KERAjet S7

Instructions manual

MS7E. Rev: 200623

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Translation of the original manual

This machine has been developed and manufactured by KERAjet and integrates the most advanced technology in ceramic
pigments, soluble salts, effects, glazes, UV inks, water based inks, etc. During all the research, manufacturing, transport, start-
up and discard processes of the machine safety regulations have been taken into great account.
Operational instructions of this machine must be near by the site of the machine at any time and must be read and known by
every operator working with it.
Apart from the operational instructions and the legally biding norms regarding accident prevention, local safety rules in the
final destination country must be observed.
These set of instructions are only valid for the machine they are refered to. The machine should NEVER be started-up
without having read the operational manual and without having understood how it works.
Images in this manual are only indicative.

PLEASE, READ THIS MANUAL CAREFULLY.

FOLLOW KERAjet INSTRUCTIONS AT ANY MOMENT.
DO NOT UNPACK NOR START-UP THE MACHINE WITHOUT THE PRESSENCE OF A KERAjet TECHNICIAN OR HIS
DIRECT CONSENT.

Manufacturer

KERAjet, S.A.
Pol. Ind. Supoi-8. Avda. del Boverot, 24. 12550 Almazora (Castellón) Spain.
P.O. Box 446. 12540 Vila-real (Castellón) Spain.
Tlf: +34 964 500 018
www.kerajet.com e-mail:kerajet@kerajet.com

Technical assistance ACS +34 964 010 150.

24 hours service +34 678 280 381. ONLY AFTER OFFICE TIMETABLE.
Technical requests and Spanish spare parts: sat@kerajet.com

Machine nomination

System: KERAjet S7 700 1400 1800

Serial Number:……………………………

Direction:…………………………………. Date:………………………………

Other special elements/devices integrated in the machine: ………………………………………………………..............

………………………………………………………………………………………………………………………………………

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SUMMARY

1. CE Statement .................................................................................................................4
2. Machine description ......................................................................................................... 5
2.1. General overview ................................................................................................... 5
2.2. General description of the machine ….................................................................... 5
2.3. Specifications ......................................................................................................... 6
2.4. General dimensions ................................................................................................ 8
2.5. Moving parts ........................................................................................................... 11
2.6. Colour Modules .......................................................................................................13
2.7. Print units …............................................................................................................ 15
2.7.1. Print units featuring ........................................................................................15
2.7.2. Communication of the print units with the machine …................................... 15
2.7.3. Colour module communication system …...................................................... 15
2.7.4. K8 glaze modules …...................................................................................... 16
2.7.5. K9 powder modules ....................................................................................... 17
2.7.6. Side print modules……………………………………………………………….. 17
2.8. Main ink tanks …..................................................................................................... 17
2.9. Electric panels …..................................................................................................... 18
2.10. Tile detection and height barrier systems …..........................................................18
2.11. Active ink system …............................................................................................... 19
2.12. Chiller …................................................................................................................ 20
2.13. Pneumatic circuit .................................................................................................. 22
2.14. Cleaning system …............................................................................................... 23
2.15. Conveyor …........................................................................................................... 25
2.16. Conveyor wiper …................................................................................................. 26
2.17. Tile centraliser …................................................................................................... 27
2.18. UPS system …...................................................................................................... 28
2.19. Optional elements …............................................................................................. 28
2.19.1. Relief detector ….......................................................................................... 28
2.19.2. Gap cleaning management ……….............................................................. 29
2.19.3. Multientry Kit …............................................................................................ 29
2.19.4. Moving printing units …................................................................................ 29
2.19.5. Height barrier …........................................................................................... 29
2.19.6. KERAjet Modul ............................................................................................ 29
2.19.7. KERAjet Visio .............................................................................................. 29
2.19.8. Print head cleaning equipment..................................................................... 29
3. Operational positions ....................................................................................................... 30
4. Description of the intended use of the machine ............................................................... 31
5. Installation instructions .....................................................................................................31
6. Start-up and operation …..................................................................................................32
6.1. Colour management ............................................................................................... 33
6.2. Regulation of the active ink system ….....................................................................33
6.3. Introduction to control software ...............................................................................34
6.4. Start-up …............................................................................................................... 35
7. Operators training ….........................................................................................................35
8. Risks ................................................................................................................................ 35
8.1. General safety instructions …................................................................................. 37
8.2. Specific safety instructions ….................................................................................. 37
8.3. Secondary risks …...................................................................................................38
9. Preventive measurements ............................................................................................... 42
10. Stability conditions …......................................................................................................43
11. Transport, handling and storage ……….......................................................................... 43
12. Emergency procedures and reset modes ….................................................................. 44
13. Fine tuning and maintenance ........................................................................................ 45
13.1. Corrective maintenance ….................................................................................... 45
13.2. Preventive maintenance. General instructions ..................................................... 45
13.3. Preventive maintenance for each element ........................................................... 46
13.4. Tasks to be carried out by the operator..…........................................................... 49
14. Problem solving ….......................................................................................................... 49
15. Noise emissions ............................................................................................................. 52
16. Waste management ....................................................................................................... 53
17. Spare parts …................................................................................................................. 53
17.1. Spare parts involved in operational safety …....................................................... 53
17.2. Suggested spares …............................................................................................. 53

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1. CE Statement

CONFORMITY DECLARATION

According to Directive 2006/42/EC, Anex II, part A,

The manufacturer:
KERAjet, S.A.
Pol. Ind. Supoi-8, Avda. del Boverot, 24
12550 Almazora (Castellón) ESPAÑA

Empowered to issue the technical file:

Manuel J. Villanova Dolz
C/ Estany Llarguer, 11, 2º I. Burriana 12530 (Castellón) ESPAÑA

DECLARES:

Under itss own responsibility, that the ink-jet machine with the next denomination:
denomination

TRADE MARK: KERAjet

MODEL: KERAjet S7 – 700/1400/1800

It complies with the provisions of Directive 2006/42/EC of the European Parliament and of the Council of
17 May 2006 on machinery and is in accordance with the provisions of the following European directive too:

Directive 2014/30/EU
of the European Parliament and of the Council of 26 February 2014 on the harmonisation of the laws
of the Member States relating to electromagnetic compatibility.

and the following harmonised standards have been applied:

- EN ISO 12100:2010 Safety of machinery.

machinery. General principles for design. Risk assessment and risk
reduction.
- EN 60204-1:2006
1:2006 Safety of machinery. Electrical equipment of machines. Part 1: General requirements.

The legal representative:

José Vicente Tomás

DCEI Rev. 190114 General Manager KERAjet, S.A.

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2. Machine description

2.1. General overview

This machine has been designed to be integrated in a production line and we'd like to suggest it to be installed in a suitable
cabinet. By doing so, the machine and the operator will be allocated in a controlled working area (factory dusty enviroment,
low/high temperatures, high noise levels or hit by chance).
The machine is basically comprised of main frame, moving system, conveyor, ink system, PLC, PC and dedicated software,
boards, hood (safety barrier for the operator) and safety systems.
The interface of the machine are the touchscreen and a wireless keyboard..
The machine is provided with an industrial UPS, a chiller and a vacuum fan for the steam of the working area.
The KERAjet S7 machine is robust designed , with removable colour modules and multiple head technology. Its globally PC
controlled active ink system and individually card monitoring and its elevated moving structure, achieves a high reliability level.
The KERAjet S7 machine may work in different ways, depending on the concrete requirements of each customer: tile by tile,
continuous, roller mode, canvas and multiresolution.
Our specific software, developed by KERAjet, has been made as an intuitive and user friendly graphic setting which makes
the operator get the best performance is a short time. It may manage up to 4 productions at the same time and arrange a new
one while others are running. There's no need to stop production to load a new production or to make any correction on the
same.
This set comprises three sizes:
■ KERAjet S7 - 700 (up to 700mm)
■ KERAjet S7 - 1400 (up to 1330mm)
■ KERAjet S7 - 1800 (up to 1803mm)
Real printing width depends on the sort of print unit.
The amount of print unit depends on its kind.

2.2. General description of the machine

In the following images the external parts of the machine are described.
Next, the main elements and their location are set.

1
7

2
8

4
10
5

1. Hood 6. Beacon
2. Centraliser 7. Screen
3. Conveyor 8. Keyboard
4. Left electric panel 9. Scraper
5. Front cabinet 10. Right electric panel

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15

11

14

12 13

11. Conveyor motor 14. Main power switch

12. Support 15. Wheel
13. Back panels

2.3. Specifications

■ Main features:
- New distributed ink control system. PLC and electronic cards remote control.
- Up tp 12 different liquids working simultaneously while in operation. Quick ink change.
- Exclusive continuous ink recirculation system. Highest printing stability.
- Colour modules in frames with single or up to four units configuration.
- Removable module control for each frame.
- Automatic purge and cleaning system.
- Ink heating and cooling system with individual temperature control.
- Automatic maximum height barrier safety system for each module frame.
- Robust elevated moving system.
- Industrial UPS.
- Online tile temperature sensor.
- Exclusive meniscus-differential pressure controlling system.
- Maximum tile thickness: 46mm. It might be increased if requested.
- It may work with up to four independent production lines simultaneously in the same machine
- Online sampling without stop production
- Conveyor top speed depends on manufacturing process and the sort of print heads installed in the machine. Generally
speaking, we may set it up to 90m/min.

■ Print head technology:

- Drop On Demand technology (DoD Printing).
- Available print heads: K4, K6, K8, K9, K12, etc.
- Network connector: 10/100/1000 Base T.

■ Software:
- Image modes: CMYK, RGB, MULTICHANNEL.
- Specific colour management software: Colorjet, Colorjet pro, ColorDirect, etc.

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■ Installation requirements:
- Input voltage: 400V 3P+N+TT.
- Frequency: 50-60hz.
- Nominal input power: 23kVA for K700, 35kVA for K1400 and 50kVA for 1800. It depens on the amount and kind of print
heads installed in the machine.
- Compressed air: 1100 l/min, 6 bar pressure for 10 sec. every 30min (1,1 kW compressor 1,1kW, 200 litre tank).
- Optimal environment conditions: 25ºC-35ºC.
- Moisture: 30-80%.
- Suction installation: 140 mm flexible tube for steam evacuation.

■ Inks:
- Any KERAjet certified ink available in the market.

■ Weight:
- KERAjet S7 - 700:
Maximum weight: 2750kg. No ink included.
Maximum weight of the packaged machine, including accessories: 3650kg.
External package measurements: length 4960mm, width 1910mm, height 2270mm.
- KERAjet S7 - 1400:
Maximum weight: 3450kg. No ink included.
Maximum weight of the packaged machine, including accessories: 4450kg.
External package measurements: length 4960mm, width 2300mm, height 2270mm.
- KERAjet S7 - 1800:
Maximum weight: 4400kg. No ink included.
Maximum weight of the packaged machine, including accessories: 5460kg.
External package measurements: length 4960mm, width 2800mm, height 2270mm.
The UPS unit and the chiller are packed up in a box which weighs 460 kg.
Machine weight depends on the amount of print heads and accessories installed.
3
The ink of a circuit may have a 30 litres volume, which means that for a 1,3 kg/dm density it weighs 39 kg. Therefore, a 12
inks machine might increase it weight by 468 kg.

■ Management software:
The machine is equipped with the software programmes that, among other functions, manage, load and show the designs,
select the print heads and define the printing mode: image by image, roller or canvas. Working parameters monitoring:
pressures, temperatures, pump %'s, etc. They also set the ink circuit pressures and check PLC scanned values, set the working
routines managed by the PLC and the set-points, monitor the print units parameters, make printing settings, guided operations
as IP address changes, etc. Some specific design tasks might also be carried out such as ripping or tone changes from the
production line by generating new files.

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2.4. General dimensions

KERAjet S7 - 700 Dimensions.

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KERAjet S7 - 1400 Dimensions.

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KERAjet S7 - 1800 Dimensions.

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2.5. Moving parts

The user may find the rack guiding system of the Z Movement (up – down) by watching from the front of the machine (two
sets of rack pinion for each colour module group moving at the same time).
Colour modules, while in rest, are positioned on the cleaning trays which are designed to collect the excess ink from the ink
circuits and send it back into the main tanks or waste..

1
6

1 KJ18633 GUIDE
2 KJ16174 SLIDE
3 KJ14161 SPINDLE SENSOR
4 KJ22611 GEAR BOX R1/100
5 KJ10283 PRINT HEAD MOTOR BRACKET K-700
5 KJ22896 SERVOMOTOR BRACKET
6 KJ21588 SERVOMOTOR K700
6 KJ22993 SERVOMOTOR K1400

2
3

1 KJ16809 SPIRAL GEAR

2 KJ22989 Z MOV. TEETH RACK S7
3 KJ22162 Z MOV. SHAFT K700S7
3 KJ22598 Z MOV. SHAFT K1400S7
4 KJ22172 PLATE BEARING

X Movement: cleaning trays will move sideways, in order to let the colour modules come down to printing position, by a
pneumatic transmission. Conveyor movement is also in the X direction.
Y Movement: cleaning racks when moving along the colour module.
It's been stated that ink circuits are numbered from right to left, therefore, the one on the right hand side is ink 1. The
maximum ink capacity is up to 12 different liquids (inks or effects) in independent circuits.

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The following systems are mounted to print pieces with special heighs.
Movement Z modules:
The user can observe from the front of the machine, on both sides, the zipper system in charge of performing the Z
Movement, raising-lowering the color modules.
The color modules, in their rest position, rest on the cleaning trays whose mission is to collect excess ink from different ink
circuits and then, return it to the main tanks or to the reject tank.
1

3
5 4

1 KJ34504 SPIRAL GEAR

2 KJ16174 SLIDE
7 3 KJ34632 MOTOR
4 KJ34574 REDUCER
5 KJ29087 BEARING
6 KJ34511 GEAR RACK
7 KJ34624 GUIDE

Movement Z cleaning tray:

Vertical movement of the cleaning tray frame that moves upwards to allow clearance for the piece to be printed. The
transmission is by spindle, one on each side.

1 KJ33261 GUIDE
6 2 KJ34551 ENDLESS SPINDLE
3 KJ16847 BEARING
4 KJ16846 COUPLING
5 KJ16265 BUMPER
6 KJ34634 MOTOR

4
3
2
1

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The machine has a control button (bypass) at the front to make the conveyor run or stop. It keeps the line running while the
machine is at rest. This option may also be controlled from the control panel.

Bypass

2.6. Colour modules

A colour module is a removable unit which has two independent ink circuits.
Features of the different colour modules, and how they are arranged, are configured to meet customer's production
requirements. This means, type of print heads, amount of them and their layout and ink distribution.
Each circuit is provided with an ON/OFF switch which powers up or down each of them individually. Some types of print
heads need a power off delay, so two different switches are installed in those colour modules.
Colour modules, thanks to their modular and removable features, have a fast cleaning maintenance and a simple upgrade
operation when a new colour module is installed in an existing running machine. This modularity gives the machine a great lot of
advantages.
They are installed in frames which bundle them depending on the required printing height of each of the units.

In order to remove a colour module, first of all, the operator has to press on “Print head access” option from the control panel.
The module will rise and then the fixing screws have to be removed. Only one module at a time can be removed in order to
prevent deformations and frame unbalancing.
The machine is provided with a set of safety sensors that prevent it from starting while any of the modules is out of place or
the hood is open.

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6 7 8
9
1

1 KJ16174 SLIDE
2 KJ19545 PRESSURE CYLINDER
3 KJ13259 PRESSURE SENSOR
4 KJ12245 TEMPERATURE SENSOR PT-100
5 KJ16775 ELECTROVALVE
6 KJ17144 SILENTBLOCK
7 KJ13674 INDUCTIVE SENSOR
8 KJ18145 SWITCH ETHERNET SW02C
9 KJ18633 GUIDE

1 3

1 KJ10379 PRINT HEAD TAP

2 KJ18887 K41K42CA40 PRINT HEAD INPUT INK SET
2 KJ18953 K6 PRINT HEAD INPUT INK SET
3 KJE0273 PCB PRINT HEAD CABLE
3 TAFS02 FS02 CARD
3 TAAN4030 AN4030 PRINT HEAD CARD
3 TA50P CA50 PROGRAMMED CARD
3 TAAN4020 K6 PRINT HEAD ANALOGIC CARD
3 TAAN4021B AN4021B CARD
4 PHK42 K42 PRINT HEAD
4 PHK6 K6 PRINT HEAD

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2.7. Print units

Colour modules are basically the print head support of each ink circuit. The print units are installed in built-in spaces made in
the bottom of the colour module frame. In the top you may find the ink collector tubes, a fraction of the cooling circuit and
communication cables.
Regarding cables, each print unit is powered from one or two cables (K6 units need two power cables with different nominal
load), which are connected directly to each control card, and a data cable which transfers the required information (data) to
each card.
For each ink circuit, the customer requested units are installed, depending on tile size to manufacture (format) and its
production typology.

USER HAS TO MAKE SURE THAT UNDER NO CIRCUMSTANCE, THE MACHINE WILL GET NO POWER INPUT
(UNEXPECTED BLACKOUT, THUNDERSTORMS, ETC.). MAY THIS HAPPEN, INK RECIRCULATION WOULD STOP AND,
THEREFORE, PRINT HEADS WOULD GET DAMAGED IRREVERSIBLY. IT'S HIGHLY ADVISABLE CONTACTING KERAjet
SUPPORT IN CASE YOU MAY NEED TO STOP THE MACHINE FOR A PERIOD OF TIME IN ORDER TO CARRY OUT THE
REQUIRED MAINTENANCE BEFORE THE HALT, OR WHEN INSTALLING A UPS DEVICE. IN MOST CASES, THE MACHINE
IS PROVIDED WITH A UPS. A STEADY 6 BAR COMPRESSED AIR SUPPLY IS ALSO REQUIRED FOR THE AUTOMATIC
CLEANING CYCLES.

2.7.1. Print units featuring

We call print head the printing device without any control card, cables, input pipes, information or power.
We call print head unit the print head and the control card set.
Print head units main features are amount of nozzles, printing width, resolution, drop size, dimensions, etc.
The area of the print head where nozzles are located is called “nozzle plate”.

2.7.2. Communication of the print units with the machine

Print units parts are the required print head and the electronics. The kind of electronics depends of the sort of print head.
In general, these systems have their own control, power and information storage resources that control the nozzles of the
print head along with the device self-management functions and data transfer from the main PC.
Electronic cards, for a correct operation, have to be configured and updated periodically: this is achieved by their own FW
and HW (Firmware and Hardware) in each card. The main computer has an option in the control software (Config CA) designed
for this task.
Please, contact KERAjet to make sure the most suitable version in your machine.
Each control card is linked to a print head and has an IP address, unique for each of them, which is connected to the control
PC of the machine.
This communication is organised in a subnetworks system. This system identifies the location of each print head regarding
its position in the colour module and the ink circuit where it is integrated. In order to have a print head or card replaced in a
correct way, user must take into account the IP location where it's going to be installed and adapt the IP of the device to the
correct IP address (directly linked to the location where it's going to be installed).
Please, bear in mind that whenever an electronic card is checked by KERAjet, it's handed on to the customer with a
standard IP address which makes it very easy to identify so it may be quickly replaced. This IP is 192.168.0.81.

2.7.3. Colour module communication system

The subnetwork communication system allows the installation of colour modules with different print head typology in the very
same machine.
Next, we'll explain which is the location of each print head inside the colour module and the rule that is used to find it.
From the different kind of print heads, we'll use the K4 configuration.
The name of each location inside the colour module is determined according to the following rule: each ink circuit will have at
the front the 192.168.1 indication for bar number 1, followed by its position in the module. Please, always bear in mind that print
heads are numbered starting from the inside of the machine towards the outside, and odd numbers are on the right side of the
bar and even ones are on the left as you may see in the next picture.

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Example of a K4 print head in a KERAjet S7 – 700:

In this way, ink circuit 1 is integrated by the following IP address: 192.168.1.1, 192.168.1.2, 192.168.1.3, 192.168.1.4,
192.168.1.5, 192.168.1.6, 192.168.1.7, 192.168.1.8, 192.168.1.9, 192.168.1.10, as set out in the line in dashes image.
Ink circuit number 2: 192.168.2.1, 192.168.2.2, 192.168.2.3, 192.168.2.4, 192.168.2.5, 192.168.2.6, 192.168.2.7,
192.168.2.8, 192.168.2.9, 192.168.2.10.
The same rule applies to the other circuits.

2.7.4. K8 glaze modules

K8 print heads are exclusively made by KERAjet and have been designed for digital printing on ceramic tiles.
PC communication is made in the same way as in the standard colour modules.
A pneumatic system is used to prepare and send the glaze from customer's tank into K8 modules and bring it back once it's
collected by the cleaning tray.
Glaze preparation is made by two 50 and 20 microns filters in the same pipe.
Pumps, filters and pipes are installed in a column. The frame has supports and wheels to make it easy to move and locate.
This column is located outside of the machine as close as possible to the K8 module and next to the glaze tank.

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2.7.5. K9 powder modules

K9 print heads are exclusively made by KERAjet and have been designed for digital
printing of powders and atomised products on ceramic tiles.
PC communication is made in the same way as in the standard colour modules.
Each module is made of two different systems so it may print using two different
products.
Powder is stored in a hopper on top of the print heads.
For low powder consuming products, refill may be carried out manually. For higher
consumption an automatic device might be installed.

2.7.6. Side print modules

These side print modules are designed for printing on the sides of the
product.
Up to 4 ink circuits can be installed with just one print head per circuit.
Communication with PC is made in the same way as with colour
modules.
They work in the same way as the horizontal modules.
For ink purge and splash collecting there’s a cleaning tray under the
print heads and another tray attached to the conveyor.
In order to install these modules, a narrower than usual conveyor has to
be assembled. By doing so, modules will be kept inside the machine
protected by the hood.

2.8. Main ink tanks

Main ink tanks are located inside the frontal panels of the machine. These tanks have user friendly refilling inlets.

Main tanks are made as a set of elements. They are comprised of:

■ Suction pump. It's located at the back of the tank and it sucks ink back during cleaning cycles and purge from the cleaning
trays into the main tank.
■ Peristaltic pump. It refills the ink in the secondary tank from the main tank.
■ Filter. It filters ink while in circulation.
■ Ink stirring pump. The tank has a stirring pump that prevents the ink from hardening on the bottom and, therefore, keeps it
in its best conditions. A programmable timer sets the on/off times of the pumps.

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Front/back view of the main ink tanks:

1
5
2

3 6

1 KJ10023 PERISTALTIC PUMP

2 KJ10020 5 MICRONS FILTER SET
3 KJ17278 TOP + O-RING
4 KJ18955 VACUUM VALVE SET
5 KJ19047 STIRRING PUMP SET
6 KJ17438 STIRRING PUMP JOINT
7 KJ17289 NBR JOINT
8 KJ22420 3K MAIN INK TANK

2.9. Electric panels

Regulation, control and data acquisition devices are installed in the panels at both sides of the main frame of the machine
and below each of the colour modules (inside the back panels of the machine).
The electric diagram is attached to this manual, along with the computer documents, for any query or maintenance question.

PLEASE, GET FAMILIAR THE BASIC ELEMENTS OF THE ELECTRIC PANEL, MAINLY THOSE RELATED TO SAFETY.

■ Main panel:
You may find it in the side panels of the machine. It is comprised of the general operation and control devices:
- Main switch to cut input power.
- Main PC: controls the different elements of the machine. It's installed on the touchscreen support.
- Movement controlling drivers: they control servomotors operation (Z shaft and conveyor).
- Vacuum driver: controls fan speed.
- Power supplies: send DC into the print units depending of their typology.
- Different safety devices for operators and elements: differential switch, circuit breakers and thermal breakers.
■ Independent control for each colour module:
They are located in the back panels of the machine. Each colour module is controlled individually.

2.10. Tile detection and height barrier systems

The machine has two similar detection systems which are comprised of an emitter-receiver, a mirror and a signal amplifier.
Both systems let the operator get a controlled tile input and stop it in case there's any problem or maximum height is exceeded.
It is comprised of a high accuracy laser and a mirror which are installed one in front of the other.
Operators may access the amplifier from the panels at the back. You may find up to four amplifiers when the multiple entry
system is installed. We'd like to suggest to have them identified so they can't be manipulated by unauthorized personnel.
Amplifiers can be set to have their sensitivity threshold increased. This option is very useful when mirror or laser emiter have
lost their initial efficiency.
Tile detector amplifier has 2 channels: one of them is used as follows, channel A, and the other, channel B, is used for other
applications such as tile counter.
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■ Tile detection system. It detects tiles coming from the line before they get
to the printing area.
This device is installed on the conveyor frame.
Amplifier has to be set as D.on: Dark on.
■ Maximum height stop system. It prevents thicker tiles than the lowest
colour module from getting into the machine.
The emitter-receiver moves automatically to the suitable height depending
on the colour modules heights.
It's got to be configured as L.on: Light on. It's connected to the conveyor
driver so it can stop and get blocked immediately.

KJ14161 SPINDLE SENSOR

KJ18442 60x40mm MIRROR
KJ20808 7x7mm MIRROR
KJ21810 LASER EMITTER
KJ21811 AMPLIFIER

2.11. Active ink system

Ink circuits are comprised of a KERAjet exclusive control system.
Each circuit may be individually restarted or disabled, as in maintenance or inspection operations, from the control panel.
Each colour module has a system that is called “backpack” which is comprised of control, management and distribution of
two ink circuits.

3 7

1 KJ20663 CT 01B CONTROL BOARD

2 KJ12463 LEVEL SENSOR
3 KJ13307 SPHERICAL VALVE
4 KJ20334 PUMP
5 KJ18521 FLOW REVERSING VALVE
6 KJ10020 5 MICRONS SET
7 KJ16775 ELECTROVALVE

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■ Ink circuit diagram:

1. Main tank 9. Level check

2. Stirrer 10. Pump
3. Peristaltic pump 11. Flow rev. valve
4. Filter 12. Temperature sensor
5. Manual valve 13. Pressure sensor
6. Secondary tank 14. Expansion cylinder
7. Excess collecting pipe 15. Collecting tubes
8. Level sensor 16. Print head

Flow reversing valve (11.) is only installed with K4 print heads.

2.12. Chiller
KERAjet B7 chiller, provided with the KERAjet machine, heats up or cools
down inks and keeps print head electronics refrigerated.
From KERAjet software parameters, technicians set temperatures of each ink
circuit individually during start-up, so may the customer choose inks from different
suppliers or with different features, parameters are set to match them. One sensor
in each ink circuit sends actual temperature back to the PLC.
It is comprised of two ink circuits:
■ Cooling circuit equipped with a refrigerator. It brings temperatures down at
the print head electronic cards and the inks.
■ Liquid heating circuit equipped with a tank and an electric resistor. It brings
ink temperatures up to 46ºC.

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Cooling circuit.
The heat removing system of the print head cards is comprised of a liquid filled circuit which connects the chiller with the
supports of the cards of each colour module. This circuit is working permanently and is connected to every collector requiring
refrigeration.
Electrovalves are also connected to this circuit and open or close the access of the liquid to the ink collector depending on
the requirements.
Refrigeration is produced by a cooling circuit.
From the KERAjet software, technicians set circuit temperature, 40ºC on average.
There's a safety thermostat in the cooling circuit that is set to 0ºC.

Heating circuit.
The ink heating circuit is comprised of a liquid filled circuit which connects the chiller with the secondary tanks.
This circuit is on permanently.
Liquid temperature is set from the KERAjet software in the PC, 55ºC on average.
There's a safety thermostat that is set to 75ºC.
Electrovalves are also connected to this circuit and open or close the access of the liquid to each of the secondary ink tanks
depending on the requirements.

Each ink circuit has a temperature sensor which tells the PLC whether it has to open or close the electrovalve depending on
ink heating needs.
■ It's provided with a specific instructions manual.
■ Main features:
- Temperature range: 20 – 60 ºC
- Cooling gas: R134a. Amount of cooling gas: 0,25 kg.
- Pressure of the recirculation circuits: 1,5 – 2 bar.
- Liquid Volume: 2 x 5 l.
- Cooling power: 1863 W. Heating power: 1500 W.
■ The device requirements are:
- Input voltage: 400V 3P+N+TT. Frequency: 50-60hz.
- Nominal power: 3,5kVA
- Optimal environment conditions: 25ºC-35ºC.
- Moisture: 30-80%.
■ Maximum weight of the device, no liquid included: 80kg.
■ External dimensions: width 627mm, depth 602mm y height 998mm.

THE KERAjet B7 CHILLER HAS TO BE ALWAYS ON TO MAINTAIN INK TEMPERATURES AND REFRIGERATE PRINT
UNITS.

■ Fixings and machine connections:

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■ Recirculation circuits:

These circuits have a diverting valve at the end of the collecting lines to recirculate the liquid while in start-up
start or whenever
there's no filled ink circuit. While in normal operation these valves have to be shut. The PT-100
PT 100 sensors
s send temperature
values to the PLC so it may turn on/off the cooling circuit or the heating resistor.
Whenever there’s enough room, circuit components are covered with flexible isolating tube to prevent energy loss and
condensations on metallic surfaces.

■ Spares:

KJ20539 CHILLER FIXING SET

2.13. Pneumatic circuit

The pneumatic unit controls and sets up the compressed air from
the factory before its supplied into the machine to be used at the
vacuum pumps and the pneumatic circuit that moves the cleaning
trays, the contactless scrapers, the conveyor scraper and the glaze
circuit. The filter removes impurities which may bring about control
failures.
Basically, it's comprised of:
- Manual shutting valve with silencer. It receives the compressed
air input from the plant.
- Filtering unit and pressure regulator with gauge.
- Diverting module with pressure switch, output electrovalve for the
vacuum pumps and pneumatic circuit.
Each circuit is described in different sections.

KJ26250
26250 MAINTENANCE PNEUMATIC TIC UNIT

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 KERAjet

2.14. Cleaning systems

In order to keep a tidy ambient inside the machine and prevent any tile pollution, there are two cleaning systems:

Steam suction
The machine is provided with an ink vapour system that are generated while printing.
Due to tile high temperature, some ink vapour is produced which may affect printing quality.
In order to get a healthy environment, that ink vapour has to be removed from the cabinet of the machine and processed.
Suction air is made by a centrifugal fan that is installed on top of a metallic filter. The vacuum flow is adjusted by the driver of
the fan motor.
Below the cleaning trays you may find the vacuum funnels, a few millimetres away from the tile.
The vacuum system prefilters the sucked vapour, so it has to be connected to the suction installation of the factory with a
140 mm diameter tube.
In the bottom of the filter there are two valves which have to be periodically open while the fan is off to remove any ink and
deposits inside.

3
1

1 KJ19913 FAN OUTLET SEAL

2 KJ19914 CIRCULAR FLANGE SEAL
3 KJ16480 CENTRIFUGAL FAN
4 KJ17263 INK FILTER COVER SEAL

Print head cleaning trays

Cleaning trays collect ink drops produced in the colour modules when print heads purge or splash depending on the system
installed.
All the elements are installed in a set that moves sideways, from the rest position of the colour modules to one side, in order
to let the modules come down to their working position. This lateral movement is made by a 24 VDC motor.
Cleaning is made by wiping the bottom of the colour module with sponges moving along with the trays.
Print head purge is done on these sponges.
Apart from cleaning, sponges work as ink filters.
There's a pneumatic suction, from vacuum pumps, that sucks ink in the sponges and sends it back into the main tank.
Ink falling on the trays is discarded by the steam suction system or is collected in a waste tank.
Each colour module has a cleaning tray that collects inks from two ink circuits.

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4
5

2 6

3
7

1 KJ10369 SPRING
2 KJ24147 24 V DC MOTOR
3 KJ23445 CLAMP
4 KJ16291 SPONGE L
4 KJ19396 NIPPLE SPONGE 40 K6
5 KJ16644 TRANSPARENT NIPPLE 117X30X11
5 KJ17867 TRANSPARENT NIPPLE 40 K6
6 KJ21829 PULLEY
7 KJ16174 SLIDE

■ Tray special heighs.

1
5

1 KJ16291 SPONGE L
2 KJ16644 TRANSPARENT NIPPLE
3 KJ10369 SPRING
4 KJ24147 MOTOR 24 V CC
5 KJ16174 SLIDE

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 KERAjet

■ Pneumatic diagram of the cleaning trays:

1. Cleaning trays.
2. Main tank.
3. Vacuum.
4. Collecting circuit.
5. Pneumatic unit.

2.15. Conveyor
As KERAjet S7 has been designed to get integrated into a production line, it's been manufactured with a conveyor so it may
be installed into it. Speed may be synchronized with that of the production line.
It's been made of stainless steel to prevent corrosion. The conveyor withstands chemical and mechanical attacks from inkjet
products.
It can be removed easily from the front for replacement or maintenance. It has some spaces in case it has to be moved with
a fork lift.
The conveyor has regulation systems which are used to have it levelled with the production line and the print units.
Centraliser, wiper, tile detector and relief detector are installed on it.
It's wrapped up with covers to prevent entrapments in the band, drums and motor.
Conveyor view where the centraliser at the entry and the wiper at the exit are displayed.

KJ12754 Ø30 DRUM BEARING SUPPORT KJ22927 K1400S7 MOTOR-DRUM

KJ17258 K1400 CONVEYOR SUPPORT ROLLER KJ22930 K1400S7 TIGHTENING DRUM
KJ17259 S1 700 BAND SUPPORT ROLLER KJ22935 PLANETARY GEARBOX
KJ20878 SERVOMOTOR KJ24840 K1800S7 BAND
KJ22226 K700S7 (750x9450mm) BAND KJ25045 K1800 BAND SUPPORT ROLLER
KJ22792 K700S7 MOTOR-DRUM KJ25048 K1800S7 TIGHTENING DRUM
KJ22797 K700S7 TIGHTENING DRUM KJ25050 K1800S7 MOTOR-DRUM
KJ22924 K1400S7 (1390x9450mm) BAND

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2.16. Conveyor wiper

It keeps clean and in perfect conditions the band of the conveyor. It's always located below the band and at the exit of the
machine.
It's comprised of a soapy water recirculation circuit to have the band cleaned and a lift/descend system for the wiper.
The waste hopper may be easily removed for cleaning.
Soapy water in the tank has to be replaced whenever operator observes it's not cleaning effective.
From the control board, located on one side of the front cabinet, a switch turns on the recirculation of the cleaning water and
a lever moves up or down the cleaning wiper.
Solid resistant recirculation pump.
Watering of the band from wide water jets to prevent blockages.
Safety system:
Cleaning position lock.
The pump only starts when in working position, never in access one (actuators down).
Configurable right/left system.

■ Hopper and controls view.

1
2

1 KJ17950 GUIDED CYLINDER 25-40

2 KJ17951 SLIDE
3 KJ17954 K700S6 WIPER
3 KJ18054 K1400S6 WIPER
3 KJ25027 K1800S6 WIPER
4 KJ17144 SILENTBLOCK

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 KERAjet

1 KJ26593 PNEUMATIC PUMP

2 KJ19661 PE TANK SIEVE
3 KJ22420 3K MAIN INK TANK

■ Wiper pneumatic diagram:

1. Pneumatic unit.
2. Panel manual valve.
3. Shutter valve.
4. Guided cylinder.
5. Manual valve.
6. Pneumatic pump

2.17. Tile centraliser

It is a device that aligns and centres the tiles on the production line before reaching the printing area.
It's an easily set and adjusted part. Operator may set the position of the tile on the conveyor belt depending on the needs
and tile format.
It may be from single up to quadruple, depending on the amount of tiles to be centred at the same time.
Also, it may be provided with cone rollers or wear resistant strip.

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5
6

1 KJ20970 V7 ANGLED CENTRALISER GUIDE

2 KJ18731 CLAMP SHAPE
3 KJ20105 V7 CENTRALISER BRAKE
4 KJ19794 CONE ROLLER
5 KJ19346 K700 CENTRALISER CHROMIUM PLATING D30 SHAFT
6 KJ19357 LINE BEARING
7 KJ16387 ADJUSTABLE HANDLE
8 KJ21023 LEFT V7 CENTRALISER ROLLER GUIDE
8 KJ21024 RIGHT V7 CENTRALISER ROLLER GUIDE

2.18. UPS System

The UPS gives the reliability of a battery backed up for input power cuts.
It keeps the machine powered on long enough to make the basic ink
recirculation and automatic cleaning tasks.
Rectifier/Inverter combined technique.
User friendly display.
The device is refrigerated to matain batteries in good conditions.
User control interface with alarms settings.
Blackouts free for network transfers to UPS.
Inside installed for KERAjet S7 – 700 and outside installed for 1400 and
1800

ONLY TRAINED TECHNICIANS MAY INSTALL, CHECK AND MAINTAIN UPS DEVICES (INCLUDING BATTERY
REPLACEMENT).
MAY YOU HAVE ANY QUESTION ABOUT OPERATION, OPTIONS OR MAINTENANCE, PLEASE CONTACT KERAjet.

2.19. Optional elements

2.19.1. Relief detector

It is an artificial vision device which can recognise different reliefs and synchronise printing accordingly.
It is comprised of a 16 mm lens, mirror, high speed camera and a laser, installed on a support specifically designed for
KERAjet machines.

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It has a relief management software that can recognise from 9 up to 255 different reliefs. It is provided with a specific
instructions manual.

KJ20808 7x7mm MIRROR

KJ21810 LASER UNIT
KJ21811 AMPLIFIER

2.19.2. Gap cleaning management

It's an available option in KERAjet equipments which coordinates the other elements of the production line with KERAjet
machines so the operator can make gaps in the line acting on the press/dryer as he may wish.
This gaps may used for automatic cleaning.
An small electric installation with photocells and cables is required.

2.19.3. Multientry kit

This option increases machine productivity as the it might be working with up to 4 lines simultaneously. The only limit is the
maximum printing width of the machine.
Only some mechanic modifications (centraliser and sensors for each line), software upgrade and Firmware and Hardware
updates are required.

2.19.4. Moving printing units

This piece of equipment is specifically designed for vertical or inclined surfaces. It has a specific instructions manual.

2.19.5. Height barrier

This element detects tile height differences and automatically adapts printing height accordingly. It has a specific instructions
manual.

2.19.6. KERAjet Modul

It's an optional equipment designed by KERAjet to print the tile backside, without any manipulation. Control marks may be
made on tiles individually.

2.19.7. KERAjet Visio

Optical tile control. It detects and warns about defects on printing.

2.19.8. Print head cleaning equipment

When a print head is not printing properly, after having tried what's suggested in the problem solving part, you may remove it
and make a thorough cleaning with this equipment.

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3. Operational positions
The following pictures suggest a layout of the complementary elements of a KERAjet S7 machine, in single and double entry.

We'd like to suggest having the machine installed in a protection cabinet. In this case, the operational position is defined by
the cabinet. The operator is located inside. Tile flow of the production line runs through the cabinet and the machine.
The backside of the cabinet must have an access for the back doors for the maintenance operations. We suggest letting
enough space between the protection cabinet and the elements around as some maintenance interventions need some room
for manoeuvre.

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At the front of the machine you may find the touchscreen and the keyboard to set the working parameters and the conveyor
on button. You also have the main ink tanks which have to be kept filled at the correct level. As it works automatically, operators
just have to check for unlikely anomalies in tile flow, ink failure or equipment cleaning.
There are three emergency mushrooms at the front, two at the back and two inside the panels.
Please, bear in mind that the machine can only work while the hood and the back doors are closed.
For maintenance or inside cleaning you must stop printing.
Please, check cleaning elements and conveyor wiper.
Use personal protection equipment for a safety operation: please, avoid unsuitable clothing which may get trapped in the
moving parts of the machine, wear rubber gloves, safety shoes and, whenever required, safety goggles.

4. Description of the intended use of the machine

KERAjet S7 is an industrial machine designed to print images on ceramic tiles, plastic, wood, cement, cardboard, glass, etc.
KERAjet S7 may work in different modes depending on customer's requirements: tile by tile, roller, canvas or multiresolution.
It digitally prints by using ceramic pigments, salts, effects, powders, glaze, UV inks, water based inks, etc.
Maximum printing widths depend on the kind of unit, which approximately are:
■ KERAjet S7 - 700, 700mm.
■ KERAjet S7 - 1400, 1330mm.
■ KERAjet S7 - 1800, 1803mm.
Printing lengths depend on product mechanical features. They may change depending on tile curvature and finishing. It
might be longer than 2 metres may the connection with production line be correct.
Maximum conveyor speed is 90 m/min. During machine start-up customer's printing quality requirements are checked at
production speed and also tile reaction when and emergency mushroom is pressed.
Maximum tile thickness when printing is 46mm. Any thicker tile will collide with the frame and will stack it and bring about
breaks in the elements of the machine.
As KERAjet S7 works in the same conditions as the production line and operators are trained on how to operate it, a misuse
has never been observed.
Safety measurements to adopt are the same as those applied on customer's production line.

5. Installation instructions
■ An auxiliary compressed air equipment is recommended to be used in factory supply cuts. Intake requirements are 1100
l/min, 6 bar for 10 sec. every 30min. We suggest a 1.1kW compressor with a 200 litres tank 8 bar pressure.
■ Installing a protection cabinet for the equipment is also recommended. Such cabinet will allow the operator have
environment temperature under control, prevent dust and protect from noise or other external hazards.
■ An air conditioner system should be installed in the cabinet so inside temperature may be around 27ºC y 30ºC.
■ The customer has to provide a suitable power input, a compressed air inlet, a dust suction installation for ink vapour and a
different outlet for suction from the cleaning trays.
■ There are no special instructions for noise and vibrations reduction during installation.
■ Approximate dimensions of the recommended cabinet. Depth: 5m for KERAjet S7 700 and 6m for KERAjet S7 1400/1800.

Connect to the exhaust main pipe of the factory to have it purified.

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6. Start-up and operation

Location, installation and first start-up of the machine will be made under a KERAjet technician supervision.
Depending on production requirements, KERAjet technician sets: printing size, line speed, configuration and installation of
the system in case of single or several entry, specific software, general equipment check, tests and printing sets.
The process, basically consists of:
■ Protection cabinet installation supervision.
■ Equipment unpackage and box content check.
■ Wheels and support installation. Lock wheel fixing screws. Leave supporting screws longer than the lower part of the
wheels so they are those standing on the floor.
■ Dismantling transport metallic supports. They're screwed and, generally, they'll be located at the front and back of the
equipment.
■ Set the machine in the line. Agree on level. Line consent.
■ Turn off main switch and all the circuit breakers in the main electric panel and individually those in the colour modules (no
voltage position).
■ Check that all input phases are balanced and earth is correct.
■ Connect the machine to the factory electric network. Power up general differential switch and the circuit breakers in the
main panel and in the “backpacks” of the KERAjet equipment.
■ Check that the UPS is working fine.
■ Fill main tanks with the ink supplied by the customer, up to the right level. Do not go above maximum level. We suggest
labelling ink tanks with code and ink supplier.
■ Refill chiller with transfer fluid and connect it to the machine. Open chiller output taps.

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 KERAjet

■ The ink vapour exhaust device integrated in the machine has to be properly installed to the main suction facility of the
plant for its final filtering and evacuation out of the factory. The device has a filter which pre-treats such air flow from ink waste.
Close outlets at the bottom of the ink filter.
■ Connect power and compressed air to the cleaning filters of the machine.
■ The recirculation tank of the wiper has to be filled with 20 litres of water. Add 20cc of a dispersing mixture or a surfactant (if
not, soap + antifoaming).
■ Equipment previous test.
■ Active ink regulation setting.
■ Start-up.
■ Printing check and setting.

PRECAUTIONS TO BE OBSERVED BEFORE THE START-UP OF THE EQUIPMENT.

YOU MAY PRESS ON THE EMERGENCY MUSHROOMS AT ANY MOMENT. PLEASE, OBSERVE WHERE THEY ARE
INSTALLED. WHILE IN PRODUCTION, KEEP HOOD DOWN.
THE FIRST OPERATION OF THE MACHINE IS SEARCH FOR REFERENCES. THE OPERATOR, ONCE THE PROCESS
IS ACCEPTED, HAS NO CONTROL ON THE MACHINE. HE MAY ALWAYS PRESS ON THE EMERGENCIES.
PLEASE, CHECK THAT THE METALLIC COVERS FOR TRANSPORT IN THE COLOUR MODULES HAVE BEEN
REMOVED.

6.1. Colour management

Colour management means adapting KERAjet equipment resources to the specific products of each customer.
KERAjet designers install, configure and train users in a customized colour management.
Basically, this procedure involves:
■ Graphic digitisation, taking pictures or file acquisition.
■ Linearization file ripping with the technical data of the machine. Colorjet o Colordirect.
■ Colorjet linearization acquisition.
■ Ripping and printing of the colour test chart with the previously acquired information (.lut).
■ Test chart acquisition and profile generation.
■ Photoshop: profile installation and image processing.
■ Colorjet (Multichanel, CMYK o RGB) or Colordirect (Multicanal o CMYK): Rip converted image with the suitable printing
scheme.
■ Print.

6.2. Regulation of the active ink system

Each ink circuit works with an active ink system(SRA as spelled in Spanish). Compared to others, this system has printing
stability and less amount of elements in the circuit among other advantages.
The process is controlled and monitored by the PC and its controlling interfaces.
Each circuit has to be set for a correct operation. This task is carried out for the first time by KERAjet technicians.
Please, bear in mind that each ink circuit requires different parameter settings that depend on the features of the print units
and of the ink rehology.
Remember that each colour module has 2 ink circuits.

Initial regulation procedure of the active ink system

■ Visually check hydraulic, pneumatic and electric connections.
■ Close all the print head taps, except those of one of them.
■ Open bypass of the ink collector.
■ Open peristaltic pump valve.
■ Configure from ConfigCT: meniscus pressures, differential pressures, pressure sensor offsets, pump percentages startin
values, purge pressure, pump percentages and each nominal ink temperature.
■ Check ink level in the main tank.
■ Close all doors and hoods.
■ From control panel choose the ink to regulate and access “Regulation”.
- Ink has to come up from the main tank, located inside the frontal panels of the machine, up to the secondary tank in the
“backpack”, in the back panel.
- It's likely that “ink level” alarm is triggered if the circuit has not been filled up completely. Stop regulation and start again.
■ Check whether the system has reached the regulation set point set in the ConfigCT. This process may last for three
minutes at least.
■ Stop the system.
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 KERAjet

■ Open print head valves.

■ Restart regulation process and wait until regulation set point has been reached again.
■ Check surface of the print head nozzle plate, may a small line of ink show up on every nozzle line that means that the
system is properly regulated. In case of drops or ink accumulation, that means that the meniscus pressure is too positive. May
the surface be dry, it's likely that meniscus pressure is too negative.
■ Check if temperature has reached regulation set point.
■ Repeat the process for every print module.
■ Set conveyor speed as requested.
■ Go to ink section and check pressure values of each active ciruit and pump percentages.
■ Print a nozzle test on a paper. It will show you whether selected print heads match size and whether their control system
work properly.
■ May an alarm be triggered, please, check on the monitor what's the issue (check alarms section included in control panel
manual).

Events which might occur

■ May the IN pump working percentage get higher than 40% and meniscus pressure (pressure at the print heads) and
differential pressure (flow) remain steady, filter needs replacement.
■ May the OUT pump % increase, it's likely that air is getting in the circuit.
■ Working % of one of the pumps is very high and the other is almost zero. Please, check pumps in manual individually as
it's likely that one them failed and stopped operating. You may set maximum and minimum alarm triggering values so the SRA
gets stopped.
■ Meniscus and differential pressures can't go stable and the system gets stopped. There's an air bubble in the circuit.
Change flow direction from the flow reversing valve. May values don't become stable, open two print head taps al least and
check stability and close them again. These actions are intended to remove the air bubble from the circuit (purge the circuit).
Please, bear in mind that for each print head there's an input and an output pipe.
■ Pressures don't go stable even with the before mentioned actions. Calibrate pressure sensors of the circuit.
■ It's very likely that in case the circuit does not go stable, there's an ink leakage which has to be detected and corrected. In
this case, air is getting into the circuit.

Regulation procedure after a stop

This procedure is only suggested for an ink circuit regulation after a casual stop.
■ First, check alarms.
■ Restart ink system from “Regulation” option.
■ Please, wait until consigned pressures and temperatures are reached.
May they get to the setting points, the system will work correctly.
May it not be so, regulate by checking pump % and what may go on with pressure values. Please, be aware of the alarms,
check section "14. Problem solving" and contact KERAjet and report the data.

6.3. Introduction to control software

The equipment is provided with a software that comprises several programs, each of them have a specific role when
controlling, monitoring and configuring KERAjet S7.
All this programs have a technician access level (not available for operators which saves all the critical parameters of the
machine) and an operator one (designed for user's operation on a daily base).
■ Carga. Design file management: load, close, centre, etc. Last released versions manage two productions at the same time,
so one is active while the other is inactive. This means that the operator may arrange next production while the previous one is
still running.
Operator may also print a test image or pick print a selected image in order to check that printing settings are correct and
monitor on-line parameters in general, either those for production 1 or those for production 2: speed, printing height and
production.
■ ConfigCA. Edits and monitors print units parameters: print settings, status, software and hardware versions of the print
units control cards, etc.
Furthermore, it has a very useful set of tools for the customer. Such tools, are small software programs which help the
operator in strictly technical matters: print unit change, Firmware and Hardware card upgrade, save/recover previous backup,
etc.
■ ConfigPLC. This program sets the configuration parameters of the machine, in either technical level or user one (factory
parameters). They are general parameters which set stable working routines.
It also enables the chiller and sets cooling circuit temperature and other factory parameters such as ink temperatures, etc.
You have to read the parameters when opening ConfigPLC, this is because the PLC is not connected all the time with the
program, just when parameters are read from the software, the systems acquires running values which are being captured by
the PLC from sensors.

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 KERAjet

THERE'S A FOLDER IN THE PC OF THE MACHINE WHICH HOLDS MANUALS IN FILES ALONG WITH OTHER
INTERESTING INFORMATION.
C://COMPUTER/KERAJET/SOFTWARE/TECHNICAL SUPPORT/MANUALS

6.4. Start-up
■ Start-up the machine and PC from the main switch.
■ Turn on circuit breakers, press on reset button and switch on the colour module switches, one at a time and wait for each
of them to turn on and cards start working.
■ Open PC control-management programs in software folder of the desktop: ConfigPLC, CARGA, ConfigCA.
■ ConfigPLC: Press on “Read params”. The system is not logged in online, so, operator has to press on this button to acuire
updated PLC values. Please, check critical operational parameters. Those really critical are in the “Factory params” tag and
should be checked in “Technical” mode.
■ ConfigCA: Finally, please, open this program and at “Select print units” select them all and check parameters in general:
No communication error, no PZVolt set to zero, no PZT set zero or with a range very different from the rest, all FW/HW in the
same version. Minimize.
■ CARGA: Press on “Printhead selection” and select them all. May any print head go in error, locate it, unplug power and
Ethernet cables, wait for a minute and plug them back. Open “Carga”, press on “Open file” and select a test file in the right
printing mode. Open file to be printed and load image.
■ From control panel, start printing. Place a thinner than height settings tile at the KERAjet software and, may consent not
be present, press on the black bypass button. The conveyor will run for a test at least.

Machine stop
• Bring all the bars to rest position and stop conveyor
• Stop printing from “Carga”, close all the running programs and switch off the PC
• Turn off the module switches
• Finally, turn off the main power switch at the front of the machine

WARNING: TURNING OFF THE MAIN POWER SWITCH WITHOUT FOLLOWING THE ABOVE STEPS MAY DAMAGE
THE ELECTRONICS OF THE MACHINE.

7. Operators training
Due to the operational sophistication level, during start-up and later setting up, KERAjet staff will train those operators
designated by the customer to work on the machine.
This manual will be used as documentation of that operators' training.
Special attention will be paid on the safety systems of the machine.

8. Risks
KERAjet ensures that its equipments are designed and manufactured according to current safety regulations and that,
permanently, aims at reducing risks from operating the machine for all its lifespan, including transport, installation-start-up,
operation, maintenance, disposal and dismantling.
A customer who's purchased a KERAjet machine, has to make sure, first of all, that operators identify emergency stop
elements (emergency mushrooms), locate them, understand how they work and are responsible for their good condition, from
the installation moment, till the equipment is dismantled.
KERAjet eagerly uses the information in the Technical Orientation documents, and takes those harmonised norms which are
related to the safety of its equipments.
Emergency mushroom head buttons location.

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 KERAjet

■ Front cover view:

■ Back covers views:

■ Back panels views:

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 KERAjet

Yellow buttons next to the emergency ones disable all ink systems of the machine (all ink circuits). May you like to stop just
jus
one, please, do it from control panel.

8.1. General safety instructions

Next, general safety operations which have to be applied compulsory when operating a KERAjet
KERA S7 machine are described.
As a general rule, we recommend a suitable operation of the machine, paying high attention and using suitable personal
protection equipment.

Electrical hazard. Electric cabinets.

Hands crushing. Crushing. Conveyor and scraper blade.

■ Warning. It's compulsory to identify those parts in the machine singled out as dangerous by the manufacturer and to take
great in order to avoid any mishap.
■ Electric discharge risk. Please, keep panels closed and do not insert any item nor dismantle anything.
■ It's utterly prohibited to remove protecting covers as well as to disable any safety element or system. Hood and panels
must always be closed.
■ Use of personal protection equipment which may be already in use in the production line where the machine is going
go to be
installed is compulsory (gloves, goggles, safety shoes, etc.).
■ We recommend reading this manual and keeping it nearby the machine as a reference book.
■ Please, do not insert any item in the slots or joints of the machine.
■ Please, do not lean n on the machine nor any of its parts.
■ Please, do not place any load on the machine.
■ Please, do not access moving parts of the machine while it's running.
■ Please, do not water the machine. Do not clean with hose.
■ Please, do not clean nor remove any part of the machine while it's running.
■ Fire hazard. Please, do not pour water, oil, nor any other product on the machine. Use emergency button in case of fire.
■ May you detect that safety elements have been altered of disabled, please, do not start the machine.
■ Please, take care when unloading and locating the machine as it's pretty heavy.
■ Please, do not leave the machine unattended for long periods of time. Some tiles may get broken or stack and this may
bring about a risky situation. A well trained
ained operator intervention would be critical in hazardous situations.
■ Please, keep a CO2 fire extinguisher nearby the machine as this is the suitable one for fire in low voltage machines.
■ Please, keep the machine in good cleaning conditions in order to prevent slip mishaps.

8.2. Specific safety instructions

KERAjet has reduced as much as possible any risk from using the machine. In order to achieve it, KERAjet
KERA has integrated
safety in the design and manufacture stages by applying the required protection
protection measurements and using materials or products
harmless for people in contact with the machine.
When operating KERAjet S7 following safety laws and norms is compulsory.
Next, a set of important suggestions and safety norms are detailed for a correct and safe use of the machine:
■ The machine has to be used and operated only by authorised personnel who has been properly trained by KERAjet
KERA
technicians. Please, behave responsibly and operate the machine just for the porpuse it was designed for.
■ The machine must only be start up once KERAjet
KERA technicians finished their location and start up, and the operators at the
factory had been properly trained.
■ Please, keep hood always closed. Bear in mind that the machine makes some automatic movements and operators might
get trapped or hit.
■ The equipment might miss basic operational parameters or some elements might get damaged if software is altered in
technician access mode.
■ Chemical products inserted in the machine might be irritating or a hazardous for the environment
vironment if not handled or
discarded according to the manufacturer. Please, request you ink supplier before using it. Read safety instructions. Take
required personal protection measurements.
■ Trapping risk. Please, don't wear garments or any other object
object which might be likely to get trapped with any part of the
machine.
■ Use emergency button for any anomalous situation: noise, smoke, collision, etc.
■ Always use KERAjet original spare parts.
MS7E. Rev: 200623 37
 KERAjet

■ May you detect any issue in the machine, please, follow support procedure and contact KERAjet support service.
■ Please, do not allow sensor amplifiers to be altered as maximum height barrier might be disabled and this would bring
about a collision.
■ Detection systems integrated in the machine as well as the relief detector (only under request) have a laser. In order to
use lasers in a safe way, do not expose eyes to it as this would damage your vision. Do not connect an altern current power
supply to the sensor as it might explode or get burnt. Do not dismantle it from its place nor direct it to other persons or animals.
Please, check and apply safety regulations in force in your country.
■ Lasers integrated in the tile detection and height barrier systems are type 1. Please, check regulations and set safe
working routines. They are regulated according to UNE-EN 60825-1:2008 norm. Type 1 lasers emit visible radiant energy which
might produce glare effects, mainly in low light environments. Please, never change settings of the equipment as the machine
will be unprotected from maximum height barrier; in that case, KERAjet is not liable for any spoilt material nor personal damages.
■ Please, be careful as some surfaces are hot and may produce thermal burns if touched. For safety reasons, the machine
has thermostats which stop heating when a given point is reached.
■ May your machine have any K6 print head module, please, bear in mind that power supply to these units is around 150
VDC (per unit) and this might be a risk if handled unduly.
■ May your machine have a water wiper, when supplying pneumatic pressure to the device (a double effect valve is
installed), an automatic up/down movement will be produced by the pneumatic actuators. Please, be careful, risk of trapping. In
order to avoid projecting water, and it may get inside the machine, there's a safety system that turns on the water jets pump only
when wiper is up.
■ Emergency button must not be used for normal stop.
■ User must not modify the design and configuration of the machine without requesting KERAjet or its authorised dealer.
■ Please, check periodically emergency beacon.

8.3. Secondary risks

DETECTED RISK RISK POINT/AREA STATUS PROTECTION AND DESIGN SECONDARY RISK
MEANS SET

A) WHEN THE A) SUITABLE WIRING DESIGN.

A) ELECTRIC OR MACHINE IS
A) Fire risk from
FIRE RISK FROM ELECTRONICS POWERED, NOT B) HIGHLY FLAMABLE
1 shortcircuit.
SHORTCUT. ELEMENTS. JUST WHILE IN ELEMENTS ARE ISOLATED OR
OPERATION. KEPT APART.

MACHINE COVERS:
Machine operation when
A) MAIN HOOD. hood and doors are open.

B) BACK DOORS. The safety system which

RISK OF disables movements when
TRAPPING FROM C) SAFETY OPTION THAT hood is open might be
THE MOVING DISABLES MACHINE disabled during start up.
A) MOVING PARTS MOVEMENTS WHEN HOOD OR
PARTS OF THE A) OPERATION. You may do it by
OF THE MACHINE. BACK DORS ARE OPEN.
MACHINE WHILE accessing KERAjet
2 X and Z axes
IN OPERATION OR B) SEARCH FOR software and disable this
movements.
WHILE IN SEARCH REFERENCES. EMERGENCY BEACON GOES system deliberately. Safety
FOR ON AND A WARNING MESSAGE elements will keep on
REFERENCES. APPEARS ON THE CONTROL working the same.
. PANEL.
This operation is only
D) RESTRICTED SOFTWARE. allowed to KERAjet
technicians.
E) MOVEMENT SPEEDS
SLOWER THAN 5m/min.

A) INK VAPOURS SUCTION

EMBEDDED IN THE MACHINE.
HAS TO BE TURN ON FROM
INHERENT RISK
CONTROL PANEL.
FROM USING
A) ACTIVE OR
IRRITANT AND A)ALL OVER THE A) Risk from use of
INACTIVE B) USE OF CHEMICAL
3 HARMFUL MACHINE. chemical products.
MACHINE. RESISTANT MATERIALS THAT
CHEMICAL
PRODUCTS. MINIMIZE INK LEAKAGE.

C) LEAKAGE PROOF INK

TANKS.

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 KERAjet

DETECTED RISK RISK POINT/AREA STATUS PROTECTION AND DESIGN SECONDARY RISK
MEANS SET

COLLISION RISK A) THE AMPLIFIER HAS A

FROM IMPROPER PROTECTION COVER.
HANDLING OF THE A) Collision between tile
A) WHILE IN
SIGNAL AMPLIFIER A) TILE DETECTION. and machine because of
4 OPERATION. B) SUITABLE TRAINING OF THE
OF THE TILE improper handling.
OPERATORS IN RELATED
DETECTOR RISKS.
DEVICE.

A) No restricted access:
A) MAIN HOOD.
RISKS FROM THE machine operation even
INSTALLED LASER with open hood and direct
B) THE DEVICE IS ATTACHED
SYSTEMS: beam view.
WITH SCREWS WHICH FIX ITS
WORKING POSITION.
B) The emitter may be
■ TILE DETECTOR removed from its position
C) LASER EMITTER HAS A
SYSTEM. and, by directing to the
WARNING AND INSTRUCTIONS
A) WHEN THE eyes, it may bring about
TAG.
A) TILE DETECTOR glare effects, mainly in low
Low power laser, it MACHINE IS light environments.
LASER EMITTER.
POWERED UP
5 might produce glare Type 1 laser,
effects. based on EN 60825-1. (NOT JUST WHILE
660 nm. 1,35mW. IN OPERATION). A) MAIN HOOD. A) No restricted access:
machine operation even
■ MAXIMUM TILE
B) THE DEVICE IS ATTACHED with open hood and direct
HEIGHT SYSTEM. WITH SCREWS WHICH FIX ITS beam view.
WORKING POSITION..
Low power laser, it B) The emitter may be
C) LASER EMITTER HAS A removed from its position
might produce glare WARNING AND INSTRUCTIONS and, by directing to the
effects. TAG. eyes, it may bring about
glare effects, mainly in low
light environments.

A) Collision among
machine parts and basic
COLLISION RISK start up parameters.
AMONG MACHINE
PARTS DUE TO A) OPERATIONAL You may disable conveyor
CHANGES IN A) ALL OVER THE A) DURING PARAMETERS ARE movement safety system
6 BASIC MACHINE. OPERATION. PASSWORD PROTECTED IN when hood is open during
OPERATIONAL THE SPECIFIC SOFTWARE start up. In order to take
PARAMETERS OF PROGRAMS OF THE MACHINE. this option you'll need to
THE MACHINE. access KERAjet restricted
software mode and
intentionally have it
disabled.

A) IN CASE
THERE'S ANY A) EVERY MODULE HAS FIXING
COLOUR MODULE SCREWS AND HAVE TO BE
OUR OF ITS INTENTIONALLY REMOVED TO
POSITION WHEN BRING THE BAR OUT.
RISK OF CUTS A) Operator may get hit
A) INK REMOVABLE THE MACHINE
AND HITS FOR because of system
7 MODULES. GOES ON,
THE OPERATOR. B) THE MACHINE HAS A malfunction or misuse.
SEARCHES FOR
DETECTION SYSTEM THAT
REFERENCES OR
BLOCKS THE MACHINE WHEN
IN AUTOMATIC
CLEANING ANY BAR IS OUT OF PLACE.
OPERATIONS.

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 KERAjet

DETECTED RISK RISK POINT/AREA STATUS PROTECTION AND DESIGN SECONDARY RISK
MEANS SET

A) INDEPENDENT ON/OFF
A ) WIPER SWITCH A) Operator misuse of the
WET WIPER SWITCH.
A) WIPER. CONNECTED TO double effect lifting
8 TRAPPING.
THE MACHINE. cylinder.
B) OPERATORS TRAINING.

A) MAIN DIFFERENTIAL A) While the machine is in

A) THE MACHINE
SWITCH IN THE GENERAL operation, please, keep
IS POWERED UP.
PANEL OF THE MACHINE. the panel unlocked so
access to the main
differential switch is free.

A) INDIVIDUAL CIRCUIT
A) ELECTRIC PANEL.
BREAKERS FOR EACH GROUP A) Chiller under voltage.
B) CHILLER OF ELEMENTS.
B) CHILLER. DISMANTLING
Chiller is under voltage as
RISK OF ELECTRIC WHILE STILL B) THE CHILLER IS FULLY
9 pump and the rest of the
DISCHARGE. C) UPS. CONNECTED TO COVERED AND ANY elements have to be on
THE MACHINE. INTERVENTION IS NOT continuously.
D) ALL OVER THE ALLOWED.
MACHINE.

C) INTERVENTION
ON THE UPS, A) UPS IS FULLY COVERED A) UPS handling and
EVEN WHEN AND CLOSED WITH SCREWS. dismantling, batteries
DISCONNECTED exchange included, is
FROM POWER dangerous unless carried
INPUT WITHOUT B) THE UPS IS SENT FULLY out by specialised
BASIC ELECTRIC COVERED AND SHOULD ONLY technicians (EVEN WHEN
TRAINING (E.G. BE SUPPORTED BY KERAjet OR IN UNPLUGGED FROM
WHILE REPLACING POWER).
BY A QUALIFIED TECHNICIAN.
BATTERIES).

A) TRANSPARENT POLYMER
RISK OF BURNS A) WHEN THE COVER.
FROM CONTACT MACHINE IS A) Risk of burns from
A) SECONDARY
10 WITH HEATED POWERED UP, contact with secondary
TANKS. B) THERMOSTAT SET TO 90 ºC.
SECONDARY NOT JUST WHILE heated tanks.
TANK WORKING
TANKS. IN OPERATION.
TEMPERATURE 55ºC.

A) HOOD.
150 VDC A) Operator wrongly
DISCHARGE FROM B) COLOUR MODULE SIDE handles input power of
A) K6 PRINT HEAD
11 WRONG A) MACHINE ON. COVERS. these print heads when
POWER CABLES.
HANDLING OF THE power is still on.
K6 POWER INPUT. C) MAIN SWITCH OF THE
COLOUR MODULE.

CONVEYOR A) WHILE IN A) Leaning on the moving

12 A) CONVEYOR. A) CONVEYOR COVERS.
ABRASION. OPERATION. conveyor.

A) May anyone try to cross

A) LOWER DRUMS
CONVEYOR A) WHILE IN A) ROLLERS NEXT TO THE under the machine his hair
13 OF THE
CRUSHING. OPERATION. MACHINE. or clothes might get
CONVEYORS.
trapped.

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 KERAjet

DETECTED RISK RISK POINT/AREA STATUS PROTECTION AND DESIGN SECONDARY RISK
MEANS SET

A) WHILE IN
OPERATION.
TRAPPING BY THE A) HIDDEN AND COVERED A) May anyone try to work
14 COLOUR MODULE A) RACK. MECHANISM BY COLOUR on the control sensors
MOVEMENT. B) WHILE IN MODULES TOP COVERS. when moving.
SEARCH FOR
REFERENCES.

NOISE AT THE A) INK FILTER AND TURBINE A) Noise level of these

A) WHILE IN
15 SUCTION OR A) FANS. HAVE TO BE INSTALLED OUT devices is higher than 70
OPERATION.
TURBINE. OF THE CABINET. dB(A).

A) On the sides another

A) HANDLE IN THE CENTRE OF
HAND TRAPPING A) WHEN CLOSING operator might get
16 A) HOOD. THE HOOD WITH SLOT FOR
IN THE HOOD. HOOD. crushed if leaning on the
FINGERS.
frame.

A) SUCTION. A) TANKS HAVE MAXIMUM

FILLING LEVEL MARKS. A) Mistake when tank
INK SPLASH FROM A) WHILE TRAY manufacturing of when
17 B) INK TANK
SUCTION DEVICE. CLEANING. installing closing
COLLAPSE FROM B) THICKER INK TANKS THAN
elements.
SUCTION. REQUIRED.

A) While filling up or hand

SLIP FROM INK A) AROUND THE A) CLEANING SYSTEMS,
18 A) ALWAYS. cleaning some drops
SPILL. MACHINE. SUCTION, PANELS, ETC.
might fall on the floor.

Machine operation when

hood and doors are open.

The safety system which

A) SAFETY SYSTEM THAT disables movements when
DISABLES MACHINE hood is open might be
A) WHILE IN
CONVEYOR IF THE HOOD OR disabled during start up.
OPERATION.
PNEUMATIC A) PNEUMATIC BACK DOORS ARE OPEN.
19 MOVEMENTS CYLINDERS OF THE You may do it by
TRAPPING. CLEANING TRAYS. B) WHILE IN
SWITCHES ON EMERGENCY accessing KERAjet
SEARCH FOR
BEACON AND DISPLAYS AN software and disable this
REFERENCES.
ALARM IN THE CONTROL system deliberately.
PANEL. Safety elements will keep
on working the same.

This action is only allowed

to KERAjet technicians.

A) There's a valve which

A) PUMP COVER. prevents ink return when
INK SPLASH FROM
A) PERISTALTIC A) WHILE FILLING dismantling the pump.
20 PERISTALTIC PIPE
PUMP. INK CIRCUIT. May you leave it closed,
EXPLOSION. B) CLOSE FRONTAL PANELS.
the pipe in the pump may
explode.

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 KERAjet

9. Preventive measurements
■ The machine must be operated after KERAjet technicians finish start up and operators in charge of the machine have
been properly trained. The person in charge of the machine has to make sure that all the operators of the machine understand
how to operate it, risks while operating it and, mainly, safety systems. Please, provide KERAjet support contact number and
email address so request may be made.
■ Please, keep hood closed and operator access level when in operation. The person in charge must not allow operators to
disable safety systems nor keep hood open. These situations are only allowed under special conditions specifically approved by
KERAjet.
■ Keeping panels locked is compulsory. The key has to be kept by a supervisor. They can only be opened by authorised
personnel, educated in electricity and trained by KERAjet technicians.
■ Please, follow transfer fluid supplier instructions: handling, waste management and safety. Request and read safety
documents of the supplied chemical products before handling. Set waste collecting protocols.
■ Please, appoint persons in charge of the machine.
■ Please, train operators on suitable machine operation, safety operating norms and risks before starting operating. May you
have any doubt, please, contact KERAjet customer support service.
■ Please, do not allow any misuse when operating any of the elements of the machine (neglected operation of some of the
equipments of he machine may bring about an accident).
■ Safety and technical sheets of the transfer fluid are attached. Please, check them before handling.
■ Please, handle chemical products carefully. Ink and solvent manufacturers chosen by you must provide you with safety
instructions before using them. Please, read carefully and provide operators with recommended PPE: gloves, suitable soap, etc.,
as well as how to handle waste and good practices.
■ Please, check preventive maintenance section and set required maintenance routines.
■ Please, provide KERAjet operators with suitable PPE: safety boots, powder-less gloves, cloth, general cleaning paper,
safety goggles and hearing protector.

External safety
KERAjet S7 machine has user easy access safety systems (emergency buttons), located at the front, at the back and inside
the back panels. Please, find location in section 8. Risks.
May you need to stop machine operation for any reason or emergency, please, press on any emergency button and the
machine will stop working immediately. Automatically, the machine will wait until the emergency button is released. The machine
will display in the control panel “Emergency button pressed”.
Sound beacon is designed to warn when the machine goes in error. Yellow and noise stand for colour module and cleaning
trays movements. Red stands for blockage when in alarm.
Whenever any of the colour modules is out of place, the machine won't start working.
Control panel messages can be splitted in error messages (the machine is stoped) and warning ones (once accepted when
pressing on OK operation will carry on).
Stop SRA buttons stop ink recirculation systems (all the pumps) and are located in the back panels of teh machine.
The machine has a main switch which when in off position may be locked. This will bring 100% safety when maintenance.

PLEASE, BEAR IN MIND THAT IN CASE OF A DANGEROUS SITUATION, IF THE MACHINE HAS TO BE STOPPED, YOU
MUST PRESS EMERGENCY BUTTONS, NOT SRA ONES AS THESE WON'T STOP THE MOVEMENTS OF THE MACHINE.

Safety while in operation

The KERAjet S7 machine is equipped with mechanical and electronics means: PLC, piezoelectric technology, robust UPS
and state of the art electronics for print units control (among others).
Regarding software, operator has limited access to critical parameters of the machine (factory parameters). In this way,
several basic operational parameters of the machine are always protected in order to prevent dangerous situations such as
collisions among mechanical parts, inappropriate movements while in maintenance operations or basic parameters loss.
Regarding trap preventing covers, main hood must be closed when in operation, keeping operator away from machine
moving parts and, therefore, preventing any mishap.
The hood and the cabinet back doors have a locking system which disables any colour module movement may the hood and
doors be open while the machine is starting.
In this line of thought, other areas which may mean a risk if not covered, such as drums, bearings, electric panels, etc., are
covered with specially designed covers which keep operator safe and, at the same time, protect parts from working conditions
(dust, humidity, etc.).
The machine has a suction system which extracts, and previously filters, ink vapours when printing. This system sends
vapour to the factory suction installation so it may be processed. It protects operator from particles and ink vapour produced in
the cabinet.
Emergency stop system works like a positive mechanical action and has a redundant safety relay which ensures a good
performance. It's located inside the main electric panel.
There's a low power protection system for the print heads. Reset is inside the operational panel and may only be possible
once the issue is fixed.
MS7E. Rev: 200623 42
 KERAjet

10. Stability conditions

The machine has to be levelledly installed with production line.
In order to achieve this, it has height adjustable supports and
the conveyor has an adjustable screw system.
Machine stability is assured by these four supports on each of
the corners of the machine.
Along with the supports, there are free wheels for
maintenance and transport.
KERAjet S7 - 1400 has an extra couple of supports in the
centre and the 1800 has other two more couples.
The wheels are heavy duty, equipped with ball bearings and
polyurethane covered, that ensure soft and stable transport.
May any support or wheel get broken by chance, only a small
tilt of the machine may happen as height from the ground is just a
few centimetres. Furthermore, its gravity centre is always close to the geometric support centre, depending on the machine
version.

11. Transport, handling and storage

The machine will be carried to the installation site specified by the customer. Both location and installation will be carried out
by qualified KERAjet technicians.
Exported machines are packaged in a closed box, fixed to a wood or metal base and fully covered for protection. For
national transports by lorry, they may be standing on their supports and fixed to prevent any slipping on the way to destination.
The machine includes the following independent parts: Water wiper tank, chiller (no transfer liquid in the inside tank),
essential spare part kit, any other components requested by the customer (e.g. relief detector).
When unpacking the machine, please, check that it has not been damaged during transport. Also check accessories and
tools which have to match shipping list. Please, let KERAjet know any inconvenience you may find as soon as possible.

IMPORTANT NOTICE:
WHEN DELIVERED, THE MACHINE IS CARRYING SEVERAL TRANSPORT REINFORCEMENTS: A BAR AT THE FRONT
OF THE COLOUR MODULES AND SEVERAL FIXINGS AT THE BACK.
THESE FIXINGS HAVE TO BE REMOVED BEFORE STARTING UP THE MACHINE. MAY THEM NOT BE REMOVED,
THE MACHINE MAY GET DAMAGED OR OPERATORS MIGHT GET HURT.
MAIN TANKS ARE ALSO FIXED TOGETHER AND TO THE MACHINE.

The machine has turning wheels for pusing it and adjustable supports.
The frame has slots for forklift transport.
It also has four lifting points on the top, one for each corner, to be lifted by crane using ropes. These lifting points are M24
DIN580, which may withstand a 1800kg axis load. 3 m long ropes have to be used from the lifting points to the crane hook. You
may also use loading boom and shorter ropes as long as they are in vertical position. Please, do not compress the machine as it
may affect inside parts.

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 KERAjet

KERAjet S7 – 1800 is not provided with lifting points as it can't be lifted by crane. Internal deformations may alter settings in
the elements.

When wheels are touching ground, you may push it manually to its final location. Next, please, set height by adjusting
supports.
The machine has to be moved horizontally.
For a safe moving of the machine, please, proceed as suggested:
- Unplug it and cut compressed air.
- Install safety reinforcements that lock colour modules together along with the frame which were installed initially when the
machine was handed over to the customer.
- Remove or put apart those parts of the production line where it is installed.
- Unplug and take away the chiller, the suction filter and the wiper tank.
- Move the machine always in vertical position.
- Undo the operations above when installing it in its final position and set it as a new start up.
Please, pay attention to dimensions and weights mentioned in section 2.3. Specifications.
Wheels are located to the inside of the base in order to prevent crushing the supports when moving the machine manually.
Storage of the machine must be done with the same original package to have it protected from dust and casual hits.
May any production stop be shorter than a month, the machine must be kept on and all ink circuits running. However, may it
be longer, please, empty and clean all ink circuits, purge and clean print heads and keep the circuits running with solvent. In any
case, please, request KERAjet technicians for suggestions on how to proceed depending on the characteristics of your machine.
Anywhere the machine may be located, always use its supports as that's the system designed for a suitable and stable
condition. Please, bear in mind that it's heavy and big. Never use other supports than the original ones, as it may tilt or bring
about unstable conditions that may affect operators' safety.

12. Emergency procedures and reset modes

May any anomalous condition or risky situation for the operators, the machine or the environment occur, please, proceed as
follows:
■ Stop all moving parts of the machine.
A collision has happened, there's a risk of trapping or may any other dangerous condition happen:
- Press on emergency button.
Such device has to be distinguished from the SRA stop which does not stop the conveyor.
- Reset the machine.
Unlock all the emergency buttons and restore them to the operational position (out).
■ Please, stop all ink systems quickly.
E.G., when there's an ink leakage.
- Press SRA button
Movements of the machine won't stop.
Please, bear in mind that if ink stops flowing through the print heads for long they may get irreversibly damaged.
Use this action only if strictly needed.
MS7E. Rev: 200623 44
 KERAjet

SRA buttons will disable all ink systems of the machine (all ink circuits). May you like to stop just one, please, do it from
control panel.
- Reset the machine
Restart ink regulation of all of the circuits, one by one, from the control panel.
■ An alarm has appeared in the control panel and the machine has gone blocked.
When there's an error in the machine, a message for the operator appears on the screen.
At the same time, the machine goes blocked and the emergency beacon goes on.
Operators must fix the issue and press OK to carry on production in a safe way.
There are two different kinds of messages:
- ERROR message. The machine goes blocked.
- ALARM message. The machine carries on working, but, warns the operator about some issued which has to be fixed at the
earliest. Any movement is disabled until the situation is fixed.
E.G., when a door is opened while in operation, an alarm will be rised, but the machine won't stop printing, however, may the
door still be opened when printing is finished, colour modules won't get back to rest position (till the doors are closed) as the
moving system is disabled.
- Reset the machine
■ Smoke or fire comes out from any part of the machine.
For low voltage equipment fires you must use CO2 fire extinguishers.

13. Fine tuning and maintenance

Machine setting is made while in start up, as detailed previously. It must be carried out by KERAjet technicians at least, for
the first time.
Whenever the wear of any mechanical component affects printing quality, it has to be replaced.
Please, make safe maintenance interventions:
1. Move the machine to a safe position. Turn off any power, elements in position, etc.
2. Block the position. Make completely sure that the machine will not move during the maintenance intervention.
3. Check that the machine has been moved to a safe position. Check power supplies.
4. Make the intervention on the machine.
5. Check safety systems and make sure there’s nobody around the machine. Remove locks.
6. Start-up of the machine

13.1. Corrective maintenance

For any anomaly or unexpected stop, please, call KERAjet technical support.
For Spain, information is:
Office timetable. (08:30 -13.30/15.30-18.30). Phone: 0034 964 010 150 Requests.
Out of office timetable, weekends and holidays. 24/7 service: +34 678 280 381.
Contact email address: sat@kerajet.com
In case of stop-warning and light beacon, please, check control panel section and tell KERAjet support what's the error
message on the screen. A phone call might be enough to fix the issue.
Please, do not take any action in case you do not understand what's going on as you may put yourself at risk or some other
people.

13.2. Preventive maintenance. General instructions

Please, follow suggestions from KERAjet support team regarding suitable maintenance. Good maintenance will make your
machine last longer. Technicians know the exact features of your working environment, machine, kind of production, etc. They
may train you about how to carry out tasks in a completely safe way for you and for your machine.
■ Please, check visually after every shift and write down any anomaly.
■ Use a wet cloth when cleaning (never use it soaked in solvent) while the machine is not running (never in the print head
zone).
■ Check that all safety devices work correctly (emergency buttons and doors open sensors).
■ Keep level of the transfer fluid in the chiller in the middle of its capacity.
■ Keep ink tank levels in the middle of their capacity.
■ We suggest carrying out a general check of the machine by KERAjet technicians once per year at least.
■ Keep mirrors and emitters of the tile detection and height barrier system clean and aligned.
■ Check differential circuit breaker once per month.
■ Wheels need no maintenance as they are not used at all. May it be required, please, apply some grease in the turning
bearing. The axis wheel bearing is sealed.

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 KERAjet

■ Supports. Please, check fixings and nut supports. There should be no loose element.
■ PC, keyboard and touchscreen. Clean every certain time removing dust and spots.
■ Hood springs. Do not need any greasing nor oiling.
■ Please, make sure that operators understand the water wiper and replace cleaning water periodically. May it not be so, the
device won't be efficient. Wiper use with dirty water may damage irreversibly the pump.
■ Request persons in charge to make periodical visual inspections and check the machine and cleaning (these routines may
prevent production stops in the future).
■ Don't leave the machine unattended for long periods of time. Always keep trained operators in the KERAjet machine while
it is running.
■ Do not remove those sealed elements provided by KERAjet unless direct permission from KERAjet to do it. Please,
contact KERAjet and request.
■ Please, do not dismantle on your own any of the sealed parts such as pumps nor any other elements that are so provided
by KERAjet unless direct permission is given. If not, KERAjet won't accept any warranty on those parts nor any damage on the
machine.
■ Colour modules must only be removed from their position when in maintenance operation by a KERAjet technician or
authorised person in charge. Once tasks are finished, modules must be returned to their original position and fixed again. A
position sensor enables/disables module operation.
■ In order to extract colour modules, always make a “Print heads access” previously from control panel or they may get
damaged.

13.3. Preventive maintenance for each element

■ Colour modules movement
- Slides and guides. Please, check grease every 6 months. Lithium grease mineral oil based. You may grease the slide and
the line guide from the slide grease input.
- Teeth gear. Grease manually with sticking grease for gears. Grease may be applied with a brush or sprayed, please,
always check that there's enough grease. Start with weekly checks on grease statues and increase frequency depending on
experience (as it depends on environmental conditions).
- Servomotor. Completely covered and self-refrigerated. Please, use life span as a reference for periodic maintenance.
Bearings: 20.000 hours. Oil seal: 5.000 hours. Encoder: 30.000 hours. They may be replaced for fixing.
- Servodrive. Please, use life span as a reference for periodic maintenance. Aluminium electrolytic condensers: 28.000 hours.
Fan: from 10.000 up to 30.000 hours. Current protection: Aprox. 20.000 operations. Aluminium electrolytic condensers suffer
from deterioration even when the device is stored upowered.
- Endless gearboxes are lubricated for life with a long life high quality synthetic oil, poliglicol based. This makes them
maintenance-free.
- Panel bearing support. No grease required.
- Proximity inductive sensors. Please, make the following checks every 6 months in order to ensure a stable sensor
condition for a long time. 1. Check installation position, fixing, or performance of the proximity sensor and of the detectable parts.
2. Search for loose connectors and cables, incorrect contacts and line disruptions. 3. Check there's no metallic fragments nor
dust. 4. Check that temperatures do not rise too much nor there are other anomalous environment conditions. 5. Check lighting
of the indicators (for products with a operational indicator). Please, never open nor fix the sensor on your own.

■ Print units
- Print units. Please, do not allow any handling in the print heads. KERAjet has specific cloths for a correct nozzle plate
cleaning. This area is very sensitive and might get irreversibly damaged. May the print head make some lines when printing
which can't be removed by manual cleaning, you should make a complete cleaning with solvents. KERAjet has designed a
device to carry out this sort of cleaning in a very easy way.

■ Main ink tanks

- Polyethylene main tank. Every month, please, check for leakage while cleaning tray operation is on. Pressure value is
negative and any leakage will make the sponge print head cleaning be less efficient. May you detect this issue, look for external
cracks. Depending on ink composition, ink gases may affect the tank.
- 5 microns filter. Filters can't be open as they are thermally sealed. Ink filters must be replaced in case of specific alarm or
whenever meniscus and differential pressures are stable but pump % are too high.
- Peristaltic pump. Replacing peristaltic pipes every three months is highly suggested or whenever cracks or leakage (life
span will depend on ink features). Motor life span 5000 hours approximately. Never use soaps nor abrasive products when
cleaning outside cover of the machine. Please, only use a wet cloth and neutral soap. May any splash of a reactive or corrosive
product get the machine, clean it immediately with a wet cloth.
- Stirrer. No need to grease. Every year, please, check inside the stirrer and turbine so they are kept clean and free of solids.
- Suction. Keep outlet clean. Check every 3 months.

■ Electric panels and elements

- Light and noise beacon. Run it from time to time (six months) to check noise and lights.

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- Cable chain. It's maintenance free, no need to grease and, practically, it has no erosion. It might long 10 million double
courses.
- Proximity inductive sensors. Hood and doors. Check as follows every 6 months to ensure a long and stable operation of
the sensor. 1. Check installation position, fixing, or performance of the proximity sensor and of the detectable parts. 2. Search
for loose connectors and cables, incorrect contacts and line disruptions. 3. Check there's no metallic fragments nor dust. 4.
Check that temperatures do not rise too much nor there are other anomalous environment conditions. 5. Check lighting of the
indicators (for products with a operational indicator). Please, never open nor fix the sensor on your own.
- Power supply. Occasionally small electric discharges may happen, burns of product failures. Please, do not dismantle,
modify, fix nor touch inside of it. Remove all power supply cables connected to the mother board.
- Fan. Please, check filter cleaning and fun operation. Depending on the amount of dust in the environment, you must check
the filter more frequently; we suggest making a check after 2000 working hours and have it replaced if required. The fan is
maintenance free; life span is no les than 40.000 use (L10, 40°C). Therefore, filter fan is almost maintenance free. Components
may be cleaned from time to time, depending on cleaning conditions, using a vacuum or compressed air.
- PLC. Life span of the battery is 5 years at 25ºC, approximately.
- Infrared temperature sensor. Dust and dirt on the lens and scratched lens may bring about incorrect value acquisitions.
When lens is dirty, remove dirt with a blowing device designed for lens cleaning or any other suitable device. May it not be
possible to remove dirt by blowing, please, clean the lens softly with a wet cotton stick or a lens cleaning cloth wet with ethylic
alcohol. Please, start with monthly controls and increase them depending on how you find lens cleaning.

■ Tile detection system and maximum height barrier

- Laser sensor. Please, always switch off power supply before setting or connecting/disconnecting it. Do not use solvents,
nor similar products when cleaning the emitter. May any dust particles get stuck to the front of the emitter, please, use the same
brushing blower as that of the camera lens. Do not blow dirt or dust with your mouth. When removing dirt or dust particles, clean
it softly with a cloth (as those for lens) wet in alcohol. Do not clean too vigorously. Scratches in the filter might bring about
acquisition mistakes. Please, check it every 6 months.
- Amplifier. Please, always keep protecting cover in its place when the amplifier is being used, may it not be so it may work
incorrectly. Do not use solvents when cleaning. Please, clean it softly with a cloth wet in alcohol. Check it every 6 months.

■ Active ink system

- PT-100 temperature probe. Screwed and washer. Maintenance free device. Please, check acquisition mistakes every 24
months. May they occur, calibrate or have the probe replaced.
- 5 microns filter. The filter and the structure are thermally welded, can't be dismantled. Filters can't be open as they are
thermally sealed. Ink filters must be replaced in case of specific alarm or whenever meniscus and differential pressures are
stable but pump % are too high.
- Level sensor. Every year dismantle and remove solid ink depositions. Do not use chlorine based solvents. Do not tight nut
too much.
- Gear pump. They are sealed and leak proof. Thanks to its magnetic coupling, it does not need mechanic seal. It works for
long periods without any spare replacement required.
- Pressure sensor. They are maintenance free. We suggest calibrating them every year. Frontal membrane mustn't get
deformed under any circumstance, even contacting it with your fingers may deform it too much. Never insert any item in the
pressure hole. Do not jet any liquid on the membrane.

■ Chiller
- Maintenance of this device has to be carried out according to the specifications of its own manual.
- Electrovalves of the recirculation circuits. They must be set on at least once per month to prevent operational failures.
Inspection of these valves is required every 6 months to check operation and cleaning.

■ Pneumatic circuit
- Maintenance pneumatic unit. Whenever condensed level reaches up to 10 mm below filtering part, please, open purging
screw turning anticlockwise (bottom view orientation). Replace filtering cylinder when low flow is observed even when pressure
setting remains unchanged.
Remove air from the device. Turn filter cylinder anticlockwise and remove the used filtering spare. Insert the new one in the
cylinder and screw it by hand. Tight filter cylinder. Reset the device.
Clean the external side of the device with a soft cloth if required. The best cleaning products are soapy water (máx.+60 °C)
petroleum ether (free from aromatic elements).
A good compressed air quality make pneumatic elements last longer.
Please, check thoroughly leaks in the pneumatic circuit, mainly in connectors, joints, extensions, pneumatic actuators,
valves, filters, pressure gauges, etc.
Valves and electrovalves are maintenance free.
- Pneumatic actuator. If necessary, clean the cylinder with a soft cloth. Any non-abrasive cleaning agent is permitted. On the
other hand, the cylinders do not need maintenance due to their lifetime lubrication. Cleaning the grease that lubricates the stem
surface will decrease the life of the product.

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■ Cleaning system
- Pneumatic actuator. May it be required, please, clean the cylinder with a soft cloth. Do not use any abrasive cleaner. On
the other hand, cylinders are maintenance free as they are greased for life. Please, do not remove the grease on the shaft as
you may shorten their life span.
- Centrifugal fan. Before handling the fan, please, make sure it isn't powered and that nobody may turn it on while you are
working on it. Please, check the device periodically. Inspection frequency will depend on working conditions so no dirt gets on
propeller, turbine, motor nor grid that would bring about hazards and would shorten life span of the device. When cleaning,
please, take great care the propeller nor the turbine get unbalanced.
- Filter. Purge it every shift. In the bottom of the filter there are two valves which have to be open periodically while the fan is
off, in order to remove dried and condensed inks from inside. Please, check sealants for leaks.
- Cleaning trays. Depending on production, temperature and type of material condensed water or ink may appear on the tray
that may bring about production losses may drops fall on the tiles. Please, clean trays frequently to prevent this production loss.
The internal side of the trays is equipped with a waste output that is purging continuously. Please, clean it whenever dirt and ink
accumulation is observed.
- Cleaning sponge and support. Replace whenever clogged or deformed.
- Suction hopper supporting wheels. Bearing inside is greased for life and can't be greased again.

■ Conveyor
- Servomotor. Completely closed and self-refrigerated. Please, use life span as a reference for periodical maintenance.
Bearings: 20.000 hours. Oil sealant: 5.000 hours. Encoder: 30.000 hours. They may be replaced for fixing.
- Servodrive. Please, use life span as a reference for periodical maintenance. Aluminium electrolytic condenser: 28.000
hours. Axial fan: from 10.000 up to 30.000 hours. Current protection: Aprox. 20.000 operations. Aluminium electrolytic
condensers deteriorate even while Servodrive is unused.
- Planetary gear. Patent pending sealing system, Titanium carbonitride covered surface (TiCN) that prevents leaks and
increase life span above 30.000 hours. Grease with synthetic grease Nyogel792D for a soft operation, leak free sealed meeting
IP65 grade and maintenance free.
- Conveyor band. Please, check wiper for a correct cleaning. Check sides in case there's any friction with a metallic part
wearing them down. Check connection visually. Inside face of the conveyor has to be kept clean as well.
- Drums. Surface has to be kept clean to prevent conveyor pulling discontinuities.
- Bearing support. Lithic based bearing grease. Please, grease every 2.000 hours.
- Return roller. Bearings are greased for life with lithic based grease, water repellent, that ensure greasing for roller life span.
Please, keep clean to prevent discontinuities in conveyor pulling and frame misalignment.
- Conveyor tensioning. Please, check conveyor tension when hot/cold seasons begin. Because of expansions in the
conveyor frame, the band may get loose and, therefore, affect print or get too tighten and produce mechanic deformations.
- Silentblock. May any deformation or crack, please, replace them.

■ Wiper
- Guided cylinder. Please, check actuation every 6 months to ensure correct operation. Check external damage, air leakage,
or violent operation, and, if required, have it replaced. May you detect dry grease in the shaft, please, clean it with a soft cloth. In
case of unbalanced operation, please, restrict output from strangling valves. Check guiding shafts and bearings regularly to
ensure that they work correctly in the environmental conditions. In case of notches in the shaft, guiding quality of the bearing
performance or noise increase, please, replace cylinder.
- Slide. No need for greasing and under normal circumstances. Please, replace them when worn.
- Rail. Please, do not grease, remove dust with a soft cloth. Rails need no greasing nor maintenance, as with slides.
- Pump. No need for greasing. Please, check annually that stirrers and turbine are kept clean and incrustation free.
- Polyethylene tank. Please, clean wiper tank at the end of every shift.
- Tank sieve. Please, clean it along with the polyethylene tank.
- Wiper. Please, replace wiper whenever cleaning is not correct. You may use its 4 edges (turning it around).
- Wiper hopper. Please, clean wiper edge, jet collector and box inside every shift depending on needs.

■ Tile centraliser
- Line bearing and guides. Please, keep guides clean and greased. As there aren't so many movements to do, greasing
might be for life. May it be required, you can grease the bearings from the inside as both sides are sealed.
- Cone rollers. Please, check that they roll when softly touched, each screwed shaft must be tighten accordingly. Keep clean
so tiles are centred correctly.
- Clamp profile. Please, check wear in order to correct line bearing position so they keep on centring tile to be printed in a
proper way. Whenever wear is too much, have it replaced.

■ UPS
Any maintenance or repair must be carried out exclusively by authorised technicians. In the UPS, there aren't any part which
may be fixed by the operator. Please, keep the UPS free from dust. May the environment be very dusty, please, use a vacuum
cleaner. When the battery alarm is displayed on the screen, please, remove them. Please, take into account every warning,
precaution measurements and notice before replacing batteries.
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13.4. Tasks to be carried out by the operator

- Cabinet general cleaning
- Suck dust around the machine. Please, do not blow it.
- Please, check fans in the line are all on.
- Check that temperature in the cabinet is between 27ºC and 30ºC
- Please, check that average tile temperature at the machine entry is lower than 50º to prevent condensation issues.
- Check that suction hoppers under the cleaning trays have no leakages.
- Check that ink tank levels are between 5 lit. and 10 lit.
- Check that wiper water is clean, may it not be so, please, replace it.
- Check that wiper and its box are clean.
- Confirm that wiper is performing well on the band.
- When in bypass, please, turn on suction to remove heat from the inside of the machine.
- Check that the suction motor is on.
- Confirm that pneumatic pressure gauge is between 5 and 6 bars. When in purge, pressure should drop down to 4 bars but
no more.
- Check that chiller is on and that transfer liquid is correct.
- Check band status.
- Empty suction filter every shift.
- Check that suction is doing well in the sponge supports.
- Check sponge cleaning and maintenance.
- Check that print head automatic cleaning is carried out according to settings.
- Check that tile detecting and height barrier photocells are clean. Check that amplifiers' reading values are greater than 500,
if not, please, clean mirrors with a dry cloth or paper.
- Confirm that ink tank stirring is carried out according to settings.
- Check that secondary tanks are having enough ink from “ink levels” menu.
- Check that IN and OUT pump % are lower than 45% and that difference between them is lower than 15%.
- Please, write down pump working %. In case IN pump % is too high from its normal working value, it may mean that the
filter is getting clogged. In case OUT pump % is too high from its normal working value, it may mean that there's an air leakage.
Please check the person in charge of maintenance.
- Check that all inks are working fine from “Ink/Status” menu.
- Check that ink temperatures are +/- 1.5 °C from settings.
- Check that meniscus and differential ink pressures are steady (while in printing, maximum change should be +/- 5 mbar
and in rest +/- 1 mbar).
- Check that card communications are ok (from ConfigCA--> make a read).
- Please, check that printing height is no more than 2 mm above maximum tile thickness.
- Check centralising and alignment. May they not be right, please, centre and align accordingly. Take once per month, a print
head and overlap backup.
- Please, print a nozzles test tile to check whether there are printing flaws in the running product. May any print head affect
production, please, contact the person in charge of maintenance, if not, keep it recirculating.
These operations must be carried out on regularly depending on production in the machine to ensure a correct performance.

14. Problem solving

Next, some issues that might be found when in production are described. Please, take into great account that in case the
operator is not familiar with the suggested maintenance operations, does not have the required spares or is not suitably trained,
he has to contact KERAjet before carrying out any intervention in the machine.

ISSUE LIKELY REASON SUGGESTION ACTION

1. Ensure heating circuit performance in

1. Identify which is the module
the secondary ink tank.
and circuit of the issue.
2. Ensure circuit valve is open.
1. Print defects. 2. Check heating circuit of the
1. Ink is cold. 3. Raise individual circuit temperature
Lines are detected. secondary tank.
and wait.
3. Check that displayed value is
4. Print a test file and check if the
real
problem is still present.

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ISSUE LIKELY REASON SUGGESTION ACTION

1. Check whether the line is 1. Check overlaps from the “Carga”

2. Print defects. Overlaps. 1. Configuration.
between two print heads. software.

1. Purge ink circuit by reversing ink flow

for 30 seconds and return to initial
3. Print defects. Line in the
1. Ink recirculation. 1. Ink circuit. direction.
middle of the print head.
2. Raise print head RANK 3 points.
3. May it not work, proceed to issue 5.

1. Check that print head

1. Tone is different between 1. Set RANK voltages.
temperatures are the same or
4. Print defect. Different two print heads. 2. Set print head sector voltages
very similar.
tones. 2. Tone is different in one (PTRIMS).
2. Print head sector voltages
part of the print head. 3. Call KERAjet support.
(PTRIMS).

5. Defects clearly seen on 1. Dirty or damaged print 1. Flush solvent through the print 1. Call KERAjet support.
the design. heads. head with a syringe. 2. Replace print head.

1. Restart print head by disconnecting

1. Check communication with
power and ethernet cables and having
card. Orange ON led
1. Control card failure. them connected again.
2. Check Ethernet cable.
6. Print unit is inactive and 2. Cable failure. 2. Make sure that print heads are
Exchange it with a working
does not communicate nor 3. Switch failure. selected from CARGA software.
cable.
print. 4. IP configuration does not 3. Load image again.
3. Change switch port of the
match the gap in the bar. 4. Replace card by dismantling print
cable, then check again.
head.
4. Configuration.
5. Contact KERAjet support.

1. Ink circuits are open.

2. Ink expiry date.
7. One of the colours is not 3. SRA system is on. 1. May all be ok, please, contact KERAjet
1. Ink circuit failure.
printing. 4. Ink working temperature is support.
correct.
5. Voltage values.

1. Check connectors.
1. Check pump with issue. 1. Check that all input and output
8. One of the main pumps 2. At “Inks”, select ink circuit, empty it and
2. Air is getting into the connectors are correctly
goes off. try to regulate the SRA system.
circuit. installed.
3. Please, contact KERAjet.
3. Broken pump.
4. Replace pump.

1. Print head pressure is 1. Set meniscus pressure from control

9. Ink dropping. 1. Check values.
too positive. panel.

10. Print heads run out of 1.Print head pressure is too 1. Set meniscus pressure from control
1. Check values.
ink. negative. panel.

1. Remove all pressure sensor input

1. Air gets into the system. 1. Check all pipes and pump
pipes (calibrate in open air) and installed
11. Pump system comes to 2. Pressure sensors do not connectors are correctly set and
them back again.
a stop. work correctly. air is not getting into the system.
2. Call KERAjet support.
2. Check sensors’ operation.

1. Chiller.
12. Operator
1. PLC is giving no answer. 2. Transfer liquid recirculation 1. Restart PLC from circuit breaker.
increases/decreases ink
2. Chiller neither heats nor circuits. (Check electric diagram).
temperature of a bar but
cools down. 3. Check valve opening.
there’s no change.
4. Check parameter settings.

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 KERAjet

ISSUE LIKELY REASON SUGGESTION ACTION

1. Clean mirror with tissue. DO NOT use

any solvent.
2. Align emitter and mirror. Do not stare at
1. Laser emitter and mirror the laser beam as it may damage your
1. Dirt or laser alignment.
are misaligned. eyes.
13. The machine does not 2. Locate amplifier at the back of
2. Laser emitter or mirror 3. May the issue not get fixed after
detect any tile. the machine.
have decreased restarting the machine, please, replace
performance. mirror. You may find a spare one in the kit
that came along with the machine.
4. May emitter or mirror decrease
performance, please, replace them.

1. Clean mirror with tissue. DO NOT use

any solvent.
1. Tile is thicker in one the
2. Align emitter and mirror. Do not stare at
areas than maximum
the laser beam as it may damage your
height settings.
1. Dirt or laser alignment. eyes.
14. Maximum height 2. Mirror is dirty or
2. Locate amplifier at the back of 3. May the issue not get fixed after
alarm. misaligned with emitter.
the machine. restarting the machine, please, replace
3. Laser emitter or mirror
mirror. You may find a spare one in the kit
have decreased
that came along with the machine.
performance.
4. May emitter or mirror decrease
performance, please, replace them.

1. From control panel, select 1. From main console access

Inks/Pressures and pumps. Inks/Regulate and press on empty. Once
Meniscus pressure values have this process is finished, press on regulate
1. Ink leakage somewhere to be negative ( concrete values again. Access from main console
15. SRA stop. Stop of the
in the circuit. depend on type of print head). Inks/Pressures to monitor the process.
recirculation and control
2. Failure in any Differential pressure should be May it come to a stop again, please,
system of a circuit.
component of the circuit. around 100 mbar. Values should check that there’s no ink leakage
be steady. somewhere. When purging the circuit, we
Pump %’s, shouldn’t be above suggest opening 2 print head taps when
25% and almost the same. the regulation is being carried out.

1. Sensors are not aligned

and the pump won’t start
1. Check pneumatic actuator 1. Set correctly pneumatic actuator
16. Water in the wiper is unless wiper is detected
position sensors. position sensors.
not working. up.
2. Jets are clogged.
3. Pump is not working.

17. Printing misalignments

1. Printing delays and overlaps have to
are detected when 1. Printing misalignments. 1. Check printing settings.
be set.
printing.

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 KERAjet

Support procedure
May you detect any issue in the machine, please, FOLLOW SUGGESTED STEPS IN THIS TABLE:

STEPS TO BE TAKEN WHERE TO LOOK

1 Try to shorten the issue. Element / System / Symptom

2 Warn the press if the machine is blocked or you need to stop. Compenser / Press gap

Stop the machine from control panel.

3 May any error message appear, please, fix it before pressing on OK (reset).
Control panel
Contact KERAjet in case you’re not sure or you don’t know how to fix the
issure.

4 Turn off the PC (close before all the programs) and switch off the machine.

5 Restart PC and machine.

6 Check whether the issue is still present. Element / System / Symptom

Before calling technical support:

- Try to explain what’s happening in your machine in a short explanation.
- Try to identify accurately what elements or systems might be bringing about
the issue.
Please, write down the following values:
7 - Serial number of the machine, type of print head and printing mode. Read print head data at ConfigCA
- Error message displayed on the control panel.
- Print head temperature and ink systems.
- Chiller temperature.
YOU DO NOT NEED TO OPEN THE HOOD NOR PANELS TO CHECK ALL
THIS DATA, NOR MANIPULATE IN THE TILE ENTRY/OUTPUT.

Direct phone 0034 964 010 150

8 Please, contact KERAjet and report all the data.
Email: sat@kerajet.com

Remote support
KERAjet technical staff can get connected to the machine remotely to control the machine or in case of any event on it.
The Teamviewer remote access and support freeware software is used.
This piece of software is already installed in the PC.
A good quality connection to the internet is required.

15. Noise emissions

In this machine noise emissions come from the electric motors of the colour modules and conveyor, pumps in the circuits
and the gears of the systems. There’s also a pneumatic circuit which moves the wiper, cleaning trays and suction. Electronics
emit typical buzz of any electric equipment.
All these elements emit very low noise, so there’s no need to take any special protection for operators.
The suction system is equipped with a centrifugal fan that has a 74dB(A) noise level when working at 2800 rpm (according
to the manufacturer). Impeller blades are positioned forward, dynamically balanced according to ISO 1940 norm, to reduce
noise and prevent vibrations. Depending on the amount and type of print heads a bigger fan may be installed but with a similar
noise level.
Suction capacity is controlled from a driver that controls fan speed. Usually, it works slower than 2800 rpm so noise emission
is lower than 74 dB(A).
Filtering system must be installed out of the cabinet so noise emissions should be set according to customer’s requirements.
May the customer provide a powerful enough suction installation we might avoid this noise emission.
In the production lines where digital printing machines are installed, there are other louder equipments than KERAjet S7,
such as transportation and material transformation/application machines.
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 KERAjet

16. Waste management

■ Please, follow waste management instructions from the ink supplier.
■ Once the machine will be discarded at the end of its life span, please, follow waste management regulations.
■ This machine can’t be treated as home waste. Handing it on to a regulated and registered waste managing company is
compulsory.
■ For any further information regarding recycling, waste treatment or discarding of this product, please, contact your local
authorities or an authorised dealer.
■ Please, check regulations and laws concerned.

17. Spare parts

17.1. Spare parts involved in operational safety

■ Elements in the machine involved in operator's health and safety are:
- Ink suction system.
- Conveyor covers, one at the front and two at the back.
- Ink “backpack” system electronics cover
- Hood
- Warning sign tags.
- Power supply connector covers.
All these elements are very robust and they shouldn't fail when in operation or misuse.
■ Electric safety equipments in the panels are:
- Redundant safety relay
- Differential circuit breaker to prevent from indirect contacts
- Main switch
- Inductive sensors installed in the doors of the back panels and hood, which inhibit module and clean tray movements when
activated.
- Emergency buttons, three at the front and two at the back, in the inside of the machine, two more and other two for the ink
system.
■ Suggested spare parts:
- Emergency button
- Two proximity sensors
- Warning signal tags

17.2. Suggested spares

Depending on the kind and amount of print heads in the machine you may be interested in a certain amount of spare.
KERAjet technicians will suggest about amount and kind of the following spares.
Apart from those described in Section 2, we'd like to include:

■ Several components:

KJ12452 TRAPPING WARNING TAG

KJ16877 VOLTAGE WARNING TAG 35mmx31mm
KJ16943 PRO BASIC 2 COLOURIMETER
KJ18318 TRANSPARENT POLYAMIDE TUBE PA126 HF 2,5x4
KJ18319 TRANSPARENT POLYAMIDE TUBE PA126 HF 4x6
KJ18320 TRANSPARENT POLYAMIDE TUBE PA126 HF 8x10
KJ18363 TRANSPARENT POLYAMIDE PA126 HF 6x8
KJ18364 TRANSPARENT POLYAMIDE PA126 HF 10x12

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 KERAjet

■ Electric components:

KJ10012 COMPLETE ETHERNET SWITCH 8P

KJ10537 POWER SUPPLY 100 - 240VCA 5VDC 2,8A
KJ10541 PLC MODULE 16 INPUT 24Vc
KJ10574 TEMPERATURE PROBE PT-100
KJ11229 POWER SUPPLY 1000W 21A E:220V S:48V
KJ11857 PLC MODULE ANALOGIC INPUTS
KJ12120 EMERGENCY STOP
KJ12147 PLC MODULE 16 DIGITAL OUTPUTS PNP
KJ12468 CABLE M12 5M
KJ13674 NPN INDUCTIVE SENSOR
KJ14161 SPINDLE SENSOR
KJ14695 CABLE RJ45 STANDARD 2 m GRAY
KJ16799 INFRARED TEMPERATURE SENSOR
KJ16920 FAST INPUT/OUTPUT PLC MODULE
KJ16930 CABLE RJ45 550 mm
KJ16951 CABLE RJ45 GRAY 1,15 mt
KJ17582 CABLE RJ45 5,5 m
KJ17584 CABLE RJ45 7,5 m
KJ17657 SOLID STATE RELAY
KJ17779 PLC CONTROL MODULE
KJ18293 POWER SUPPLY 480W/24V/20A
KJ18528 POWER SUPPLY 24048
KJ19496 SD 05 MULTI TRIGGER BOARD SET
KJ20380 POWER SUPPLY- Reg. 35V
KJ20418 POWER SUPPLY 2000W 42 AMP E:220V S:48V
KJ21820 POWER SUPPLY 2000-24
KJ22833 SG SWITCH

All the elements in this manual might change their location in the machine.
PLEASE, KEEP THIS MANUAL FOR ANY FUTURE ENQUIRY.
ALTERING THIS MANUAL OR ANY PART OF IT IS COMPLETELY PROHIBITED.
KERAjet, S.A.

MS7E. Rev: 200623 54