Toucan LT board printer Setup and Operating instructions Unpack the Toucan LT board printer as you would any Toucan LT. Follow all cautions associated with installing a standard Toucan LT. Change in wash instructions: Proceed with a single wash with Head conditioner because the printer has been inked up and tested during the manufacture of the board printer. Remember to verify flow of liquids through the printer during the wash and ink fill. Complete the installation of the Toucan LT: Align the printheads and print the copies of the Adjustment Parameter sheet and Test prints. One set are to be stored in the left end of the printer and one set to return to Mutoh America Inc. Follow the published Toucan LT installation document. February 21, 2006 1/12 Toucan LT board printer setup
Assembly and Setup of the Board printer: During the ink fill unpack the tables from their shipping box. Notice that on the front and rear of the Toucan LT Board printer there are two large brackets on which there is a large stainless mounting pin on each one. This pin will screw up and down as required in a later step. Mounting Pin on front and back of printer. Mounting Pin bracket on the sides of tables. The mounting pins are the main support on the right and left sides of each table where there is a corresponding mounting pin support bracket on each side of the table. Notice that the bracket in front of the ink pump station must be removed to verify ink flow during the wash and ink fill processes. A 3mm Allen wrench is required to remove the bracket. Identifying the tables and spacer fins: Tables: The rear table (at right) is identified by the absence of screws along the inside edge of the table. The outside edge is a finished edge while the inside edge (the edge closest to the printer) is smooth aluminum. The front table (at left) is identified by a row of screws, each with a rubber spacer, along the smooth aluminum edge. February 21, 2006 2/12 Toucan LT board printer setup
Tip: The front finished edges can be protected during everyday setup and teardown by saving two of the long protective foam packing bats that came in the original packaging to protect the table edges during shipping. When the table is to be stored the bats can be pressed in place along the front edge. When the tables are in use these bats can be placed underneath the printer table across the table leg braces. Spacer fins: There are 3 wider fins for the space over the dryer and 2 thin fins to bolt on the rear table. Assembly of the tables: Rear table assembly: The two stainless fins must be attached to the inside edge before being mounted to the printer. This attachment is done with machine screws and nuts that have a knurled edge. The knurled edge will pull tight into the holes and seat, becoming captive. Note: Remove the protective film BEFORE assembling the fins to the table. Align the two fins, side by side, so that they are flush with the top of the table. Insert the screws, start each screw first and then tighten them all. Note: In order to draw the knurl into the hole it may be necessary to hold the nut while tightening until it gets started, then tighten a little more to seat it. February 21, 2006 3/12 Toucan LT board printer setup
Mounting the rear table: Have two people set the table upright and raise the outside edge high enough for the side mounting brackets to clear the alignment pins and the fins to slide in under the rear static tinsel strip. Set the holes on the pins and then lower the outside edge till the feet touch the floor. First: Raise far end up to insert fin end into back of printer Second: slide table into back of printer Third: Once the table is inserted then lower the far end to set the alignment brackets onto the pins. Lower the outside edge until the feet touch the floor. Mounting the front table: Three large stainless fins are to be attached to the inside edge of the front table. This attachm ent can be done either before or after mounting the table. Remove the white protective film BEFORE attaching the fin. Align the holes (keyhole slots) in the fins with the screws, slide them in place and press down firmly. Set the alignment brackets onto the pins and lower the outside edge till the feet touch the floor. Confirm that the surface of the three front fins are level with the table. Adjust as required. February 21, 2006 4/12 Toucan LT board printer setup
When tables are mounted on front and rear the tables are now ready for leveling and final board position. Leveling the tables: Leveling the tables of the Toucan LT consists of leveling the tables to the height of the grid rollers and then dropping the inside edge of each table into their operational position. This final position is done to minimize drag of the board as it passes across the table through the printer. Use the leveler feet of the tables and the alignment pins of the printer to adjust both until the surface of the table is level with the grid roller. See diagram next page. February 21, 2006 5/12 Toucan LT board printer setup
Grid roller Note: If a four foot long level is not available then use a piece of rigid material to span the distance between the table and the grid roller. Check each table side level front to back and across the outside edge from right to left. Final adjustment of the tables: Once the tables are level to the grid roller, lower the mounting pins approx. ¼ to ½ turn. This should create just enough space so that a board passing through the printer stops touching the rear table about 4 inches prior to entering the back of the printer. February 21, 2006 6/12 Toucan LT board printer setup
The picture to the left shows a table, which is still too high where the media slides on the rear table to the end. There should be a slight gap between the board and the table starting at about 4 inches (at the arrow). The picture at right shows a front table which is lowered just enough so that the printed board does not touch the front table until about 4 inches onto the table. This same gap should be on both the front and the back tables. When properly aligned, the only thing the board should touch while inside the printer is the grid and pressure rollers. Remember to tighten the locking nut on the shaft of each leveling foot. All eight adjustable feet should be touching the floor. February 21, 2006 7/12 Toucan LT board printer setup
Operating the Toucan LT: The board printer can be operated in either Board or Roll modes. It is important to note that in order to switch back and forth the printer must be powered OFF and then back ON again. 1. Operating in Roll mode the Toucan LT Board printer works just like a Toucan LT. 2. Operating in Board mode requires answering a couple of questions upon Power ON: To operate in Board mode, Power ON the printer and answer Board to the first question on the display. (Board or Roll) Consider the next question with the word IS in front. IS the Y-rail set? Yes or No If NO is the answer then the printer will prompt with Set rail to highest height and insert board. Note: The Toucan LT is fitted with a crank at the far left end. Turning the crank Clockwise will Raise the pressure rollers up to a maximum height where media up to ½ inch can be loaded. Turning the crank Counter Clockwise will drop the Y rail down and as in the case with switching back to Roll mode it would be cranked down to the lowest position. With the crank turned so that the Y-rail is in the highest position load a board. Note: Remove the crank when you are not adjusting the Y-rail as its weight or someone touching it may cause the crank to turn. Loading and centering a board: The block of white polypropylene that has two pins inserted on one side is mounted into holes in the center of the Platen so that a board can be pushed through and centered from the back. It is imperative that this block be removed once the board is loaded straight and square in the printer. February 21, 2006 8/12 Toucan LT board printer setup
Caution: Failure to remove the block before the next step may result in damage to the printer. Look in from the front to insure that no pinch rollers are less than half on the edge of the media. Try to align the board edges so that a roller is either completely ON or OFF the board edges. Top arrow is the correct position, 1. a roller is completely ON the board. 2. edge of media is between two rollers. Bottom arrow is the incorrect position where only ½ or less of a roller is on the board. Once the board is properly aligned AND the block is removed, confirm the question on the panel by pressing ENTER. The printer will prompt to set the head gap. Down Y rail and set head gap. The head will unlock and move out to the center of the printer. Gently pull the head carriage down to the far left edge of the board. Aligning the head gap : 1. Use the head gap gauge and a flashlight to align the head gap. 2. With the head carriage at the far left end of the board, set the head gap gauge under the bumper under the left side of the head carriage behind the fan. View from table height to make this adjustment. Notice that the gauge has three heights; lowest = GO, not so low = No Go and the top of the gauge. Turn the crank to lower the carriage bumper until it just touches the lowest No Go height. February 21, 2006 9/12 Toucan LT board printer setup
Confirm this step is correct by manually moving the carriage, side to side so that as it touches the second setting (No Go) the gauge moves. Note: The bumper and board may not be completely parallel but lowering the carriage to the correct depth should move the gauge as mentioned above. Picture at left shows a gap between the bumper and the head gap gauge. Lower the carriage until the bumper touches the gauge. Picture at right shows no gap between the bumper and the head gap gauge. If the carriage can be moved back and forth over the No Go setting, without moving the head gap gauge, then the carriage must come down a little more. Once the contact of the bumper to the head gap gauge is correct the gauge should mo ve when the bumper presses against the NoGo height sliding the gauge sideways. 3. Final step is to adjust the crank additionally ½ turn DOWN. Caution: REMOVE the flat white block from the PLATEN before confirming. The head carriage will hit the white block if it is not removed. February 21, 2006 10/12 Toucan LT board printer setup
Press ENTER to confirm the completion of this step. The Board is now loaded properly in the printer but further menu items must be selected for optimal printing. Using board media: After setting the head gap with the gauge, the printer will display an initialization menu where the User can be changed or Top detect can be switched to OFF as desired. Note: Turning OFF Top detect ma y be helpful if profiles are being worked on or something has been previously printed on the board and it is not desirable to pass a printed image back under the pressure rollers. 1. With Top detect ON the printer will pull the board back to find the front edge. 2. With Top detect OFF the printer will only look for the right and left edges. Think of the board printer as being in permanent sheet mode. Tip: When you are doing profiles and don t want to have to reload the board each time, cancel the printing just as it finishes the last of the print. Normally everything will print but the printer will not see that the job was finished so it won t force the reload of the board. Note: If the media slips when the printer tries to scroll the board front to back or forward during printing then it may be necessary to add ¼ more turn DOWN on the crank. Caution: Excessive down force should be avoided as this may overdrive the PF motor circuit and may cause a system failure. Setting up the User media settings: Here are the recommended settings for the Users of board media: Note: Though all four Users are visible in both Roll and Board modes it is recommended that Users 1 to 4 be reserved for Roll media where three heaters are required. Select either of Users 5 to 8 as they are reserved for Board mode where only the Platen heater is required. Neither the Pre nor After heaters come in contact with the media when in Board mode so they are not an option while in Board mode. 1) Set the Head Height to Middle. 2) Set the Thickness to whatever media thickness was used during the Initial installation alignment procedure. The backlit material that may have come with the printer is approx 160 um (microns). 3) Change P Move to Machine. This will cause the printhead carriage to pass the full width of the printer during printing but it will give the ink the best chance to settle properly during printing. 4) Side Margin can be changed. The Toucan LT is capable of printing full bleed, edge to edge, However, there is a caution: Once the User is changed to 0mm, DO NOT perform a Check nozzle pattern. Doing so will cause a CPU error and force the restart of the printer. Also the default of any User is 5mm and when you select another User it will default back to 5mm. Even the first User will be 5mm when it is reselected. February 21, 2006 11/12 Toucan LT board printer setup
5) Distance adjustment: It is still important so run the Distance Adjustment for each board type. The dealer should install the Mutoh America TLTMOG pattern on the harddrive during the initial installation. ftp://ftp.mutoh.com/toucan%20lt/ Open the folder TLTMOG for Distance adjust Test for LT and download the file by the same name. Additional recommendations: 1) Send images in Uni-directional to give the ink a chance to settle properly. 2) Corona coating (roughening of the surface) will assist in minimizing banding or the reticulation effect. February 21, 2006 12/12 Toucan LT board printer setup