MUTOH Falcon Outdoor Jr. Operation Instructions Manual

Mutoh America

Inc.

Falcon

Outdoor Jr.

Operation Instructions

MUTOH AMERICA INC. PN: MAI-75039

Rev. 1.A – 07/26/05

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COPYRIGHT NOTICE

This document may not be reproduced by any means, in whole or in part, without written permission of the

copyright owner.

This document is furnished to support the Mutoh Falcon Outdoor Jr. printer Series. 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 N.V.

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.

FCC-WARNING

This equipment complies with the requirements for a Class A computing device in the FCC rules, part 15,

subpart J.

Operation of this device in a residential area may interfere with television reception or operation of utilities.

Printers generate weak radio signals and may interfere with television reception and utilities. If the printer

does interfere with radio or TV reception, try the following:

¾ Change the direction of your radio and TV reception antenna or feeder.

¾ Change the direction of the printer.

¾ Move either the printer or the receiving antenna so there is more distance between them.

¾ Be sure the printer and the receiving antenna are on separate power lines.

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Dear Customer,

As you know, Mutoh Europe’s core business is outdoor printing and sign making.

Developed at Mutoh Europe, the Falcon Outdoor Jr. is specifically targeted at smaller sign shops looking for

an affordable and versatile printer able to produce indoor and outdoor durable graphics on a selected range

of inexpensive uncoated PVC and banner media as well as on coated substrates such as paper, tyvek,

backlit/frontprint film.

Offering a media width of 954 mm (37.55”) and a maximum print width of 934 mm (36.77”), Falcon Outdoor

Jr. incorporates Mutoh’s proven Eco-Solvent Plus ink concept to produce high quality, bright, vivid outdoor

durable images.

Falcon Outdoor Jr. integrates two heating elements, one fixer and one dryer. These heating elements will

promote durability (chemical, abrasion), dot gain as well as drying and will offer a wide media compatibility.

The heating elements are digitally controllable via a separate temperature control LCD.

Please find detailed information on how to handle the Mutoh’s Falcon Outdoor Jr. in this manual.

Happy printing !

Mutoh America Inc.

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TABLE OF CONTENTS

QUICK START

SEH

PRINTSERVER AND INTERCON NETTOOLS SETUP AND DIAGNOSTIC FEATURE (FILE DOWNLOAD) ...............10

1. SAFETY INSTRUCTIONS.....................................................................................................................................103

1.1. INTRODUCTION ......................................................................................................................................................13

1.2. WARNINGS, CAUTIONS AND NOTES .......................................................................................................................13

1.3. IMPORTANT SAFETY INSTRUCTIONS .......................................................................................................................13

1.4. WARNING LABELS..................................................................................................................................................16

2. PRODUCT OVERVIEW...........................................................................................................................................17

2.1. GETTING TO KNOW THE PRINTER PARTS AND COMPONENTS ..................................................................................17

2.1.1 Explanation of fixer and dryer........................................................................................................................18

3. SETTING UP THE UNIT..........................................................................................................................................20

3.1. INSTALLATION REQUIREMENTS: SELECTING AN ADEQUATE PLACE FOR SETTING UP YOUR EQUIPMENT .................20

3.2. WHAT’S IN THE BOX?............................................................................................................................................21

3.3. UNPACKING YOUR FALCON OUTDOOR JR. PRINTER ...............................................................................................22

3.4. PARTS LIST ............................................................................................................................................................24

3.4.1. Contents of the stand box:.............................................................................................................................24

3.4.2. Contents of the printer box:...........................................................................................................................24

3.4.3. Contents of the accessories box: ...................................................................................................................25

3.5. ASSEMBLING THE PRINTER.....................................................................................................................................26

3.6. INSTALLATION OF THE WASTE BOTTLE...................................................................................................................29

4. PREPARING FOR A JOB.........................................................................................................................................31

4.1. CONNECTING THE POWER CABLE ...........................................................................................................................31

4.2. CONNECTING THE INTERFACE CABLE.....................................................................................................................32

4.2.1. Tips to use high-speed ECP parallel communication....................................................................................32

INSTALLATION OF SEH NETWORK INTERFACE BOX..........................................................................................................

D

IAGNOSTIC ASSISTANCE USING ‘FILE Download’ FEATURE OF THE SEH BOX

S

TEP ADJUSTMENT ‘MICRO-BANDING ELIMINATION ON FALCON OUTDOOR’

4.3. LOADING ECO-SOLVENT PLUS INK CASSETTES (FIRST TIME) .................................................................................36

4.4. LOADING MEDIA ....................................................................................................................................................38

4.4.1. General recommendations with regard to printer media...............................................................................38

4.4.2. Loading cut sheet media................................................................................................................................38

4.4.3. Loading roll media........................................................................................................................................41

4.4.4 Loading media in combination with the Roll Take-Up System.....................................................................46

4.4.5. Eco-Solvent Plus Media List.........................................................................................................................52

4.5. ADJUSTING HEAD HEIGHT.....................................................................................................................................53

5. HANDLING THE PRINTER....................................................................................................................................55

5.1. GUIDED TOUR AROUND THE OPERATION PANEL .....................................................................................................55

5.1.1. Keyboard Concept.........................................................................................................................................59

5.1.2. Menu Structure - overview............................................................................................................................60

5.2. HEATER SYSTEM OPERATION PANEL ......................................................................................................................61

6. DAILY MAINTENANCE & TROUBLESHOOTING............................................................................................63

6.1. CLEANING THE PRINTER.........................................................................................................................................63

6.2. REPLACING THE ECO-SOLVENT PLUS INK CASSETTES ...........................................................................................65

6.3. REPLACING THE CUTTING BLADE ...........................................................................................................................66

6.4 CLEANING THE WIPERS...........................................................................................................................................68

6.5. EMPTYING THE WASTE BOTTLE..............................................................................................................................69

7. APPENDIX..................................................................................................................................................................71

7.1. PRINTER SPECIFICATIONS ......................................................................................................................................71

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QUICK START FOR SEH AND FALCON OUTDOOR PRINTERS

SEH PRINTSERVER AND INTERCON NETTOOLS SETUP AND DIAGNOSTIC

FEATURE (FILE DOWNLOAD)

TO INSTALL AN SEH BOX FOR ANY OF THE FALCON OUTDOOR SERIES

PRINTERS FOLLOW THESE STEPS.

1. DO NOT connect the SEH box to the printer at this time.

2. Put the CD in the computer, if ‘autorun’ starts then follow the info to install “English” and choose ‘Intercon

NetTools’ then Go to 9. If ‘autorun’ does not start then proceed.

3. Click – My Computer

4. Right click on the CD icon

5. Select “Explore” from menu

6. Double click on the “NetTool” folder

7. Double click on “Windows” folder

8. Double click “NetTool” Setup

9. Follow prompts to complete installation

• Connect the SEH box ONLY to the network cable, DO NOT attach to the printer at this time. Use a

crossover cable if you are connecting directly to a computer. Use a standard cable if you are connecting

using a ‘switch’, ‘router’ or ‘hub’. Crossover direct connection should not be used for production work.

• After completing 1 – 9 above, launch “InterCon – NetTools” from the desktop icon or find InterConTools

in your Programs folder.

• Double click on the IP address (most likely all zeros). (Loading properties menu should open).

• Select TCP/IP tab on the left.

• Remove the ‘checks’ in the boxes from all items except ARP/Ping. Specifically DHCP.

• ‘Check’ the TCP/IP box and Enter your IP address and submask then click OK. A Gateway is not

required.

CAUTION: The IP address must match all three of the first 3 triads (sets of three numbers) and the only

difference is the last ‘triad’ where the printer is usually ‘1’ number different from the computer. All four triads

of the SUB NET mask must match exactly as well.

• Select ‘rebuild’ on the Intercon NetTools menu. Verify the IP address line changes to your entered

address. The printer icon should show a red X through it.

• Connect the SEH box to the printer LPT port. The red X should come off when the printer is powered

ON. Click the Refresh or Rebuild buttons to make it change if it doesn’t automatically refresh itself.

Notice that the SEH utility now shows the name of the printer.

Print server is now configured for your network and IP address.

• Setup up your RIP software for the IP address of the SEH box.

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DIAGNOSTIC ASSISTANCE USING ‘FILE DOWNLOAD’ FEATURE OF THE SEH BOX.

Both the WEB interface (IP address in browser) or Intercon Nettools have the ability to transfer a file directly

to the IP address. This is important as sometimes the problem in the print is RIP related and if the RIP is

used to create a ‘test’ file then it could have the problem in it.

Mutoh provides a ‘test print’ file for each model of printer. For the Falcon Outdoor or Falcon Outdoor Junior

these files are a low ink density Diagonal nozzle check pattern designed to show whether ‘Step Adjustment’

is correct or not. (ignore the Distance Adjustment feature on the FO series). Once the ‘Step Adjust’ is dialed

in then images printed with the correct profile should be able to be printed.

Each of the SEH options have a ‘Download / file’ section where you will be prompted for a file. Locate the

‘testprint’ file that is appropriate

Please realize that a ‘light band’ can be either missing / misdirected nozzles or that Step Adjust is too high.

Confirm that nozzles are firing and then start this procedure for Micro Banding.

A ‘dark band’ can be from either Step Adjust being too low or it can be from the platen heater not being hot

enough. For this reason it is suggested that if no light band is showing then change the Step adjust higher to

create a light band. Then reduce the number in small steps until either you have no band or a slight dark

band remains. Once you reach this point adding ‘heat’ to the platen should then minimize the banding to an

acceptable amount for solvent printing.

Remember

1. Check nozzles first. Clean as required.

2. Dial out the light and first. Create a light band if necessary.

3. For the bark band that remains after dialing out the light band, start by increasing the platen heat in

small steps.

4. If a small dark band remains after step 3 then Adjust the ‘Step Adjust’ a little lower.

If increasing the platen heat does not remove the dark band then it may be that there is too much ink being

laid down so the RIP profile may need to be adjusted. Call your dealer for assistance with this RIP profile

possibility.

STEP ADJUSTMENT ‘MICRO-BANDING ELIMINATION ON FALCON OUTDOOR’

The nominal paper movement accuracy is ± 0.1 percent, or ±1 mm per meter of moving distance. Different

media types may show different behavior and when the paper movement error exceeds the target

specification, banding can occur. This banding can take the form of either thin dark or light horizontal bands.

If the above happens, these bands will occur in both bi-directional and unidirectional print modes. Thin dark

bands indicate that the printer firmware is under-compensating and that print swaths are overlapping.

Alternatively, thin light lines indicate that the printer firmware is over-compensating, and that print swaths are

not far apart.

The media feed micro ‘step adjustment’ feature gives the user the ability to set the step compensation

algorithm. To eliminate micro-banding, you can enter a positive or negative percentage of compensation, (±

3.00 percent), in 0.01 percent increments.

A positive value will extend the step and compensate for overlapping print swaths; a negative value will

shorten the step and compensate for non-butting print swaths. Some trial and error testing is typically

required to find the optimum value for any given media type.

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Plot OK

Step 1:

To enter the Menu system, press the [MENU] key.

* Menu * Command >

Step 2:

The key contents change to the yellow section on the outside of the

control panel. Bring up the “Function” menu by pressing the [Menu

up] key or [Menu Down] key.

* Menu * Function >

Step 3:

Press the [ENTER] key to enter the “Function” menu and shift to the

next level.

Step Adjustment : Change

Step 4:

Bring up the “Step Adjustment” item by pressing the [Menu up] key

or [Menu Down] key.

Step Adjustment : Clear

Step 5:

Press the [Value/+] or [Value/-] key to select “Change” or “Clear” and

press ENTER.

Step Adjustment : 0.00%

Step 6:

When pressing “Change”, enter the new value using the [VALUE/+] /

[VALUE/-] keys. Using the [MENU UP] / [MENU DOWN] keys,

you can select which digit you want to change. The value can be

changed in 0.01% increments.

Press [ENTER] to confirm the new value.

Step Adjustment : Change

Step 7:

If no other items are to be changed, press the [BACK] key.

* Menu * Function >

Step 8:

Do not press any other keys for 3 minutes or press [BACK] key

Plot OK

Step 9:

The permanent ONLINE-status display is restored.

Note:

To find the optimum correction value for a certain media, you will need to go through

a series of test cycles. Preferably send to the plotter a small test image such as a

neutral grey square (between 50% and 70% Grey) and check the micro-banding as

described above. Make a note of your correction value for a certain media type, as

the required value will always be the same for this media type.

Note:

Before using this function, always perform a nozzle-check to see if all nozzles are firing

correctly. Nozzles which are not firing or misfiring might mislead you when entering

correction values.

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1. SAFETY INSTRUCTIONS

1.1. INTRODUCTION

This chapter explains the meaning of safety terms for personnel who operate this equipment, important

safety instructions and the positions of the warning labels.

Important :

Be sure to follow all instructions and warnings on this manual when using the

equipment.

1.2. 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.

Safety terms Details

Important Must be followed carefully to avoid death or serious bodily injury

Caution Must be observed to avoid bodily injury (moderately or lightly) or damage to your

equipment

Notes Contains important information and useful tips on the operation of your printer

1.3. IMPORTANT SAFETY INSTRUCTIONS

General safety instructions that must be observed to use the equipment safely are explained below.

¾ Do not place the printer in the following areas. Doing so may result in the printer tipping or falling over

and causing injury.

o Unstable surfaces

o Angled place

o Areas subject to vibration by other equipment

¾ Do not stand on or place heavy objects on your printer. Doing so may result in the printer tipping or

falling over and causing injury.

¾ Do not cover the ventilation hole of your printer with cloth, such as a blanket or table cloth. Doing so

could obstruct ventilation and cause fire.

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¾ Do not place the printer in humid and dusty areas. Doing so may result in electrical shock or fire.

¾ Do not use a damaged power cable. Doing so may result in electrical shock.

¾ Do not attempt to plug in electrical plugs with wet hands. Doing so may result in electrical shock.

¾ Do not connect earth cables in the following areas.

• Gas pipes → Doing so may cause fire or an explosion.

• Earth terminals for telephone line or lightening rod → Doing so may cause a large flow of voltage if

lightening occurs.

• Water pipes or faucets → If there is a plastic part in the pipe, the earth will not work properly.

¾ Do not insert or drop metal or inflammable objects into openings, such as ventilation outlets. Doing so

may result in electrical shock and fire.

¾ Stop using your printer if a liquid is spilled into it. This may cause electrical shock or fire. Turn the

printer off as soon as possible, unplug the power cord, contact your local MUTOH dealer.

¾ Be sure to use the attached cable. Otherwise, electrical shock or fire may occur.

¾ Be sure to use the specified voltage (AC 100 V to 120V, or AC 220V to 240V). Otherwise, electrical

shock or fire may occur.

¾ Use electricity directly from a power outlet (AC 100 V to 120V, or AC 220V to 240V). Do not put many

loads on one electrical output. Otherwise, heat may be generated and cause fire.

¾ Be sure to use an outlet with an earth terminal and use the terminal correctly. Otherwise, electrical

shock or fire may occur.

¾ Follow the instructions below when handling the power cable.

o Do not modify the cable.

o Do not put heavy objects on the cable.

o Do not bend, twist or pull the cable.

o Do not wire the cable near equipment that generates heat.

¾ Follow the instructions below when handling the power plug. Otherwise, fire may occur.

o Wipe away dust and any other residue before inserting the plug.

o Ensure that the plug is firmly inserted as far as it will go.

¾ When handling ink cassettes, be careful that ink does not get in your eyes or on your skin. However, if

this happens, flush immediately with water. Otherwise, your eyes may become congested or inflamed

slightly. If you feel discomfort, consult a doctor immediately.

¾ Do not disassemble ink cassettes. Otherwise, ink may get in your eyes or on your skin.

¾ Be careful not to pinch your fingers when opening and closing the front cover.

¾ Follow the instructions below when connecting the network interface cable. Otherwise, electrical shock

or fire may occur.

o Do not touch the connector.

o Do not connect the network cable connector that is not the same specification to the interface board.

¾ When cutting the roll media, be careful of the following. Incorrect handling can result in injury to the

hands and fingers from the razor blade.

o When holding the media, do not place fingers over the media cut groove.

o Move the razor blade slowly along the media cutting groove.

¾ Do not use thinner, benzene, alcohol or other active agents. Doing so may result in damage or paint

peeling from the casing.

¾ Be careful not to spill water inside the printer. Doing so may result in a short circuit.

¾ Be careful not to touch the heaters during or after operation. Doing so may result in burns.

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¾ Only use Eco-Solvent Plus ink and appropriate Eco-Solvent Plus cleaning liquid. Using other ink (e.g.

dye or pigment) will cause permanent damage to the printer.

¾ Never open the covers fixed with screws. Doing so may result in electrical shock or a malfunctioning in

the printer.

¾ Do not touch the cutter blade. Doing so may result in bodily injury.

¾ Do not cut hard objects or drop the cutter. Doing so may damage or chip the cutter blade.

¾ Do not bend or pull the waste fluid tube. Doing so may cause that the waste fluid will leak out and

malfunction in the product.

¾ Do not touch the cleaning wiper or the head cap unit while cleaning the cleaning wiper. Doing so may

result in poor head cleaning because of oil on your hands.

¾ Do not tilt the printer, stand it against a wall or turn it upside down. Doing so may cause ink to leak

inside the printer. Movement after transport is also not covered by the warranty.

¾ When installing options, do not touch the elements on the circuit board. The elements on the boards

can be very hot and can cause burns.

¾ Have two or more people unpack and assemble the printer.

¾ When lifting the printer out of the packing box, be sure to remove the vinyl cover first, then grab the

holding grips on the sides of the printer. Lifting the printer with the vinyl cover on may cause your

hands to slip and drop or damage the printer.

¾ Have two or more people transport the printer.

¾ Ensure that the plug has been disconnected from the power socket when it is not to be used for a long

time.

¾ Earth wires must be connected to wires or terminals that fulfil the conditions below.

o Earth terminals of power sockets

o Earth wires with copper morsel that is at least 650 mm under the ground

¾ Earth wires must be connected to wires or terminals that fulfil the conditions below.

¾ When setting roll media, place it on top of a desk or other flat surface. Setting roll media with the

scroller standing up may damage them.

¾ Keep the printer horizontal during transportation.

¾ Be sure to do the following before attaching options.

o Turn the printer off.

o Unplug the power cord from the socket.

o Unplug cables connected to the printer. Otherwise, damage to the printer or your computer may

occur.

o Remove electrostatic charge from your clothes and body by touching the metal parts of the printer.

o Electronic components such as the memory may malfunction if exposed to an electrostatic charge.

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1.4. WARNING LABELS

Be sure to note the following when handling the labels.

Notes :

Make sure that all labels can be recognized. If text or illustrations cannot be seen

clearly, either clean or replace the label.

When cleaning labels, use a cloth with water or neutral detergent. Do not use a solvent

or gasoline.

If a warning label is damaged, lost or cannot be recognized, replace the label. When

replacing warning labels, contact your local MUTOH dealer.

Safety Labels are attached to the internal and external area of the printer to alert you to potentially

hazardous situations or conditions. The following safety labels are used in and on the printer:

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2. PRODUCT OVERVIEW

2.1. GETTING TO KNOW THE PRINTER PARTS AND

COMPONENTS

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N° Part Description

1 Cover

The protective cover protects the action environment. Opening the

cover immediately pauses printing which resumes when the cover is

closed.

2 Operation Panel

Positive touch keyboard with integrated LCD-Display.

3 Media Hold Lever

Lowers / releases pressure rolls to load / unload media.

4 Power switch

ON / OFF Power Switch.

Full shut down takes about 5 seconds.

5 Paper Basket

Media collecting basket prevents finished prints to fall on the floor

when they are sheet-off.

6 Print Plate

The print plate is a firm, flat base which supports the media during

printing.

7 Waste bottle

Collects Eco-Solvent Plus ink flow resulting from: purging, cleaning.

8

9

Paper Guide

The Paper Guide supports the media and incorporates the fixer (8;

heater element below printhead) and dryer (9; heater element)

10 Slip Ring

Prevent that Scroller to slip.

11 Eco-Solvent Plus ink

cassette slots

Hold / detect the Eco-Solvent Plus ink cassettes which are in use.

12 Scroller

Feeds through the roll media core to hold the media.

13 Scroller receiver

Set of 4 wheels which keeps the scroller into place.

Caution:

Do not put anything on the cover.

2.1.1

Explanation of fixer and dryer

Print Head

Media Direction

Fixer (Direct Heater)

Post Heater (dryer)

The FIXER will make it possible :

• To overcome the temperature gap between the room and the target printing temperature.

• To establish fast and immediate anchorage of the Eco-Solvent Plus inks onto/into the uncoated

substrate

• To optimize dot gain control on a wide media range

• To limit ink coalescence effect

The DRYER will make it possible

:

• To finalize the fixation process.

• Helps to make the prints touch-dry.

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3. SETTING UP THE UNIT

3.1. INSTALLATION REQUIREMENTS: SELECTING AN

ADEQUATE PLACE FOR SETTING UP YOUR EQUIPMENT

The location where you set up your equipment is very important. Please see to it that it meets following

conditions:

Power supply:

- Voltage: 200 to 240 VAC or 100 to 120 VAC

- Frequency: 50/60 Hz ± 1 Hz

- Current: < 10 A (110 V)

< 5 A (220 V)

Ambient conditions:

Operating environment

- Temperature: 18°C to 35°C

- Humidity: 20% - 60% non-condensing

- Recommended working environment

Temperature: 22-30°C

Humidity: 40-60%

Storage environment

- Temperature: -10°C to 60°C

- Humidity: 20% - 85% non-condensing

Variation rate

- Temperature: 2°C per hour

- Humidity: 5% per hour

¾ Avoid using your Falcon Outdoor Jr. printer near heating systems, such as stoves or heaters.

¾ Avoid using your printer under strong lighting, such as halogen lamps, light bulbs or direct sun light.

When selecting a place for your printer, leave at least 200 mm in front and at the sides, and 300 mm at the

rear, as shown in the illustration below.

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MUTOH Falcon Outdoor Jr. Operation Instructions Manual

MUTOH Falcon Outdoor Jr. Operation Instructions Manual

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