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MUTOH Zephyr TS User Manual Download Page 253

User’s Guide Zephyr TS

Troubleshooting

AP-75390 - Revision 1.0

253

8

Chapter 8  Troubleshooting

Nozzle recovery procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255

UV lamp alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258

How to analyse the pattern. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  261

Verifying the heads  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262

Headslant adjustment procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  262

Front and back adjustment procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  264

Procedure test print 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  264

procedure test print 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  267

Uni-directional adjustment procedure  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  269

Basic adjustment  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  269

Fine adjustment  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  273

Bi-directional adjustment procedure  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  278

Basic adjustment  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  278

Fine adjustment  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  282

Error messages  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287

Internal hardware error  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  287

Internal software error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  287

Internal hardware / software error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  287

Dongle related error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  287

Invalid dongle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  287

Dongle failed to communicate or initialize  . . . . . . . . . . . . . . . . . . . . . . .  287

No card reader found . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  288

No dongle detected  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  288

Print engine software error / Print swathe timeout error  . . . . . . . . . . . . . . . .  288

Emergency stop / emergency switch related errors. . . . . . . . . . . . . . . . . . . .  288

Water level error  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  288

UV related errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  289

UV left / right lamp extinguished during operation . . . . . . . . . . . . . . . . .  289

UV cassette out  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  289

Summary of Contents for Zephyr TS

Page 1: ...User s Guide Zephyr TS Preliminary ...

Page 2: ......

Page 3: ...nd are an addition to the terms of Mutoh s Microsoft OEM Customer License Agreement for Embedded Systems Agreement Capitalized terms used below and not otherwise defined have the meaning set forth in the general terms and conditions of the agreement These applicable additional licensing provisions shall supersede any inconsistent terms contained in the general terms and conditions of the agreement...

Page 4: ...3 B 8400 Oostende BELGIUM www mutoh eu IMPORTANT NOTICE Trademarks mentioned in this guide Mutoh Zephyr TS are registered trademarks or product names of Mutoh Europe nv Windows95 Windows98 Windows NT4 0 Windows2000 Windows XP and MS DOS are registered trademarks or product names of Microsoft Corporation Other company and product names may be registered trademarks or product names Note The product ...

Page 5: ...s 16 1 5 Safety instructions 16 1 6 Safety labels 18 Chapter 2 Zephyr TS documentation 21 2 1 Working with the User s Guide 21 2 2 Working with the help file 22 Chapter 3 Product overview 25 3 1 Front view 26 Detailed picture of the emergency stop and light switch 28 3 2 Rear view 29 3 3 Using the footpedal 30 3 4 Installation environment 31 Environmental requirements 31 Dust free state 31 Network...

Page 6: ... 53 Maintenance tab 54 Media control tab 54 Calibration tab 55 Ink tab 55 Statistics tab 56 Setup tab 57 Non assigned tabs 58 Status bar 59 4 5 Loading media 61 Loading roll media 62 Loading sheet or rigid media 70 4 6 Unloading media 78 4 7 Feeding media 79 Feeding media forwards backwards by step 79 Feeding media continuously forward backward 80 Return to the print position 81 4 8 Unwinding and ...

Page 7: ...ing the job properties 126 Adding copies in the print pool 134 Deleting print jobs from the job pool 135 Deleting print jobs from the job pool when done 136 Working with the autopilot 137 Adding items to the print queue 138 Adding copies in the print queue 140 Setting the print job sequence 141 Aborting copies 144 Pausing the current print job 146 Pausing the print queue 148 Removing items from th...

Page 8: ... input settings 172 Keyboard preference 173 Mouse settings 175 Time and date 176 Creating and restoring a parameter backup 177 Enabling disabling the confirmation dialogue on startup 179 5 3 Network setup 180 TCP IP setup 182 Vnc server 183 5 4 Making job management settings 184 Autopilot priority settings 185 Engine settings 188 5 5 Media setup 190 Media settings 192 Last loaded media 199 Clippin...

Page 9: ...ance 235 Bi weekly maintenance 241 Monthly maintenance 244 7 2 Done by an Authorized Mutoh Technician 251 Chapter 8 Troubleshooting 253 8 1 Nozzle recovery procedure 255 8 2 UV lamp alignment 258 8 3 Verifying the heads 262 Headslant adjustment procedure 262 Front and back adjustment procedure 264 Uni directional adjustment procedure 269 Bi directional adjustment procedure 278 8 4 Error messages 2...

Page 10: ... 1 0 19 2 10 Print engine software error Print swathe timeout error 288 Emergency stop emergency switch related errors 288 Water level error 288 UV related errors 289 Print head control system error 290 Chapter 9 List of keyboard short cuts 291 ...

Page 11: ...ative or the person placing the product on the market or putting it into service ensures that the item meets all the essential requirements of all applicable EU directives and that the applicable conformity assessment procedures have been applied Your product is designed and manufactured with high quality materials and components which can be recycled and reused When this crossed out wheeled bin s...

Page 12: ... the quality and safety of the machine FCC This equipment has been tested and found to comply with the limits for a Class A digital device pursuant to Part 15 of the FCC Rules These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment This equipment generates uses and can radiate radio frequency energy and if n...

Page 13: ... time exposure Always ensure that gloves are free from defects and that they are stored and used correctly Exact breakthrough time has to be obtained from the manufacturer of the gloves Wash hands after removal of gloves Eye protection Wear UV suitable safety glasses Avoid contact lenses Body protection Wear protective work clothing with long sleeves disposable overalls are preferable Immediately ...

Page 14: ...pair expenses will have to be paid by the customer For handling waste see section 13 on the MSDS sheet Recommendation dispose of product according to federal state provincial and local regulations Do not store ink waste in direct sunlight to prevent the ink from curing Waste tank has to be opaque preferably black Never fill the waste tank completely because of possible swelling due to curing Leave...

Page 15: ...on make sure that the quartz surface is clean Use a damp cloth if necessary with a small amount of isopropanol to degrease the quartz surface Never touch the quartz surface with bare hands This can cause changes in the spectrum of the lamp Mercury The UV lamp contains a small amount of mercury which is toxic when inhaled or ingested If a cold lamp is broken carefully clean up the spill with sulphu...

Page 16: ...e shared by other electrical devices Be sure to insert the power plug completely into the power source It is recommended to use the provided power cable If another power cable is used make sure that it fulfils the specifications set by Mutoh Europe nv To prevent fire or electrical shocks follow the instructions below when handling the power cable Do not cut or modify the cable Do not put heavy obj...

Page 17: ...power cord and contact your local Mutoh dealer Be sure to power OFF the printer and unplug the power cable from the outlet before cleaning the printer Use a damp cloth to clean the printer Do not use thinner benzene alcohol or other active agents Doing so may result in damage or paint peeling from the casing Do not tilt the printer when it is loaded with ink Doing so may cause ink to leak inside t...

Page 18: ...printer This means that the printer is equipped with UV lights Ultra Violet light will lead to damage of the eyes when staring into it Make sure to wear proper protection glasses The disposal materials of the Zephyr TS are harmful to the environment For more information about disposal please refer to section 13 on the MSDS sheet Informs that the area can be very hot Be careful not to burn your han...

Page 19: ...t is harmful to you Wear proper protection to prevent injuries Always wear gloves when performing actions in this area Always wear safety goggles when performing actions in this area Label Description Caution This unit has two power supply cords To reduce the risk of electrical shock Disconnect both power supply cords Before servicing ...

Page 20: ...User s Guide Zephyr TS Safety instructions 20 AP 75390 Revision 1 0 ...

Page 21: ...11 with the left mouse button and you will jump back to the first chapter of this manual called Safety Instructions Depending on your type of PDF reader and your settings you will see an extra window called Bookmarks Another feature in this manual is the interactive index The index works in the same way as a link Search for a specific word click on the page number and you automatically jump to the...

Page 22: ...only find the main chapters with a sign by their side Click on the sign to open the bookmark and show all sub chapters Scroll through them and click on a bookmark to jump immediately to the corresponding chapter If you search for a specific word use the Index tab There are two methods of working with the index The first method is scrolling through the list Double click on the item to jump to the c...

Page 23: ... and click the add tab This topic is now added to your favourites Click on the remove or display button to remove or display your favourite topic To easily read the help file page per page you can use the forward and backward buttons Pressing these buttons will automatically put you through to the next or previous page When clicking multiple links for more information you can go back to your main ...

Page 24: ...User s Guide Zephyr TS Zephyr TS documentation 24 AP 75390 Revision 1 0 ...

Page 25: ... view 26 Detailed picture of the emergency stop and light switch 28 Rear view 29 Using the footpedal 30 Installation environment 31 Environmental requirements 31 Recommended environment 31 Variation rate 31 Storage environment of ink 31 Dust free state 31 Network requirements 32 Printer dimensions 33 ...

Page 26: ...rt chip Refer to Refilling the ink on page 156 3 Keyboard and mouse The keyboard and mouse are used to interact with the User Interface 4 Monitor The monitor displays all necessary information to operate the Zephyr TS 5 Emergency stop Light switch If a situation requires an immediate shutdown of all printer activities push the emergency stop without hesitation Refer to Emergency Shutdown on page 4...

Page 27: ... by overload or short circuit 11 Connector front right foot pedal Connector front winder One of the four connection points to connect the foot pedal Connection point to connect the front winder 12 Service cover Access to PC and UV unit This cover is for service technicians only 13 Winder 100 To wind or unwind roll media up to 100 kg 14 Connector front left foot pedal One of the four connection poi...

Page 28: ...etailed picture of the emergency stop and light switch N Description 1 To switch ON or OFF the Zephyr TS light system 2 If a situation requires an immediate shutdown of all printer activities push the emergency stop without hesitation Refer to Emergency Shutdown on page 48 ...

Page 29: ... purification Refer to the Zephyr TS Installation Guide and the APS User s Guide 2 Ink supply cover Access to ink bottles degasser pump and ink temperature regulator 3 Service cover Access to ink filters For service technicians only 4 Connector rear left foot pedal Connection point to connect the foot pedal 5 Unwinder To wind or unwind roll media up to 100 kg 6 Heater plate Supports and heats the ...

Page 30: ...starts a different operation Use pedal 1 to feed the media backwards Refer to Feeding media continuously forward backward on page 80 Use pedal 2 to feed the media forward Refer to Feeding media continuously forward backward on page 80 Use pedal 3 to load or unload media Refer to Loading media on page 61 Refer to Unloading media on page 78 ...

Page 31: ...llowing conditions Recommended environment Temperature 18 C to 30 C Humidity RH 40 to 65 non condensing Variation rate Temperature 2 C per hour Humidity RH 5 per hour Storage environment of ink Temperature 5 C to 35 C 3 4 2 Dust free state The area where installing the printer must be reasonably free of dust and other airborne particles Do not place the printer in a carpeted area or where using sa...

Page 32: ...to the customer s network The printer s network interface is capable of GigaBit transfer speeds but will also communicate with a 100 1000 Base T network It is strongly recommended to connect the RIP directly to the network connect the printer directly to the network The network connection between rip and network and printer and network Ethernet Gbit Category 5E GBit or higher It is strongly recomm...

Page 33: ...ottles Installing the optional rigid printing tables and or APS Maintenance done by the end user or an authorized Mutoh technician We recommend a minimum area of 6 m x 5 m 1 2 3 4 5 6 N Description 1 Zephyr TS UV Printer 2 Inlet power cable 3 Outlet for Air Purification System with diameter of 150 mm 4 Front rigid printing table OPTIONAL 5 Rear rigid printing table OPTIONAL 6 Air Purification Syst...

Page 34: ...User s Guide Zephyr TS Product overview 34 AP 75390 Revision 1 0 ...

Page 35: ...Interface 53 Job management tab 53 Maintenance tab 54 Media control tab 54 Calibration tab 55 Ink tab 55 Statistics tab 56 Setup tab 57 Non assigned tabs 58 Status bar 59 Loading media 61 Loading roll media 62 Loading sheet or rigid media 70 Aligning the rigid media using the alignment pin 75 Aligning the rigid media using the guiding profile 76 Unloading media 78 Feeding media 79 Feeding media fo...

Page 36: ...d media 89 Changing media details 91 Media control settings 92 Vacuum settings 92 Tensioning settings 93 Lever pressure settings 96 Preparations before printing 97 Using the media retainers 97 Checking the temperature and pressure settings 99 Performing a nozzle check 101 Using the calibration tab 102 Using the maintenance tab 104 Set the correct distance adjust step 106 How to determine and chang...

Page 37: ...e 136 Working with the autopilot 137 Adding items to the print queue 138 Adding copies in the print queue 140 Setting the print job sequence 141 When not working with the autopilot function 141 When working with the autopilot function 142 Aborting copies 144 Pausing the current print job 146 Pausing the print queue 148 Removing items from the job queue 149 Remove 1 item 149 Remove all items 150 Ch...

Page 38: ... Verifying the chip volume 159 Ink refill 160 Working with Mutoh s Smartchip management system 162 Transportation 165 Short distance transportation 165 Medium distance transportation for short term 165 Medium Long distance transportation for long term 166 ...

Page 39: ...e 224 Step 4 Load media Loading media on page 61 Step 5 Perform a nozzle check Performing a nozzle check on page 101 Step 6 Perform a distance adjust Set the correct distance adjust step on page 106 Step 7 Send a file from the rip to the printer Importing a file into the job pool on page 118 Step 8 Edit the job properties if necessary Viewing and editing the job properties on page 126 Step 9 Add t...

Page 40: ...44 Emergency Shutdown on page 48 Cleaning the heads on page 224 Cleaning the receiver box on page 232 Checking the temperature and pressure settings on page 99 Heater settings on page 203 Adjusting the throttle on page 242 Performing a nozzle check on page 101 Be sure to read and understand the safety warnings before handling the printer Important If a situation requires an immediate shutdown of a...

Page 41: ... splash you have 3 options ENTER pressing the ENTER key on the keyboard will immediately start up the User interface ESCAPE pressing the ESCAPE key on your keyboard will result in starting up in a windows based environment The User interface will not start up Refer to Starting up from a windows based environment on page 44 Automatic start up If you do not touch the enter or the escape key the prin...

Page 42: ...e the heater settings This way you can immediately start printing once the time has passed Refer to Heater settings on page 203 Step 8 The initialization of the printer is complete once the monitor displays the Zephyr TS User Interface Note Make sure the heaters are not operating the complete half hour If heating it so long Feed the media forward before using it This to prevent that media curls le...

Page 43: ... of the receiver box is against the metal buffer Step 12 Verify that the value of the ink system pressure is 52 5 mbar 0 5 Refer to Checking the temperature and pressure settings on page 99 Step 13 Position the media retainers correctly Refer to Using the media retainers on page 97 Step 14 Perform a nozzle check to verify if the nozzles are in good shape Refer to Performing a nozzle check on page ...

Page 44: ...sh While displaying the boot splash you have 3 options Step 3 The User Interface starts up in the same way as when starting up normally Option Description Enter Pressing the ENTER key on the keyboard will immediately start up the User interface Escape Pressing the ESCAPE key on your keyboard will result in starting up in a windows based environment The User interface will not start up and the prin...

Page 45: ...y that all nozzles are available Refer to Performing a nozzle check on page 101 Step 3 In case not all nozzles are available perform a head cleaning Refer to Cleaning the heads on page 224 Step 4 Remove the media Refer to Unloading media on page 78 Step 5 Open the left maintenance cover Step 6 Close the 4 ink valves The ink valves are closed if the handles are horizontal positioned Step 7 Clean ou...

Page 46: ...tdown the complete Zephyr TS Click the Software button to shutdown the software If you choose to shutdown the software you will end up in a Windows based environment Refer to Starting up from a windows based environment on page 44 When powering OFF the printer a new window appears This window shows you the progress of the UV lights cooling down and asks if you did close the ink valves ...

Page 47: ...ed at the right bottom side of the printer Step 10 Switch OFF all optional devices such as Air Purification Systems Note It is very important to let the UV lamps cool down before switching OFF the power switch If you do switch OFF the printer before the UV lamps cooled down the life time of the UV lamp will drastically decrease O F F ON ...

Page 48: ...s all necessary actions when an emergency occurs Step 1 Push the emergency stop located on the right side of the Zephyr TS Be sure to read and understand the safety warnings before handling the printer Important If a situation requires an immediate shutdown of all printer activities push the emergency stop without hesitation Caution All printer operations will stop immediately The shutters close s...

Page 49: ...tion panel displays an error click OK to try to re initialize the software If the re initialization does not work minimize the User Interface to see the desktop In the task bar right click on the tray icon and choose KillAll Step 5 Restart the software If the operation panel displays an error shut down the printer Refer to Switching the power OFF on page 45 Step 6 Leave the printer for 1 minute be...

Page 50: ...er OFF on page 45 Step 1 Switch OFF the power switch of the Zephyr TS Refer to Switching the power OFF on page 45 Step 2 Open the left maintenance cover Be sure to read and understand the safety warnings before handling the printer Caution When an emergency occurs place the emergency capping to prevent that ink cures into the print head O F F ON ...

Page 51: ...to prevent ink leaks The ink valves are closed if the handles are horizontally positioned Step 4 Take the emergency capping in the middle and push the spring downwards Note In case the carriage stands over the print platform open the front cover and move it to the left side of the printer ...

Page 52: ... Guide Zephyr TS Basics 52 AP 75390 Revision 1 0 Step 5 Slide the emergency capping over the receiver box guidance Step 6 Release the emergency capping spring The emergency capping is now protecting the heads ...

Page 53: ...ation concerning the printer Below you will find an overview of the different tabs and the corresponding procedures 4 4 1 Job management tab Use the job management tab to Import a picture into the job pool Importing a file into the job pool on page 118 View and edit job properties Viewing and editing the job properties on page 126 Delete a picture in the job pool Deleting print jobs from the job p...

Page 54: ...head purge Cleaning the heads on page 224 Perform a nozzle check Performing a nozzle check on page 101 4 4 3 Media control tab Use the media control tab to Load media Loading media on page 61 Unload media Unloading media on page 78 Feed media Feeding media on page 79 Set the media settings Media Settings on page 85 ...

Page 55: ...djustment procedure on page 262 Check the front and back alignment Front and back adjustment procedure on page 264 Making settings to print on of rigids Unloading media on page 78 4 4 5 Ink tab Use the ink tab to Load ink Refilling the ink on page 156 Check the ink status Verifying the ink level on page 157 Check the head temperature Checking the temperature and pressure settings on page 99 Check ...

Page 56: ...k on the amount of imported jobs Usage statistics on page 213 Reset the UV lamp counter UV statistics on page 210 Verify the disk space Disk space on page 213 Get feedback on UV statistics UV statistics on page 210 Get feedback on motor statistics Motor statistics on page 212 View the event log Event log on page 214 Get information concerning the serial numbers Information on page 215 Get informat...

Page 57: ...nd date on page 176 Set the mouse settings Mouse settings on page 175 Create or restore a parameter backup Creating and restoring a parameter backup on page 177 Set the network settings Network setup on page 180 Make job management settings Making job management settings on page 184 Set the user preference media settings Media setup on page 190 Set the heater settings Heater setup on page 200 Set ...

Page 58: ...ures you often use For example Nozzle check Performing a nozzle check on page 101 Return to print position Return to the print position on page 81 Abort job Aborting copies on page 144 Pause job Pausing the current print job on page 146 Pausing the print queue on page 148 Load media Loading media on page 61 Unload media Unloading media on page 78 ...

Page 59: ...e brackets 2 Print Status Displays the status of the printer Depending on the status you will get a different message Refer to Checking the print status on page 151 3 Heater Status Displays the status of the heaters C Refer to Heater setup on page 200 4 UV lamp status Displays the current status of the UV lamp Depending on the status you will get a different message Refer to UV setup on page 204 5...

Page 60: ...edia feed forward Feeds the media forward Selectable in each tab except while printing Refer to Feeding media on page 79 Note In case an error occurs an envelope will appear in the status bar Double click the envelope to read the error message In case a cover is open a printer symbol will appear in the status bar This icon will disappear as soon as you close the corresponding cover When importing ...

Page 61: ...ng sheet or rigid media Refer to Loading sheet or rigid media on page 70 Loading roll media Refer to Loading roll media on page 62 Be sure to read and understand the safety warnings before handling the printer Note When not printing for a long period and leaving the Zephyr TS powered ON it is best to unload the media If media stays loaded in the printer the media will become wrinkled ...

Page 62: ...ia on page 79 Using the footpedal on page 30 Using the media retainers on page 97 Step 1 Verify that the printer is ON Refer to Switching the power ON on page 40 Step 2 Open the front cover Be sure to read and understand the safety warnings before handling the printer Important Be sure to read and understand all safety warnings Take appropriate safety measures when working with the Zephyr TS ...

Page 63: ... printable This affects the installation method on the unwinder Step 4 Verify how you want the media to be wound up at the front This affects the installation method on the winder OUTSIDE PRINTABLE MEDIA INSIDE PRINTABLE MEDIA Front Rear Front Rear N Description 1 Roll unit 2 Empty core 3 Front tensioning bar ...

Page 64: ...pecifications before loading roll media Depending on how you want to wind up the media select the correct tensioning settings Step 5 Loosen the handles to move the roll units left and right until the roll media core fits Step 6 Install the media between the two roll units at the back of the machine Metrical Imperial Maximum loading capacity 100 kg 220 lb Maximum media width 1651 mm 65 Inner core d...

Page 65: ...les To do so position the left and right roll unit on the same distance from the 0I0 label Step 8 Tighten the wheel at the side to fix the media core between the 2 roll units Step 9 Feed the media forward with the foot pedal Refer to Using the footpedal on page 30 X Y Note Do not load media before the first or further than the last media pinch roller ...

Page 66: ... Step 11 Go to the front side of the printer Step 12 Install an empty core between the front roll units in the same way as described above Make sure the core is longer than the media width Note Make sure to remove the media retainers These will obstruct the smooth media loading N Description 1 Roll Unit 2 Media roll 3 Rear tensioning bar 4 Print platform and pressure rollers ...

Page 67: ...avigate the User Interface on page 53 Pushing the middle foot pedal Using the footpedal on page 30 The monitor displays the following screen Step 14 Click load media Step 15 If preferred you can set the media name Step 16 Fill in the thickness of the media in the media details window Step 17 Select the checkbox automatic width measurement ...

Page 68: ... Step 22 Close the front cover Step 23 Press the foot pedal while holding the media Refer to Using the footpedal on page 30 The pressure rollers move downwards and the media is loaded Step 24 Feed the media until you are able to stick it to the front core Step 25 Cut the front side of the media into a V shape This to become an equal tension on the media when loaded Step 26 Tighten the media to the...

Page 69: ...ioning rear winder If this is the case add some extra weight to the rear winder for proper functioning Note Before starting a print job make sure to set the correct distance adjust for the loaded media Refer to Set the correct distance adjust step on page 106 In case of working with cockling sensitive or furry media adjust the head gap Refer to Setting the correct head gap on page 114 ...

Page 70: ...power ON on page 40 Step 2 Install the rigid printing tables Refer to Installation Guide rigid printing tables heater Step 3 Open the front cover Be sure to read and understand the safety warnings before handling the printer Note We recommend to work with Mutoh s rigid printing tables when printing on rigid materials Please refer to the installation guide of the rigid printing tables for more info...

Page 71: ...nto the rear table according to the preferred procedure Using the alignment pins and dowels Refer to Aligning the rigid media using the alignment pin on page 75 Using the guiding profile Refer to Aligning the rigid media using the guiding profile on page 76 Step 6 Position the front guidance left and right on top of the media and fix them ...

Page 72: ...t sensor the monitor displays the media control screen Step 10 Click on load media The monitor displays the following screen Step 11 Fill in the thickness of the media in the media details window Note Make sure to keep the media against the two dowels at the back Note In case the edges of the rigid media are slightly curled increase the current thickness with 0 2 mm This to prevent head strikes ...

Page 73: ...ase select cutsheet rigid Step 14 Fill in the media settings in the media details window Step 15 Set the media control settings as preferred Refer to Media control settings on page 92 Step 16 Open the front cover and lift up the front alignment sensor Step 17 Close the front cover Note In case you prefer to measure the media manually you need to fill in all settings ...

Page 74: ... your rigid media Unloading media on page 78 The media loading procedure is finished Note Before starting a print job make sure to set the correct distance adjust for the loaded media Refer to Set the correct distance adjust step on page 106 In case of working with cockling sensitive or furry media adjust the head gap Refer to Setting the correct head gap on page 114 Note In case of using the alig...

Page 75: ...nment pin as far as possible This to align the media in the best possible way Determine if you need to use only the alignment pin or the extra dowels as well Load the media against the alignment pins in case half of a pinch roller is not on the media use the dowels 1 2 1 2 1 2 N Description 1 Rigid media 2 Pressure rollers ...

Page 76: ...er s Guide Zephyr TS Basics 76 AP 75390 Revision 1 0 Aligning the rigid media using the guiding profile In case you prefer to work with the guiding profile load the guiding profile onto the alignment pins ...

Page 77: ...User s Guide Zephyr TS Basics AP 75390 Revision 1 0 77 4 Step 1 Load the rigid media against the guiding profile ...

Page 78: ...ON on page 40 Step 2 Open the media control tab by Clicking the media control tab Pushing the middle foot pedal Using the footpedal on page 30 The monitor displays the following screen Step 3 Click on Unload media Step 4 The pressure rollers will raise Step 5 Feed the media backwards with the foot pedal to roll it up to the core Refer to Feeding media on page 79 Step 6 Unload the media Step 7 Stor...

Page 79: ...ge 151 Loading media on page 61 Step 1 Verify that The printer is currently not operating Refer to Checking the print status on page 151 The media is properly loaded Refer to Loading media on page 61 Step 2 Click the media control tab The media control window opens Step 3 Fill in the distance you want to feed the media in the media feed window Step 4 Each time you click the Forward or Backward key...

Page 80: ...o Using the media tab on page 80 Using the status bar at the bottom of the User Interface Refer to Using the status bar on page 81 Using the media tab If you are using the media control tab proceed as follows Step 1 Verify that The printer is currently not operating Refer to Checking the print status on page 151 The media is properly loaded Refer to Loading media on page 61 Step 2 Click the media ...

Page 81: ... so make sure that The media is properly loaded Loading media on page 61 The printer is currently not operating Checking the print status on page 151 4 7 3 Return to the print position As soon as you click this button the media goes to the position where the printer stopped printing There are several options to return the media to the print position Using the foot pedal Refer to Using the footpeda...

Page 82: ...fy that The printer is currently not operating Refer to Checking the print status on page 151 The media is properly loaded Refer to Loading media on page 61 Step 2 Click the media control tab The media control window opens Step 3 Click return to print position to feed the media to the print position Using the status bar Click Return to print position in the statusbar to return the media to its pri...

Page 83: ...e it is no longer loaded in the printer Please follow the procedure below for more information Step 1 Click media control The media control window opens Step 2 Click Unload media The media tensioning control is now available Depending on which media core you want to control click the correct button Note Another method is operating the foot pedals Refer to Using the footpedal on page 30 ...

Page 84: ... passes the B heater Step 3 Open the front cover Step 4 Place the Mutoh paper cutter to the frontside of the B heater and cut the roll media 1 2 N Description 1 Mutoh paper cutter 2 B heater Fixer Note When loading new roll media make sure that the front edge of the media is cut straight Note Be aware that cutting the media in combination with the return to print position feature is risky This bec...

Page 85: ...preview settings on page 87 Job preview settings on page 88 Media details on page 89 4 10 1 Preview settings With this menu you can choose either to show or hide the media and job preview settings Step 1 Click the media control tab Step 2 Verify that the media is correctly loaded Refer to Loading media on page 61 Step 3 Click Load media Be sure to read and understand the safety warnings before han...

Page 86: ... In the preview settings window you will make different settings concerning media and job preview settings Refer to Media preview settings on page 87 Refer to Job preview settings on page 88 Note In case this window does not yet appear load media first according to Loading media on page 61 ...

Page 87: ...too large to print on the current media Function Description Show the required media Shows you a preview of the file on the required media Show current media Shows you a preview of the file on the current media Note If you notice a grey zone on the right side of the file It means that the pre ripped width of the file is larger than the width of the current media If this is the case the file will b...

Page 88: ...a settings attached Refer to Media details on page 89 Function Description No Job preview Choose this option if you do not need a preview Show the next job in the queue Shows a preview of the next job in line Show another job If you select the option Show another job you need to browse to the job you prefer To browse to the job you need click on the button at the right side and select the file The...

Page 89: ...ou want to change the pre ripped media settings or when loading sheet media Media details when loading sheets or rigid media Please read this chapter to know what settings you need Step 1 Verify that the media is properly loaded Step 2 Click Load media The media load window opens Be sure to read and understand the safety warnings before handling the printer ...

Page 90: ...ays the media width automatically if measuring the media automatically If measuring the media manually you need to fill it in Requested media If the RIP file contains media information the media width will appear Position Only available when the Automatic width measurement checkbox is not selected Current measured media Displays the media position automatically if measuring the media automatically...

Page 91: ...Browse to select the job you want to print Step 2 If there are contradictions between the required and the current media you will see them in the media details window Step 3 When clicking OK a warning message appears asking if you are sure you want to work with the conflicting media Note Notice in the example above that the current media is smaller than the requested If you do not choose a differe...

Page 92: ...setting to set when the vacuum has to operate Be sure to read and understand the safety warnings before handling the printer Mode Description Always The vacuum will always operate whether there is media loaded or not Never The vacuum will never operate no matter whether there is media loaded or not During print The vacuum will operate as soon as the printer starts printing When media loaded The va...

Page 93: ... to know how to operate the Unw W100 Step 1 In the media control window you are able to make 3 settings concerning the tensioning Use the Mode option to set which winder has to operate Note Another possibility to make these adjustments is via the Setup tab Refer to Media settings on page 192 Mode Description None None of the winders will operate Both Both the winders will operate Front Only the fr...

Page 94: ...nder Mode Description Direction Front Inside Choose this option if you want to wind the printed media inside Direction Front Outside Choose this option if you want to wind the printed media outside Direction Rear Inside Choose this option if you are using inside printable media Direction Rear Outside Choose this option if you are using outside printable media N Description 1 Roll unit 2 Media roll...

Page 95: ...e inside or outside This affects the winding method on the winder N Description 1 Roll unit 2 Empty core 3 Front tensioning bar Note another possibility is via the Setup tab Refer to Media settings on page 192 Note Try to avoid rolling media onto a core with printed media on The media might become wound up improperly ...

Page 96: ... 2 Lower the pressure rollers to activate the lever pressure adjustment Mode Description Low Use this setting for soft media or when the levers leave a mark Normal This should be the standard setting Medium Use this setting for heavy or smooth rigids High Use this setting for really smooth rigids Note As a general rule you can state that when the smoothness and or the weight of the media increases...

Page 97: ...ter is operating Follow the instructions below to use the media retainers Step 1 Verify that the media is loaded properly Refer to Loading media on page 61 Step 2 Open the front cover Step 3 Attach the media retainers to the print platform Step 4 At the bottom side of the print platform fix the media retainer with the spring to the bracket Be sure to read and understand the safety warnings before ...

Page 98: ...User s Guide Zephyr TS Basics 98 AP 75390 Revision 1 0 Step 5 Position the media retainers to both sides of the media Step 6 Close the front cover Note We recommend an overlap of 5 10 mm ...

Page 99: ...e cooling system and how to verify the negative pressure of the system Step 1 Click the Ink tab Step 2 In the categories window click on Ink Be sure to read and understand the safety warnings before handling the printer Note It is very important that the system reaches the correct temperature before printing The printer will not work properly until the water had reached it s correct temperature ...

Page 100: ... of the degasser Note To obtain optimal printing quality the following values need to be reached before starting printing The temperature of the cooling system must be 43 C The temperature of each head must be 43 C The ink system pressure must be 52 5 mbar 0 5 The degasser pressure must be between 800 and 900 mbar The ink sub pressure pump must be 50 5 In case it exceeds refer to Adjusting the thr...

Page 101: ... Loading media on page 61 Cleaning the receiver box on page 232 Nozzle recovery procedure on page 255 Step 1 Verify that the printer is ON Refer to Switching the power ON on page 40 Step 2 Verify that the media is properly loaded Refer to Loading media on page 61 There are 2 possibilities to perform a nozzle check Option 1 is via the calibration tab option 2 is via the maintenance tab Depending on...

Page 102: ... AP 75390 Revision 1 0 Using the calibration tab Step 1 Click the calibration tab Step 2 In the categories window click Nozzle check Step 3 The nozzle check window gives 2 options Printing the blocks nozzle check Step 1 Click on Blocks ...

Page 103: ...are no missing nozzles In case there are irregularities perform a head cleaning Refer to Cleaning the heads on page 224 Printing the Stripes nozzle check Step 1 Click on Stripes Prints the nozzle check stripes pattern 1A 1B 2A 2B 3A 3B 4A 4B 1A 1B 1A 1B Note In case you have performed several nozzle checks and head cleanings and there are still missing nozzles refer to Nozzle recovery procedure on...

Page 104: ...a head cleaning Refer to Cleaning the heads on page 224 Using the maintenance tab Step 1 Click the maintenance tab Step 2 In the Quick launch maintenance window go to the nozzle check section and click on Start now Prints the nozzle check blocks pattern Note In case you have performed several nozzle checks and head cleanings and there are still missing nozzles refer to Nozzle recovery procedure on...

Page 105: ... are no irregularities in the pattern there are no missing nozzles In case there are irregularities perform a head cleaning Refer to Cleaning the heads on page 224 1A 1B 1A 1B Note In case of performing several nozzle checks and head cleanings and there are still missing nozzles refer to Nozzle recovery procedure on page 255 ...

Page 106: ...this feed distance a test pattern called Distance adjust is available in the User Interface Be sure to read and understand the safety warnings before handling the printer Underfeed Overlap Step between the print passes is too small This results in overlapping print passes Which means you have to increase the step value Overfeed Gap Step between the print passes is too large This results in print p...

Page 107: ...40 Step 2 Load the media to print on Refer to Loading media on page 61 Step 3 Perform a nozzle check This to be sure that all nozzles are present and not misfiring If necessary perform a head cleaning Refer to Performing a nozzle check on page 101 Refer to Cleaning the heads on page 224 Step 4 Click the calibration tab Note Make the decision whether or not you will be using the winder 100 before s...

Page 108: ...User s Guide Zephyr TS Basics 108 AP 75390 Revision 1 0 Step 5 In the categories window click Step correction The step correction window opens ...

Page 109: ...S Basics AP 75390 Revision 1 0 109 4 Step 6 Click on Default The test pattern is printed Step 7 Analyse the test print Search where the two arrow heads touch each other correctly 0 2 0 15 0 1 0 05 Current 0 05 0 1 0 15 0 2 ...

Page 110: ...ther correctly check the colour density of the print pattern In case the density of each half circle is equal use the value next to the pattern In case the density of each half circle is not equal fine tune the step adjust pattern To do so look for the turning point where the dark side switches side Reprint the step adjust pattern with a correction value for example 0 12 0 15 0 15 0 1 Note Be awar...

Page 111: ...User s Guide Zephyr TS Basics AP 75390 Revision 1 0 111 4 Step 9 Change the step in the step correction window ...

Page 112: ...ge the step on the fly If you notice while printing there is underfeed or overfeed change the step on the fly Please proceed as follows Step 1 Verify that the printer is printing Step 2 Click the job management tab Step 3 In the categories window click on Print status ...

Page 113: ...alue of the step correction If you notice some overfeed gap decrease the value To adjust the value simply click it with your mouse Note It may take a while before the new step is valid Caution The step adjust you have just made on the fly is only suitable for the current print This means that when making a new print or reprinting the previous file you need to set the correct step adjust before sta...

Page 114: ... Setting the correct head gap When working with cockling sensitive or furry media you need to adjust the head gap in order to avoid head crashes To adjust the head gap proceed as follows Step 1 Click on Calibration Step 2 In the categories window select Alignment ...

Page 115: ...you are working with cockle sensitive or furry materials increase the head gap to avoid head crashes When changing the head gap the Unidirectional and Bidirectional alignment should be redone Refer to Uni directional adjustment procedure on page 269 Refer to Bi directional adjustment procedure on page 278 Note Make sure to perform each alignment before using the new head gap ...

Page 116: ... and backward alignment for a certain head gap click Save A new window opens Step 2 Select the location where you want to store this parameter and click Save Note The advantage of saving the head gap setting is that you do not have to perform the forward and backward alignment each time you change the head gap ...

Page 117: ... Guide Zephyr TS Basics AP 75390 Revision 1 0 117 4 Loading an alignment Step 1 Click Load A new window opens Step 2 Select the preferred head gap setting and press open Step 3 The head gap is now readjusted ...

Page 118: ...Guide Zephyr TS Basics 118 AP 75390 Revision 1 0 4 12 Using the job manager 4 12 1 Importing a file into the job pool Step 1 Click the job management tab Step 2 In the categories window click on Job pool queue ...

Page 119: ...o the Zephyr TS s hard disk via the network before making print calculations It will remain there until it is deleted by the user Advantages of the import by copy Safe the data is always on the printer s hard disk Possibly faster the data is locally available and doesn t has to go over the network or USB again Caution Be aware that the hard disk is divided into 4 partitions Partition 1 C drive has...

Page 120: ... on Import by copy A new window appears Step 2 Browse to the pre ripped file and click Open Step 3 The file is now copied to the Zephyr TS s PC hard drive Note While importing the file an import button appears in the statusbar Click this button to open the import queue ...

Page 121: ...l be accessed remotely via USB or over the network Advantages of the import by link Very fast import into the Zephyr TS s job pool there s actually no direct data transfer Save hard disk space on the Zephyr TS Possible disadvantages Slow networks can result in slower printing Step 1 Click on import by link k A new window appears Caution Be aware that the hard disk is divided into 4 partitions Part...

Page 122: ... The Zephyr TS is foreseen of two USB slots on the front of the PC If you have pre ripped files on a USB stick open the USB stick select the files and drag them into the job pool Note While importing the file an import button appears in the statusbar Click this button to open the import queue Note While importing the file an import button appears in the statusbar Click this button to open the impo...

Page 123: ...mport multiple jobs into the job pool the Zephyr TS will buffer and import them one by one into the jobpool To check the import status proceed as follows Step 1 Click the Job management tab Step 2 In the categories window click on Job pool queue The job pool window appears Step 3 Click on show import queue ...

Page 124: ...ill see all jobs are queued until they are imported into the jobpool Note While in this window you can also import other files by link or copy To do so click on the import by link button or the import by copy button in the title bar Refer to Importing by link on page 121 Refer to Importing by copy on page 119 ...

Page 125: ...pool it can be handy to get a quick preview of these files To get a preview proceed as follows Step 1 Click the Job management tab Step 2 In the categories window click on Job pool queue The job pool window appears Step 3 Next to each job there is a magnifier Position your mouse arrow on top of the magnifier to let the job preview appear ...

Page 126: ...ipped job properties and change them To do so please follow the procedure below Step 1 Click the Job management tab Step 2 In the categories window click on Job pool queue The job pool window appears Step 3 Select the job of which you want to view or edit the job properties Step 4 To view or edit the job properties there are several options Click on View Edit job properties ...

Page 127: ...ob properties Double click the magnifier next to the job The job properties window appears Note As you see in the left side of this window there are two tabs The general tab and the advanced tab Click on each tab to let the different settings appear Refer to General on page 128 Refer to Advanced on page 130 ...

Page 128: ...n this tab you will find an overview of the job details print settings media details and layout editor Details window In the details window you will find an overview of items such as file size dimensions In here you can also change the file name if you would like to ...

Page 129: ...b when done Refer to Working with the autopilot on page 137 Media details window In the media details window you get an overview of the needed media to print this file These settings come with the RIP If you want to use the currently loaded media click Use current If you click Use current a warning message appears asking if you are sure you want to overwrite the media details Note In case you choo...

Page 130: ...e the printout and make offset setting on a specific media Advanced In this tab you will find an overview of the job details print settings media details and layout editor Note As you can see in the example above some settings are faded This is because they are only selectable when working with rigids or sheet media ...

Page 131: ...of the leading lamp and the trailing lamp If you choose the option symmetric the power will be the same in both forward as backward direction Note It is recommended to use the intelligent heater control Note Please note that the leading lamp is the first lamp and the trailing lamp is the second lamp Note Enabling the checkbox will override the UV settings coming from the rip software The UV settin...

Page 132: ...cations such as making glossy prints With the scanwidth option you can set the time between two print passes This is useful to let the ink bleed if wanted or let the temperature of your media decrease When the UV lamp constantly moves over the media the temperature will increase Setting the correct scanwidth It is possible to specify the carriage movement along the media This will have a direct ef...

Page 133: ...tore the default job properties In case you want to restore the default job properties proceed as follows Step 1 Right click on the job of which you want to restore the job properties Step 2 Select Restore the original job properties A new window appears Step 3 Select OK if you want to restore the job properties Step 4 The job properties are now automatically restored to their original properties ...

Page 134: ... print job the amount of copies decreases in the print pool If you wish to increase the total amount of prints in the print pool proceed as follows Step 1 Click the Job management tab Step 2 In the categories window click on Job pool queue Step 3 Select the job of which you want to increase the amount of copies Step 4 Double click on the amount of copies and change the value ...

Page 135: ...Step 1 Click the Job management tab Step 2 In the categories window click on Job pool queue Step 3 Select the job you want to delete from the job pool Step 4 To delete the job there are several options Click the delete button Press the Delete key on your keyboard Right click the job and select delete job ...

Page 136: ...ete the job from the job pool and hard drive 4 12 7 Deleting print jobs from the job pool when done Step 1 Click the Job management tab Step 2 In the job pool select the trash bin checkbox of the print jobs you want to delete when printed Step 3 As soon as you have printed the print file the print file is being deleted from the job pool ...

Page 137: ...d automatically To work with the autopilot proceed as follows Step 1 Click the Job management tab Step 2 In the job pool select the print jobs of which you want to work with the autopilot Step 3 Click the Autopilot mode button The printer imports all selected files in the print queue and prints them according to the autopilot settings Refer to Adding job selection criteria on page 185 Note The pri...

Page 138: ...eral options Please follow the procedure below for correct performance Step 1 Click the Job management tab Step 2 In the categories window click on Job pool queue The job pool window appears Step 3 You have the following options Add one copy of the selected job to the print queue Click the button shown below to add 1 copy to the print queue ...

Page 139: ...eue When selecting this option a new window appears Set the quantity of prints you want to add to the print queue and click OK Add X copies to the front of the queue Click the button shown below to add multiple copies to the front of the print queue When selecting this option a new window appears Set the quantity of prints you want to add to the print queue and click OK ...

Page 140: ...t queue To add a copy follow the procedure below Step 1 Click the Job management tab Step 2 In the categories window click on Job pool queue The job pool window appears Step 3 In the job queue select the print job of which you want more copies Step 4 Click on the copies value and change it ...

Page 141: ...s follows When not working with the autopilot function Step 1 Click the Job management tab Step 2 In the categories window click on Job pool queue The job pool window appears Step 3 Import the preferred print jobs into the print queue Step 4 In the print queue select the job of which you want to change the sequence Step 5 Click on the move up or move down button to change the print job sequence ...

Page 142: ...tion If one of the criteria of your autopilot settings is the priority adjust them as described below Step 1 In the job pool select the job of which you want to change the priority Step 2 Go to the view and edit job properties window Refer to Viewing and editing the job properties on page 126 ...

Page 143: ...neral tab Step 4 In the print settings window click the priority setting with your mouse A drop down menu opens Step 5 Select the priority you want to give to the print job Step 6 Click OK The priority of the job is now changed This is visualized with a different colour of flag ...

Page 144: ... still printing Refer to Checking the print status on page 151 Step 2 Click the Job management tab Step 3 In the categories window click on Job pool queue Step 4 Select the file in the printing queue you want to abort Step 5 Click Abort job Note When aborting a print it might happen that the last passes are not cured yet Do not touch this part with your bare hands and do not dispose them together ...

Page 145: ...option to skip abort the copy retry or pause the copy Option Description Skip The print job is skipped and the next job in line will become active Retry Clicking Retry will result in printing the copy once again Pause The pause key pauses the current print job Be aware that restarting a job after a pause may result in bad printing quality ...

Page 146: ...below Step 1 Verify that the print job is currently printing Refer to Checking the print status on page 151 Step 2 Click the Job management tab Step 3 In the categories window click on Job pool queue Step 4 Select the file in the printing queue you want to pause Step 5 Click Pause job Be sure to read and understand the safety warnings before handling the printer ...

Page 147: ... AP 75390 Revision 1 0 147 4 As soon as you click Pause job a warning message appears Step 6 You have now the option to continue or abort the current copy Note Please note that pausing a print job may result in bad printing quality ...

Page 148: ...g the print status on page 151 Step 2 Click the Job management tab Step 3 In the categories window click on Job pool queue Step 4 Click Pause print queue The Pause print queue button changes into Start print queue Step 5 To restart the print queue Click the Start print queue button Be sure to read and understand the safety warnings before handling the printer Note Pausing the print queue does not ...

Page 149: ...emove 1 item Refer to Remove 1 item on page 149 Remove all items Refer to Remove all items on page 150 Please refer to the corresponding chapter Remove 1 item Step 1 Verify that the print job you want to remove is currently not printing Refer to Checking the print status on page 151 Step 2 Click the Job management tab Step 3 In the categories window click on Job pool queue Step 4 Select the print ...

Page 150: ...removed from the print queue Remove all items Step 1 Verify that no jobs are being printed Refer to Checking the print status on page 151 Step 2 Click the Job management tab Step 3 In the categories window click on Job pool queue Step 4 Click the remove all button All jobs are removed from the print queue ...

Page 151: ...ecked Print job status Copies left Estimated time Average print speed Preview Print job status To check the print job status proceed as follows Step 1 Verify that the printer is printing Refer to Checking the print status on page 151 Step 2 Click the job management tab Step 3 In the categories window click on Print status Be sure to read and understand the safety warnings before handling the print...

Page 152: ...s The print status window is subdivided in different windows Each window will be discussed below Print info window The print info window displays The current status of the printer The passed time Amount of copies left Step correction Refer to How to change the step on the fly on page 112 ...

Page 153: ...ngs Here you have also the possibility to adjust the heater settings Refer to Current heater status on page 202 UV power window This window gives you the possibility to adjust the force of the UV lamps Refer to UV setup on page 204 Preview window The preview window displays the job progress The grey area is the area that still has to be printed ...

Page 154: ...bar Jobs displays how many print jobs are still queued Duration Displays the total required time to print all print jobs Media length Displays the total media length of all print jobs Printed surface Displays the printed surface in m These values are based on the current media or the requested media To switch between these refer to Estimated print duration on page 189 ...

Page 155: ... 1 0 155 4 4 14 Viewing the job action history It is possible to view the history of which job is printed and when Proceed as follows Step 1 Click the job management tab Step 2 In the categories window click on History The print history window opens ...

Page 156: ...uring printing a warning message will appear If this message appears the printer will keep on printing for 12 minutes If there is not enough ink left in the printer when starting a print job the following message will appear If this message appears you need to refill the ink before you can start your print job ...

Page 157: ...ck the ink level via the ink tab or via the statusbar Checking the ink status via the statusbar refer to Status bar on page 59 Checking the ink status via the ink tab please proceed as follows Step 1 Click the ink tab Step 2 In the categories window click on Ink Be sure to read and understand the safety warnings before handling the printer Important If the ink volume reaches the ink near end or th...

Page 158: ...8 AP 75390 Revision 1 0 The ink status window opens Step 3 In this window you can verify the status of the remaining ink If you notice there is not enough ink left you need to refill it to keep printing Refer to Ink refill on page 160 ...

Page 159: ...ab Step 2 In the categories window click on Chip volume The chip volume window opens Step 3 In this window you can verify the status of the remaining ink If you notice there is not enough volume left you need to refill it to keep printing Refer to Working with Mutoh s Smartchip management system on page 162 ...

Page 160: ...the left side of the printer Step 3 Pull out the Bulk Ink System Be sure to read and understand the safety warnings before handling the printer Caution Before using the ink and cleaning bottles be sure to read and understand the MSDS sheets on the MSDS CD delivered with the printer This product is tuned for the use of Mutoh UV bulk ink and cleaning If using other manufacturers products the output ...

Page 161: ...5 Fill the ink bottle with maximum 2 litre ink Use for each bottle another funnel Note It is best to pour a complete UV bottle at once into the ink supply system Important Be sure to fill the bottles with the correct ink colour Please refer to the ink order label attached to the bottle holder ...

Page 162: ...volume to keep printing Tools necessary Procedure Step 1 Click the ink tab Step 2 In the categories window click on Chip volume The following screen appears in the ink volume window Step 3 Click on Load chip volume Be sure to read and understand the safety warnings before handling the printer N Description Qty 1 Smart chip card delivered with the ink 1 colour ...

Page 163: ...Basics AP 75390 Revision 1 0 163 4 The monitor displays the following screen Step 4 Insert the smart chip with the chip side up The monitor displays the following screen Step 5 Click Continue to load ink volume to the printer ...

Page 164: ... Basics 164 AP 75390 Revision 1 0 Step 6 After clicking Continue the procedure to load ink volume will be performed automatically The monitor displays the following screens When the procedure is finished the monitor displays ...

Page 165: ... term moving machines to exhibitions etc Please contact your authorized Mutoh technician when transporting the printer Step 1 Make sure the ink valves are closed Secure the ink valves with tie wraps to avoid that they don t open accidentally during packing and transportation Step 2 Empty and clean the ink waste bin Put fresh paper inside to absorb ink that might drip out from the print heads Step ...

Page 166: ...at the ink bottles are less than half full When there is too much ink it might spill out during transportation Fix the ink bottles caps to avoid falling off during transportation Pack the keyboard table keyboard mouse separately in a protective packaging Packaging the Zephyr TS in the original box is strongly recommended When packing in the original box the printer can be re secured on the pallet ...

Page 167: ...ackup 177 Creating a parameter backup 177 Restore a parameter backup 179 Enabling disabling the confirmation dialogue on startup 179 Network setup 180 TCP IP setup 182 Vnc server 183 Making job management settings 184 Autopilot priority settings 185 Adding job selection criteria 185 Removing job selection criteria 186 Priority of the job selection criteria 186 Streaming 187 Engine settings 188 Pri...

Page 168: ...sioning 194 Lever pressure adjustment 196 Default media settings 197 Last loaded media 199 Clipping margins 199 Media load settings 199 Heater setup 200 Current heater status 202 Heater settings 203 UV setup 204 Status window 205 UV lamps control 205 Default UV power 206 ...

Page 169: ... located at the top of the display there are 3 unassigned tabs These tabs can personalised for procedures you often use To personalise a tab click on the arrow to open the drop down menu You have now created a short cut to a common used procedure To access this procedure click the tab of use the corresponding F key ...

Page 170: ...ce such as selecting a different language setting the time and date changing the keyboard layout creating or restoring parameters To make these settings follow the procedures below Step 1 Click the Setup tab Step 2 In the categories window click on General The general setup window opens In this window you can do the following Changing the language ...

Page 171: ...ettings Refer to Keyboard settings on page 174 Changing the mouse settings Refer to Mouse settings on page 175 Changing the time and date Refer to Time and date on page 176 Creating and restoring a parameter backup Refer to Creating and restoring a parameter backup on page 177 Enabling Disabling the confirmation dialog on startup Refer to Enabling disabling the confirmation dialogue on startup on ...

Page 172: ...ge the language of the User Interface proceed as follows Step 1 In the language and input window select a language via the drop down menu Select the desired language Step 2 Once you select a language click apply As soon as you have selected a new language the user interface will change in the chosen language ...

Page 173: ...To change the regional and language layout proceed as follows Step 1 In the language and input window click adjust near keyboard layout The regional and language options window opens Step 2 Optimise the settings to your preference and click OK Note Make sure to use the keyboard delivered with the printer Using another kind of keyboard could lead to system failure Note For more information on this ...

Page 174: ...e the keyboard settings proceed as follows Step 1 In the language and input window click adjust near keyboard settings The Keyboard properties window opens Step 2 Optimise the settings to your preference and click OK Note For more information on this topic please refer to your IT administrator ...

Page 175: ...he language and input window click adjust near mouse settings The mouse properties window opens Step 2 Optimise the settings to your preference and click OK Note Make sure to use the mouse delivered with the printer Using another kind of mouse could lead to system failure Note For more information on this topic please refer to your IT administrator ...

Page 176: ... date To change the time and date proceed as follows Step 1 Click adjust near the time date window x The date and time properties window opens Step 2 Optimise the settings to your preference and click OK Note For more information on this topic please refer to your IT administrator ...

Page 177: ...for the basic functionality of the printer and should be restored in case there are problems to start the printer or when the printer software is reinstalled The user settings are settings that have been set up by the operator e g language uv powers heater preferences etc To create or restore a parameter backup proceed as follows Creating a parameter backup Step 1 Click on Create backup As soon as...

Page 178: ...ep 3 Click OK A new window appears asking for confirmation In the comment line you are able to write some extra comment Step 4 Click OK As soon as the parameter backup is finished successfully a new window appears Step 5 Click OK You have now created a parameter backup ...

Page 179: ...ew window appears asking for confirmation Step 5 Select the backup you want to restore and click OK As soon as the parameter is restored a new window appears Step 6 Click OK Step 7 Restart the printer to let the changes take effect Refer to Switching the Power ON OFF on page 40 5 2 6 Enabling disabling the confirmation dialogue on startup When starting up the printer it displays a confirmation dia...

Page 180: ...ion 1 0 5 3 Network setup In order for your Zephyr TS to be able to communicate well with your local network some settings have to be made To make these settings proceed as follows Step 1 Click on the Setup tab Step 2 In the categories window click on Network ...

Page 181: ...TS User preferences AP 75390 Revision 1 0 181 5 The network setup window opens In this window you are able to Set the Tcp IP setup Refer to TCP IP setup on page 182 Work with the Vnc server Refer to Vnc server on page 183 ...

Page 182: ...ngs When clicking the Adjust button a new window opens In this window you have the ability to choose to obtain an IP address automatically or use a personal IP address The IP address must be between 000 000 000 000 and 223 255 255 254 The subnet mask must between 000 000 000 000 and 255 255 255 252 The default gateway must between 000 000 000 000 255 255 255 255 Note For more information on this t...

Page 183: ...d to make some settings in the Vnc server Step 1 Click Settings A new window appears Step 2 Make all necessary settings to make it possible to access the Zephyr TS over the network Step 3 To remotely control your Zephyr TS install a vnc viewer on a computer from which you want to control your printer Note Depending on you vnc viewer you need to fill in some settings such as vnc server IP password ...

Page 184: ... job management settings This chapter explains how to set the autopilot setting select a print engine or make some settings concerning the estimated time Step 1 Click on the Setup tab Step 2 In the categories window click on Job management The Job management setup window opens ...

Page 185: ...indow you are able to make several settings concerning the autopilot and the default job settings Adding job selection criteria Step 1 Click on Add to add job selection criteria to the list A drop down menu with the other possibilities appears Step 2 Click on an item in the drop down menu to add it to the criteria list ...

Page 186: ...cted criteria is removed Priority of the job selection criteria Step 1 Select a criteria of which you want to change the priority Note The changes made into the job selection criteria will only become active if you click the save button When pressing the undo button you cancel the made changes When pressing the restore recommended settings button the autopilot settings returns to the fabric defaul...

Page 187: ...wn arrow The priority of the job criteria changes Streaming Streaming means that you start printing while the job is still incoming Note If the Zephyr TS is connected to a slow network 10k it might happen that the printer prints quicker than it receives data This will lead to bad printing quality ...

Page 188: ...nt graphics applications select the print engine with the G in its name In this case 2 0 G When changing print engine drivers the BiDir adjustment must be realigned In case you have an alignment saved for each print engine driver load this calibration Refer to Loading an alignment on page 117 In case you did not save any calibrations recalibrate the printheads Refer to Verifying the heads on page ...

Page 189: ...vision 1 0 189 5 Estimated print duration When printing a file the Zephyr TS is capable of displaying the estimated time of arrival You are able to decide if this estimation has to be performed based on the current media or based on the requested media ...

Page 190: ...preferences 190 AP 75390 Revision 1 0 5 5 Media setup This chapter explains how to make media settings such as Vacuum settings Tensioning settings and much more Step 1 Click on Setup Step 2 In the categories window click on Media ...

Page 191: ...r s Guide Zephyr TS User preferences AP 75390 Revision 1 0 191 5 The Media setup window opens This window is sub divided into several sub windows Each window will be discussed in the upcoming sub chapters ...

Page 192: ...phyr TS User preferences 192 AP 75390 Revision 1 0 5 5 1 Media settings In the media settings window you will make several settings concerning the vacuum tensioning lever pressure adjustment and default media settings ...

Page 193: ...ust the force Mode Description Always The vacuum will always operate no matter if there is media loaded or not Never The vacuum will never operate no matter if there is media loaded or not During print The vacuum will operate as soon as the printer starts printing When media loaded The vacuum will operate as soon as the media is loaded Loading media on page 61 When media detected The vacuum will o...

Page 194: ...00 Step 1 In the media control window you are able to make 3 settings concerning the tensioning Use the Mode option to set which winder has to operate Mode Description None When not using the Unwinder winder 100 set the mode to none Both When using the unwinder and winder set the mode to both Front When only using the winder set the mode to front Rear When only using the unwinder set the mode to r...

Page 195: ...se the option direction front inside if you want the media wound up with the printside inside Direction Front Outside Choose the option direction front outside if you want the media wound up with the printside outside Direction Rear Inside Choose the option direction rear inside you are using inside printable media Direction Rear Outside Choose the option direction rear outside you are using outsi...

Page 196: ...ia is already loaded click Unload media Step 4 As soon as the media is unloaded reload the media to let the lever pressure adjustment take place Refer to Loading media on page 61 Note Depending on your Firmware it might happen that an option called Custom is available This was the last used lever pressure when changing from FW 1 00 to FW 1 01 This option will no longer be selectable once you have ...

Page 197: ...u are able to set what actions have to be fulfilled when the print operation is done You can choose between the following actions Mode Description None After the print operation has finished no media feed operations will take place Media feed The media is fed over a distance that is set in the post print feed distance Eject If you are working with sheet media the media is ejected when working with...

Page 198: ...t feed distance This setting enables you to feed the print job before it is being printed Setting a positive value feeds the print forwards Scan width With the scan width setting you can define how to printer has to operate Swath interval With this setting you can define the time between two print swaths Mode Description Job The carriage moves only over the printing area Media The carriage moves o...

Page 199: ...ts of a print job that overlap with the defined margins will be clipped 5 5 4 Media load settings If you are printing on roll media and you want to print a file that is ripped for another media than the currently loaded media it is best to select this option Otherwise the media load window will keep appearing for each conflicting media asking if you are sure you want to print on this media Note We...

Page 200: ...00 AP 75390 Revision 1 0 5 6 Heater setup This chapter explains how to make settings such as clipping margins and other media settings when working on the Zephyr TS Step 1 Click on the Setup tab Step 2 In the categories window click on Heaters ...

Page 201: ...ser s Guide Zephyr TS User preferences AP 75390 Revision 1 0 201 5 The Heater setup window opens This window is sub divided into several windows Each window will be discussed in the upcoming sub chapters ...

Page 202: ...er Caution When working with rigids make sure that all heaters are OFF Heating rigids will make them deform This could lead to head strikes Note The main goal of the heating system is to minimize media curls due to the heat of the UV lamps When flexible media is loaded into the printer the media is conditioned and equally warmed to avoid sudden temperature shocks Note The heater settings are only ...

Page 203: ...rinting until the heaters have reached their temperature of not You can also set the time the heaters have to remain active after the print job A max 50 C B max 50 C C max 50 C C Heater element Temperature function Pre heater A Max 50 Conditions the media to avoid sudden temperature shocks to avoid curling Fixer B Max 50 Control the temperature and to make sure there s a smooth transition in tempe...

Page 204: ...tings proceed as follows Step 1 Click on the Setup tab Step 2 In the categories window click on UV The UV setup window opens This window is sub divided into several windows Each window will be discussed in the upcoming sub chapters Be sure to read and understand the safety warnings before handling the printer ...

Page 205: ...tatus of both the leading and tracking UV light UV lamps control With this option you can manually control the uv lamps Press the deactivate button to deactivate the uv lamps You can also set a deactivation time To do so select the checkbox With this option the UV lamps will automatically shut down when the time is passed ...

Page 206: ...r preferences 206 AP 75390 Revision 1 0 Default UV power This window gives you the possibility to set the UV power of each lamp If you select the symmetric option the power in the forward and backward direction will be the same ...

Page 207: ...P 75390 Revision 1 0 207 6 Chapter 6 Printer statistics Usage 208 UV statistics 210 Resetting the UV statistics counters 211 Viewing the UV reset history 212 Motor statistics 212 Disk space 213 Usage statistics 213 Event log 214 Information 215 ...

Page 208: ...ide Zephyr TS Printer statistics 208 AP 75390 Revision 1 0 6 1 Usage This chapter gives you an overview on the main usage statistics Step 1 Click the Statistics tab Step 2 In the categories window click on Usage ...

Page 209: ...09 6 The statistics window appears This window is subdivided in 4 windows UV statistics window UV statistics on page 210 Motor statistics window Motor statistics on page 212 Disk space window Disk space on page 213 Usage statistics window Usage statistics on page 213 ...

Page 210: ...n 1 0 6 1 1 UV statistics Gives an overview on Total burn time of each UV lamp How many time you have switched ON OFF the UV lamps It is also possible to reset the counter when installing a new UV cassette Refer to Resetting the UV statistics counters on page 211 ...

Page 211: ...ics counters Step 1 To reset the UV statistics counter of a certain UV lamp click Reset of the corresponding lamp Step 2 As soon as pressing Reset a new window appears Step 3 Fill in the serial number of the UV lamp and click OK The serial number can be found on the front side of the UV cassette ...

Page 212: ...iewing the UV reset history To view the UV reset history click on UV lamp reset history As soon as clicking UV lamp reset history a new window appears In this window you get the UV lamp history 6 1 2 Motor statistics Gives you an overview of each motor its total distance ...

Page 213: ...s Total amount of printed jobs The green value are the print jobs that were printed OK The red value are prints that were aborted or failed to print Caution Be aware that the hard disk is divided into 4 partitions Partition 1 C drive has a capacity of only 1 Gigabyte This partition is used for the User Interface and Windows We do advise not to store anything on this partition Note In case the hard...

Page 214: ... you an overview on the event logs Step 1 Click the Statistics tab Step 2 In the categories window click on Event log The Event log window appears Note Each event that takes place is registered on the hard disk These events can be handy for the Mutoh Service technician to diagnose what the problem is ...

Page 215: ...90 Revision 1 0 215 6 6 3 Information This chapter gives you information concerning the serial number and other printer information Step 1 Click on the Statistics tab Step 2 In the categories window click on Information The Information window appears ...

Page 216: ...User s Guide Zephyr TS Printer statistics 216 AP 75390 Revision 1 0 ...

Page 217: ...5 Cleaning a single head 228 Cleaning the receiver box 232 Weekly maintenance 235 Cleaning the UV filters 235 Cleaning the shutter glasses 237 Bi weekly maintenance 241 Verify the ink sub pressure control valve 241 Adjusting the throttle 242 Monthly maintenance 244 Clean encoder strip 244 Vacuum the UV box filter 245 Clean and grease the roller strips 247 Removing ink remains from print platform 2...

Page 218: ...hine In the periodical services some parts need to be checked cleaned or replaced by the end user or by a Mutoh service technician Note Please use Original Mutoh spare parts Any problems caused by use of non original Mutoh inks spare parts consumables will not be covered by the warranty Note This maintenance is based on use 8 hours day 5 days week and 44 weeks year If a machine is used more mainte...

Page 219: ... page 235 Cleaning the shutter glasses Cleaning the shutter glasses on page 237 Bi weekly maintenance Verify the ink sub pressure control valve Verify the ink sub pressure control valve on page 241 Adjusting the throttle Adjusting the throttle on page 242 Monthly maintenance Cleaning the encoder strip Clean encoder strip on page 244 Vacuum the UV box filter Vacuum the UV box filter on page 245 Cle...

Page 220: ...ring rigid printing routines especially at the highest head heights ink mist may be generated This mist will accumulate on the bottom of the ionization bar which will result in a lower efficiency of the bar If the bar is not working properly it might happen that not all static electricity is neutralized which could lead to inferior output quality as shown on the picture below To avoid this phenome...

Page 221: ... Brush Open ended spanner SW 8 9 Gloves Step 2 Be sure that the pressure rollers are raised Step 3 Load a sheet of media in the printer which covers the complete print platform avoiding dust particles falling into the printer via the vacuum holes Step 4 Power OFF the printer Step 5 Loosen the screws fixing the ionization bar with the open ended spanner ...

Page 222: ...390 Revision 1 0 Step 6 Lay the ionization bar upside down on a piece of paper Step 7 Put on a pair of gloves Step 8 Soak a polyknit wiper with isopropanol and clean the guides Note Be careful not to get stuck to the ionization points as they are very sharp ...

Page 223: ...n 1 0 223 7 Step 9 Moisten the brush with isopropanol and clean the ionization points Step 10 Reinstall the ionization bar when it is completely clean Do not push the bar completely to the back The front of the bar and brackets should match as shown on the picture ...

Page 224: ...ure below to perform a cleaning Be sure to read and understand the safety warnings before handling the printer N Description 1 Polyknit wipers 2 Gloves 3 Safety goggles Caution Use appropriate safety equipment before performing a head cleaning The gloves delivered with the Zephyr TS must be replaced after 10 minutes when working with ink Refer to Safety instructions on page 11 Note In case nozzles...

Page 225: ...on if there are less than 10 missing nozzles per head Powerful Performs a purge of 10 seconds Choose this option if there are more than 10 missing nozzles per head Step 3 Select Normal or Powerful and click Start now The carriage moves upwards and starts a purge of the heads A message window appears in the User Interface Do not click the OK button before proceeding as described below Note If you c...

Page 226: ...nce cover Step 5 Take a polyknit wiper and wipe each head Caution Make sure to wear Safety goggles and gloves before cleaning the heads Refer to Safety instructions on page 11 for more information regarding safety Note When wiping heads use a clean piece of polyknit tissue to avoid colour contamination ...

Page 227: ...ginal position The head cleaning procedure is now finished perform a nozzle check to verify if all nozzles are available Refer to Performing a nozzle check on page 101 Caution Dispose all uncured UV contaminated waste e g gloves and polyknit wipers into a dedicated trash bin Uncured UV waste must be disposed in accordance to local law and regulations Refer to Safety instructions on page 11 ...

Page 228: ...tenance cover Step 5 Click the maintenance tab Step 6 Now there are several options Manual Use this setting to move the carriage up This to verify the heads or wipe the nozzles Normal Performs a purge of 3 seconds Choose this option if there are less than 10 missing nozzles per head Powerful Performs a purge of 10 seconds Choose this option if there are more than 10 missing nozzles per head Yellow...

Page 229: ... upwards and starts a purge of the heads A message window appears in the User Interface Do not click the OK button before proceeding as described below Step 8 Open the left maintenance cover Caution Make sure to wear Safety goggles and gloves before cleaning the heads Refer to Safety instructions on page 11 for more information regarding safety ...

Page 230: ...The carriage moves downwards to its original position Step 12 Open the left maintenance cover Note When wiping heads use a clean piece of polyknit tissue to avoid colour contamination Caution Dispose all uncured UV contaminated waste e g gloves and polyknit wipers into a dedicated trash bin Uncured UV waste must be disposed in accordance to local law and regulations Refer to Safety instructions on...

Page 231: ...perform a nozzle check to verify if all nozzles are available Refer to Performing a nozzle check on page 101 Red Yellow Blue Black Note In case of opening the ink valves too early it might happen that some ink drips out of these heads This is not a problem just wipe each head with a polyknit wiper Note When wiping heads use a clean piece of polyknit tissue to avoid colour contamination ...

Page 232: ...P 75390 Revision 1 0 Cleaning the receiver box Required tools Step 1 Open the left maintenance cover Step 2 Take out the receiver box Be sure to read and understand the safety warnings before handling the printer N Description 1 Gloves 2 Safety goggles ...

Page 233: ... ink in a special UV container Step 4 Take out the dirty paper cloth Step 5 Clean the receiver box with a bit of paper Step 6 Put in a new paper cloth Note Handling waste Refer to section 13 on the MSDS sheet Recommendation Dispose products according to federal state provincial and local regulations ...

Page 234: ...User s Guide Zephyr TS Periodical maintenance 234 AP 75390 Revision 1 0 Step 7 Position the receiver box back in its place Step 8 Close the left maintenance cover ...

Page 235: ... 4 Weekly maintenance Cleaning the UV filters Required tools Step 1 Open the left maintenance cover Step 2 Position a flathead screwdriver into the slot and carefully pull up the top cover N Description 1 Safety goggles 2 Gloves 3 Isopropanol 4 Plastic box 5 Flathead screwdriver ...

Page 236: ...p 5 Put the filter in a small plastic box and put some isopropanol with it Let the filter soak for a minute and clean it with a piece of paper Step 6 If the filter is clean dry it with some paper Step 7 Place the filter back Position the front side of the filter in the groove Step 8 Reinstall the top cover Step 9 Perform the same operation for the other UV filter ...

Page 237: ...the left maintenance cover Caution Printing without shutter glass is not recommended Ink and ink dust will cure on the inner shutter glass This is very hard to keep clean and is not covered by the warranty N Description 1 Gloves 2 Safety goggles 3 Hexagon socket wrench diameter 2 5 mm 4 Acetone 5 Glass bowl 6 Crosshead screwdriver ...

Page 238: ...S Periodical maintenance 238 AP 75390 Revision 1 0 Step 2 Loosen the 4 screws of the UV lamp cover and remove it Step 3 Remove the bracket holding the shutter glass by loosening the screw with a hexagon socket wrench 2 5 mm ...

Page 239: ...lly slide out the shutter glass Step 5 Let the shutter glass soak in a glass bowl filled with acetone Caution Never touch the quartz surface with bare hands Grease and dirt will reduce the lamp intensity resulting in less curing Note Cured UV ink becomes softer when soaking it in acetone ...

Page 240: ...plastic scraper Step 8 Carefully place back the shutter glass Step 9 Screw the bracket holding the shutter glass back in its place Step 10 Fix the cover holding the UV light Step 11 Reinstall the UV lamp cover with the 4 screws Note In case you can not yet remove all ink remains leave the shutter glass overnight in a covered glass bowl with acetone ...

Page 241: ...ink sub pressure control valve Step 1 Click on the Ink tab Step 2 In the categories window click on Ink The ink status window opens Step 3 In this window you can verify the ink sub pressure control valve value This value must be 50 12 5 In case the value is 62 5 or 37 5 refer to Adjusting the throttle on page 242 ...

Page 242: ...g the throttle Follow the procedure below Required tools Step 1 Loosen the screws to open the left service cover Be sure to read and understand the safety warnings before handling the printer N Description 1 Safety goggles 2 Crosshead screwdriver N Description 1 Left service cover ...

Page 243: ... throttle at the bottom left side Step 2 To adjust the value to become a value of 50 12 5 proceed as follows Close the throttle in case the value is larger than 62 5 Open the throttle in case the value is smaller than 37 5 Step 3 Once you have adjusted the value place the left service cover back and fasten the screws ...

Page 244: ...1 0 7 1 6 Monthly maintenance Clean encoder strip Tools necessary Step 1 Power OFF the machine Step 2 Open the front cover Step 3 Clean the encoder strip with a polyknit wiper soaked in isopropanol N Description 1 Polyknit wipers 2 Isopropanol 3 Safety goggles 4 Gloves ...

Page 245: ... UV power supply box attracts a lot of dust during operation Therefore the filter should be vacuumed every six months Tools necessary Step 1 Remove the keyboard and mouse from the keyboard table Step 2 Gently lift up the keyboard table to remove it N Description 1 Vacuum cleaner 2 Crosshead screwdriver ...

Page 246: ...ephyr TS Periodical maintenance 246 AP 75390 Revision 1 0 Step 3 Loosen the screws to open the right service cover Step 4 Vacuum the grid at the front of the UV power supply box 1 N Description 1 Right service cover ...

Page 247: ...the 4 roller strips Step 3 Allow the solvent to evaporate until the surface is completely dry Step 4 Grease the 4 roller strips Step 5 Power ON the printer and print a few swaths to equally spread out the grease over the roller strips and carriage bearings Step 6 Clean the encoder strip because it might be possible that some grease splashed on the encoder strip during the first swaths of printing ...

Page 248: ...from print platform Required tools Step 1 Verify that the printer is not operating Step 2 Unload media Refer to Unloading media on page 78 Step 3 Open the front cover Step 4 Carefully remove all ink remains with a scraper from the print platform N Description 1 Gloves 2 Scraper 3 Safety goggles ...

Page 249: ...nk curing You need to replace the UV cassettes in case the curing is not performed optimally To replace an UV cassette proceed as follows Required tools Step 1 Power OFF the machine Be sure to wait the predefined 5 minutes until the lamps are cooled DOWN Step 2 Push the carriage to the middle of the print platform Step 3 Remove the UV lamp cassettes by loosening the one screw with a hexagon key of...

Page 250: ...User s Guide Zephyr TS Periodical maintenance 250 AP 75390 Revision 1 0 Step 5 Reset the UV lamp counters in User Mode of the User Interface ...

Page 251: ...e interventions planned in a timely manner It is very important not to skip a maintenance intervention in order to maintain constant print quality and to keep your warranty Please refer to the table below to know what the authorized Mutoh technician must do N Description Frequency 1 Replace filters Ink filters Carriage filters Hydrophobic filters Sub pressure regulator filter Every 12 months 2 Che...

Page 252: ...User s Guide Zephyr TS Periodical maintenance 252 AP 75390 Revision 1 0 ...

Page 253: ...nt 269 Fine adjustment 273 Bi directional adjustment procedure 278 Basic adjustment 278 Fine adjustment 282 Error messages 287 Internal hardware error 287 Internal software error 287 Internal hardware software error 287 Dongle related error 287 Invalid dongle 287 Dongle failed to communicate or initialize 287 No card reader found 288 No dongle detected 288 Print engine software error Print swathe ...

Page 254: ...s Guide Zephyr TS Troubleshooting 254 AP 75390 Revision 1 0 UV left right lamp failed to ignite 289 UV left right lamp overheat error 289 UV lamp shutter timeout error 290 Print head control system error 290 ...

Page 255: ...User s Guide Zephyr TS Troubleshooting AP 75390 Revision 1 0 255 8 8 1 Nozzle recovery procedure The following procedure explains what must be done when nozzle do not recover ...

Page 256: ... a cleaning and wipe of the nozzle row Is there improvement Yes The ink started curing on the nozzles Repeat the previous step If there is no improvement contact your local Mutoh technician No Are the nozzles disturbed over the complete head Refer to addit onal picture 1 Yes Shut down the printer and change the rewire cable on the Xusb box with a well printing head When print ing a new nozzlecheck...

Page 257: ...User s Guide Zephyr TS Troubleshooting AP 75390 Revision 1 0 257 8 Additional picture 1 Example of a head where all the nozzles are disturbed ...

Page 258: ...e printer is ON Refer to Switching the power ON on page 40 Important During this procedure prints will be made on which there are cured and non cured areas Therefore be sure to always wear UV resistant gloves do NOT dispose the printed media together with household rubbish Dispose non cured media samples according to the local regulations N Description Qty 1 Polyknit wiper 5 2 UV resistant gloves ...

Page 259: ...User s Guide Zephyr TS Troubleshooting AP 75390 Revision 1 0 259 8 there is media loaded Refer to Loading media on page 61 the UV lamps are ready Step 2 Click the Calibration tab ...

Page 260: ... AP 75390 Revision 1 0 Step 3 In the categories window click on UV Step 4 Click on the test button to print the UV alignment print A test pattern is being printed Left lamp printed second Right lamp printed first cured not cured cured not cured ...

Page 261: ...of the cured non cured zone Now there are 3 possible results The cured non cured zone is lying on top of the border line No UV lamp adjustment necessary The cured non cured zone is lying above the border line The left or right UV lamp needs to be adjusted Contact your Mutoh Service technician The cured non cured zone is lying below the border line The left or right UV lamp needs to be adjusted Con...

Page 262: ...at the heads are adjusted precisely as well mechanical as firmware wise You can verify the following settings to make sure the heads are perfectly aligned 8 3 1 Headslant adjustment procedure Proceed as follows to align the heads perpendicularly with the print direction Step 1 Click the calibration tab Step 2 In the categories window click on mechanical ...

Page 263: ...he test print as follows Heads are properly aligned if all lines are printed horizontally refer to head 3 and head 4 Heads are misaligned if the lines in the middle are printed slantwise refer to head 1 and head 2 1A 1B 2A 2B 3A 3B 4A 4B 1A 1B 2A 2B 3A 3B 4A 4B Note If a head is misaligned contact your local authorized Mutoh technician to align the heads properly ...

Page 264: ...if all heads are aligned in one line Head 1is the reference head There are two different alignment patterns Test print 1 Test print 2 Procedure test print 1 Step 1 Click the calibration tab Step 2 In the categories window click on mechanical Note Be sure to always perform the rough adjustment first before continuing to the fine adjustment ...

Page 265: ... 2B 2A 1B 3B 3A 4B 4A 1B 1A 2A 3A 1A 1A 1A 1B 1B 1A 1B 1A 1A 4A 2B 3B 4B 1B 1B 1B 2A 2B 2A 2B 3A 3B 3A 3B 4A 4B 4A 4B 1 2 3 N Description 1 Only the A nozzle rows will be printed and compared with head 1 2 Only the B nozzle rows will be printed and compared with head 1 3 Both nozzle rows A and B will be printed and compared to each other ...

Page 266: ...p 5 Analyse the test print as follows Head 1 is properly aligned The nozzles of head 1 and 4 are in one line Head 2 is misaligned Contact an authorized Mutoh technician Head 3 is misaligned Contact an authorized Mutoh technician 2A 3A 4A 1A 1A 1A head 1 is the reference ...

Page 267: ...User s Guide Zephyr TS Troubleshooting AP 75390 Revision 1 0 267 8 procedure test print 2 Step 1 Click the calibration tab Step 2 In the categories window click on mechanical Step 3 Click on Test 2 ...

Page 268: ...uthorized Mutoh technician Though the nozzles of head 2 are positioned exactly in between two nozzles of reference head 4 head 2 is misaligned The bottom line of nozzles must always be the one of the reference head in this case head 4 magenta Contact an authorized Mutoh technician Head 3 is properly aligned The nozzles of head 3 are exactly in between the nozzles of the referenced head 4 1B ref 4A...

Page 269: ...69 8 8 3 3 Uni directional adjustment procedure This alignment procedure also has a rough and fine adjustment pattern Basic adjustment Proceed as follows to make the rough adjustment Step 1 Click the calibration tab Step 2 In the categories window click Alignment ...

Page 270: ...er s Guide Zephyr TS Troubleshooting 270 AP 75390 Revision 1 0 Step 3 Click on Forward alignment Uni directional Basic Step 4 The UniDir wizard will open Step 5 Make the following settings Nozzle rows All ...

Page 271: ...n one line In the example above this is in the 2 situation 1B ref 1A 2A ref 1A 2B ref 1A 3A ref 1A 3B ref 1A 4A ref 1A 4B ref 1A 8 7 6 5 4 3 2 1 0 1 2 3 4 5 6 7 8 8 7 6 5 4 3 2 1 0 1 2 3 4 5 6 7 8 8 7 6 5 4 3 2 1 0 1 2 3 4 5 6 7 8 8 7 6 5 4 3 2 1 0 1 2 3 4 5 6 7 8 8 7 6 5 4 3 2 1 0 1 2 3 4 5 6 7 8 8 7 6 5 4 3 2 1 0 1 2 3 4 5 6 7 8 8 7 6 5 4 3 2 1 0 1 2 3 4 5 6 7 8 2A ref 1A 8 7 6 5 4 3 2 1 0 1 2 3...

Page 272: ...ach nozzle row and make the settings in the wizard Step 9 Click the next button Step 10 Make one of the following decisions Test Print the summary of the made settings Repeat Repeat the complete adjustment procedure Finish Finish the procedure Abort Aborts the alignment procedure without completing it ...

Page 273: ...e fine adjustment Step 1 Click the calibration tab Step 2 In the categories window click the Alignment tab Note When performing the basic adjustment the printer will ask to perform the fine adjustment next If choosing to perform the fine adjustment the printer will automatically display the fine adjustment wizard ...

Page 274: ...ser s Guide Zephyr TS Troubleshooting 274 AP 75390 Revision 1 0 Step 3 Click on Alignment wizard Unidirectional Fine Step 4 The UniDir wizard will open Step 5 Make the following settings Nozzle rows All ...

Page 275: ...t key The following pattern will be printed 1B 3 1B 2 2A 3 2A 2 2B 3 2B 2 3A 3 3A 2 3B 3 3B 2 4A 3 4A 2 4B 3 4B 2 1B 1 2A 1 2B 1 3A 1 3B 1 4A 1 4B 1 1B 0 2A 0 2B 0 3A 0 3B 0 4A 0 4B 0 1B 1 2A 1 2B 1 3A 1 3B 1 4A 1 4B 1 1B 2 2A 2 2B 2 3A 2 3B 2 4A 2 4B 2 1B 3 2A 3 2B 3 3A 3 3B 3 4A 3 4B 3 ...

Page 276: ...yr TS Troubleshooting 276 AP 75390 Revision 1 0 Step 7 Analyse the test print as follows Check where the printed nozzles are on one line In the example above this is in the 2 situation 2A 3 2A 2 2A 1 2A 0 2A 1 2A 2 2A 3 ...

Page 277: ...8 Choose the best pattern for each nozzle row and make the settings in the wizard Step 9 Click the next button Step 10 Make one of the following decisions Test Print the summary of the made settings Repeat Repeat the complete adjustment procedure Finish Finish the procedure ...

Page 278: ...justment procedure The heads will now print all at the correct time in uni directional mode This should also be the case in bi directional mode Basic adjustment Proceed as follows to make the rough adjustment Step 1 Click the calibration tab Step 2 In the categories window click Alignment ...

Page 279: ...ephyr TS Troubleshooting AP 75390 Revision 1 0 279 8 Step 3 Click on Alignment wizard Bidirectional Basic Step 4 The alignment wizard opens Step 5 Make the following settings Nozzle rows All Step 6 Click the next key ...

Page 280: ...n one line In the example above this is in the 2 situation 8 7 6 5 4 3 2 1 0 1 2 3 4 5 6 7 8 8 7 6 5 4 3 2 1 0 1 2 3 4 5 6 7 8 8 7 6 5 4 3 2 1 0 1 2 3 4 5 6 7 8 8 7 6 5 4 3 2 1 0 1 2 3 4 5 6 7 8 8 7 6 5 4 3 2 1 0 1 2 3 4 5 6 7 8 8 7 6 5 4 3 2 1 0 1 2 3 4 5 6 7 8 8 7 6 5 4 3 2 1 0 1 2 3 4 5 6 7 8 8 7 6 5 4 3 2 1 0 1 2 3 4 5 6 7 8 1A 1B 2A 2B 3A 3B 4A 4B 8 7 6 5 4 3 2 1 0 1 2 3 4 5 6 7 8 ...

Page 281: ... for each nozzle row and make the settings in the wizard Step 10 Click the next button Step 11 Make one of the following decisions Test Print the summary of the made settings Repeat Repeat the complete adjustment procedure Finish Finish the procedure Step 12 Proceed to the fine adjustment procedure ...

Page 282: ...he fine adjustment Step 1 Click the calibration tab Step 2 In the categories window click on Alignment Note When performing the basic adjustment the printer will ask to perform the fine adjustment next If choosing to perform the fine adjustment the printer will automatically display the fine adjustment wizard ...

Page 283: ...User s Guide Zephyr TS Troubleshooting AP 75390 Revision 1 0 283 8 Step 3 Click on Alignment wizard Bidirectional Fine The Alignment wizard Fine opens Step 4 Make the following settings Nozzle rows All ...

Page 284: ...g pattern will be printed 1B 3 1B 2 2A 3 2A 2 2B 3 2B 2 3A 3 3A 2 3B 3 3B 2 4A 3 4A 2 4B 3 4B 2 1B 1 2A 1 2B 1 3A 1 3B 1 4A 1 4B 1 1B 0 2A 0 2B 0 3A 0 3B 0 4A 0 4B 0 1B 1 2A 1 2B 1 3A 1 3B 1 4A 1 4B 1 1B 2 2A 2 2B 2 3A 2 3B 2 4A 2 4B 2 1B 3 2A 3 2B 3 3A 3 3B 3 4A 3 4B 3 1A 3 1A 2 1A 1 1A 0 1A 1 1A 2 1A 3 ...

Page 285: ...r TS Troubleshooting AP 75390 Revision 1 0 285 8 Step 6 Analyse the test print as follows Check where the printed nozzles are on one line In the example above this is in the 2 situation 2A 3 2A 2 2A 1 2A 0 2A 1 2A 2 2A 3 ...

Page 286: ...Choose the best pattern for each nozzle row and make the settings in the wizard Step 8 Click on the next button Step 9 Make one of the following decisions Test Print the summary of the made settings Repeat Repeat the complete adjustment procedure Finish Finish the procedure ...

Page 287: ... the problem remains please contact a authorized Mutoh technician to resolve this issue 8 4 3 Internal hardware software error An internal hardware software error has occurred The printer will automatically try to reinitialize to check if the problem can be recovered If this doesn t succeed try to switch off the printer and restart If after this action the problem remains please contact a authoriz...

Page 288: ...ecovered If this doesn t succeed try to switch off the printer and restart If after this action the problem remains please contact a authorized Mutoh technician to resolve this issue 8 4 6 Emergency stop emergency switch related errors The emergency stop is pushed in or the carriage is too much on the left or right side activating one of the emergency switches Make sure the emergency stop is pulle...

Page 289: ...f a new UV lamp cassette is inserted Step 5 If the problem is still not solved after lamp change contact your authorized Mutoh technician UV left right lamp failed to ignite The UV subsystem tried to ignite the UV lamps However this ignition has not succeeded Step 1 The printer will automatically reboot check if the problem persists Step 2 Try to swap the Right and Left lamp to check if the proble...

Page 290: ...o reboot the printer If the problem reoccurs please contact your authorized Mutoh technician 8 4 9 Print head control system error An internal error has occurred in the print head control system which is connected to the USB port of the control computer Try to reboot the printer If the problem reoccurs please contact your authorized Mutoh technician ...

Page 291: ... Job management tab on page 53 F2 Opens the Maintenance tab Refer to Maintenance tab on page 54 F3 Opens the Media control tab Refer to Media control tab on page 54 F4 Opens the Calibration control tab Refer to Calibration tab on page 55 F5 Opens the Ink tab Refer to Ink tab on page 55 F6 Opens the Statistics tab Refer to Statistics tab on page 56 F7 Opens the Setup tab Refer to Setup tab on page ...

Page 292: ...ties Refer to Viewing and editing the job properties on page 126 Ctrl O Opens the job import window Refer to Importing a file into the job pool on page 118 Shift Ctrl C Import a job into the job pool by copy Refer to Importing by copy on page 119 Shift Ctrl L Import a job into the job pool by link Refer to Importing by link on page 121 Ctrl I shows the import queue Refer to Viewing the import queu...

Page 293: ...fer to Feeding media forwards backwards by step on page 79 Arrow down Feeds the media by step backwards Depending on the preset distance the media will be fed Refer to Feeding media forwards backwards by step on page 79 Ctrl arrow up Feeds the media continous forwards until you loosen one of the keys Refer to Feeding media continuously forward backward on page 80 Ctrl arrow down Feeds the media co...

Page 294: ...User s Guide Zephyr TS List of keyboard short cuts 294 AP 75390 Revision 1 0 ...

Page 295: ...ean and grease the roller strips 247 Clean encoder strip 244 Cleaning a single head 228 all heads 225 the ionization bar 220 the receiver box 232 the shutter glasses 237 the UV filters 235 Clipping margins 199 Creating a parameter backup 177 Current heater status 202 D Daily maintenance 224 Default media settings 197 UV power 206 Deleting print jobs from the job pool 135 Depending on print volume ...

Page 296: ...t tab 53 preview settings 88 K Keyboard layout 173 preference 173 settings 174 L Language and input settings 172 Last loaded media 199 Lever pressure adjustment 196 settings 96 Loading roll media 62 sheet or rigid media 70 M Maintenance tab 54 Making job management settings 184 Manually media cutting 84 Media control settings 92 control tab 54 details 89 details when loading sheets or rigid media ...

Page 297: ...amp cassettes 249 Resetting the UV statistics counters 211 Restoring job properties 133 parameter backup 179 Return to the print position 81 S Safety instructions 11 Safety labels 18 Setting the correct distance adjust step 106 the correct head gap 114 the print job sequence 141 unassigned tabs 169 Setup tab 57 Statistics tab 56 Status bar 59 window 205 Storage environment of ink 31 Streaming 187 ...

Page 298: ...93 settings 92 Verifying the chip volume 159 the heads 262 the ink level 157 the ink sub pressure control valve 241 Viewing the import queue 123 the job action history 155 the job properties 126 the UV reset history 212 Vnc server 183 W Warnings cautions and notes 16 Water level error 288 Weekly maintenance 235 Working with Mutoh s Smartchip management system 162 with the autopilot 137 with the he...

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Page 300: ...CA INC Tel 1 480 968 7772 Fax 1 480 968 7990 E mail sales mutoh com http www mutoh com MUTOH EUROPE nv Tel 32 0 59 561400 Fax 32 0 59 807117 E mail mutoh mutoh eu http www mutoh eu MUTOH DEUTSCHLAND GmbH Tel 49 0 221 385474 0 Fax 49 0 211 385474 74 E mail Vertrieb mutoh gmbh de http www mutoh gmbh de http www mutoh de ...

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