VastraJet

Training Manual
Machine Structure
and Specifications
Front View of VastraJet
Back View of VastraJet
 Contents
1. InkJet Technology & Print
heads
• Print head specs
• Understanding DPI and
passes
• Image quality affecting
parameters
2. Printer Electrical &
Electronics
• Printer Block diagram
• Understanding electronic
boards
• Printer Electrical and
Electronics parts
• Subassembly boards and
connections
3. Circuit Diagrams for subsections
• Unloading, Unpacking • Spare parts name, image
precautions and coding, ECN
• Installation procedure • Indenting parts and SMS
• Belt shifting control
procedure • Service Policy
• Glue application • Defective parts tagging,
process packing
• Printer software • Print head handling &
• Head alignment and packaging
calibration
• Rip Software
• Maintenance
• Trouble shooting points
and tips
1. InkJet Technology & Print Heads
1.InkJet Technology
• Piezoelectric ceramic material deforms when voltage is
applied
• Distortion creates a pressure pulse in the ink chamber and
causes a drop to be ejected from the nozzle
• When piezo normalizes, it pulls the ink again in chamber
• Companies that use such technology includes Kyocera,
Konica Minolta etc.
VastraJet Head Specifications
Konica Minolta 512i MAB-C
DPI (2 bit) Passes DPI (1 bit) Passes
360X360 2 720X360 2
360X540 3 720X540 3
360X720 4 720X720 4

Air Pipe
Ink Pipe
Konica Minolta 1024i MAE - C

Back Side

Nozzle One Front Side

Difference Between Konica Minolta 512i MAB-C and 1024i MAE-C

Head Specifications Konica Minolta 512i MAB-C Konica Minolta 1024i MAE - C

Native DPI 180 (90 x 2 rows) 360 (90 x 4 rows)

Nozzle rows 2 rows x 256nozzles 4 rows x 256nozzles
Drop size 14PL 13PL
Active Nozzles 512 of 1024 1024
Print Width 72.4mm 72.4mm
Head Classifications
512 LN/MN
1024 LNB/MNB
LNB
Drop Size
M-Medium Structure
512i LNB L-Large N- Without Heater
S-Small H-With Heater
MAB A- Aqeuous (Water Based)
1024i MHE
M – Medium - 13 and 14 pl
SHE L – Large - 42, 35 and 30 pl
MAE S – Small - 6 pl

SAE
Understanding DPI and passes
In case of 512(native DPI = 180)
For eg.360 x 540
• X DPI=360, Y DPI=540
• (Y DPI)540=180 native dpi x 3 =3pass

In case of 1024(native DPI = 360)

Example1: 540 x 1080
• X DPI=540, Y DPI=1080
• (Y DPI)1080=360 native dpi x 3 =minimum 3 pass (3,6,9etc)
Example1: 540 x 720
• X DPI=540, Y DPI=720
• (Y DPI)720=360 native dpi x 2 = minimum 2 pass (2,4,6,8etc)
Image quality effecting parameters

• Head plate to Belt gap

• Head angle and vertical (physical) alignment
• Head Calibration as per dpi, mode and speed
• Head voltage
• Stable negative pressure
• Ink Quality
• Carriage and Conveyor Belt smooth and precise movement
• Air in head pipes
2. Printer Electrical & Electronics
 Printer Block Diagram
Encoder Refill Connections Limit Switch Left NO, right NC
24V

LVDS
USB
LVDS
Head Board Main Board

Computer
X Motor Y Motor
System
24V(Pumps)
Head Cables Refilling
(Different for 512 and Connections
24V(Electronics)
1024)
 Left
Capping
Mainboard Limit
Switch
Right
Limit
J23 Left Limit Switch
Switch J17 Right Limit Switch
Main Board J3 USB
is separate for 512i and J6 Y Motor
1024i) J27 Refilling Connectors
J4 24 V for Pump
LVDS USB J1 24 V for Electronics
Board codes:- J5 X Motor Driver
512i - KM0408GBT/NBT J301 LVDS
1024i - KM0508GBT/NBT
Wiping NC
Board versions:-
X Motor Dir-
v4 Driver
v5.2 Dir+
Pul-
Y Motor Pul+
24 V Refiling Refilling Connector Sequence
(Electron Connectors 24 24 Lk O C M Y K B P
ics) 24 V (Pumps)
 Head Board (512) Refill Connections 24V
Encoder Sensor B P Y M C K O Lk

LVDS

Y C B O
Head
Cable
Slots
M K P Lk
Head Board (1024)
Encoder Sensor B P Y M C K O Lk Refill Connections 24V

LVDS

Y C B O
Head
Cable
Slots
M K P Lk
AC Servo Motor
Encoder Feedback for precise positioning
4 Pin : Motor Power Connector
9 Pin : Encoder Connector

Power
Connector
Encoder Connector

AC Induction Motor (for Brush Motor)

Dark Grey Wire : L1

Light Grey Wire : L2
White Wire :N
Remaining two Blue Wires : Not in Used
(Jumpered together)
 AC Servo Driver
V1- White colored
V2- Black colored
V3 - Black colored

• Programming is different
for all above versions
• Connecting cables are
different for v1 and
v2/v3
• Programming for X, Y,
Take up is different
Servo Driver connections
Servo Driver connections
Sensors
Proximity Sensor Encoder Sensor

Heater Sensor

Float Sensor

Pressure display
switch
Types of Relays used
• SSR (DC-AC)- Current Relay- 75A- used for IR and Glue dryer
• SSR (DC-AC)- Voltage Relay- 75A- used for IR and Glue dryer
• SSR (DC-AC)- Voltage Relay- 40A- Brush, Glue Dryer fans, Jetting pump
• SSR (DC-DC)- 40A - Actuator relays
• Electromagnetic(EM) Relay with base – Heater sync, Actuator control,
Y motor control, Degassing, Negative pressure, Overflow protection
 Heater SSR

Actuator and other SSR

Dry Fan Actuator Relays

Jetting Pump Brush Motor

 EM Relays : for Y Motor Control and Heater Sync

Heater Sync Actuator control

 Degassing, Overflow and Negative Pressure Relays

Negative
Pressure
Relay

Degassing Relay

Overflow Relay
Pumps
Diaphragm Pump (Air pumps)

Peristaltic Pump (Ink pumps)

Submersible Pump (Jetting pump)

Solenoid
3-Way Solenoid Valve Solenoid Manifold
Power Supplies
3. Wiring Diagram for Sub Sections
Color codes
• PLC wires:-
• Brown(0.5sqmm): +24VDC
• Blue(0.5sqmm): COM
• Other 24V wires:-
• Blue(0.5sqmm): +24VDC
• Black(0.5sqmm): COM
• Red: L, Black: N, Green: GND

Power distribution
• Print Engine: 1.5KW
• Glue heater: 2.5KW
• IR heater: 4KW (2KWx2)
Mains power
Fuses
• DC fuse- PLC, DTC, Actuator
• AC fuse- Jetting, Fans, Brush,
Transformer
HMI (v1)
HMI (V2)
PLC PLC extension Heater controller
PLC in out
OUT Signal IN Signal
Y2 Belt dir X1 Emergency
Y3 Belt pulse X13 Tub sensor up
Y4 Conveyor switching Online offline X14 Tub sensor down
Y6 Brush motor X15 Tub sensor maintenance
Y7 Actuator up/down X16 Heater synchronization
Y10 Actuator up/down
Y11 Takeup Servo On
Y12 Takeup Dir
Y13 Tower light-red
Y20 Jetting pump
Y21 Glue dryer
Y22 IR heater
Y24 Glue dryer fan
Y25 tower light-yellow
Conveyer Belt ONLINE and OFFLINE Switching
MB
Y Motor
HMI Control Relay

PLC Y
NC
Servo
Y2 Dir(-) Driver
Y3 Pul(-)
+24
+24
14 13
(+24V)

OFFLINE/ONLINE Signal
Y Motor Control Relay Heater Sync Relay
Heater Controller
Heater Controller IR Heater and Glue Heater
Actuator Wiring
Actuator

Continue to Next Slide

Negative Pressure & Refill System
Negative Pressure Pipeline
Take Up Block Diagram
Regu
lator
SMPS 5V
Servo Driver

6/18
17/9 Y11
14/32 Y12
PLC
DTC 1000
2(-) / 6(-)

3(+) / 5(+)
(6-8
jumper) HMI
Take up wiring
PLC Delta Driver

Y12 14/32
Y11 17/9
8/29 5VGND
4+7 /17+11 +24V
5V
6/18
GND
13/14 24V GND 5V SMPS
+5V

Regulator
Delta Driver
DTC CN3
1000
2 /6 GND
3 /5 +24
6
Heater Controller Jumpers
8
Brush Motor

+ Lin 220VAC

SSR
Brush Motor
L1
- Lout
L2 Brush Motor
N
Capacitor
Subassembly boards and connections
i) ACB 01

ii)Purging board

iii)Refill card
iv)IPSC board
Unloading and Unpacking Instructions
Packing Details
VastraJet is shipped in an iron cage and base called "Pallet ", wrapped in
three layers with antistatic moisture locked plastic covers. The packing
and unpacking dimensions with weight are given as follow:
Machine Dimension: 3810 x 1780 x 1640mm (Length x Width x Height)
Packing Dimension: 4005 x 1920 x 1870mm (Length x Width x Height)
Machine Weight: 1200kg
Machine Weight with Packing: 1400kg
 Unloading and Unpacking Instructions
The machine is fixed at four corners of the “Pallet” with a set of four bolts
(replacing the leveler fitting holes),
Tub along with trolley, supply and take up pipes, water tank will be enclosed
with the machine.
Tool Requirements
• Fork lift, Hydra Crane
• Spanner 10 mm, 17 mm, and 24 mm (6mm bolts and 10mm nuts used for
Iron pallet joints)
• Wire Cutter, Allen key set
• Door keys/Nose plier

Precautions: Do not lift the extreme ends of the machine by machine or hand,
as it may result in serious damage (sensitive areas).
Installation procedure

• Placing
• Levelling
• Assembling accessories
Printing blanket (Conveyor belt) Tensioning adjustment

Note: Inside of belt should be checked for any foreign materials before
setting it in motion and to be removed, if any.
• When the printing blanket is slackened, carry out the below steps:-
• Tighten the belt such that it is enough to make the belt in slightly stretched
mode
• Make sure to tighten the Belt adjuster bolts equally (rounds)thread by
thread on left and right.
 Printing blanket (Conveyor belt) Tensioning
adjustment
• Measure the full circumference of the belt at both edges(Should be 2515mm when
loose). If the measured value differs in both edges, adjust the belt adjuster bolts to
make the circumference equal.

• Mark any two points vertically at a measuring span of 1000mm in the Belt. Start
tensioning the belt by adjuster bolts thread by thread equally on both sides, till the
length becomes 3mm (max) in excess (i.e.,1003mm)
Circumference of Conveyor belt = 2515mm
Percentage
stretched 0.20% 0.30% 0.40%
Length stretched 5mm 7.5mm 10mm
Total elongated
length 2520 2522 2525
Conveyor belt shifting control procedure
I. If the belt is shifting one side more than 5mm in 1 hr, do the following
a) Wait for the running print to be completed, if repeats are given, stop
immediately after the running image is completed, and prevent giving next
command.
b) Takeout the fabric, Lower the tub and run glue cycle in reverse direction with
70% speed.
c) When the belt is rotated reversely (without adjusting), further shifting is
arrested and belt starts moving in opposite direction. Closely monitor the
process until it comes in the centre. Once belt has positioned centrally, glue
cycle has to be stopped and shifting control adjustment has to be done as
mentioned further in next section
II. If the belt shifting has crossed 5mm outside the roller, print has be stopped
immediately and belt has to be repositioned in centre by loosening the tensioner
screws, else severe damage to belt can happen.
Conveyor belt shifting control procedure

• Belt shifting can be controlled ‘on the fly’ as well as when print is
stopped
• To control belt shifting, the shifting control knob has to be adjusted in
the required direction to control belt shifting.
Glue Procedure
Stage 1: Prima coat
Stage 2: Therma coat(activates at 35’C)
Stage 3: Perma coat(activates at 25’C)

An interval of 4hrs is required for the glue to set and dry. After each
glue coat, run the glue cycle for 50 minutes with glue heater ON. After
final successful coat of Perma, printing can be started.
The Stage 3 can be repeated depending on the condition of coat and
frequency of printing hours.
Glue Coating Procedure
Clean and dry the conveyor, by Wash Cycle
Put masking PVC tape on both edges of the Conveyor Belt, by simultaneously
moving the belt through HMI in slow speed.
Keep the following items ready :-
• Glue container(500-600ml), whichever required
• Home cleaner liquid spray
• Pouring container
• Waste bin
• Woven cotton bud sticks (for spreading the glue)
• Working Exhaust fan

Note: Extreme care to be taken during the glue process, any negligence may
render the coat unsuitable for use, and complete process may be required to
be repeated. 3 persons will be required for this process.
Follow these steps to start the glue coating process:
Step 1: Put the Press Roller down.
Step 2: Set the HMI to Glue Cycle mode, set the belt speed as 7 (Ensure that
belt direction is reverse, and washing tub should be down).

Step 3: Go to the back of the machine. Pour the 70% glue equally throughout
the belt, near the Press Roller, leaving the 10cm from both the edges.
Step 4: Let the two persons hold the Press Roller firmly, so that it doesn’t
move.
Step 5: Once the glue has crossed the press roller, speed can be increased to
20. Using the cotton bud stick, keep spreading the glue from the area where
glue is in excess, to the area wherever the glue is less in quantity.
Step 6: Wherever the glue under the press roller is diminishing, pour
the remaining glue over such areas.
Step 7: When glue below the Press Roller seems to be diminishing at
some areas, and becoming of higher viscosity and uneven, person
standing in front, should start spraying the cleaner liquid continuously
till the end.
Step 8: Later spray/pour the cleaner liquid throughout the belt, until
the remaining glue appears to be deactivated, due to mixing of cleaner
liquid.
Step 9: Once the glue seems to be deactivated, stop spraying liquid, and
do simultaneously and quickly below steps:-
• Slightly rotate the Press Roller in opposite direction, to move the sticky portion
upwards away from the belt.
• Lift the Press Roller from the both sides at a time and stop the glue cycle
immediately from the HMI screen.
Step 10: Remove the excess deactivated glue and throw in the waste bin.
Wipe up only the area where liquid is present, touching dry belt will
damage the coating.
Step 11: Once excess glue is removed, run glue cycle for 30-50 min with
glue dryer on.

Step 12: Wipe off the glue from the Press Roller, with the help of cleaner
damp towel.
While cleaning the Press Roller, cover the belt surface with poly sheet to
avoid the glue remains falling on the belt surface.

Step 13: Leave machine idle for 4 hours to let glue dry and set. (Next
glue coat has to be done only after resting period of 4 hours) Above
process has to be repeated for every glue coat process.
Printer Manager
Features
and Options
Head Alignment and Calibration
To open the Calibration Wizard, click on the Main
MenuToolsCalibration Wizard path
Mechanical Checks
Print Heads have to be adjusted manually. Both alignment are correlative and
needs to be verified repeatedly, until the Print Heads are perfectly aligned.
1) Angle Check
Print Heads should be mounted at exactly 90 degrees to the carriage scan direction.
If it is not, the pattern line printed by a particular Print Head will appear broken

2) Vertical Check
To execute vertical alignment test, click on the
Vertical Check button on the Calibration Wizard.
When you press the Next button, you are redirected to the Calibration
Wizard, as shown in the below image:
Horizontal Calibration (including Bidirection) to be done for every dpi, and
speed
Step Calibration
To verify and correct fabric feeding and avoid horizontal white or dark
bands to appear in the print output. To be done if Fabric type/thickness
changes.

Approximate Base Step value should be 14600

Trouble shooting
• Printer Not Initializing/Initialization Incomplete
• Emergency Button is pressed
• No Power Supply to Head Board (beep can be heard)
• Servo Driver not ON or faulty or programmed incorrectly
• Carriage Safety switch is activated
• Encoder sensor not connected or faulty (Carriage will top at right)
• Default Jumpers are not placed in Main Board
• LVDS is not connected properly
• Main Board is faulty or it’s settings are incorrect
• Printer Manager Not Showing “Ready”
• USB Cable is Loosely Connected to the Printer
• USB Cable is Faulty
• Printer not Initialized
• USB driver is not Installed
• Carriage Stops During Printing
• USB cable is loose or faulty
• Open heavy file that can slow down the data transfer
• Ground wire is disconnected
• Encoder Scale is having ink stains
• Pulley teeth wear out or belt is slipping
Trouble shooting
• Conveyor Belt Not Working
• 1. No signal to Conveyor Belt
• 2. Displayed error code in Servo driver
• 3. Conveyor Belt Coupling is loose
• HMI not going online
• 1. Sensor position is disturbed
• 2. Actuator not working
• 3. Washing tub fuse blown
• 4. No output from transformer/rectifier
• 5. PLC connection is loose or faulty
• 6. Relay or relay connection is faulty
•
 Trouble shooting
• Heater Not Working
• 1. Inlet power not connected or MCB trip
• 2. Heater coil/thermistor/thermo-stat circuit is open
• 3. 24 V Input is not getting supply to SSR
• 4. Improper settings in PID or faulty
• Negative Pressure Drop/Not Working
• 1. Meniscus vacuum switch is OFF
• 2. Negative Pressure switch program is disturbed
• 3. Vacuum is not generated by pump (pump failure)
• 4. Any ink/air tube is having leakage/cut/loose on fitting joints
• 5. Vacuum pump connector is loose/open from Relay
• Water Seepage in Belt
• 1. Sponge roller shape is distorted
• 2. Sponge roller or Squeeze roller movement is jammed
• 3. Washing tub is not engaged properly
• 4. Glue dryer is not working
 Maintenance
• Print Head care
• Print Head is an important and delicate part of the printer. It must be handled carefully.
For head maintenance, following had to be taken care
•
• Water based inks takes much time to dry, and can't clog easily. Rather its fumes gets deposited on the
nozzle/nozzle plate causing blockage. So manual wiping is not recommended, instead extra inks on the nozzle
surface have to be absorbed softly with soaking head cleaning roller.
•
• Head cleaning roller has to be kept dipped in clean RO-water tray and squeezed before cleaning. Cleaning
should be done only single time, i.e. it has to be cleaned and squeezed to reuse next time.
• Purging station area has to be always cleaned frequently (to free from lints getting set on surface)
• Nozzle test has to be taken 2-3 times a day to constantly monitor the status. If any nozzles are found blocked,
normal purging should be done and after cleaning, again nozzle test has to be performed. For powerful
cleaning, “P” switch has to be kept pressed for few seconds and then required Color switch has to be pressed.
• Degassing pressure has to be monitored, should be between -75 to -95KPa. Failing to which may result in
nozzle blocking.
• Humidifier has to be always in working condition, which keeps the head nozzles wet and open.
• Carriage cover should always be fixed to safe guard electronics, after head maintenance
Maintenance

• Precautions:-
• Never try wiping with tissue paper or any piece of cloth, which may damage the
Nozzle plate
• Never use weared out head cleaning roller, replace roller when required.
• Color bar should always be enabled while printing and idle spray should always
be enabled with 10000 value
• Avoid ink spilling on the print head and cables, if in case working with ink pipes.
• Uneven or partly peeled off glue coating on belt may damage the head nozzle
plate.
• Never use wrinkled or non-ironed fabric roll.
• Wrinkle on fabric will attract accidents like entangling of fabric with head base
• surface and may damage the head nozzle plate
•
Maintenance
Daily Maintenance
• Water renewal twice a day in water tray kept for head cleaning roller.
• Water renewal every 4 hours in Water tank.
• Add 2 spoons of caustic soda in every water recycle
• Water renewal in wiping tray. Check water level in capping, shouldn’t go empty.
• Keep the capping plate surface clean, particularly before capping.
• Head cleaning roller to clean after every cleaning.
• Wiper blades to clean by water rinse.
• Wash cycle to run after finishing of every fabric roll, remove the fabric thread remains if any.
• Humidifier water level check.
• Waste ink tank to be emptied
• Purging tray ink has be emptied if full and cleaned on daily basis.
• Check ink level in Main ink tank and fill
• Maintain air pressure as recommended
• Check for any blockage in negative pressure regulator air inlet holes and clean if required.
• Belt shifting has to be regularly monitored and adjusted if required.
• Press roller and fabric guiding rollers to be wiped to remove the ink stains daily.
• Precautions:-
• While Print engine off and capping elevated, never move the carriage over the capping station
• Never turn the capping knob when printer is running
• Keep the Humidifier knob in minimum position
• Always pour distill water in capping tray to avoid germs
• Replace the head cleaning roller, if surface weared out.
Maintenance
• Washing Tub Maintenance
• Washing Tub is an integral part of the Printer. Its maintenance is equally important as the
production job work. Every week whole tub unit has to be cleaned thoroughly.
• The timely maintenance increases overall productivity by minimising the downtime of machine.
And also increases the life of tub related parts.
• Cleaning of water tank, jetting pipes, brush roller and refreshing tank water frequently, helps to
prevent fabric threads, mold or algae choking the water flow in the tub, jetting pipe and water
tank.
•
• Precautions:-
• Tub should always be lowered before turning off machine.
• Never run washing tub with jetting pump off.
• Never engage washing tub without running glue cycle for recommended time (not less than 30
minutes), when fresh glue coating is done.
• Always use clean RO processed water for washing system, for longer life of related parts.
• Cable tie the jetting pump float wire as instructed by engineer
• Cable tie the jetting pump outlet pipe
Dos and Don’ts
• Keep the room dust free and temperature maintained between 25°C and 28°C
• Use sponge roller, dipped and squeezed in RO water.
• Clean head sponge wiper after every wiping.
• Water filter plates should be fitted when jetting pump is on
• Don’t hang up the jetting pump float manually, may damage the pump
• Always care about the wrinkles on fabric, it may damage the heads
• Conveyor belt shifting has to be monitored regularly and to be adjusted with the help of
adjusting roller
• Keep humidifier knob to minimum, to avoid ink fumes spreading
• Humidifier must be on while printing, always check water in humidifer
• Maintain the head negative air pressure between -2.7 to -3.2. Adjust slightly.
• Change RO water twice a day in head sponge wiper water tray.
• Maintain the water level in Water tank and refresh water every 3-4 hours
• Add 2 spoons of caustic soda in every water recycle in tank
 Dos and Don’ts
• To avoid air in head pipes, always maintain the ink level more than 1litre in Main tank and wipe the
heads immediately after purging head..
• Water tank filter plates should be cleaned every hour to remove stuck threads, to avoid overflow
• If negative pressure is increasing/fluctuating automatically, clean the nozzles of regulator knob
• Always use clean RO processed water for washing system, for longer life of related parts.
• It’s time for tub maintenance if:-
• Jetting pipe have choked nozzles.
• When brush roller is filled with threads
• When sponge roller is not moving and has become slippery
• When Belt has shifted out of the roller
• Do not give next print command,
• Remove fabric from belt
• Move the belt in reverse direction with help of glue cycle
• After belt centred, adjust the shifting control knob/roller slightly as taught
 Dos and Don’ts
• Don’t wipe the head with tissue paper or cloth piece, which may damage the Head nozzle.
• Never remove both the water filter plates, when jetting pump on.
• Do not over tension the fabric tensioner
• Do not over adjust the belt shifting control roller/knob
• Do not keep the shifting control roller screws loose.
• Never keep the printing continue, if the belt has shifted more
• While tub maintenance, never pull the tub without disconnecting the brush motor connector
• Do not run the belt without jetting on
• Do not run the jetting pump with water tank empty
• Don’t switch off the printer
• without making the tub down
• without closing the finger valve
• Don’t leave the heads uncapped/ without pulling the sponge tray
• Never move the carriage over the capping station when printer off and capping up,
• Never turn the capping knob when printer is running
• Do not run the printing when glue layer is peeling off
Rip Softwares
• Rip Master
• Neo Stampa
• Ergosoft