Foreword

This installation guide is briefly describing the operational aspects of the NEPTUNE machine. In this
document, the step-wise instructions for installing and operating the 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 service engineer.

This guide refers as the reference tool which guides the service engineer how to install the NEPTUNE
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 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 1.1 NEPTUNE June 2019

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 Table of Contents
1. Site Layout................................................................................................................................................. 3
2. Site Requirements ..................................................................................................................................... 3
Hardware Requirements ........................................................................................................................... 3
Supporting Software ................................................................................................................................. 4
Site Requirements ..................................................................................................................................... 4
Power Requirements ................................................................................................................................ 4
Proper Earthing ......................................................................................................................................... 5
Environmental Requirements ................................................................................................................... 5
3. Safety Requirements ................................................................................................................................. 6
4. Preparation before Installation ................................................................................................................. 6
5. Handling Precautions ................................................................................. Error! Bookmark not defined.
6. Unpacking the Printer ............................................................................................................................... 7
7. Assembling the Printer.............................................................................................................................. 8
8. Ink Filling ................................................................................................................................................. 11
9. Head Installation ..................................................................................................................................... 13
10. Installing the Printer Manager .............................................................................................................. 17
Printer Manager Settings ........................................................................................................................ 23
Printer Settings ................................................................................................................................... 23
Head Voltage Settings ......................................................................................................................... 25
11. Head Alignment .................................................................................................................................... 27
Calibration Wizard .............................................................................................................................. 27
Step Calibration................................................................................................................................... 29
Mechanical Checks .............................................................................................................................. 30
Horizontal Calibration ......................................................................................................................... 32
12. Do’s and Don’t....................................................................................................................................... 34
13. Maintenance ......................................................................................................................................... 35
Print Head Maintenance ......................................................................................................................... 35
Head Purging ........................................................................................................................................... 35
Head Spraying ......................................................................................................................................... 37
14. Troubleshooting Guide ......................................................................................................................... 38
15. Error Handling ....................................................................................................................................... 42

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1. Site Layout

The Site Layout of the machine is shown as below:

Fig 1: Displaying the Site Layout

Machine Dimension (LxWxH): 4500 x 1000 x1400 mm

2. Site Requirements
Hardware Requirements
Table 1: The Hardware Requirements are given as below:

Parts Specifications

Operating System Windows 7/10

Processor Intel Dual core

RAM 2 GB or greater

HDD Enhanced IDE 360 GB

Video Resolution 1024x768 16-bit Color

USB Port USB 2 ports Minimum (2.0)

Internal PCI Slot 1 for Interface card

CD Drive CD Rom R/W Drive

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Supporting Software
Table 2: List of Supporting Software

Parts Software

Operation system Windows 7/10

Driver of print card Provide by ColorJet CD

Operating Software of printer Provide by ColorJet CD

Site Requirements
The site requirements are given as below:

• Dimension of printer: LxWxH 4500 x 1000 x 1400 MM

• Minimum working area requirement: LxWxH 5500 x 2500 x 3000 MM
• Avoid using carpet on floor as it can generate electrostatic charge and can accumulate dust.
• There should be ample space to load and unload the media as well as ink.
• The machine should be installed in a room which is air conditioned and is dust free and adequate
ventilation is available in the room. It is also important that adequate space should be available
around the machine for easy operation and maintenance.

Power Requirements
The machine needs the following power connections.

• Uninterrupted Power supply of 220V (+ / - 10%), 50Hz (+ / - 2 %)

• The power requirement will be as follows:
Machine 700W
PC 500 W
Heater Pre 1000 W
Heater Post 1000 W

It is recommended that 5 KW UPS be installed for the machine, alternatively one may go in for a 2 KW
UPS and let the Heaters run on RAW 220 Volts.

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Proper Earthing
The quality of printouts will depend on the earth connection provided to the machine. During printing,
the media generates lot of static charge that can affect the placement of dots and also excessive charge
may damage the print heads which would be a very expensive damage.

It is recommended that a separate earth connection should be provided to the machine and the earth
resistance should be in the range of 4-5 ohms. The distance of the PC from the machine should not be
more than 2 -3 feet.

Note: It should be ensured that the earth point for the Printer and the PC is same this is important for the
safety of the interfaces.

The Earth Connection for the system should be shown in the drawing:

PC Monitor

Line Uninterrupted
Power Supply Line
Neutral Distribution
Board
Earth
Neutral Printer

Separate
Earth Schematic Connection of Power

Fig 2: Displaying the Earth Connection

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 Requirements
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.

Software Errors

While using the Printer Manager software, it is possible that some errors may occur. In such case, all the
errors or system messages will be displayed on the Error Information area. Read the error message and try
to resolve it. If you are not able to resolve the issue, please contact us or call at our customer care number
for more assistance.

4. Preparation before Installation

To install the printer, you must follow the below mentioned instructions for better use and long life of the
printer:

• 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 like a forklift.
• Install the Printer Manager software by following all the instructions mentioned in the Installation
Guide.
• If any damage in packaging is founded, 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.
• While assembling, check the labels on the box "right and left" and “front and rear”.
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6. Unpacking the Printer
This is advisable that please open the printer box in the presence of a service engineer. If any damage is
found in the box, kindly report the same to the dealer with their respective picture.

The Neptune machine is packed into two iron pallets. One pallet is used for packing the upper body of the
machine and other for cabinets.

The upper body of the machine is packed into the below iron pallet:

Top Frame

Fig 3: Iron Pallet for Upper Body of the Machine

The machine’s cabinets are packed into the below pallet:

Top Frame

Fig 4: Iron Pallet for Machine Cabinet

Gently, remove the top frames of both pallets and then, lift up the machine from both corners with the
help of at least two people and assemble the machine by following the steps given in the “Assembling the
Printer” section.

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7. Assembling the Printer
Assembling of the printer is done in the presence of a service engineer. The total weight of the printer
with stand is 300 KG (Approximate). For the safety concerns, the assembling process requires at least 6
persons.

Follow these steps to assemble the printer:

Step 1: Remove the packing of both cabinets of the machine and place them in an even platform.

Step 2: Fix all the four levelers into both ends of the machine, as shown below:

Levelers

Fig 5: Fixing the Machine Levelers

Step 3: Tight all the Allen Bolts of M10 x 20 with M10 Washer to fix the Truss at both cabinets (8 Allen Bolts
on each cabinet), as shown below:

Fig 6: Fixing the Truss

Note: Don’t fully tighten the Truss screws.

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Step 4: Place the Center Jack on the Truss to ensure the direction.

Step 5: Tight all the Allen Bolts of M6 x 16 with M6 Washer to fix the Center Jack, as shown below:

Fig 7: Fixing Center Jack

Step 6: Prepare the media supply rollers with supply pipe pins.

Step 7: Unscrew the bearing holders from the cabinets and insert the media pipes to right end, as shown
below:

Step 8: Insert and fix the Spur Gears, as shown below:

Fig 8: Fixing the Spur Gears

Step 9: Install the Media Motor again.

Step 10: Carefully lift the upper body of the printer and place on the stand so that its screw holes align.

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Step 11: Tight all the Allen Bolts of M8 x 16 with M8 Washer (8 Allen Bolts each side), as shown below:

Fig 9: Placing Upper Body of the Machine

Step 12: After fixing the upper body of the machine, fix the Fan Housing and tight all the Allen Bolt of M
10 x 20.

Step 13: Tight all the Truss screws to fix it.

Now, the Neptune Machine gets assembled and the front view of the machine is shown as below:

Fig 10: An Assembled Neptune Machine

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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: Open the left door of the printer to find out main tanks.

Step 2: Fill recommended ink in main ink tank (as per the color sticker) as per the requirement, as shown
below:

Fig 11: Filling Ink in Main Ink Tank

Step 3: Fix the sub ink tank connectors to the ink refilling pins in the Head Board, as shown below:

Fig 12: Connecting Sub Ink Tank Connectors

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Ink gets filled in the Sub tanks as shown below:

Fig 13: Refilling Ink in Sub Tanks

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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.

Note: Don’t apply much pressure on Print Head while handling it.
Follow these steps to install the Print Head:

Step 1: Remove the Ink Inlet caps gently to avoid damage to the Print Head.

Step 2: Fix the Air Releasing and Ink Sub Tank pipes on the Ink Inlet Tube, as shown below:

Ink Sub Tank Pipe

Air Pipe

Nozzle Cap

Fig 14: Fixing Air and Ink Sub Tank Pipes

Step 3: Remove the Nozzle Cap from the Print Head (Refer to Fig 14).

Note: Don’t put the Print Head (nozzle facing) on the rough or dusty surface.

Step 4: Mount the Print Head in the slot on the Head Plate.

Step 5: Fix both screws (4x16 mm screws) gently on the Print Head, as shown below:

Fig 15: Fixing the Head Screws

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Step 6: Fix the Ink Sub Tank pipe into the other end, as shown below:

Fig 16: Connecting the Ink Sub Tank Pipe

Step 7: Remove the cap of the Air Releasing Pipe (Refer to Fig 16).

Step 8: Hold the pipe down and press the Purging button of a particular color, as shown below:

Purging Button

Fig 17: Displaying the Air Releasing Pipe and Purging Button

Note: Carefully perform the above step to avoid the chances of ink spilling.

Additionally, perform the same action for all colors and release ink up to 5ml.

Step 9: Simultaneous, release the purging button and cap the Air Releasing Pipe.

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Step 10: Insert one end of the head cable on the top of the Print Head by following the arrow mark, as
shown in the image below:

Arrow Mark

Fig 18: Inserting the Head Cable on the Top of Print Head

Note: While inserting the head cable, the machine must be Switch OFF.

Step 11: Similarly, insert the second end of the head cable on the Head Board, as shown below:

Fig 19: Inserting Head Cable to the Head Board

To verify the head cable orientation, please carefully view the highlight area on the above image.

Step 12: Check whether the Waste Bottle is attached or not.

Step 13: Perform the Head Purging for all colors.

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Step 14: Perform the Head Blotting to gently clean the Print Head. The Head Blotting is shown in the image
below:

Fig 20: Displaying the Head Blotting

Step 15: 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. Installing the Printer Manager
Before installing the Printer Manager software, please confirm that the DotNet Framework is available in
your system. If it is not installed, then first install it.

With the Printer Manager, you need to install the following:

• DotNet framework
• USB Driver

Let’s discuss the installation process in details.

Follow these steps to install the Printer Manager software:

Step 1: Verify whether DotNet framework is installed in your computer system or not. If not, then first
install the framework using the CD or download the installer from the below mentioned link:

http://www.microsoft.com/en-in/download/details.aspx?id=17718 and follow the instructions appear on

the screen.

Step 2: Copy and paste the Printer Manager software from the CD to the secure location.

Step 3: Double-click on the Printer Manager Software (.exe file) icon, as shown below:

Fig 21: Starting the Printer Manager Installation

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On-clicking the Printer Manager icon, the Startup screen appears, as shown below:

Fig 22: Starting the Installation Process

Step 4: Click on the Next to confirm that you want to install the Printer Manager software and follow all
the instructions appear on the screen.

Now, the Printer Manager gets installed successfully and displayed the Ready status. In case, if it is not
properly installed, then the status is Offline. To open the Printer Manager, click on the Printer Manager
icon. The Printer Manager window appears on the screen, as shown below:

Fig 23: Displaying the Printer Manager Window

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Note: USB driver is automatically installed with the Printer Manager software. If not, then follow the
below given steps.

Step 5: Open Device Manager, right-click on the My Computer icon and select the Manage option from
the context menu, as shown below:

Fig 24: Selecting the Manage Option

Step 6: Select the Device Manager option from the Computer Management window (Refer to Fig 25). The
Device Manager and its related options get expanded on the middle pane of the Computer Management
window, as shown below:

Fig 25: Displaying the Device Manager Screen

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Step 9: Select the Wide-Format Printer option under Other devices and right-clicked on it. The context
menu appears on the screen (Refer to Fig 25).

Step 11: Select the Update Driver Software option from the context menu, as shown below:

Fig 26: Configuring the USB Driver

The Update Driver Software window appears, as shown below:

Fig 27: Displaying the Update Driver Software Window

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Step 12: Select the Browse my computer for driver software option from the Update Driver Software
window (Refer to Fig 27).

Step 13: Select the location where the driver software is stored by clicking on the Browse button, as shown
below:

Fig 28: Selecting the Driver Location

Step 14: Click on the OK button to start the driver update process (Refer to Fig 28). The process gets
started for updating the driver software and the process progress screen appears, as shown below:

Fig 29: Displaying the Process Progress

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Now, the driver updating process gets completed successfully, as shown below:

Fig 30: Updating the Driver Successfully

On completing the process, click on the Close button to close the process.

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Printer Manager Settings
Printer Settings
This option enables users to update the default settings of the printer viz. Print, Move, Preference, and
Calibration. To open the Setting window, click on the Main Menu→Setting→Edit path. The Setting
window appears on the screen, as shown in the image below:

Fig 31: Displaying the Setting Window

Describing the printer manager setting that service engineer needs to verify with the following table:

Tab Name Section Name Field Name Correction Value

Printer Print Setting Feather Select the “Custom option
and feather percentage
should recommend
between (10-30).
Clean Setting Auto Clean 0
Spray Setting Spray Period 180
Print Pre-spray Time 0.5
Spray Before Print Enabled

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Describing the different sections of the Setting window, as given below:

• Print setting
o Auto skip white: Enable to auto skip the white space in the image during printing.
o Step Time: Set time interval of the feed motor during printing.
o Job Space: Set space between multiple jobs.
o Feather: Select 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 same with image: If enabled, the height of the color bar is same as the image
height.
• Spray setting
o Auto Spray: Set the duration (number of passes) for auto spraying.
o Spray Period: Define the duration for spraying (set as 180). If the duration increased, spray
frequency gets decreased.
o Print Pre-spray Time: This is the duration of spray before start of print.
o Idle Spray: Spray during carriage at home position. This option must be enabled.
o Spray Before Print: This option enables spray before start of print.

The Move tab is shown in the image below:

Fig 32: Displaying the Move Tab

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The Preference tab is shown in the image below:

Fig 33: Displaying the Preference Tab

Using the Preference tab, the measuring unit can be set or changed.

Head Voltage Settings

Follow these steps to update the head voltage:

Step 1: Click on the Main Menu→Tools→Real Setting path, as shown in the image below:

Fig 34: Selecting the Real Setting Option

The Temperature window appears on the screen.

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Step 2: Enter the left and right base voltage values of each color Print Head under the Base Voltage section,
as shown below:

This value must be same as highlighted in Fig 36.

Fig 35: Setting the Base Voltage Value

The left and right base voltage values of each color Print Head must be matched with the values printed
on the same color Print Head. The Left and Right Base Voltage values of Print Head is shown in the image
below:

Fig 36: Displaying the Head Voltage Printed on the Print Head

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 35).

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 11. Head 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 37: Selecting the Calibration Wizard Option

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

Fig 38: Displaying the Calibration Wizard

Based on the above figure, the list of mechanical checks appears and as per these checks, Print Heads
need to be adjusted with the help of tools provided. The list of mechanical checks is given as below:

• Angle Check
• Vertical Check

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When you press the Next button, you are redirected to the Calibration Wizard, as shown in the below
image:

Fig 39: Displaying the Printer Calibration Options

Note: Base Step value should be 64150.

Step Calibration
The printer step calibration is performed to verify and correct media feeding. The printer prints a complete
image pass by pass. A pass is the horizontal carriage sweep perpendicular to the media movement. After
each pass the printer moves the media forward for the next pass. This movement of media is called a step.
The distance by which the media is moved is called the step size and it has to be accurate. Step size errors
cause horizontal white or dark bands to appear in the print output.

Step size needs to be adjusted for multiple factors like thickness and roughness of the print media etc.
Step calibration should be used to fine adjust the step size and has to be done for each desired pass. Step
value can be adjusted using the Steps field, as shown below:

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The Step Calibration and it’s parameters are shown in the image below:

Fig 40: The Step Calibration Parameters

First, feed the Base Step Value as 64150 (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 pass from the list and click on the Print button (Refer to Fig 40).

Step 2: Feed the correction value in the Revise field (the correction value up to two decimal places) (Refer
to Fig 40).

Step 3: Click on the => icon (Refer to Fig 40) on the Step Calibration window. The correction value result
will be reflected in the Step field (Refer to Fig 40). The same step value will also be displayed in the Steps
field on the Quick Access Toolbar.

Mechanical Checks
Accurate mechanical alignment is the key for achieving good print quality. In case of misalignment, the
Print Heads have 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 straight line pattern is formed, as shown below:

Fig 41: The Good Quality Angle Test

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When there is angular error in a head’s placement, the line formed by a particular Print Head will appear
broken, as shown in the image below:

Fig 42: Defect in Angle Check

Let’s discus the next vertical check.

Vertical Check

The vertical alignment test is performed to check the vertical alignment of all heads with reference to the
Magenta head. To execute vertical alignment test, click on the Vertical Check button on the Calibration
Wizard.

Samples of Good and Bad Vertical Alignment Test Result is shown in the below figure:

Fig 43: The Good and Bad Vertical Alignment 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).

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Note: During the mechanical checks, it may possible that it will disturb the angle check or vertical check.
Thus, repeat the mechanical check until the perfect alignment condition is achieved.

Horizontal Calibration
Horizontal Calibration checks the bi-directional, left, and right alignment and corrects it by adding or
subtracting the correction value from the default set value. It has to be performed for each print mode
(360 and 720 dpi) 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, the Left to Right test print would
align accurately with the Right to Left test print at“0” position. In case of error in the Bi-Direction offset,
the Left to Right and Right to Left print would align at some other point on the scale.

The Bi-direction Calibration result is shown in the image below:

Fig 44: The Bi-Direction Calibration Output

Based on the above figure, you can notice that the Bi-direction calibration is good at “0” position. The
correction value is “0” which means you need not to correct the bi-direction value. Sometimes, the
correction value can either positive or negative. If the correction value is positive, then you need to add
it in the current bi-direction adjust value or subtract the same if negative.

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Left to Right and Right to Left Calibrations

Left to Right Calibration is 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 that the error position is “0”. If the test Print Head’s position saved in the system is
inaccurate then it would not align at “0” position, but at some other point on the calibration scale. The
position at which the test head aligns perfectly with the reference head, indicates the error in position.

The Left Calibration Result is shown in the image below:

Fig 45: Displaying the Left & Right Checks

Left Calibration Right Calibration

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 12. Do’s and Don’t
Do’s

• Perform Nozzle test daily before using the machine

• Use only the recommended ink in the machine
• Check and refill the ink main tank regularly to avoid air lock
• Check the waste bottle regularly
• Keep the Night Plate cleaned
• Always put wet tissue on the Night Plate
• Align the Core Holder brackets as per the media position
• Feed Adjust value has to be adjusted in decimal format up-to two decimal places

Don’t

• Avoid ink spilling on the Print Head and head cables

• Don’t use expiry ink and store the ink at favorable environment
• Avoid printing without Colorbar
• Don’t use Night Plate without a wet tissue
• Don’t print without Media Clamp
• Don’t handle Print Head without anti-static protection
• Don’t leave the Print Head without capping
• Don’t apply much pressure on the Print Head during installation
• Don’t carry out head alignment and calibration without using magnifying lens
• Avoid head damage due to media and Print Head confliction

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 13. Maintenance
Print Head Maintenance
Print Head is a delicate part which needs to be cleaned as per the recommended methods to have long life
and to ensure consistent print quality. Below sections give recommended steps to clean the Print Heads.

Head Purging
Head purging refers to the method in which heads are cleaned by forcing pressurized ink though the nozzles.
In the Neptune printer, head purging buttons for each color are available on the carriage, as shown in the
below figure:

Head Purging

Fig 46: Head Purging Buttons

Note: If nozzles are found blocked even after normal purging, then try the powerful purging (“P” switch in
purging board has to be kept pressed for few seconds and then required color switch has to be pressed).

Head Blotting

Head blotting refers to the process in which the head surface area is cleaned with the help of tissue paper
or cloth. Blotting removes ink drops adhering to the Print Head nozzle surface. Gently touch or wipe with
a clean recommended head cleaning tissue on the head’s nozzle plate. One should make sure that the
tissue is clean, soft, and also does not have any chemicals on it.

Follow these steps to clean the Print Head:

Step 1: Press the Purging button of the desired color.

Note: Please note that purging button should be pressed only for a second (until few drops of ink come
out).

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Step 2: Spread the cloth tissue on the open palms and insert hands below the print head position, without
touching the Nozzle Plate.

Step 3: Gently touch the nozzle plate using the clean and fresh cloth tissue at two different positions.

Note: - Remember!! NOT TO WIPE

Step 4: After blotting, remove the tissue without touching the print head or head plate as shown
below:

Now, print head is cleaned and blotted, give the test print command to verify the nozzle status.

Step 5: Repeat above steps, if required.

Note: Please strictly follow the below mentioned instructions:

• Avoid using the same tissue paper to wipe the Print Head.
• Wiping with dry and inferior quality tissue paper will damage the nozzle film by making scars
(see image in next page).
• Strictly use recommended tissue paper (Contact your dealer for tissue paper).
• Always use wet tissue paper to absorb the residue ink.
• Don’t wipe hard, just absorb the residue inks on nozzle plate.
• Softly touch with a lint free bloating tissue paper (duly wet by cleaning solvent) by changing the
tissue paper position with respect to nozzle plate.
• Do not apply force while absorbing residue inks with tissue paper after purging.
• Leaving head plate uncapped while printer off, will block nozzles permanently due to ink
solidification.
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 • Color bar should always be enabled while printing and idle spray should always be enabled for
long life of the Print Head.

Head Spraying
Head spraying should be performed only when small percentage of nozzles are blocked. This method is
used to avoid mixing of colors. When heads are sprayed all the nozzles are actuated at a high rate which
helps in opening up dry nozzles of the printer. To perform head spraying, click on the Spray button
available under the Quick Access Toolbar, as shown below:

Fig 47: Displaying the Spray Button

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14. Troubleshooting Guide
Error Name Reasons Remedial Actions
Printer Not 1. No Power Supply to Head Case 1: No Power Supply to Head Board
Initializing/Initi Board (Beep can be heard) a) Check 24 V power supply output
alization and replace the Power Supply
Incomplete b) Check the 24 V Power Supply on
Head Board connector, if there is
no power, then check cable
continuity and replace it, if
required.
2. Servo Driver not ON or faulty Case 2: Servo Driver not ON or faulty
or programmed incorrectly a) Check the Red LED on Servo Driver,
if LED is not glow then check the
power connection and trace the
fault.
b) In case, machine is not initialized
correctly, then contact Head
Office.

3. Encoder Sensor not connected Case 3: Encoder Sensor not Connected or

or faulty (Carriage will top at
right)
4. Main Board is faulty or it’s
settings are incorrect
5. Head Board is faulty
6. Emergency Button is pressed
7. Default Jumpers are not placed Case 7: Place Jumpers on the Main Board,
in the Main Board
8. LVDS is not connected properly Case 8: Connect LVDS properly.
9. Incorrect pulley is used
Faulty
Case 4: Main Board is Faulty or it’s Settings
are Incorrect
a) No power on Main Board
b) Check power 24V and 5V on Main
Board
c) Replace the Main Board, if faulty
Case 5: Head Board is Faulty
a) Check 24V power on the Head
Board connector.
b) Replace the Head Board, if
required.
Case 6: Emergency Button is Pressed
a) Release the Emergency Button, if
pressed.
b) Check 220V on emergency.
if not available.
Case 9: Use compatible pulley by
contacting Head Office.

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 Printer 1. USB Cable is Loosely Case 1: Tighten the USB cable.
Manager Not Connected to the Printer
Showing 2. USB Cable is Faulty Case 2: Replace the USB cable, if faulty.
“Ready” 3. Printer not Initialized Case 3: Please refer to the “PRINTER NOT
INITIALIZING” section.
4. USB driver is not Installed Case 4: Please refer to the “Installing the
Printer Manager” section.
5. Main Board and Head Case 5: Kindly contact to the Head Office or
Connector Board (HCB) is not CES.
compatible (an error appears)
Carriage Stops 1. USB cable is loose or faulty Case 1: Tighten the USB cable or replace it,
During Printing if required.
2. Open heavy file that can slow Case 2: Use compatible and small size
down the data transfer images for printing.
3. Ground wire is disconnected Case 3: Connect the ground wire to the
system.
4. Encoder Scale is having ink Case 4: Check and Replace Encoder Scale
stains
5. Pulley teeth wear out or belt is Case 5: Replace the Pulley or Carriage Belt
slipping
6. Ripped file is having error Case 6: Correct the ripped file error, if any.
7. Check I/P and O/P voltage in Case 7: Replace the power supply, if
24V SMPS on full load. Voltage voltage drop is found and also check the
drop, if any. power Inlet to the machine.

Print Margin Is 1. Encoder Scale is having ink Case 1: Clean the Encoder Scale.
Shifting Or stains
Junk Printing 2. Encoder Sensor is not clean Case 2: Clean the Encoder Sensor.
3. Pulley or belt is slipping Case 3: Check for any wear & tear in the
pulley or belt and replace it, if required.
4. Data cable is faulty (Steps) Case 4: Check by swapping the direction of
data cable and replace it, if required. The
data cable is connected between Head
Board and Main Board.
5. Main Board is faulty Case 5: Replace the Main Board, if faulty.
Print Is Blur 1. Improper Head height Case 1: Correct the head height by
(Not Sharp) following the steps given in the Head
Height Adjustment section.
2. Improper head alignment Case 2: Calibrate the printer again by
referring the “Head Alignment” section.
3. Recommended ink not used Case 3 & 4: Use only the recommended ink
4. Ink stored at unfavorable and stored it in favorable environment
environment conditions.
5. Head voltage is not properly Case 5: Feed the Head Voltage value as
fed in Printer Manager mentioned in the Print Head.
6. Improper step calibration Case 6: Correct the step calibration using
the Step Calibration section.

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 7. Vibration in movement:- Case 7: Perform the following actions as
o LM block is wear out per the requirements:
o Incorrect pulley a) Replace the LM block
alignment b) Align the pulley with respect to
Belt
Heater Not 1. Inlet power not connected. Case 1: Check the Inlet power in connector
Working near heater. Check for any fault in circuit
and ON the MCB after correcting the fault.
2. Heater Case 2: Perform the following actions:
coil/thermistor/thermo-stat 1. Check the continuity/resistance
circuit is open between heater wire and
thermistor
2. Replace the defective part, if any
3. 24 V Input is not getting Case 3: Check 24VDC Voltage at SSR when
supplied to SSR PID shows replay ON. And at same time
check 220VAC In Out terminal and replace
SSR, if required.
4. Improper settings in PID or Case 4: Perform the following actions as
faulty per the requirements:
a) Correct the PID settings, if
required.
b) Check continuity in out terminal
and replace it, if required.
Lines In Print 1. Head nozzles are blocked or Case 1: Perform the Nozzle Test (Refer to
getting blocked during printing the Nozzle Testing section) and clean the
Print Head. Addition, confirm the following
things:
• Check if recommended ink is used
• Check head voltage settings
• Check the room temperature
2. Incorrect feed steps Case 2: Use the Feed Adjust option to
adjust the feed value (Refer to the Print
Head Calibration section).
3. Head alignment incorrect Case 3: Check and correct the alignment
settings by following steps mentioned in
the “Head Alignment” section.
4. Y motor connectors are loosely Case 4: Tighten the connectors from both
connected either motor side or places viz. motor side and main board.
Main Board
5. Motor belt is loose/slipping Case 5 & 6: Tighten or replace the
6. Pulley is loose in its shaft Belt/Pulley, if required.
7. Grit Roller Shaft movement is Case 7: Observe the shaft rotation carefully
not smooth or stucking and repair the stuck part, if any.
Additionally, replace the Grit Roller
bearing, if required.
8. Feed Motor or driver is faulty Case 8: Replace the Feed Motor or driver,
if faulty.

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 Some Head 1. Head is not getting cleaned Case 1: Perform the Nozzle Testing to clean
Nozzles Not the head nozzles (Refer to the “Nozzle
Firing Testing” section).
2. No ink in ink sub tanks Case 2: Check the ink level in the main tank
and ink refill connections.
3. Check if any air lock or no ink in Case 3: Replace the Print Head or Head
the ink pipes Board or Main Board, if not working or
faulty.
4. Check the ink and air pipe for Case 4: Check and refill the Ink sub tanks, if
any cuts or loose connection required.
5. Ink sub tank level is not correct Case 5: Replace the ink and air pipe, if
required.
6. Print Head or Head Board or Case 6: Check the level of ink in the sub
Main Board is faulty tanks and adjust with respect to head
nozzle surface.
Media Supply 1. Switch not ON in Auto/Manual Case 1: Turn ON the Supply witch.
Not Working in
Auto/Manual 2. Media is not in sensor range Case 2: Check and correct the Media
for Auto mode Sensor range.
3. Media sensor settings are Case 3: Correct the Media Sensor settings.
incorrect for Auto mode
4. Media Sensor Input/Output Case 4: Correct the Media Sensor
power is not proper for Auto Input/Output power.
mode
5. Capacitor is weak or faulty Case 5: Check and replace the capacitor, if
required.
6. Supply Motor is faulty Case 6: Replace the Supply Motor.
7. Media Sensor is faulty Case 7: Replace the Media Sensor.
8. SSR 10 amp switch is faulty or Case 8: Replace the SSR 10amp switch.
24 V not coming at SSR
Complete Head 1. Head voltage is not fed in Case 1: Fed Head Voltage in Printer
Not Firing Printer Manager Manager.
2. Head cable is not properly Case 2: Check the Head cable and connect
connected with the Head it properly.
Board
3. Head Board connectors are Case 3: Check the connectors and connect
not properly connected on the them properly.
Print Head
4. Ink stains are visible on the Case 4: Inform to the Head Office
Head connector
5. Head or Head Board or Main Case 5: Replace the Head or Head Board
Board is faulty or Main Board by contacting to the Head
Office.
6. Ink sub tanks are empty Case 6: Refill the Ink Sub tanks, if empty.

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15. Error Handling
Error Code Error Description Error Description
400100D1 Print position overrun Please try to print images or narrow
width or increase printing the origin
position.
400100F6 Encoder Error! Problem in Encoder Sensor and Scale
400100FC Touch limit sensor Jumpers are connected
04020002 Pumping cyan Low ink level in tank
04020003 Pumping magenta Low ink level in tank
04020004 Pumping yellow Low ink level in tank
04020005 Pumping black Low ink level in tank
04020008 Incorrect input in the Time Limit Password Re-input correct password.
or may consist the forbidden character
04020009 Illegal time-limit of the password Re-input correct password.
0402000A Time limit password and manufacturer ID Re-input correct password.
doesn’t matched
0402000B Time limit password and board ID doesn’t Re-input correct password.
matched
0402000C First Warning: 100 hours left against Request for a new time password from
current time-limit password the dealer.
0402000D Second Warning: 50 hours left against Request for a new time password from
current time-limit password the dealer.
0402000E Last Warning: 1 hour left against current Request for a new time password from
time-limit password. After this, issue job the dealer immediately.
gets stopped
04020021 Print data is more than fire number • Encoder Scale/Sensor is not aligned
• Encoder Scale is having ink stains
• Incorrect pulley is used
• Servo Driver programmed incorrectly
• Incorrect print mode is selected
• Main Board settings are incorrect
• Pulley/Belt teeth are wear out
04020034 Pump ink overtime Low ink level and warning is enabled in
Printer Manager.
20020002 Motion COM timeout LVDS is loose or faulty.
20020003 Head board COM timeout LVDS is loose or faulty.
20020004 Print data mismatch with fire Kindly refer to the error code 04020021.
40020001 Data header error. USB and common Earthing related issue.
40020009 Image too width. Kindly refer to the error code 400100D1.
4002000C Head board Step 1 Initialization problem.
4002000E LVDS Error Check the data cable and power supply.
40020011 EEPROM Read Failed Re-update the FW. In case, the problem
is still, then replace the Main Board.
40020012 EEPROM Write Failed Re-update the FW. In case, the problem
is still, then replace the Main Board.

NEPTUNE Page 42 of 45
 40020014 Head Board is reset Check the power supply of the carriage
board and the data cable.
40020016 Head Board settings mismatches with Incompatible Head Board and replace it,
factory if required.
40020017 Board manufacturer ID doesn’t matched Update or replace the Main Board.
with FW
40020018 Serious Error: Exceed the time against the Contact the dealer for time password
time limit password expiration.
Kindly refer to the error code 40020001
4002001A USB1.1 connect
and restart the machine.
Serious Error: The language of the Please reset the software language or
software setting does not correspond to input the new language matching
4002001B authority. Please reset the software password again.
language or input the new language
matching password again
4002001C PINCONF writing FPGA errors. Main Board is faulty.
40030000 USB communication error Kindly refer to the error code 4002001A.
Printer id not supported! Please upgrade Please upgrade the software and replace
40030006
software! the main Board.
PRT resolution mismatch with printer Incorrect Print Mode is selected.
40030009
resolution!

NEPTUNE Page 43 of 45
 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