A TUTORIAL For

CrystalJet CJ6000II series

inkjet printer

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 Table of Contents
1 Features.....................................................................................................................................3
1.1 Appearance ....................................................................................................................3
1.2 Names of parts and functions ........................................................................................4
1.3 Model definition............................................................................................................5
1.4 features ..........................................................................................................................5
1.5 Compatible print heads..................................................................................................6
1.6 Multiple useful functions: ..............................................................................................7
1.6 Multiple useful functions: ..............................................................................................7
2 Installation and calibration........................................................................................................8
2.1 Working space.....................................................................................................................8
2.2 Working environment: ........................................................................................................9
2.3 Power supply.......................................................................................................................9
2.4 Important instructions of using the printer ........................................................................9
2.5 Install the printer...............................................................................................................10
2.6 Software installation .........................................................................................................12
2.7 Calibration .........................................................................................................................13
2.7.1 Connect the print heads to the firing board ..........................................................13
2.7.2 Calibration of the Print heads ................................................................................14
3 Working principles of the printer ............................................................................................20
3.1 Ink supply system ..............................................................................................................20
3.1.1 Ink flow chart .........................................................................................................20
3.1.2 Circuit structure ................................................................................................21
3.2 Heating system.............................................................................................................21
3.3 Positive clean system ........................................................................................................22
4 Introduction of Circuit diagram and Electronic parts..............................................................23
4.1 circuit diagram...................................................................................................................23
4.2 Electronic parts ............................................................................................................24
5 Routine maintenance..............................................................................................................34
5.1 Maintain the print heads..............................................................................................34
5.2 Maintenance of other parts of the printer........................................................................34
5.2.1 Motion system.................................................................................................34
5.2.2 Ink supply system ............................................................................................35
5.2.3 Waste ink collecting system ............................................................................35
5.2.4 Other maintenance .........................................................................................35
5.3 appendix............................................................................................................................35
5.3.1 standard procedure of cleaning the print heads ....................................................35
5.3.1 standard procedure of packing the print heads .....................................................36
6 Troubleshooting ......................................................................................................................38

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 1 Features

1.1 Appearance

Front view

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 1.2 Names of parts and functions

Number Names of parts Function

1 Capping tray To protect the printheads

2 Platen The media is sent out, sliding on the platen. three heaters are
installed inside the platen.

4 Carriage Print heads are installed inside

5 Feed PVC panel To control feed motor movement.

6 Anti-splash board To prevent ink splashing everywhere

7 LCD controlling panel To control the auxiliary functions

8 One key clean button Used to clean the print heads

9 Waste tank ink level To indicate when the waste tank is full.
indicator

10 Take-up PVC panel To control the take-up roller movement

11 Power Switches of drying To turn on/off drying fan(heating fan)

fans

12 Take-up sensor To detect media

13 Take-up roller To furl media

14 drying fan To dry media after printing

15 Main tank ink level To indicate when the main tank is empty.
indicator

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1.3 Model definition

1.4 features

6000 series large-format printers, newly developed by Guangzhou

CrystalJet Company, are equipped with high-quality component

processed with mature technology.

1. High-power AC servo motor and German-made timing belt

secure a very stable and endurable motion system. The structure

of the carriage girder is optimized to be more torsional rigid, and

the straightness of it is much more precise, the lead rail is

upgraded from 20 series to more accurate 30 series to improve

printing accuracy.

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2. One-time molded super-wide aluminum annoy platen ensures

permanent accuracy. With surface of the platform being

processed with Teflon coating, accurate ink adhesion and

levelness of both the printhead and platform is guaranteed, and

printing accuracy is made possible.

3. The pressure of media being evenly absorbed to the platform

was step-less adjustable, this ensures the feeding accuracy of

both high-class thick media and low-cost thin media.

4． Safer low-voltage printhead heating makes printing on fly even

under an unfavorable ambient temperature.

5. More fast drying speed make the increase of print speed

possible.

6. New type anti-splash structure prevents ink from splashing, and

ensures cleanliness and deodorizing of the machine.

1.5 Compatible print heads

The printing speed can reach 100 ㎡/h with 8 pieces of 510_35pl

print heads (printing resolution:240X540dpi 3pass), and 125 ㎡/h

with 8 pieces of 510_60PL heads(printing resolution:240X540dpi

3pass).

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1.6 Multiple useful functions:

1.6 Multiple useful functions:

1. Positive clean function (Single -color positive clean).

2. Voltage of the printheads is self-adjusted by temperature of the

print heads to avoid nozzle clogging.

3. Calibrate the feeding speed and Bi-direction printing

dynamically in the middle of printing.

4. Perfect linear and wave eclosion to improve printing quality.

5. Self -typesetting and reduplicate printing function.

6. Convenient cleaning system is equipped for easy maintenance

of the print heads.

8. Optionally heating fans are provided to dry the printed media

quickly.

9. Indicator to prompt when ink level in the main tanks is too low.

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 2 Installation and calibration

2.1 Working space

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2.2 Working environment:

Don’t Place the machine to a vibration-prone area, don’t place the

machine to a damp, smoky or dusty area. Place it to a location with

Relative humidity 40％～70％RH and ambient temperature 22～

28℃.

2.3 Power supply

Main power：AC 220~240V 50/60HZ (AC110V optional)

Attention：The printer must be grounded well and it is better to equip a

UPS system.

2.4 Important instructions of using the printer

a) Process of starting up the printer: after making sure that main

power is off, Connect the power cable of the printer to a power

plug socket, and then connect the USB cable from the printer to

USB port of the computer. Then turn on the main power, then

the switch the power switch on after making sure that

everything is normal. Process of shutting down the printer is

opposite to the process of starting up. But one thing that need

to be mentioned is, before shutting down the printer, the

carriage should be moved to the capping station so that the

print heads can be capped and protected after the printer is

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 powered off. After powering off the printer, remove the media

from the platen. And clean the platen and other main parts of

the printer.

b)If the printer is not to be used for more than 1 hour, printheads

should be capped so that they can be moisturized to avoid the

nozzles being clogged, this is also economic because it reduces

energy consumption and extends service life of the print heads.

If the machine is not to be used for a long period of time, USB

cable should be unplugged from the computer.

c) Do not move the carriage by hand. Otherwise, it may cause

unexpected damage to the servo motor, Disconnect power

cable for the servo motor driver if you have to do so.

d)Before moving the printer, disconnect all power cables and USB

cable, and fix the carriage on the platform.

e) Keep speakers, mobile phones and other electromagnetic

devices away from the printer.

2.5 Install the printer

1. Release the fixed carriage from the platform

2. Assemble the drying fan frame in the front of the printer.

3. Install main ink tanks loaded with ink, turn on the printer to

supply ink (when ink supply system starts to work the first time,

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 alarm siren of ink shortage will ring one or more times, you

need to press the ink supply reset button to stop the siren and

to start supplying ink again), each time when sub tanks are full,

cut off ink supply, and empty them so as to clears out the

residual flush solution in the whole ink supply system.

4. Connect the printer to a PC with the attached USB cable. And

install the control system, and Run machine total length test

and horz motor test (Refer to the software installation chapter).

5. Install Print heads:

1) Take out the following parts from the spare parts package: ink

tube with

connector, print head, aluminum screw cap, seal ring, tube, print

head data cable.

2) Unpack the print head, take off the cap on the inlet and take out

the seal ring from inside the cap.

3) Thread the end without connector of ink tube through an

aluminum screw, a Seal-ring and screw cap, hold the seal ring, and

pull the tube until the ring get inside the cap and a short length of

tube remains at the end with thread of the cap.

4) Insert the short end of tube into the inlet of the print head and

fasten the fastening two screws in the diagonal direction( Machines

of different model have different way of arraying the print heads,

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See diagram below).

Note: Print head of type SPT255_12/35 should be installed with its

inlet facing inward, while inlet facing outward on Type SPT255-2C

4) Connect the tub- ends of the print heads and the tube-ends from

the sub ink tanks tightly, be careful not to miss the seal ring around

the male connector of the tube-ends from the sub-ink tank.

5) Connect print heads to the firing board with the data cables.

Note: 1.Before connecting the data cable, measure the voltage on

the firing board with a multi-meter, and then compare it to the value

in the control software and the difference between them is no more

than±0.3V.

2 When connecting the data cable of the print head, make sure the

fingers of both ends of the cable are inserted rightly in the sockets

2.6 Software installation

1. Install RIP software and control system (CrystalJet PrintMon).

Note: RIP （A raster image processor (RIP) is a component used in

a printing system which produces a raster image also known as a

bitmap. The bitmap is then sent to a printing device for output. The

input may be a page description in a high-level page description

language such as PostScript, Portable Document Format, XPS or

another bitmap of higher or lower resolution than the output device.

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In the latter case, the RIP applies either smoothing or interpolation

algorithms to the input bitmap to generate the output bitmap.Raster

image processing is the process and the means of turning vector

digital information such as a PostScript file into a high- resolution

raster image. The Common RIP softwares used that are compatible

with CrystalJet printers are Maintop, Photoprint, Postershop,

Ultraprint, Bestcolor, Qprint, etc.

2. Running Machine total length test and horz motor test (Run the

Total machine length test first, then exit the software, and alter the

parameter “Machine Total Steps” in “config” file by reducing its

value by 20 units. Otherwise, you may not pass the next test- “horz

motor test”).

2.7 Calibration

2.7.1 Connect the print heads to the firing board

if only one group of print heads is to be installed, they should be

connected to the groups of ports in the firing board facing inwards,

and the order is K, C, M, Y, LC, LM (from left to right).

After the print heads are well calibrated, they will be

horizontally aligned. And the distance between adjacent color bar

should be one nozzle’s width in a printed color bar, as diagram

shows below:
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2.7.2 Calibration of the Print heads

1)Adjust the height of the print heads: Adjust the height of the

print heads tray from the platform to 2-5mm depends on the

thickness of the media.

2)Input the rated voltage of every printhead in the control system.

3)Calibrate the print heads.

Calibrate the horizontality of the print heads

Print State pattern to calibrate horizontal alignment of print heads

All other print head need to be aligned with color-K print head so that they are
in the same horizontal level of color-K print head. In order to do so, firstly,
check lines of different colors, if they are below the horizontal level of K lines,
then you need to move the line up, and this means that you need move the
print heads inwards, vice versa.
To move the print heads, you should loosen the screws first and then adjust
the print head by hand. Just like the pictures shown below.

The M lines need to be

14 moved up
 Move the print head inwards

Loosen screws

After calibration

Calibrate verticality of the print heads

Print HVert pattern to calibrate verticality of the print heads to the
feeding direction.

To get a Hvert pattern, the printer will print two passes of image, each pass of
image has lines of all colors, to verify the verticality of the print heads to
feeding direction, you need to check if line in the second pass are in the same
vertical level with the line of the same color in the first pass, if not, what side it
deflects, if it deflects right, then the line need to move left, which means you
need to move the outer end of the print head left( or move the inner end of the
print right). Like pictures shown below:

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 Comparing
to line in the first
pass, C line in the
second pass
deflects left, so It
needs to move
right.

Move the outer end of the print head left

Calibrate same color parameter (When there is 2 groups of print heads

or more.)

Print a SamClr pattern, Calibrate parameters of same color

according the pattern.

Diagram bellow shows how to calibrate parameters of same color of the

printer with array of 4 colors, 8 staggered print heads.

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 For example, in the pattern above, there are 2 rows of black

double-lines printed by two different printheads with the same black

color ink. To calibrate the same color parameter so they can be

coordinated to work together, the lines from different rows need to be in

the same vertical level at the position of “o”. ]To align them, we need

to check to see at which position lines from different rows are in the

same vertical level if not at “o” position, use this position value(mind

positive or negative) as a correction value, and then set the correction

value in the corresponding pane in Same Color Param Setting area, The

same color calibration is for 2 or more groups of print heads.

K C M Y

K C M Y

Calibrate color registration

Print DiffClr pattern to calibrate color registration
Calibrate color registration to make different colors can be mixed at every dot
to achieve perfect color tone.
DiffClr pattern is a chart of black background with boxes filled with different
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colors. What you need to get is a chart with box “0” in every color row full of
the respective color, firstly check which box in each row is full of color, then
use the corresponding spinner controls in Diff Color Param Setting area to
decrease or increase the value that the box marked with (whether to decrease
or increase is decided by the full box is at which side of box “0”.)

Auto adjust by 180dpi：Since

Change the value

Calibrate Bi-Direction printing

Print DouClr pattern to Calibrate Bi-Direction printing.

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 What you need to get is that double- lines of two rows are aligned in same
vertically level, check the two rows of line printed by two different passed of
different direction in the pattern to see which double-line in the under row
aligns with some double-line just in the same vertical level, then use the
spinner controls in double direction adjust area to decrease or increase the
value that the double-line is marked with.
Save/Reset Param the parameters that you have calibrated only takes effect
by press the “Save Param” button, and by pressing “Reset Param” button, the
parameters return to previous ones.

Calibrate feeding speed

Print Vert pattern to calibrate feeding speed.

PASS numbers

Media setting

Before calibrate feeding speed, choose pass numbers (corresponding to

feeding resolution) first. What you need to get in the pattern is that the two
lines from different passes to intersect at “0” point. Check the two lines
intersects at which point first, but use the spinner control in the Vert setting
area to increase or decrease the value that the point marked with.

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 3 Working principles of the printer

3.1 Ink supply system

3.1.1 Ink flow chart

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3.1.2 Circuit structure

3.2 Heating system

The heating system consists of LCD controlling board, three heaters

(pre-heater, print-heater, post-heater), temperature sensors, fuses, LCD

control panel, LCD display. The temperature of the heaters is displayed

on the LCD display, and adjusted by LCD control panel, LCD controlling

board receives feedback signal from the sensors and processes the

instructions and controls the heaters’ work. While the temperature fuses

protects the system from the high temperature damage..

Schematic diagram

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 Components diagram

3.3 Positive clean system

Circuit structure

Schematic diagram

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 4 Introduction of Circuit diagram and Electronic parts

4.1 circuit diagram

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4.2 Electronic parts

1. Power supply box

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2. DC 12v, 35V power supply board

3. Main board

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The mainboard is the brain of printer, It communicate with a computer

installed with a control system by a USB cable connection. The main

board process data and instruction from /feed back to the control system,

including image data signal, servo motor signal, step motor signal, raster

and coder feedback signal as well as photoelectic sensor signal, etc all

data, instruction and feedbacks are exchanged through I/O board with

other electronic parts of the machine.

4 I/O Board

I/O board is an important part for data exchange between the

mainboard and other parts of the printer

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Electronic parts that are related to I/O board:

1) Power supply : 6Pin socket connects to DC12V,DC35V,DC24V.

2) Image signal: 14P long flat cable transmits image signal to firing

board; 16P long flat cable transmits supply power to the firing

board; 18P long flat cable receives raster signal and ink sensor

signal from firing board.

3) Photoelectric sensors signal: the distance between home station

and capping station is the maximum travelling distance of

carriage, while limit switches are used to protect the printer

when photoelectric sensors fails.

4) Servo motor movement signal: servo motor socket connects to

servo motor driver.

5) Step motor movement signal: step motor socket connects to step

motor driver.

6) Limit switches

The working principle of limit switch is shown in diagram below :

7) Photoelectric sensores

The working principle of photoelectric sensor is shows below:

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 8) . You can use the jumpers on the I/O board to switch between

two different raster to be used: the Raster inside(AC servo motor)

and Raster outside, this is only effective when the printer is

equipped with a AC servo motor system, and usually the factory

default setting is Raster outside.

8) indicating light

Normally, There are 5 lights that always lights on ,they are DC 5V

light,DC 24V light ,DC 35V light , home station photoelectric sensor

light and capping station sensor light, if the sensor is blocked, the

corresponding light goes off.

5. LCD heating board

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 1) The brightness of the LCD display can be adjusted by a “LCD

contrast adjusting knob” on the LCD heating board.

(sometimes when you see there is no display on the LCD

display, maybe just because the brightness is too low)

2) Error code: When a error code 005 displays, it means the

positive flush board was not detected, and error code 007

indicats that system fails to detect the feed board.

3) Indicating lights: Normally,DC 5v light and DC 24v light light on,

serial port light is off.

6. Firing board

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 Raster sensor system

When outside raster is to be used, raster sensor(or encoder)

should be connected to the raster seneor port on firing board .

The definition of the 4-pin port is shown in diagram below:

CHB and CHA are signal channels, while VCC is for DC +5V power

supply , and GND means grounding wire.

7. Ink supply board

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 1. The maximum time that the ink pumps keep working at one

time is 30 seconds even when the sub ink tanks have not been

fully filled with ink. When this sitution happens, the siren on

the ink supply board keeps ringing to give the alarm, and

press ink supply reset button to stop the alarm and ink supply

will start again if nothing goes wrong.

2. Alarm on startup is for the air tank.

3. Normally, only the 5V light lights on. when certain sub tanks

lack ink, the corresponding lights light up indicating ink supply

is ongoing.

8. Media feeding board

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Normally, only the 12V light is on, and 5V light lights up only when

media motor is working.

9. Media take-up board

1. Normally, only DC12V light is on, and DC 5V led light lights up

when the take-up motor is working.

10. Positive cleaning board

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 11. Ink pump adapter board

Carriage led board

Carriage led board

Main tank board

12．Clean lighting board &Main tank ink level indicator board &

Carriage led board

Ink level indicator board

Clean lighting board Carriage led board

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 5 Routine maintenance

5.1 Maintain the print heads

Because solvent ink volatilize quickly, print heads can be clogged when
stopping printing for a period of time. So correctly maintaining the print heads
is very important:
1. Always keep the carriage staying at the home station with printer
powered on if stopping printing for a short period and keep the carriage
capped by capping tray while powering off ( capping only protects the
heads for 24 hours)
2. If the printer is not to be used for a long period (more than 3 days), the
print heads should be dismantled from the carriage and cleaning
manually by using a syringe and cleaning solution, solution remained in
the print head should be cleared out completely, then wrap it well with a
food wrapping film and store safely.
3. If the printer is not to be used for a period between 1-3 days, clean the
print heads by one-key cleaning function, and move to capping station
to cap them with the capping tray.
4. When the printing quality is obviously dropping down and can’t be
improved by any other means, you should clean the print heads.
5. Maintain print heads regularly.
Cleaning light board

5.2 Maintenance of other parts of the printer

There are other parts of the printer need periodic maintenance.

5.2.1 Motion system
Parts of motion system need periodic maintenance include: lead rail, timing
pulleys, raster ruler, towline, timing belts, gears.
1. Lead rail should be cleaned and lubricated by special gear oil weekly.
2. Timing pulleys, timing belt, gears should be lubricated and maintained
every two weeks.
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3. Raster ruler is very important for positioning of carriage movement, a
blemished raster ruler affects print quality or even causes scrambled image.
Use non-woven cloth or cotton moistened by alcohol to clean the raster
weekly)
4. Towline protects ink tubes and data cable while it’s in high speed
movement. If it is derailed or skewed, the ink supply and data transmission
will be affected. Check the towline every two weeks.
5.2.2 Ink supply system
Ink supply system is vital for printing. If there is malfunction in this system,
printing can’t continue.
Check the whole ink supply system weekly to see if every tube joint is well
connected, if there are leaks in the ink tubes.
Change ink-filters every 3 months and clean the whole ink supply system
every 3 months
5.2.3 Waste ink collecting system
Clean the spittoons, anti-splash board regularly, empty waste ink tanks and
dispose waste ink regularly.
5.2.4 Other maintenance
Clean the platen, shell, and machine body every day. Wipe off dust on the
circuit boards and other electronic parts regularly.

5.3 appendix

5.3.1 standard procedure of cleaning the print heads

1. Before cleanig, prepare a glass syringe, 1 leters of cleaning solution,

a filter, some short φ6 ink tube, a waste ink container, a PE cup.

2. Use a syringe to take in 30ml cleaning

solution, connect its orifice to a filter (note
the direction), and then expel the solution
into the print head slowly. The residual ink in
the ink discharge passage and the nozzles of
the print head will be clear out with the
cleaning solution little by little.
3. While injecting the solution into the print
head, be careful not to apply a force over
35
 50kPa, just enough force to make the solution jetting out to form
smooth streams like a waterfall.

4. Keep injecting till 1-3ml solution remains

inside the syringe, remove the filter, directly
connect the orifice of the syringe to the print
head, and then draw back the ink from the
print head. Disconnect the syringe from the
print head, discharge the waste ink and clean
it.
Repeat step 2-4 several times, until the
solution discharged from the print head is
clean and clear.
5. Use an empty syringe to inject air into the
print head, expel the residual solution
inside as cleanly as possible.
6. After cleaning, Use non-woven cloth to clean and dry the print
head completely, but avoiding scratching the nozzles.

5.3.1 standard procedure of packing the print heads

Step 1 Step 2

cap
PE-film

Seal the inlet of the print head with Cut a piece of PE-film to the size of
the cap, don’t missing the seal ring. 30cmx30cm
inside

Step 3 Step 4

Make it no air
bubble and wrinkle

Cover the protection plate of the Press the PE-film gently to make it
36
printhead with PE-film. spread smoothly and air-freely on
the protection plate.
 Step 5
Step 6

Rubber
cushion
Wrap the printhead with the PE
film. Cap it with the attached
Step 7 Step 8 rubber cushion.

Put printhead into the Put it into the carton box

shockproof box

37
 6 Troubleshooting

problems Possible causes

1. Emergency button is pressed down.

2. Cables connecting limit switches are
short-circuited.
3. Malfunction in the I/O board.
The carriage doesn’t return to home station
4. Malfunction in the main board.
after powering on the machine.
5. Photoelectric sensor at the home
station fails
6. Power supply error to servo-motor.
7. Malfunction in the servo-motor driver.

1. Photoelectric sensor at the home

station fails.
The carriage moves to capping station (left) 2. Signal cable for servo-motor driver
after powering on the machine. failure( positive pole was mistaken for
negative pole)

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 1. USB port cable fails
2. USB drivers are not installed in the
computer
Carriage return to home station while printer
3. Printer drives are not installed.
can’t establish communication with the
4. USB port fails in the main board of
computer
computer
5. Malfunction in the printer’s main
board

1. Check if there is Ink in the sub-tank first.

2. The corresponding magnetic valve fails.
3. Leak in the air tube from the
corresponding valve to the sub tank
Ink of certain color doesn’t jetting out when
4. Malfunction in the air pump.
use Positive flush function.
5. Malfunction in the positive flush board.
6. Malfunction in the LCD heating board.
7. Cable connecting the LCD heating board
and positive-flush board breaks off.

1. Calibrate the horizontality of the print

heads correctly.
2. Calibrate feeding speed correctly.
3. Adjust the pressurizing force of the pinch
roller
4. Adjust the sucking force of the vacuum fan
Media feeding is not accurate 5. Adjust the straightness of the feed spindle.
6. Adjust the tightness of the step timing
belt.
7. Calibrate the parallelism of the carriage
girder to the feed spindle
8. Change malfunctioning step motor

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 1. Make sure the problem is not in the ink
supply system( full ink in the sub tank and
doesn’t spill out
2. Clean print head tray and protection plate
of the print heads, and make sure the floss
of the media doesn’t touch the print head
Frequent discontinuity of ink jetting during printing.
3. Adjust working voltage of the print heads
4. Adjust ink level ( height of the sub tanks)
5. Check the working voltage.
6. Avoid using the printer under a turbulent
environmental condition.
7 Change the firing board.

1. Make sure that the printer can pass

“machine total length” test and “Horz
motor” test.
2. Update USB drivers.
3. Use recommended computer hardware.
And reinstall operating system for the
computer.
Printer halts
4. Make sure that the printer and computer is
well grounded
5. USB cable error.
6. Malfunction in Main board of the printer
7. Long flat data cable fails
8 Avoid electromagnetic interference from
other large-power electric equipment.

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 1. Make sure that the printer can pass
“machine total length” test and “Horz
motor” test.
2. Update USB drivers.
3. Use recommended computer hardware.
And reinstall operating system for the
computer.
4. Make sure that the printer and computer is
Scrambled images well grounded
5. USB cable error.
6. Malfunction in Main board of the printer
7. Long flat data cable fails
8. Malfunction in the firing board.
9. Raster sensor malfunction.
10. Raster malfunction
11. Data cable for print head.
12. Interference from feed motor.

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