MUTOH Zephyr TS User Manual
User’s Guide
Zephyr TS
Preliminary
User’s Guide Zephyr TS
AP-75390 - Revision 1.0 3
2
Copyright notice
COPYRIGHT © 19/2/10 Mutoh Europe nv All rights reserved.
Mutoh Europe nv reserves the right to modify the information contained in this manual at any
time without prior notice.
This document may not be reproduced by any means, in whole or in part, without written
permission of the copyright owner.
Mutoh furnished this document to support the Zephyr TS series printers. In consideration of
the furnishing of the information contained in this document, the party to whom it is given,
assumes its custody and control and agrees to the following:
The information herein contained is given in confidence, and any part thereof shall not be
copied or reproduced without written consent of Mutoh Europe nv
This document or the contents herein under no circumstances shall be used in the
manufacture or reproduction of the article shown and the delivery of this document shall not
constitute any right or license to do so.
AdditionalLicensingprovisionsforMicrosoftWindowsXP embedded runtime
licenses
The following additional licensing provisions apply to the licensed product as indicated above
and 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.
You are licensed to use the software to provide only the limited functionality (specific tasks or
processes) for which the device has been designed and marketed by Mutoh. This license
specifically prohibits any other use of the software programs or functions, or inclusion of
additional software programs or functions that do not directly support the limited functionality
on the Zephyr TS.
Backup copy. You may make one (1) backup copy of the software. You use this backup
copy solely for your archival purposes and to reinstall the software on the Zephyr TS. Except
as expressly provided in this End User License agreement (EULA) or by local law, you may
not otherwise make copies of the software including the printed materials accompanying the
software. You may not loan, rent, lend or otherwise transfer the backup copy to another user.
No rental / commercial hosting. You may not rent, lease, lend or provide commercial
hosting services with the software to others.
User’s Guide Zephyr TS
4 AP-75390 - Revision 1.0
Trademarks. This EULA does not grant you any rights in connection with any trademarks or
service marks of Mutoh Europe nv, MS Microsoft Corporation or their affiliates and suppliers.
Recovery media. If software is provided by Mutoh Europe nv on separate media and labelled
“Recovery Media” you may use the Recovery Media solely to restore or reinstall the software
originally installed on the device.
Notice regarding security. To help protect against breaches of security and malicious
software, periodically back up your data.
19 February 2010
Published: Mutoh Europe nv, Archimedesstraat 13, 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 and the contents of this publication may be changed without prior
notification.
Mutoh Europe nv has made the best efforts to keep this publication free from
errors, but if you find any uncertainties or misprints, please contact the reseller
from which you bought this equipment or email us: technical.news@mutoh.eu
.
Mutoh Europe nv shall not be liable for any damages or troubles resulting from
the use of this equipment or this guide.
User’s Guide Zephyr TS
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Table of contents
Chapter 1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.1 Compliance with the following regulations . . . . . . . . . . . . . . 11
1.2 Handling inks + waste . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.3 UV-curing system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.4 Warnings, cautions and notes. . . . . . . . . . . . . . . . . . . . . . . . . 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 requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Printer dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
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Chapter 4 Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.1 Workflow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.2 Switching the Power ON / OFF . . . . . . . . . . . . . . . . . . . . . . . . 40
Switching the power ON. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Switching the power OFF. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4.3 Emergency Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Emergency capping procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
4.4 How to navigate the User 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
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 winding up the media. . . . . . . . . . . . . . . . . . . 83
4.9 Manually media cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
4.10 Media Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Preview settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
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Media details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Media control settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
4.11 Preparations before printing . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Using the media retainers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Checking the temperature and pressure settings. . . . . . . . . . . . . . 99
Performing a nozzle check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Set the correct distance adjust (step). . . . . . . . . . . . . . . . . . . . . . . 106
Setting the correct head gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
4.12 Using the job manager . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Importing a file into the job pool . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Viewing the import queue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Previewing the imported file . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Viewing and editing 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 the job queue. . . . . . . . . . . . . . . . . . . . . . . . 149
4.13 Checking the status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Checking the print status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Estimated time of arrival. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
4.14 Viewing the job action history . . . . . . . . . . . . . . . . . . . . . . . . 155
4.15 Refilling the ink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Checking the ink status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Ink refill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Working with Mutoh’s Smartchip management system. . . . . . . . 162
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4.16 Transportation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Short distance transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Medium-distance transportation for short term. . . . . . . . . . . . . . . 165
Medium-Long distance transportation for long-term . . . . . . . . . . 166
Chapter 5 User preferences . . . . . . . . . . . . . . . . . . . . . . . . . . 167
5.1 Setting unassigned tabs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
5.2 User interface setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
Language and 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
Clipping margins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
Media load settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
5.6 Heater setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
5.7 UV setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Chapter 6 Printer statistics . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
6.1 Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
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UV statistics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
Motor statistics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
Disk space . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Usage statistics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
6.2 Event log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
6.3 Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
Chapter 7 Periodical maintenance . . . . . . . . . . . . . . . . . . . . . 217
7.1 Done by end user . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
Depending on print volume and media . . . . . . . . . . . . . . . . . . . . . 220
Daily maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
Weekly maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
Internal hardware error. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
Internal software error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
Internal hardware / software error. . . . . . . . . . . . . . . . . . . . . . . . . . 287
Dongle related error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
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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
1
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Safety instructions
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Chapter 1 Safety instructions
This chapter explains the installation of Zephyr TS, warning terms that operators need to
know, caution items and warning labels on the printer main unit.
1.1 Compliance with the following regulations
Important
When installing and operating this printer, be sure to follow the directions and
warnings in this guide.
The CE marking is a mandatory European marking for certain
product groups to indicate conformity with the essential health and
safety requirements set out in European Directives.
By affixing the CE marking, the manufacturer, his authorized
representative, 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 submenu is attached to a
product, it means the product is covered by the European Directive
2002/96/EC - WEEE regulation.
Please inform yourself about the local separate collection system for
electrical and electronic products.
Please act according to local rules and do not dispose of your old
products with your normal household waste. The correct disposal of
your old product will help prevent potential negative consequences
for the environment and human health.
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Safety instructions
12 AP-75390 - Revision 1.0
This product is tested and approved by the Canadian Standards
Association (CSA), this to provide increased assurance of quality and
safety.
The product is tested according to IEC60950.
This standard tries to cover all safety aspects.
Mechanical, electrical
Choice of components
Choice of materials: flammability!
Connectors, cables …
Fire enclosure
This means the product is safe for users, service personnel and
production personnel.
CSA International certification is not a legal commitment but it
assures 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 not installed and used in accordance with
the instruction manual, may cause harmful interference to radio
communications. Operation of this equipment in a residential area is
likely to cause harmful interference in which case the user will be
required to correct the interference at his own expense.
ICES
This Class A digital apparatus complies with Canadian ICES-003.
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Safety instructions
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1
1.2 Handling inks + waste
Before handling inks/ cleaning and their waste, CAREFULLY READ THE MATERIAL
SAFETY DATA SHEETS (MSDS) and the labels for important health, safety and
environmental information. Post these documents in the work area as required by federal or
local law. All safety data sheets are periodically updated. These sheets and their translations
can be found on www.mutoh.eu
Engineering measures:
Although no Volatile Organic Compounds are released, please do work with forced
ventilation to prevent contact with ink mist/dust.
It's recommended to be equipped with an eyewash-shower.
Personal protection:
General: Keep away from foodstuffs, beverages. Always wash your hands before breaks
and at the end of work.
Protection of hands: The operator must wear suitable gloves. The selection of gloves
depends on the level of exposure. (nitrile for short-exposure times, butyl rubber gloves for
long-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 remove all soiled and contaminated clothing. Avoid jewellery and
watches because ink can be trapped between skin and jewellery which can lead to
irritation.
Important
Both UV-inks as well as the UV-curing lamps can be harmful if not handled
correctly. Follow these instructions carefully for maximum safety.
Caution
Acrylates are skin and/or eye sensitizers. Since acrylates do not evaporate,
they will remain on the skin or clothes for extended periods. This long term
exposure, caused by the non-volatility, can give rise to dermatitis. It is
essential that the given protection measures are always followed.
Important
When handling inks, it is recommended that the operator wears nitrile rubber
gloves, a protective apron and UV suitable safety glasses with side shields.
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Safety instructions
14 AP-75390 - Revision 1.0
Handling ink:
Only use original manufacturer's ink and appropriate cleaning liquid. Before filling the ink,
shake it gently. Doing so will preserve print quality.
When ink is moved from a cold place to warm place, keep the ink for three hours or more
in the new printing environment before printing.
When refilling ink, use original manufacturer's ink. This printer is designed to use original
ink. If you use inks which are not produced by the original manufacturer:
printing might become blurred
curing (speeds) might be a problem
any problems caused by using ink other than those recommended above will not be
covered by the warranty, and repair 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 4
cm open on top.
Inks / Waste
General advice: wear safety glasses and gloves
After spill: remove contaminated clothing.
After inhalation: if difficulties occur after vapour/aerosol has been inhaled, remove to
fresh air and seek medical attention.
After skin contact: wash thoroughly with soap and water.
After eye contact: wash affected eyes for at least 15 minutes under running water
while eyelids held open.
After swallowing: rinse mouth and drink plenty of water. Never induce vomiting. Seek
medical attention.
User’s Guide Zephyr TS
Safety instructions
AP-75390 - Revision 1.0 15
1
1.3 UV-curing system
UV-lamps hazards:
The UV-curing system generates hazardous amounts of thermal and UV-energies.
Radiation range of Mutoh UV-lamp: 200-460nm. Special protection for eyes and skin is
essential. Long sleeved work clothes and gloves are essential to reduce the skin's
exposure to the UV emissions.
Always wear safety glasses to protect against the radiation range of the UV-lamp.
Recommended are the glasses of 3M type 2802. Eye damage and burning of the skin can
occur with even brief direct exposure to UV light.
NEVER LOOK DIRECTLY IN THE UV-LAMP.
The exposure to UV-light is the worst for individuals in seated position. (Table height of 117
cm). Do not sit within 3 meters of the printer and do not look at the UV lamps if your eyes
are positioned below the level of the printer table. Serious injuries can result from
prolonged exposure, especially when unshielded.
UV lamps operate at very high temperatures (approx. 800°C). Therefore, never touch a
lamp which has been in operation. Let the lamp cool before any maintenance. Skin contact
with the UV lamps must be avoided. Compounds from the skin when lamps are hot will
form permanent etching on the quartz surface that can decrease the UV energy
transmission. Installation of the lamp: before the installation 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 sulphur and then dispose
of it, according to local regulations regarding mercury disposal. When a lamp in operation
breaks, the mercury will be evaporated and removed by the forced ventilation.
Ozone: Ozone is a toxic gas which the UV lamps create. As the lamp warms up, it briefly
passes through a section of the light spectrum which excites oxygen molecules enough to
create ozone. Once a UV lamp has completely warmed up, only very small amounts of
ozone are present. This amount will be fully removed by the forced ventilation.
Measurements show that the generated amount of ozone is below the exposure limits.
Maintenance:
Always wear glasses, gloves and protective clothing to protect against the ink and the
UV-emissions
When maintenance station is open to clean the heads, do not touch the UV lamp as it
can be hot.
Use gloves to remove cured ink in maintenance station or somewhere else
Dispose the cured ink according to federal, state, provincial and local regulations
Important
Handle both the UV-inks and the UV-curing lamps correctly, it can be harmful.
Always print with closed covers. Never look directly into the UV-lamp during
operation.
User’s Guide Zephyr TS
Safety instructions
16 AP-75390 - Revision 1.0
1.4 Warnings, cautions and notes
Safety terms in this manual and the contents of warning labels attached to the printer are
categorized into the following three types, depending on the degree of risk (or the scale of
accident).
Read the following explanations carefully and follow the instructions in this manual.
1.5 Safety instructions
Machines must be installed by an authorized Mutoh technician according to Mutoh's
Installation Guide, also after moving machines to another location; maintenance needs
to be done according the periodical maintenance described in the User’s Guide.
To prevent fire or electrical shock, never use a power supply source other than the one
rated for the printer in the country where you purchased the printer.
To prevent fire or electrical shock, machines must be connected to a properly grounded
electrical power outlet. Do not connect the power cable to a power strip or a power source
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 objects on the cable.
Do not bend, twist, knot or pull the cable.
Do not wire the cable near equipment that generates heat.
Do not use the cable with any other electrical device
Do not handle the cable with wet hands
Be aware of all caution and warning labels to avoid potentially hazardous situations.
Do not place the printer in the following areas. Doing so may result in the printer tipping or
falling over and causing injury.
Unstable surfaces
Sloping floors
Areas subject to vibration by other equipment
Safety terms Details
Important Must be followed carefully to avoid death or serious bodily injury.
Caution
Must be observed to avoid bodily injury (moderate or light) or damage to
your equipment.
Notes
Contains important information and useful tips on the operation of your
printer.
User’s Guide Zephyr TS
Safety instructions
AP-75390 - Revision 1.0 17
1
Do not place the printer in humid and dusty areas or in areas exposed to flammables.
Doing so may result in electrical shock or fire.
Do not cover the ventilation hole(s) of your printer with cloth, such as a blanket or table
cloth. Doing so could obstruct ventilation and could cause fire.
Do not insert or drop metal or inflammable objects into openings, such as ventilation
outlets. Doing so may result in electrical shock and fire.
Stop using your printer if a liquid has been spilled into it. This may cause electrical shock,
fire or damage to the electronics. Switch the printer off as soon as possible, unplug the
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 the
printer. Movement after installation is also not covered by the warranty.
When cutting the roll media, be careful that you handle correct. Incorrect handling can
result in injury to the hands and fingers from the razor blade.
To prevent back pains and other injuries, always work with at least 4 people to unpack or
move the printer. Keep the printer horizontally during transportation
Do NOT transport the printer to another room without contacting your local Authorized
Mutoh Dealer.
User’s Guide Zephyr TS
Safety instructions
18 AP-75390 - Revision 1.0
1.6 Safety labels
A safety label is used on parts of the printer which especially need your attention. Understand
the locations and the descriptions of the danger associated with each label before operating
the printer.
Be sure to read and understand the safety warnings before handling the printer.
Label Description
The Zephyr TS is an UV 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 hands.
High voltage warning
This label warns you to be careful not to pinch your
fingers.
The Zephyr TS is equipped with a laser. Make sure not
to stare into the laser. Staring into the laser will lead to
eye damage.
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Safety instructions
AP-75390 - Revision 1.0 19
1
Warning label concerning the power supply.
Indicates that this part 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
User’s Guide Zephyr TS
Safety instructions
20 AP-75390 - Revision 1.0
User’s Guide Zephyr TS
Zephyr TS documentation
AP-75390 - Revision 1.0 21
2
Chapter 2 Zephyr TS
documentation
2.1 Working with the User’s Guide
In this chapter we will explain how to get the most out of this manual.
For your comfort we made this manual interactive, and so we will deliver this manual in a
digital version and not in a hard copy.
Throughout this manual we have provided links where required. Click on a link, to jump to the
corresponding chapter in this manual.
For example: Click on Safety instructions on page11
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 corresponding chapter.
These bookmarks represent all chapters and sub-chapters
of this manual.
When you just start reading this manual, you will only find
the main chapters with a “+” sign by their side.
Click on the “+” sign, to open the bookmark and show all
sub-chapters.
Click on the bookmark to jump to the corresponding chapter.
User’s Guide Zephyr TS
Zephyr TS documentation
22 AP-75390 - Revision 1.0
2.2 Working with the help file
The Zephyr TS interface also includes a help file. To access it, click on the ?keyin the upper
right corner of the title bar.
At the left side of the help file you will see 4 tabs. A contents tab, index tab, search tab and a
favourites tab.
The contents tab provides you an overview of the major chapters in this help file.
When you start the help file, you will 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
corresponding chapter.
The second method is via keywords. If you are looking for a certain word, type it, and if the
subject you are looking for is integrated in the index it will highlight in the index list.
Double-click the item or click display to show the topic.
User’s Guide Zephyr TS
Zephyr TS documentation
AP-75390 - Revision 1.0 23
2
Another way to find information is to use the ‘search function’ in the help file. Type in a
keyword, and click the list topics button or press enter. You will now get a complete list of
topics where your keyword appears. Double-click an item, or click the display button to
display the topic.
If you have a certain topic that you consult frequently, the favourites tab will come in handy.
Navigate to the topic, click the favourites tab 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 topic with the
back button in the title bar.
For the latest up-to-date manuals, please refer to www.mutoh.eu
.
We hope you will find this manual easy to work with. If you experience any problem or miss
information concerning the manual, do not hesitate to contact us.
Please email to: Technical.news@mutoh.eu
User’s Guide Zephyr TS
Zephyr TS documentation
24 AP-75390 - Revision 1.0
User’s Guide Zephyr TS
Product overview
AP-75390 - Revision 1.0 25
3
Chapter 3 Product overview
Front 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
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Product overview
26 AP-75390 - Revision 1.0
3.1 Front view
1
2
3
4
5
6
7
8
9
10
1112
13
14
15
16
17
18
N° Description Extended description
1 Front cover
Keeps the operator safe from the
moving parts of the printer.
2 Smart chip card reader slot
To load ink volume using a smart chip.
Refer to Refilling the ink on page156
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
page48
The Zephyr TS is equipped with a light
system for better visuals on the current
print operation.
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Product overview
AP-75390 - Revision 1.0 27
3
6 PC
The PC runs the User Interface, which
is necessary to operate the Zephyr TS.
7 Ventilation cover
To transfer the heat coming from the
electronics box.
8 Electronics cover
To access the printer electronics.
For service technicians only.
9 Power switch
To power On and OFF the Zephyr TS.
Refer to Switching the Power ON / OFF
on page40
10 Circuit breakers
This is an automatically operated
electrical switch designed to protect the
electrical circuit from damage caused
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 points to
connect the foot pedal.
15 Service cover Access to ink regulation system.
16 Heater plate
Supports and heats the media during
printing.
17 Left maintenance cover Cover to access the maintenance area.
18 Air purification outlet
When using a local air purification
system, connect it to this outlet.
N° Description Extended description
User’s Guide Zephyr TS
Product overview
28 AP-75390 - Revision 1.0
3.1.1 Detailed 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 page48
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Product overview
AP-75390 - Revision 1.0 29
3
3.2 Rear view
mu
1
2
3
4
5
6
7
8
N° Description Extended description
1 APS connection tube
Connect your APS system to the
connection tube for optimal air
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 media during
printing.
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Product overview
30 AP-75390 - Revision 1.0
3.3 Using the footpedal
The footpedal consists out of 3 pedals. Each pedal starts a different operation.
Use pedal 1 to feed the media backwards.
Refer to Feeding media continuously forward / backward on page80
Use pedal 2 to feed the media forward.
Refer to Feeding media continuously forward / backward on page80
Use pedal 3 to load or unload media.
Refer to Loading media on page61
Refer to Unloading media on page78
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