of carriage belt for quality printing Lubricate regularly to all parts of transmission bearings If the slider is not running smoot...

Страница 49: ...ON Using and Maintenance of Print Head Print head is a key component of the printer must use and maintain it correctly so that can guarantee good printing effect and print head life Pay attention to potential problems caused by environment heat and moisture collision cleaning etc Follow the instructions given below for long life of the machine Print head should work with environment temperature 18...

Страница 50: ... on the display screen Check the power connection and replace it if faulty 5 Main Board Factory settings are disturbed Fault in Main Board Correct the factory settings Replace the Main Board if faulty 6 Head Board Fault in Head Board Replace the Head Board if faulty 7 Encoder Sensor Fault in Encoder Sensor Replace the Encoder Sensor 2 Printer Manager Not Showing Ready Problematic Parts Reasons Cor...

Страница 51: ...Ink pipes Ink pipes are having cuts Replace the ink pipes if faulty 4 Ink Drop Formation Problematic Parts Reasons Correction Steps 1 Negative Pressure Negative Pressure is not working Set the parameters of negative pressure 5 Head Nozzles Not Firing Problematic Parts Reasons Correction Steps 1 Print Head Print Head is not cleaned Clean the Print Heads 2 Head Cables Head cables are loosely connect...

Страница 52: ...fully read the error and resolve it 7 Print Margin Is Shifting Or Junk Printing Problematic Parts Reasons Correction Steps 1 Encoder Scale Encoder Scale is having ink stains Clean the Encoder Scale 2 Encoder Sensor Encoder Sensor is not clean Clean the Encoder Sensor 3 Pulley or Belt Pulley or belt is slipping Check and replace it if required 4 Data Cable Data cable is faulty Replace the Data Cabl...

Страница 53: ...tings UV Lamp settings are incorrect Correct the UV Lamp settings UV Lamp Control Board UV Lamp Control Board is faulty Check and replace the UV Lamp Control Board UV Lamp UV Lamp is faulty or aged Check and replace it if required 11 Negative pressure drop not working Problematic Parts Reasons Correction Steps Negative Pressure Switch Negative Pressure switch program is disturbed or value is incor...

Страница 54: ...s the Run button 13 Print not drying Problematic Parts Reasons Correction Steps 1 UV Lamp Settings UV Lamp settings are incorrect Correct the UV Lamp settings 2 Lamp Intensity UV Lamp Intensity level is low Control the frequency of UV Lamp using the Left or Right Lamp regulator Set the printing parameters 3 UV Lamp UV Lamp is aged Check and replace if required Contact to factory for more details 1...

Страница 55: ......

Страница 56: ...For Any Query Please Contact Us www colorjetgroup com Call us on 91 120 4548195 Email on info colorjetgroup com For Ink Enquiry sales colorjetgroup com For Support support colorjetgroup com ...

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