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Platestream 34 manual

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2. adjust the SOT sensor scan width Figure 1 11 Adjusting Scan Width and Linearity 1 From the RIP output the Grid12 ps file 2 Measure the distance between points A and C see Figure I 11 If the distance between and C is gt 12 000 30 48 cm turn the sensor position screw counterclockwise If the distance between and is lt 12 000 30 48 cm turn the SOT screw clockwise One full turn is approximately 0 030 0 08 cm To adjust the SOS sensor linearity Measure the distance between points A and B see Figure I 11 If the distance between A and is gt 6 15 24 cm turn the sensor position screw counterclockwise If the distance between A and B is lt 6 15 24 cm turn the SOS screw clockwise One full turn is approximately 0 015 0 04 cm Marker Position Adjustment Physical movement of the marker is not recommended There is however an operator panel adjustment to compensate for slight differences in marker location From the Main Menu on the control panel Press 4 More Information Press 2 Calibrate Press 4 Marker Position xx xx The image can be moved up to 0 05 0 13 cm A positive value moves the image towards the non operator side a negative value moves it towards the operator side l 17 INSTALLATION GUIDE Adjusting Image Length This procedure
3. 2 GENERAL INFORMATION CHAPTER 1 GENERAL INFORMATION Introduction The Printware Platesetter is a compact high resolution digital Platesetter for a range of small format printing applications Plates are exposed using a patented laser imaging system and auto matically processed Figure 1 1 illustrates a flowchart of the platemaking process The Platesetter is controlled by a Raster Image Processor RIP several different RIP options are available depending on the most common type of work to be done The system is driven by the host computer on which the operator composes the text and graphics to be imaged Once the print job has been composed on the host computer it is sent to the RIP where it is prepared for imaging The rasterized file is then sent to the Platesetter where the file is imaged onto a plate Figure 1 2 illus trates the basic system set up received the Feed Rollers The media is engage to pull the media pulled around the forward Capstan Roller 3 3 The laser light beam strikes and exposes selected areas of the RN EN media 4 The plate is fed through Oncethe entire page is the imager exit rollers imaged the media into the integrated advances to the cutter processor The media is cut toa specified plate length and punched 6 eo The plate is developed The finished plates fixed and dried are co
4. B 807527 001 REVISION Sheet 3 of 3 Printware Confidential Find Number 001 002 004 005 006 007 008 010 011 013 014 016 Quantity Component Used Lm Assembly Number 807535 001 KIT CABLES PLATESTREAM W SOFTWARE OPERATOR PANEL Number 807150 001 807203 001 807226 001 807530 001 807520 002 807521 001 803318 002 803319 002 803321 001 804140 002 803323 002 806306 002 Revision A Component Description Parts List Page 1 of 1 ASSY CABLE CONTROLLER PCA TO RIP ASSY CABLE POWER PROCESSOR ASSY CABLE INTERFACE PCA TO SOLENOIDS ASSY CABLE INTERFACE PCATO CONTROLLER PCA ASS Y CABLE INTERFACE PCA TO INDICATOR LIGHT ASSY CABLE RIP TO CONTROLLER PCA ASSY CABLE SCSI TO ENGINE ASSY CABLE POWER CONTROLLER FAN ASSY CABLE POWER ENGINE ASSY CABLE INTERFACE PCA TO SENSORS ASSY CABLE ENGINE TO STEPPER PCA ASSY CABLE MARKER FAN TH NT LN 7 A J A W 1 4 L Y L A AJIA AZ JU Wi ES 2 Al CHE BLL L OF Ma J U WA ia S Y KIT CABLES PLATESTREAM 807535 001 REVISION A Sheet 1 of 1 Printware Confidential
5. M E 1 ae PI 04 oZ p l z ja amp REPLENISH PUMP 807346 001 REVISION Sheet of 5 ASSY PROCESSOR MICROPLATE eo x Printware Confidential we Printware ASSY PROCESSOR MICROPLATE I 807346 001 REVISION H Printware Confidential Sheet 2 of 5 Printware Confidential JEEP GROOVE THIS SIDE Printware ASS Y PROCESSOR MICROPLATE 807346 001 REVISION H Sheet 3 of 5 y GROUND WIRE lL Pnnwar A ASSY PROCESSOR MICROPLATE 807346 001 REVISION H Printware Confidential Sheet 4 of 5 Printware Confidential Printware ASS Y PROCESSOR MICORPLATE 807346 001 REVISION H Sheet 5 of 5 Find Number 001 002 003 004 005 006 Quantity Component Used 02 9 Assembly Number 806710 001 ASSY DRIVE SHAFT PLATESTREAM PROCESSOR Number 806775 001 900960 019 901090 001 806824 001 900268 005 901079 001 Revision E Component Description Parts List Page 1 of 1 SHAFT DRIVE GEAR WORM BEARING THRUST BEARING FLANGE MOD PULLEY TIMING BELT 1 5 PITCH PIN SPIRAL Printware ASSY PROCESSOR DRIVE SHAFT 806710 001 REVISION E Sheet of 1 Printware Confident
6. 79 96 8 8 5 5 E 6 6 6 9 9 9 6 0 Figure I 5a Punch Alignment and Skew 1 23 INSTALLATION GUIDE Adjusting Punch Length with punch option installed 1 To enable the punch from the Main Menu on the control panel Press 4 More Information Press 8 Punch Press ON to turn the punch on 2 Run test plate with the punch on 3 Return to the Calibrate Transport menu Press 4 More Information Press 2 Calibrate Press 17 CalibrateTransport Punch Notches Larger punch length produces deeper notches Figure I 15 Adjusting Punch Length Bacher pattern 4 Measure the depth or position of the punch notch see Figure 1 15 or I 16 For the Bacher punch pattern see Figure I 15 the notch depth should be 0 433 11 0 mm For the pin bar pattern see Figure I 16 the center of the holes should be 5 16 0 313 or 8 0 mm from the edge 226 236 s oe ace eje s a e e e nm Figure 1 16 Adjusting Punch Length Pin bar pattern 24 INSTALLATION GUIDE 5 To increase the depth increase the value for Punch Length Adj and increase Backup Length Adj by the same amount there is a separate set of Backup Length values with the punch enabled Decreasing the values decreases depth 6 Ifnecessary follow the procedure for all resolutions to be used with the punch mode Punch and Backup Length are set inde
7. Printware 2 2 ASSY TANK EFFLUENT WITH CART ud asd 806816 002 REVISION F oe Printware Confidential Sheet 1 of Find Number 001 002 003 004 005 006 007 008 009 012 013 017 019 020 021 022 023 025 027 040 041 042 043 044 045 047 048 049 050 059 064 065 066 068 069 070 Quantity Component Used NO e 2 e Be Q Q N PB WR oo e e N e Assembly Number 806927 001 ASSY PUNCH PINBAR PLATESTREAM MICROPLATE Number 807415 002 901051 005 807460 002 901051 007 901051 008 900940 003 900940 004 900940 005 900289 003 901052 003 807301 001 900235 041 807450 001 806935 001 806934 001 807335 001 807336 001 806891 002 806936 001 900651 022 900651 020 900047 000 900445 006 900445 007 900236 008 900235 040 900233 003 900233 001 900288 006 900287 025 900521 002 900940 002 901051 002 807452 001 900053 002 806127 002 Revision J Component Description ASSY COMPRESSOR MODIFIED FITTING TUBE QUICK STRAIGHT ASSY PUNCH PINBAR 13 FITTING TUBE QUICK ELBOW FITTING TUBE QUICK STRAIGHT TUBING POLYURETHANE RED TUBING POLYURETHANE ORANGE TUBING POLYURETHANE GREEN BUSHING GROMMET SOLENOID AIR VALVE ASSY CABLE SOLENOID SCREW SHC 8 32 X 1 1 4 ASSY PLATE VACUUM BRACKET PUNCH MOUNTING NON OPERTOR SIDE BRACKET PUNCH MOUNTING OPERATOR SIDE GUIDE UPPER BUFFER GUIDE L
8. 2 2 Printware ASSY PROCESSOR 8071 79 001 REVISION U Sheet 4 of 5 Printware Confidential Printware ASS Y PROCESSOR 8071 79 001 REVISION U Sheet 5 of 5 Number Find 001 002 003 004 005 006 Quantity Component Used 02 9 Assembly Number 806710 001 ASSY DRIVE SHAFT PLATESTREAM PROCESSOR Number 806775 001 900960 019 901090 001 806824 001 900268 005 901079 001 Revision E Component Description Parts List Page 1 of 1 SHAFT DRIVE GEAR WORM BEARING THRUST BEARING FLANGE MOD PULLEY TIMING BELT 1 5 PITCH PIN SPIRAL rintware ASS Y PROCESSOR DRIVE SHAFT 806710 001 REVISION E Sheet of 1 Printware Confidential Find Number 001 002 003 004 005 006 007 008 Quantity Component Used 2 j Assembly Number 806714 001 ASSY DRYER DRIVE PLATESTREAM Number 900960 004 90027 1 004 900960 002 900582 007 900268 008 806770 001 900229 017 806729 001 Revision F Component Description Parts List Page 1 of 1 BEARING ROLLER BELT TIMING 1 5 PITCH 100 GROOVE GEAR WORM SINGLE PIN DOWEL 125 X 625 PULLEY TIMING BELT 1 5 PITCH SHAFT DRIVE BELT E RING 25 SHAFT CHANNEL DRIVE DRYER Pi Printware ASSY DRYER DRIVE 80671 4 001 REVISION F Printware Confidential Sheet of Number Find 001
9. 8 ep MOUNTED DN DIVIDER PANEL 65 INSIDE OF COVER Printware ASSY IMAGER 807741 001 REVISION C Printware Confidential Sheet 2 of 2 Number Find 001 002 003 004 005 006 007 008 009 010 O11 012 013 014 015 019 027 028 029 030 031 035 036 037 038 039 050 052 053 054 055 056 058 059 060 061 063 064 067 068 069 Quantity Component Used e WN WY WN NY NN WR Re N N a nnn Q BR BR OR N NN Assembly Number 807527 001 KIT CHASSIS PLATESTREAM W SOFTWARE OPERATOR PANEL Number 807449 001 807074 001 807447 001 807075 001 807078 001 807079 001 807212 001 807508 001 807213 001 900823 002 900594 004 900594 005 807445 001 806627 001 806615 001 901103 002 806635 001 806635 002 900821 002 901019 003 901019 004 807168 001 900173 007 900223 007 807214 001 900741 001 900445 006 900047 000 900233 003 900257 900223 007 900222 003 900904 002 900233 002 900160 010 900287 004 900233 808448 001 900969 001 900445 007 900160 005 900039 001 Revision B Component Description CHASSIS PLATESTREAM PANEL FRONT PLATESTREAM PANEL SKIN EXIT PANEL REAR PLATESTREAM HINGE CONTINUOUS COVER HINGE CONTINUOUS LOAD PANEL LOADING PLATESTREAM COVER TOP PLATESTR
10. ASSEMBLY ASSEMBLY B ASSEMBLY 0 ASSEMBLY N ASSEMBLY B MOTOR AND BELT ASSEMBLY Y Printware 3 ASSY ROLLER TRANSPORT 807244 001 REVISION S Printware Confidential Sheet 5 of 5 Number Find 001 002 003 004 005 006 008 009 010 011 012 013 014 015 016 018 019 020 021 022 023 024 025 026 027 029 030 031 Quantity Component Used U A OWN 1252 CORK Ne me e RR Re Assembly Number 804627 001 ASSY CAPSTAN DRIVE PLATESTREAM Number 804370 001 804357 001 804356 001 804358 001 804355 001 804354 001 803391 001 804359 001 900800 001 90078 1 008 804628 001 900767 001 900296 900229 001 900340 900235 013 900047 002 900287 020 900160 005 900336 001 900047 003 900652 014 900288 000 900445 900223 005 900226 004 900340 003 900160 006 Revision L Component Description PLATE DRIVE MOUNTING PLATE PULLEY MOUNTING BASE PLATE PULLEY MOUNTING LEFT SIDE PLATE PULLEY MOUNTING RIGHT SIDE PLATE MOTOR BRACKET MOUNTING BRACKET MOTOR MOUNT CAPSTAN PLATE CAPSTAN DRIVE BEARING ADJUSTABLE PULLEY COATED CAPSTAN LOWER BELT FLAT BELT FLAT 11 5 X 4 X 18 ASSY MOTOR STEPPING GROMMETS VIBRATION ISOLATOR BEARING BALL FLANGED E RING 1 4 SHAFT SCREW SOCKET HEAD CAP 10 32 X
11. EE 41414454 CABLE 803318 002 1 BROWN D BROWN 1 id i gt rp TD STEP ENGINE STEPPER PCA POWER 1 3 ORANGE FD STEP ORANGE 3 y SUPPLY 10 i YELLOW GND YELLOW 4 523190 004 WHEEL CUTTER 1 2 s S GREEN 5 3 BLACK 3 E a eo J1 NU E EE 8 GRAY GRAY 8 lt mum 7 5 1j BLACK BLACK IO 803666 001 J m UEM S SCHEMATIC PAGE 5 12 RED 12 GR INTERFACE PCA 1j ORANGE N ORANGE 13 L 523060 001 1 YELLOW EX STEP YELLOW M L BLACK 23 002 1 ware BLU TS1 ow IS GREEN EX STEP 15 2 YELLOW 2 E2 Rn inn POWER SUPPLY 1 BLUE GND BLUE 1 00 D ie H 17 VIOLET EX RESET VIOLET 17 4 WHITE z a BLACK 1 GND 220V 2 SCHEMATIC PAGE 4 IS GRAY EX RESET GRAY 1 L2 19 WHITE GND WHITE 19 CAPSTAN STEPPER z J1 NU 37 BLACK cur SP BLACK 2 21 BROWN CUT STEP BROWN 21 22 RED GND 3i ORANGE CUT RESET ORANGE 2 MARKER TRANS 24 YELLOW CUT RESET YELLOW H 1 BLACK 303323002 1 1 BLUE 25 GREEN GND GREEN 25 2 YELLOW e i 27 VIOE VIOLET 77 3 WHITE a 4 BLACK deu 28 GRAY GND GRAY 2 Bog EREE 29 WHITE STEP SYNC WHITE 29 ixi Sierras 35 52 HHBE zz J6 NU 30 BLACK STEP SYNC BLACK 30 s03666 001 BRE ees 14 E 3L BROWN GND BROWN 31 31 RED SPARES
12. 29 Interface PORA 32 Engine Stepper 34 Power Supply 37 bane 38 Chapter 5 Troubleshooting Introductlon 42 Exposure Problemi sospetto 43 Image QualityProblems Artifacts 45 Registration and 5 47 SERVICE MANUAL SERVICE MANUAL Operator Panel 49 Marker Galvanometer 50 General Imager 52 Media Jams Imager 57 Imager Module Sensor Problems 58 6 Devices vest one 59 Punch Problems t Reni des 60 Processor 5 22 nennen nnne 62 Processing Quality Problems Artifacts 64 Processor Mechanical Problems 66 Processor Sensor 67 Processor Electrical Problems
13. Platesetter processor chemistry is dirty IN CASE OF TROUBLE SOLUTION 1 Check and replace if necessary 2 Check the balance and correct if neces sary 3 Deglaze the rollers or blanket 4 Check the pressure and adjust if neces sary 1 Adjust the exposure in the Platesetter Setup menu on the control panel per plate Media Manufacturer s instruc tions 1 Clean processor and replace processor chemistry 2 Call for service 1 Clean the Platesetter rollers 2 Replace the plate material 3 Replace processor chemistry 7 4 IN CASE OF TROUBLE PROBLEM Plugged Images or Excessive Back ground Wrinkled Cracked Plates Plates have Short Press Life 75 CAUSE 1 The exposure is set too high Bad plate material The press plate clamp is improperly set Press pressure is exces sive Press blanket surface is too harsh There are abrasive particles in the press ink The press ink fountain balance is incorrect The press ink is too tacky 6 Platesetter Processor chemistry is depleted 7 Marker out of focus SOLUTION 1 Adjust the exposure using the Platesetter Setup menu on the control panel 2 Replace plate material k Check handling techniques when mounting plates and check the uniformity of the plate clamp Adjust the pressure 2 Change to a softer smoother blanket Replace the ink 4 Adjust the
14. Figure 54 2 Front View of the Imager 40 SERVICE MANUAL 41 This page intentionally left blank SERVICE MANUAL CHAPTER 5 TROUBLESHOOTING Introduction This chapter contains procedures for isolating and correcting Platesetter problems in the field SZ CAUTION Operations with this symbol require advanced technical training 42 SERVICE MANUAL EXPOSURE PROBLEMS Weak image broken type or fine lines pinholes in solids Plugged images or exces sive background 1 Verify that exposure is set correctly by checking D ax see Operator Guide for details Laser power too high can cause text to break up on press output not the plates 2 Reduce laser power 1 Verify that exposure is set correctly by checking D Laser power too low can cause plugged images and excessive background on press output not the plates 2 Increase laser power Setup ESC to exit T 2 3 4 5 Js Image Negative Right Reading Resolution 800 DPI Image Power 25 Media Width 13 12 Spool Pos 13 Media Upper Spool Input Spool A Destination Processor Display Units English 43 ON ESC OFF ENTER Setting laser power setup menu item 3 EXPOSURE PROBLEMS cont Uneven density from center to edges Hazing on fine print or fine lines Going around in circles adjusting laser power S22 be SERVICE MANUAL
15. 32 Filling the Processor Tanks 33 Loading Plate Media eee 3 5 Imaging Plates cesses iecore cese e e teet nez ds 3 8 MiniPlate enn 3 10 MicroPlate Option oie ee eed 3 11 Film ente 3 11 Loading Optional Film 3 12 Chapter 4 Operating the Platesetter Controlling Image 4 2 Adjusting 4 2 Responding to Control Panel Error Messages 4 3 Chapter 5 Supplies Introduction ave cate y 5 2 CONTENTS CONTENTS Recommended Consumables H 5 3 Tips on 5 4 Chapter 6 Preventive Maintenance IntrodUGtlOn 6 2 Maintenance 1 e 6 3 Chapter 7 Troubleshooting Print Quality 22 7 2 General 7 7 Clearing Media Path standard 7 10 Clearing Media Path MicroPlate Model 7 12 Calling for nennen 7 14 Appendix A A 2 Appendix B 2 0 4 444450000 2 Appendix C Halftoning
16. Printware ASS Y SPOOL 807096 001 REVISION D Printware Confidential Sheet 1 of 1 Find Number 001 002 003 004 005 006 007 009 010 011 012 013 014 015 016 017 018 019 020 021 022 023 024 025 026 029 030 031 032 033 034 035 036 037 038 039 040 041 042 043 044 045 Quantity Component Used N e N e e N e N Lk e Ome Assembly Number 807179 001 ASSY PROCESSOR PLATESTREAM Number 806743 001 806713 001 900960 005 806733 001 806824 001 900289 003 806786 001 807497 001 806710 001 806714 001 807494 001 806724 001 806727 001 807495 001 900289 004 806792 001 900338 001 900053 002 806715 001 900302 008 806769 001 600333 001 806731 001 807328 001 807327 001 806701 001 806702 001 806725 001 900338 002 806793 001 807204 001 900040 003 600330 001 806831 001 806704 001 806705 001 806788 001 806789 001 806790 001 523200 001 806708 001 806703 001 Revision U Component Description PANEL SUPPORT RACK ASSY CLUTCH SHAFT BEARING ROLLER BRACKET CLUTCH BEARING FLANGE MODIFIED BUSHING GROMMET ASSY TEMPERATURE PROBE ACTIVATOR ASSY LEVEL SENSOR ASSY DRIVE SHAFT ASSY DRYER DRIVE SUPPORT UPPER DUCT RAIL RIGHT GUSSET RAIL DRIVE FRAME DRIVE DRYER BUSHING GROMMET ASSY CABLE P3 TO J14 MOUNT TIE ANCHOR NYLON TIE NYLON ASSY DRAIN C
17. 1 SOLUTION Ensure that the Platesetter is plugged in Check the fuse or breaker for the outlet Try unplugging the Platesetter and plugging another electrical item into the outlet to be sure that it has power The Platesetter may not have completed its power up sequence When the Platesetter is ready the Main Menu will be dis played on the control panel with On Line indicated and no error messages Ifan error is reported on the control panel correct the problem following the procedure in Chapter 4 then press ESC and 43 Ensure that the interface cable between and the Pla tesetter is securely connected at both ends Cycle the Platesetter power Reboot the RIP Media must be reloaded after jams or other fault conditions to prevent a reoccurrence of the jam 2 3 Reload Media message should clear after reloading If message does not clear check for defective sensor PROBLEM No Plate Exits from Platesetter Plates Jam Skewed Wrinkled or Torn Plates IN CASE OF TROUBLE SOLUTION 1 Ensure that the Platesetter is not out of plate media 2 Ensure that the plate media is properly loaded and aligned 3 Open the covers and check media path See chapter 7 Clearing Media Path 4 Inspect and clean the feed rollers See chapter 7 Clearing Media Path 1 Ensure that plate media is properly loaded 2 Clean the rollers see Chapter 6 3 Replac
18. 525 52 4 P13 2 ca TS2 4 P4 2 52 5 P13 3 TS2 5 P4 3 acai TS2 6 3 4 sse TS2 7 4 1 152 7 ACT TANK HEATER TS2 B ACT TANK HEATER rid 9 O 5 ram On 7 05796 00 J A Lr N 1 J EE E Co 5 AP Printware Confidential BLOWER FAN MOTOR Printware ASS Y ELECTRICAL PANEL 806708 001 REVISION E Sheet of Number Find 001 002 004 008 009 010 012 013 014 016 017 018 Quantity Component Used gt N Ne oo Assembly Number 808228 002 ASSY TRANSPORT DRYER ROLLER PLATESTREAM Number 808229 001 806751 001 901077 001 900230 002 806747 001 900229 019 901079 001 806649 001 806649 002 807352 001 807351 001 900005 002 Revision C Component Description RACK PANEL ROLLER FOAM ROLLER DRYER
19. Add 30 sec to each time for the PlateStream 46 56 SERVICE MANUAL MEDIA JAMS Imager Module Media will not load past Guide B Media gets dog eared before going into cutter Media buckles in feed section Guide A x Media jams in Guide B machine produces 3 5 media strips Media jams in cutter 57 1 If the corner of the media is being dog eared before going into cutter inspect shutter for prob lems 2 Update Shutter assembly with teflon tape 1 Verify that the shutter plate isn t hitting the capstan roller To adjust loosen screws on the outside of the transport on the operator and non operator side Adjust the shutter plate to 1 32 to 1 16 0 8 to 1 6 mm from the capstan roller 2 Adjust the moveable shutter arm farther out 3 Ifthe media is stubbing on the shutter upgrade with a shutter assembly with Teflon tape on the shutter 1 Verify that edge guides are aligned with spool see Operator Guide for loading procedure Check adjustment of Feed Loop Switch Verify that feed rollers are turning Verify that feed are backing up Check that marker transport belts aren t slipping Adjust Marker Transport motor speed UL d 1 1 Check for small pieces of media stuck near the cutter NOTE This problem is often reported after an error message prompts the user to cut a plate If the cut plate is not removed Guide B jams can result Current firmware prom
20. Dirty silver colored spots Clean infeed and pinch rollers with D Ink 46 SERVICE MANUAL REGISTRATION AND SKEWING Image length incorrect too long or too short Image width incorrect too wide or too narrow First plate after a load misregistered on process color jobs 47 Run a Printware Grid18 from the RIP Check to be sure scaling in RIP is set at 100 Then mea sure If source of problem is platesetter errors of less than 250 3 mm can be corrected with the Opera tor Panel length adjustment procedure see Opera tor Guide Run a Printware Grid18 from the RIP Check to be sure scaling in RIP is set at 100 Then mea sure If the source of problem is indeed platesetter errors of less than 1 8 3 mm can be corrected by realigning the SOS and SOT sensors Check loading and guide positions Consider sending blank or test plates before color jobs to eliminate first plate skew REGISTRATION AND SKEWING cont SERVICE MANUAL Tracking or skewing problems 1 Adjust roller spring tensions X Tools required tension gauge pull gauge or fish scale 1 1 Attach a 2 wide 50 mm strip of thin 0 004 or 0 005 0 1 mm polyester media to the gauge Slide the strip between the roller pair to be tested and measure the force required to pull the media strip out of the roller pairs force should be the same from side to side 1 2 Adjust roller tensioner screws on eit
21. Find Number 001 002 003 005 006 007 009 010 011 012 013 014 015 016 017 018 019 020 022 023 030 031 042 049 050 051 054 055 056 057 058 064 065 067 069 071 072 073 074 075 076 076 Quantity Component Used N N NY NY Ne N N N Ne e CN FD Assembly Number 807244 001 Number 807178 001 807169 001 822307 900297 001 803305 001 806308 001 804621 001 807350 001 804604 001 900229 002 900360 000 900928 002 901023 001 900871 008 803418 002 803418 001 806870 001 804627 001 803463 001 803466 001 807236 001 806327 001 803744 001 806309 001 807091 001 901026 001 806623 002 806617 001 806618 001 901102 001 901070 003 803741 002 803772 001 900569 001 900569 008 807175 001 807176 001 807217 001 807218 001 807219 001 807325 001 807326 001 ASSY ROLLER TRANSPORT PLATESTREAM Revision S Component Description WELDMENT 13 ROLLER TRANSPORT ROLLER FEED 13 WASHER PRELOAD SPRING MOTOR TRANSPORT BEARING BALL RETAINER BEARING BRACKET CAPSTAN DRIVE MOUNTING ROLLER SUPPLY TAKE UP 13 SEGMENTED ROLLER PINCH TRACTION 13 ROLLER ALUMINUM CAPSTAN E RING 3 8 SHAFT WASHER WAVE SPRING 22MM O D X 01 NUT HEX JAM 5 8 18 TPI BUTTON MARKER LOCATING POST ADJUSTABLE SCREW SHC LOW HEAD 1 4 X 1 5 X 28 TPI ASSY LOWER PINCH TENSION ASSY LOWER PINCH TENSION SPRING
22. ACTIVATOR SLM AC STABILIZER SLM ST 5 3 SUPPLIES Tips on Supplies To get the best performance from your Platesetter follow these guidelines for storing and handling supplies Plate Media Handle imaging media by the ends Avoid excessive touching of the surface of the media Store media rolls upright on end not on their sides prevent the crushing of media avoid placing other objects on top of the media rolls Store all media as recommended by the manufacturer Plate material will absorb moisture in humid environments and lose moisture in dry environments which will affect print quality However the plate material may not be permanently damaged Improperly stored plate material will recover if stored for an extended period with the bag open in ideal humidity conditions For optimum print quality use only recommended media Do not load media that is wrinkled or torn Processing Chemistry Use only recommended processing chemistry Carefully follow all label instructions for mixing and use After use recap activator and stabilizer solution bottles tightly Store all chemicals in a well ventilated area Follow the manufacturer s instructions regarding safety storage temperature humidity and other environmental factors Rotate supplies to use the oldest items first Disposal of all chemicals must meet local environmental codes 54 6 PREVENTIVE MAINTENANCE
23. Examine the Platesetter output The most likely indications of dirty mirrors are light vertical streaks of varying width and vertical lines with fuzzy edges Turn off the Platesetter Open the top cover and raise the marker assembly Inspect the folding mirror through the marker assembly cover aperture using a flashlight See Figure 52 1 Examine the mirror for dust Cleaning the Folding Mirror Using Compressed Air CAUTION Do not remove the Marker Cover at this time Do not touch the mirror surface with your fingers Perform this procedure only if 1 Dust particles can be seen on the Folding Mirror 2 Printed plates have silver vertical streaks or vertical lines with fuzzy edges 1 Hold the compressed air canister upright and direct the nozzle or extension tube toward the mirror surface 2 Gently blow the dust away Short quick blasts of air are more effective than continuous spray ing SERVICE MANUAL Getting authorization to remove the Marker Lower Cover On the marker lower cover are two seals which read Warranty Void If Seal Broken Refer to Figure 52 1 In situations where the marker is under warranty the warranty will be void if the marker lower cover is removed without prior authorization Only Printware authorized technicians may remove the Marker lower cover after receiving authorization from Printware Technical Support To obtain authorization to remove the lower cover contact Printware Technical Su
24. SCREW B H TORX 8 32 X 5 WASHER FLAT STEEL 8 SPACER 171 I D 25 O D 25 HEIGHT Assembly Number 807527 001 KIT CHASSIS PLATESTREAM MICROPLATE W SOFTWARE OPERATOR PANEL Revision B 071 1 807473 001 PANEL REAR LOWER PLATESTREAM MICROPLATE 4 Printware KIT CHASSIS MICROPLATE 807527 001 REVISION B Printware Confidential Sheet I of 3 e BE S gt aS 2 Z 807527 001 REVISION Sheet 2 of 3 Printware Confidential Printware KIT CHASSIS MICROPLATE 807527 001 REVISION B Sheet 3 of 3 Printware Confidential Find Number 001 002 004 005 006 007 008 010 011 013 014 016 Quantity Component Used Lm Assembly Number 807535 001 KIT CABLES PLATESTREAM MICROPLATE W SOFTWARE OPERATOR PANEL Number 807150 001 807203 001 807226 001 807530 001 807520 002 807521 001 803318 002 803319 002 803321 001 804140 002 803323 002 806306 002 Revision A Component Description ASSY CABLE CONTROLLER PCA RIP ASSY CABLE POWER PROCESSOR ASSY CABLE INTERFACE PCA SOLENOIDS ASSY CABLE INTERFACE PCA CON
25. al DRYER HEATER I EF 806712 001 E DAS 06 21 00 Bg d BLACK ENG PRINTWARE INC Ae E i IN 2 wc ST PAUL MN m EN min 11 BROWN z QA MATERIAL BLUE al GREEN TOLERANCE UNLESS OTHERWISE SPECIFIED ANGLES BROWN l l l 2 21 Di Lem 9 GND POWER SUPPLY PLACE DECIMALS nud FINISH m 2 PLACE DEC ere 1 YELLOW GREEN L 220V 8 Miser 12 Title PUMPS 806843 001 Bs GREEN Z COMM CODE Size 700629 001 INSP VERSION REV FIRST USED ON B E A SCHEMATIC PAGE 6 Teproduced copied disclosed to others or disposed o directly or indreetly wi out SCALE NONE tion from Printware Inc Both the document and its contents are to be treated as confidential amp Sheet 6 of 6 proprietary and may not be used any manner not consistent with the rights of Printware Inc 1 2 3 4 5 6 PlateStream PD MH Platesetter PLATESTREAM ILLUSTRATED PARTS MANUAL ES Printware LEADERS IN COMPUTER TO PLATE 700551 Rev D Find Number 001 001 002 002 003 003 004 005 010 010 Quantity Component Used FEB OO Be ee Assembly Number 807240 XXX PLATESTREAM DOMESTIC amp INTERNATIONAL WITH RED OR INFRARED LASER Number 807241 001 807741 001 807245 001 807245 002 807046 001 807046 501 900047 000 900445 006 807117 001 807117 003
26. nated 6 The Platesetter Processor 6 Replace Platesetter Processor chemistry chemistry is depleted 7 2 CASE OF TROUBLE PROBLEM Image Binding faint reproduction 7 3 CAUSE 1 Nn e The press ink fountain bal ance is incorrect The press pressure 15 insuf ficient The press ink rollers are glazed The paper is clinging to the press blanket The press fountain concen tration 15 too strong The press blanket was not dry on roll up The press blanket is glazed SOLUTION 1 Check the balance and correct 1f necessary Check the pressure and cor rect if necessary Deglaze the rollers Check the paper supply and clean the blanket Replace with correct concen tration Allow the blanket to dry be fore roll up Deglaze the blanket Slow Roll up or Poor Ink Transfer Weak or Uneven Image lose fine lines pinholes in solids Fuzzy or Blurry Image Marks on Plate or Scratched Plates N U CAUSE 1 The press fountain concentra tion or ink is incorrect The press ink fountain balance is incorrect The press rollers or blanket is glazed Press pressure is insufficient Exposure laser intensity is set too high Platesetter processor chemistry is dirty N Laser is out of focus Platesetter rollers dirty N Bad plate material
27. 1 4 REGULAR NUT RECEPTACLE RETAINING RECEPTACLE 1 4 TURN RING EXTERNAL RETAINING FASTENER 1 4 TURN PUSH BUTTON PLATE BACKING SPOOL 06 PLATE BACKING SPOOL 020 PLATE BACKING SPOOL 015 RECEPTACLE SPOOL COND NUT LOCK 6 32 E RING 75 SHAFT SCREW SOCKET HEAD SHOULDER 8 32 X 2505 E RING 625 SHAFT SCREW PAN PHILLIPS PANHEAD 4 40 X 75 NUT LOCK 44 40 SCREW B H TORX 8 32 X 375 WASHER EXTERNAL LOCK 8 SCREW B H TORX 8 32 X 5 SPRING COMPRESSION 75X 360X 038 WASHER EXTERNAL LOCK 46 SPRING COMPRESSION 1 X 660X 072 KNOB KNURLED SHC 8 SCREW FLAT HEAD 6 32 X 38 276 277 278 280 281 282 283 287 290 294 295 297 298 299 300 305 306 307 308 309 310 311 312 313 316 317 318 319 320 321 322 323 325 326 327 328 329 330 331 332 333 334 335 336 38 N N NFP ON NY Nme Ne GQ 2 29 F2 9 N OO 29 OO OO NO 9 tA Assembly Number 807444 001 ASSY ROLLER TRANSPORT PLATESTREAM MICRO PLATE 900160 005 900233 003 900235 000 900277 004 900963 002 900236 005 900224 005 900235 002 900224 001 900928 003 900235 040 900160 012 900235 041 807093 001 807093 002 900257 900223 007 900222 003 90065 1 019 900445 009 900287 008 807225 008 807231 001 80723 1 002 807093 003 807093 004 807093 005 808201 001 808201 002 807352 001 900369 001 808201 005 808201 006 807091 005 803557 001 900336 000 900287 029 900160 004 900254 003 9
28. 25 SCREW PHILLIPS PANHEAD 6 32 X 7 16 WASHER FLAT STEEL 6 RING GRIP NUT LOCK HEX 6 32 ASSY PUNCH CHIP COLLECTOR SHAFT 19 75 SCREW PHILLIPS PANHEAD 6 32 X 1 25 BRACKET LOWER SOLID MOUNTING PUNCH ASSY CUTTER 13 SCREW SOCKETHEAD CAP 58 32 X 1 1 4 Parts List Page 1 of 1 D LAMP FIXE WASHERS 2 DETA SEE DETAIL A Printware ASSY PUNCH BACHER 220 G 806925 001 REVISION Sheet of 1 Printware Confidential Find Number 001 002 003 004 005 006 007 008 009 012 013 017 019 020 021 022 023 025 027 040 041 042 043 044 045 047 048 049 050 059 064 065 066 068 069 070 Quantity Component Used NO e 2 e Be Q Q N PB WR oo e e N e Assembly Number 806927 001 ASSY PUNCH PINBAR PLATESTREAM MICROPLATE Number 807415 002 901051 005 807460 002 901051 007 901051 008 900940 003 900940 004 900940 005 900289 003 901052 003 807301 001 900235 041 807450 001 806935 001 806934 001 807335 001 807336 001 806891 002 806936 001 900651 022 900651 020 900047 000 900445 006 900445 007 900236 008 900235 040 900233 003 900233 001 900288 006 900287 025 900521 002 900940 002 901051 002 807452 001 900053 002 806127 002 Revision J Component Description ASSY COMPRESSOR MODIFIED FITTING TUBE QUICK STRAIGHT ASSY PUNCH PINBAR 13 FITTING TUBE QUI
29. 31 GR 33 ORANGE SPARES ORANGE 22 Js 34 YELLOW GND YELLOW 34 DECURL EXIT 1 BLACK 303323 002 1 1 WHITE BLU 35 GREEN FD ITR DIR E 2 YELLOW 2 E2 i 36 BLUE FD TR DIR 36 3 yaw 806792 001 4 37 VIOLE GND VIOLET 537 37 WHITE 3 4 BLACK H 38 GRAY 5 GRAY 7 EFFLUENT TANK LEVEL PROCESSOR H J4 INU wine wire 523150 001 CABLE 806306 002 40 BLACK BLACK 40 PS 806815 002 4 BROWN BROWN 41 41 RED SCHEMATIC PAGE 6 3 ORANGE ORANG 806790 001 44 YELLOW YELLOW 44 CUTTER ASSY ORANGE 45 GREEN EX DIR GREE 45 5 1 WHITE 2 46 BLUE GND BLUE 46 REPLENISHMENT TANK STAR 47 VIOLE SPARE2 VIOLET 47 SHEAR CUTTER 1 BLACK 1 1_BLACK curre 94 i CODING FAN as GRAY SPARE2 GRAY is 3 wie 2 gt ve SENSORS 806709 001 45 WHITE GND WHITE J8 au 54 i xu 30 BLACK GND BLACK so RED J Deo f concors 806793 001 PNG ORANGE CABLE 804140 002 BLACK 1 TNO Wie WORKING TANK CABLE ORAN L BROWN NO MEDIA 3v 1 YZK RED NO MEDIA SIG E SENSORS 806800 001 NU 807226 001 07 nue ce SENSOR NO 807091 001 ware D 3 YELLOW LOAD OK 35V SHUTTER E 24V T 5 SEEN TOAD OK 90 SENSOR NO 1 806789 001 SOLENOID Iu ORANGE 1 6 BLUE LOAD OK GND Yt B mE 5 SOTER PAYS gt WHITE 3 T VIOLET LOAD KNOB 5V 507091001 3 EXIT SWITCH BLACK 2 WHITE ORANGE 3 GRAY LOAD KNOB SIG LORD NOR w mg 3 TER wur SHUTTER DRV WHITE 4
30. 5 SCREW SOCKET HEAD CAP 26 32 X 25 WASHER EXTERNAL LOCK 6 SCREW PAN PHILLIPS PANHEAD 48 32 X 1 WASHER FLAT STEEL 8 NUT SELF LOCKING HEX 28 32 WASHER EXTERNAL LOCK 10 SPACER ROUND 8 X 1 4 SCREW PILLIPS PANHEAD 10 32 X 5 SCREW B H TORX 10 32 X 625 WASHER LOCK HELICAL SPRING 10 SPACER SHAFT SCREW SOCKET HEAD CAP 10 32 X 75 WASHER FLAT STEEL 10 Parts List Page 1 of 1 Printware ASSY CAPSTAN DRIVE N i A 59 Ye dE NN JAM L 804627 001 REVISION Sheet of 1 Printware Confidential Number Find 001 002 003 004 005 006 007 008 014 016 800 Quantity Component Used N A CO A ORR Assembly Number 803666 001 ASSY MOTOR MOUNT PLATESTREAM Number 806098 002 803665 001 806199 001 900767 001 900652 014 900287 016 900160 004 900336 000 900160 011 900235 013 807439 001 Revision P Component Description ASSY MOTOR TAKEUP DRIVE BRACKET MOTOR MOUNT PULLEY MODIFIED GROMMETS VIBRATION ISOLATOR SPACER ROUND 8 X 25 SCREW PHILLIPS PANHEAD 6 32 X 1 WASHER FLAT STEEL 6 NUT LOCK HEX 6 32 WASHER FLAT STEEL 6 SCREW SOCKETHEAD 6 32 X 25 ASSY BLOCK MASS MAY NOT BE USED Parts List Page 1 of 1 Printware Confidential 600 IF REQUIRED e Printware ASSY MOTOR MOUNT 803666 001 REVISION P Sheet of 1 Number Find 001 002 003 00
31. 806912 001 807467 001 807072 001 807457 001 807115 001 807115 002 900047 000 807237 001 900229 010 807091 001 900235 020 900233 002 900160 010 90034 1 007 900445 007 Revision J Component Description ASSY CASSETTE TAKEUP ASSY SUPPLY CASSETTE 280 RECEPTACLE CASSETTE BOTTOM RECEPTACLE CASSETTE TOP COND BLOCK TAKEUP CASSETTE MOUNTING BLOCK TAKEUP CASSETTE MOUNTING WASHER EXTERNAL LOCK 8 PIN SWITCH ACTIVATOR E RING SAE 125 ASSY SWITCH SCREW SHC 4 40 X 1 75 NUT LOCK 4 40 WASHER FLAT STEEL 4 BUSHING SPACER NYLON 6 32 X 1 SCREW B H TORX 8 32 X 5 Parts List Page 1 of 1 Printware ASSY FILM OPTION 807152 002 REVISION OR REFERENCE ONLY SHOWN M PART Sheet of 1 Printware Confidential Number Find 001 002 006 007 012 013 014 015 021 024 027 028 029 030 031 032 033 034 035 036 037 039 040 041 Quantity Component Used UN Assembly Number 807467 001 ASSY SUPPLY CASSETTE Number 806625 002 806626 002 807144 002 900236 015 807464 001 807466 001 807466 002 807463 001 900774 002 900237 004 806416 003 807437 001 807454 001 807454 002 807472 001 900047 002 900445 004 900233 900047 000 900287 003 901244 001 900160 005 900157 006 807559 001 280 Revision E Component Description ASSY SPOOL PLATE ADJUSTABLE ASSY SPOOL PLATE FIXED AXLE INPUT CASSETTE SCREW SOCKET HEAD SHOULDER 8
32. 807213 001 900823 002 900594 004 900594 005 807445 001 806627 001 806615 001 901103 002 806635 001 806635 002 90082 1 002 901019 003 901019 004 807168 001 900173 007 900223 007 807214 001 90074 1 001 900445 006 900047 000 900233 003 900257 900223 007 900222 003 900904 002 900233 002 900160 010 900287 004 900233 808448 001 900969 001 900445 007 900160 005 900039 001 Revision Component Description Parts List Page 1 of 2 CHASSIS PLATESTREAM MICROPLATE PANEL FRONT PLATESTREAM MICROPLATE PANEL SKIN EXIT PANEL REAR PLATESTREAM MICROPLATE HINGE CONTINUOUS COVER HINGE CONTINUOUS LOAD PANEL LOADING PLATESTREAM MICROPLATE COVER TOP PLATESTREAM MICROPLATE BRACKET HINGE MOUNTING LATCH PULL FLUSH LATCH VISE ACTION LATCH VISE ACTION PANEL SKIN BOTTOM BRACKET CATCH MOUNTING BRACKET INTERLOCK CATCH SNAP IN BRACKET DOOR HINGE BRACKET DOOR HINGE POCKET PULL 4 84 1 84 040 070 CASTER SWIVEL W O STEM W BRAKE CASTER SWIVEL STEM W O BRAKE BRACKET DOOR HINGE MIDDLE BOLT HEX HEAD 5 16 X 1 2 WASHER LOCK HELICAL SPRING 5 16 BRACKET DAMPER MOUNTING DAMPER SCREW B H TORX 8 32 X 375 WASHER EXTERNAL LOCK 8 NUT LOCK 8 32 STUD 10MM BALL 5 16 18 THREAD WASHER LOCK HELICAL SPRING 5 16 NUT HEX 5 16 18 THREAD SPACER THREADED HEX NUT LOCK 4 40 WASHER FLAT STEEL 4 SCREW PAN PHILLIPS PANHEAD 4 40 X 5 NUT LOCK 6 32 PANEL FRONT ACCESS MAGNET STRIP 06 X 75
33. 900289 003 806782 001 806783 001 806826 001 806798 001 900967 004 900968 003 900967 005 901076 003 900338 002 900053 002 806827 001 806827 002 806830 001 806827 003 806827 004 Revision E Component Description PANEL ELECTRICAL LOWER ASSY CABLE HEATER CONTROL ASSY CABLE MOTOR CONTROL ASSY CABLE DRYER HEATER BUSHING GROMMET ASSY STRIP TS1 ASSY STRIP TS2 ASSY CABLE GROUND ASSY CABLE POWER CONTROL SCREW STAINLESS 4 40 X 375 NUT STAINLESS HEX LOCKNUT 44 40 SCREW STAINLESS PHILLIPS PANHEAD 8 32 X 5 WASHER STAINLESS EXTERNAL 8 MOUNT TIE TIE NYLON ASSY CABLE JUMPER 3 5 ASSY CABLE JUMPER 4 5 ASSY CABLE PROCESSOR MOTOR ASSY CABLE JUMPER 3 5 ASSY CABLE JUMPER 3 75 Parts List Page 1 of 1 FROM REFERENCE TSI 1 1 51 1 51 4 806827 003 ITEM 27 TS1 2 GNO 1 806826 001 ITEM 11 TS1 2 TS1 6 806827 001 ITEM 21 TS1 3 P8 3 51 3 P8 4 ET TS1 4 TS2 3 806827 004 ITEM 28 TS1 4 DRIVE MOTOR 806830 001 ITEM 23 TS1 4 BLOWER FAN MOTOR BLACK TS1 5 5 1 Sue 51 5 BLOWER FAN MOTOR BLACK TS1 6 TS2 1 806827 002 ITEM 22 TS1 6 DRIVE MOTOR 806830 001 ITEM 23 TS1 6 LOWER FAN MOTOR GREEN YELLOW 51 7 DRIVE MOTOR 806830 001 ITEM 23 TS2 1 P8 2 este TS2 1 TS2 6 806827 001 ITEM 21 TS2 2 Pare form TS2 3 TS2 8 806827 003 ITEM 27 TS2 3 ss gt TS2 4 3 2 5525
34. Assembly Number 804627 001 ASSY CAPSTAN DRIVE PLATESTREAM MICROPLATE Number 804370 001 804357 001 804356 001 804358 001 804355 001 804354 001 803391 001 804359 001 900800 001 90078 1 008 804628 001 900767 001 900296 900229 001 900340 900235 013 900047 002 900287 020 900160 005 900336 001 900047 003 900652 014 900288 000 900445 900223 005 900226 004 900340 003 900160 006 Revision L Component Description PLATE DRIVE MOUNTING PLATE PULLEY MOUNTING BASE PLATE PULLEY MOUNTING LEFT SIDE PLATE PULLEY MOUNTING RIGHT SIDE PLATE MOTOR BRACKET MOUNTING BRACKET MOTOR MOUNTING CAPSTAN PLATE CAPSTAN DRIVE BEARING ADJUSTABLE PULLEY COATED CAPSTAN LOWER BELT FLAT BELT FLAT 11 5 X 4 X 18 ASSY MOTOR STEPPING GROMMETS VIBRATION ISOLATOR BEARING BALL FLANGED E RING 1 4 SHAFT SCREW SOCKET HEAD CAP 10 32 X 1 2 SCREW SHC 6 32 X 25 WASHER EXTERNAL LOCK 6 SCREW PAN PHILLIPS PANHEAD 8 32 X 1 WASHER FLAT STEEL 8 NUT SELF LOCKING HEX 8 32 WASHER EXTERNAL LOCK 10 SPACER ROUND 8 X 1 4 SCREW PILLIPS PANHEAD 10 32 X 1 2 SCREW B H TORX 10 32 X 625 WASHER LOCK HELICAL SPRING 10 SPACER SHAFT SCREW SOCKET HEAD CAP 10 32 X 3 4 WASHER FLAT STEEL 10 Parts List Page 1 of 1 Printware ASSY CAPSTAN DRIVE N i A 59 Ye dE NN JAM L 804627 001 REVISION Sheet of 1 Printware Confidential Find Number 001 0
35. BLOCK TAKEUP CASSETTE MOUNTING BLOCK TAKEUP CASSETTE MOUNTING WASHER EXTERNAL LOCK 8 PIN SWITCH ACTIVATOR E RING SAE 125 ASSY SWITCH SCREW SHC 4 40 X 1 75 NUT LOCK 4 40 WASHER FLAT STEEL 4 BUSHING SPACER NYLON 6 32 X 1 SCREW B H TORX 8 32 X 5 Parts List Page 1 of 1 Printware ASSY FILM OPTION 807152 002 REVISION OR REFERENCE ONLY SHOWN M PART Sheet of 1 Printware Confidential Find Number 001 002 006 007 012 013 014 015 021 024 027 028 029 030 031 032 033 034 035 036 037 039 040 041 Quantity Component Used N N WRN N N N e 000a eee Assembly Number 807467 001 ASSY SUPPLY CASSETTE 280 Number 806625 002 806626 002 807144 002 900236 015 807464 001 807466 001 807466 002 807463 001 900774 002 900237 004 806416 003 807437 001 807454 001 807454 002 807472 001 900047 002 900445 004 900233 900047 000 900287 003 901244 001 900160 005 900157 006 807559 001 Revision E Component Description ASSY SPOOL PLATE ADJUSTABLE ASSY SPOOL PLATE FIXED AXLE INPUT CASSETTE SCREW SOCKET HEAD SHOULDER 8 32 X 312 HOUSING SUPPLY CASSETTE ASSY END CAP LEFT HAND ASSY END CAP RIGHT HAND COVER SUPPLY CASSETTE SEAL EMI C FOLD SCREW SOCKET FLT HD UNC 4 40 X 5 8 STRIP RETAINING FLEECE 16 87 GASKET LIGHT SEAL BRACKET GROUND BRACKET GROUND ASSY GROUNDING SPRING WASH
36. Calibrate densities Customized firmware can correct slightly uneven density profiles Send several half black half white sample plates from the Operator Panel test plate menu at the resolution of interest to Printware Refocus marker Verify that exposure is set correctly by checking Increase laser power Turn laser fogging circuit up turn potentiometer clockwise 60 or 10 minutes Note original potentiometer position If resetting does not alleviate problem return to original position Note that increasing laser power on plates increases density in black non image areas and decreases line thicknesses Use the following typical Operator Panel laser power settings as a sanity check Typical laser power setting RED INFRARED 900 DPI 65 85 50 60 1200 55 75 40 50 1800 DPI 45 65 30 40 2400 DPI 35 55 20 30 44 SERVICE MANUAL IMAGE QUALITY PROBLEMS ARTIFACTS Thin line artifacts Ensure laser exposure is set correctly Scan lines 2 Intermittent horizontal artifacts could be caused by improperly set service loops 2 1 Feed loop Intermittent artifacts beginning approximately 2 down the plate Adjust the Feed Loop switch 2 2 Exit loop Intermittent artifacts beginning approxi mately 8 to 10 down the plate Adjust the Exit Loop switch 3 Traction control if installed may be jumping This causes irregular horizontal lines 3 1 Increase the belt tension by wrapping the s
37. If this is the case the cause of the plate quality problem is not mirror cleanliness If dust particles or other particles are present on the mirror surfaces then perform the following procedures CAUTION Do not touch the mirror surfaces with your fingers Perform this procedures only if 1 Dust particles can be seen on the mirror surfaces 2 Printed plates have silver vertical streaks or vertical lines with fuzzy edges Cleaning the Galvanometer Window Reversing Mirror and Spherical Mirror Using Com pressed Air 1 Hold the compressed air canister upright and direct the nozzle or extension tube toward any mirror surfaces that appear dusty 2 Gently blow the dust away Short quick blasts of air are more effective than continuous spray ing CAUTION The Reversing Mirror has the most fragile surface Its surface is preferrably cleaned only with compressed air Even gentle rubbing using a soft tissue may destroy its surface coating Perform this procedure only if 1 Dust particles can not be removed from compressed air see above procedure 2 Spots can be seen on the mirror 3 Plates have silver vertical streaks or vertical lines with fuzzy edges 11 SERVICE MANUAL Cleaning the Galvanometer Window Reversing Mirror and Spherical Mirror and Folding Mirror if Compressed Air Does Not Remove the Particles Spots 1 Soak a clean piece of webril wipes with acetone and very carefully and gently wipe the mirror su
38. OFF 7 Reset Proc 2 Calibrate Marker 1 Sensor Status 2 Transport Motor OFF 8 Start Proc 3 Input Spool Manager 2 Takeup Cassette Remaining 25 3 Exit Motor OFF 9 Prime Pump 4 Marker Position 00 00 3 Current Plate Count 125 4 Cut Plate 5 Save Imager Setup to RIP Total Plate Count 1234 5 Shutter Close 6 Load Imager Setup from RIP Material Used 1200 6 Punch Plate 7 Edge LED OFF Calibrate Transport Input Spool Manager Sensor Status 1 Calibrate Processor 1 Spool A 000 LOAD KNOB 0 WRKGN TANK LOW 0 2 Manual Length Adj 0 000 P gt Spool B 000 FEED 0 REPLNTANKLOW 0 3 Cut Length Adj 1 950 3 edi C 000 EXITLOOP 0 EFFLTANKHIGH 0 4 Overlap Length Adj 0 725 4 SET 000 IMAGER EXITO PROC TEMPLOW 0 5 Backup Length Adj 1 350 NOMEDIA 0 PROCEXIT 0 6 Punch Length Adj 1 500 LOAD OK 0 TAKEUP CASSETTE 0 7 Miniplate Backup Len Adj 0 031 GUIDE B 0 Figure 2 1 Control Panel Functional Flowchart CONTROL PANEL The Power Up Sequence When the Platesetter power switch is turned on the Platesetter performs a sequence of tests of its internal components While the Platesetter is performing these tests the control panel display will show a series of status messages indicating the progress of the self tests If an error message is displayed correct the error according to the instructions in the Responding to Control Panel Error Messages section in Chapter 4 If the display stops at
39. PROCESSOR AC PLUG PIN ASSIGNMENTS FROM SIDE 8 DRAWER SCHEMATIC PAGE 2 RED ORANGE BLACK ORANGE BLACK RED V YELLOW BLUE ORANGE BLACK ORANGE BLACK CABLE 803321 001 ENG STP 5 ENG STP 24V ENG STP GND 24V GND ENG STEPPER CABLE 803319 002 CONT 5V CONT 12V CONT 12V CONT 24V CONT GND VENT FAN 24 VENT FAN RTN CONTROLLER CABLE 807520 002 DO NOT SCALE DRAWING RED INTRF 5V YELLOW INTRF 12V Be eee BLUE INTRF 12V ORANGE INTRF 424V BLACK INTRF GND RED OP 45V YELLOW OP 12V BLUE OP 12 BLACK OP GND DC POWER WIRE COLOR VOLTAGE RED 45V YELLOW 12V BLUE 12V ORANGE 24V WHITE SIGNAL BLACK GROUND GREEN CHASISE GND PY S DAS 06 21 00 ENG PRINTWARE INC ENG APPVL MEG ST PAUL MN QA MATERIAL TOLERANCE UNLESS OTHERWISE SPECIFIED ANGLES 5 DEG 1 PLACE DECIMAL FINISH 2 PLACE DECIMAL PLACE DECIMAL 02 010 Ti WIRING DIAGRAM PlateStream COMM CODE Size FIRST USED ON B INSP VERSION REV 700629 001 This document and the information it contains is the property of Printware Inc and may not be SCALE NON reproduced copied disclosed to others or disposed of directly or indrectly without authoriza m tion from Printware Inc Both the document and its contents are to be treated as confidential amp Sheet 2 of 6 proprietary and may no
40. Screen Calib Screen 4 Pix on Focus 3 Choose Length Sets the length of the test plate The allowable range is 12 to 22 in processor mode 8 to 22 for the MicroPlate model and 2 to 27 in cassette or Miniplate modes Note For the MicroPlate model selecting an 8 test plate will actually image a test plate about 8 5 long CONTROL PANEL More Information Menu More Information ESC to exit 1 Run Hardware 8 Punch OFF Calibrate 9 Auto Load ON Status Backup Feed Transport Miniplate Cut Length 12 Miniplate Backup ON Guide B Senso ON ESC OFF ENTER 1 Run Hardware Provides access to the Run Hardware menu 2 Calibrate Provides access to the Calibrate menu 3 Status Provides access to the Status menu 4 Backup Feed Transport Turns the capstan and feed motors on and backs up the media six inches This is used to clear media wrapped around the capstan roller see Clearing Media Path in chapter seven To stop capstan motor press ESC or OFF key 5 Miniplate Cut Length Only with Miniplate option installed Cuts the plate if accumulated Miniplate length exceeds this value Values are integer inches e g 12 13 14 15 16 17 or 18 The 18 setting cuts all plates greater than 17 5 The minimum cut length is 12 for the standard model 9 for the MicroPlate model The maximum cut length is 18 for the standard model and 17 for the Micr
41. This selection clears and displays the current plate count Total Plate Count Displays the total number of plates imaged by the Platesetter Material Displays the total number of feet of material run through the Platesetter Sensor Status Menu SENSOR STATUS ESC to exit LOAD 0 WRKNG TANK LOW 0 FEEDLOOP 0 TANK LOW 1 EXIT LOOP 0 EFFLTANK HIGH 1 IMAGER EXIT 0 PROCTEMPLOW 0 NOMEDIA 0 PROC EXIT 0 LOAD OK 0 TAKEUP CASSETTE 0 0 GUIDE ON ESC OFF ENTER The Sensor Status menu indicates the current digital status of all Platesetter sensors Explanations of all the sensor indications are shown below This menu is provided primarily for trained techni cian use LOAD KNOB This sensor is activated when the load knob is pushed A 0 indicates the load knob is pushed in 1 indicates the load knob is pulled out FEED LOOP Indicates the status of the service loop sensor in the feed area of the Platesetter T indicates that a loop is formed 0 indicates that a loop is not present EXIT LOOP Indicates the status of the exit loop sensor in the exit section of the Imager 17 indicates that a loop 1s formed 0 indicates that a loop is not present IMAGER EXIT Indicates the presence of media at the imager exit A 1 indicates that media is present e g during imaging A 0 means the sensor is clear this is the normal idle condi tion NO M
42. W SOFTWARE OPERATOR PANEL 13 807095 001 806474 001 806473 001 807096 001 807108 001 900660 008 900224 002 807167 001 807202 001 900270 006 806275 001 806400 001 806709 001 806719 009 807312 002 806719 008 807312 003 900445 007 901041 002 900040 900040 002 901255 001 807561 001 807563 001 900652 015 900040 001 Revision C BRACKET SHOCK MOUNTING LEFT GUARD CAPSTAN DRIVE GUARD CAPSTAN PULLEY ASSY SPOOL 13 HOUSING INTERLOCK STANDOFF HEX MALE TO FEMALE 6 32 X 1 1 8 SCREW TAPTITE PILLIPS PANHEAD 8 32 X 3 8 ASSY MARKER FAN GUIDE PANEL EXIT GAS CYLINDER 40 LBS PLATE LOCATING LATCH SEAL ROD LATCH ASSY PROBE ASSY TUBE ACTIVATOR ASSY TUBE STABILAIZER ASSY TUBE ACTIVATOR ASSY TUBE STABILIZER SCREW B H TORX 8 32 X 5 TANK PLASTIC 5 US GALLONS CLIP CORD ADHESIVE 19 CLIP CORD ADHESIVE 62 CABLE SERIAL DATA DB 9 PIN ASSY ADAPTER DB 9 TO DB 25 ASSY CABLE NAMEPLATE PRINTWARE SPACER ROUND 10 X 5 CLIP CORD ADHESIVE 38 gt BOTH ON NON OP SIDED B gt s 3 25 Ge 9 2 BOTH UN DP SIDE te geet 9 hy BN REI 43 5 TERMINAL TSI I Printware a ON PROCESSOR ASSY IMAGER pe ET 7 ON TERMINAL TSI E E 807741 001 REV C Printware Confidential Sheet of 2 7
43. and 3 drive motor screws 8 Reconnect the power cord 9 Turnon the Platesetter From the operator panel start the processor press 4 1 8 Observe that the belt and gears are rotating properly From the operator panel reset processor press 7 Switch off the Platesetter power 10 Replace the panels and wire tray Close the top right cover I 14 INSTALLATION GUIDE Calibrate the processor from operator panel This calibration checks to see how long it takes the leading edge of a plate to get to the exit switch of the processor This allows the Platesetter to properly detect a jam condition This calibration should be run at each resolution 900 1200 1800 and 2400 DPI 1 Load the plate material From the operator panel calibrate the processor press 4 2 1 1 enter A plate will run through the processor 3 From the operator panel press esc esc esc to return to the main menu Stabilizer Rack Activator Rack Dryer Belts Dryer Drive Clutch Rack Drive Gear Dryer Drive Belt eer Drive Motor Belt Drive Shaft Worm Gear Figure I 3 Inside view of the Processor module Heater Element PROC EXIT Switch PS A Drive R42 R43 Motor amp EM 9 Processor pP N 2 Fd NA PCA Screws Blower Figure I 4 Right side view of the PlateStream 46 Platesetter I 12 INSTALLATION GUIDE Physical Calibration Overview Follow the pr
44. gt LOADENOS SSD SENSOR 600333 001 CABLE d WHITE ah 807204 001 TI BROWN USD ONLY J6 NU I RED IT CASSETTE GND 806788 001 L BROWN WORKING TANKS LOW i BROWN 1 sooo OPTION s WHITE 1 RED RED 2 YELLOW NU x DRIER TEMP SENSOR BLACK 3 3 ORANGE ORANGE 73 Syme ONU CABLE 803321 001 WHITE 3 YELLOW YELLOW 3 7 600330 001 D GREEN 5 m o 5 mom 12 BLUE BLUE 7776 TAKTEN EXITLOOP POWER 3 ORANGE 6 i SENSOR NO VIOLET VIOLET 19 WHITE EXITLOOP GND Drawer GND BLACK 1 s GRAY GRAY s 07091 01 1 SV RED 2 WHITE WHITE 9 BROWN Er LOOPS FEED LOOP GND BLACK 3 BLACK BUACK 16 SENSOR NO 1 S BACK S 06754 INITAL RELEASE DAS 06 21 00 3 BROWN SPARE BROWN ll E 807091 001 REV ECO DESCRIPTION DRAWN BY DATE APPVL DATE 3 RED RED 12 RoE ELLOW NU DRAWN 45V PULL UP ORANGE 13 NU BY DAS 06 21 00 r Fm PRINTWARE INC gt SV FULLUP GREEN IS Zu ACT TEMP PROBE RED 1 BLUE DRIVE BLUE 16 La FRG are aa m ST PAUL MN NDS GRAY RESET GRAY IS 6 z NOE WHITE PULLUP WHITE 19 we 5 MATERIAL BLACK PUMP PRIME BLACK 20 E TMAGER EXIT SE SPECIFIED ERN SEOWA ii SENSOR NO SDEG SPARE MED gt 07091 001 m FINISH 1 NU ORANGE 23 oe d m GREEN NU GREEN 25 37 VIOLET I
45. probe on replenishment probe and the other on the P2 cable Check both replenishment probes for continuity If cable checks out OK replace the PCA Otherwise replace the cable Check probe connector Check cable P3 and PCA see procedures under Spurious low replenishment message Remove the right side end panel Push the exit switch actuator at a 45 angle An indicator light should turn on after a 6 second time delay from the switch clicking on If there is not an audible click when the switch is actuated readjust the switch If it cannot be readjusted replace the switch Ifthe switch actuates but the light doesn t come on replace the switch and cable Ifa new switch and cable does not resolve the problem replace the PCA SERVICE MANUAL PROCESSOR ELECTRICAL PROBLEMS Processor keeps running after media exits Dryer not heating Ensure imager exit switch works by manually feeding media over the switch and watching to see that it toggles between 1 and 0 in the Sensor Status menu If the switch works lower the upper media guide Guide C to force media to feed closer to the switch or reform or adjust switch upward Check and re seat connectors J4 and J12 on the Processor PCA Check fuses F3 and F4 on the processor PCA Check the Processor PCA 3 1 Check that dryer heater LEDs A and B are on when the heater should be on i e processor and Heater Up To Temperature light not on If L
46. 006 807092 001 807065 001 900289 004 806127 001 807050 001 806360 001 80638 1 001 807066 001 807067 001 900235 005 900276 007 900222 002 ASSY ROLLER TRANSPORT PLATESTREAM Revision S GUIDE UPPER EXIT BRACKET LOWER SOLID MOUNTING BRACKET BUFFER GUIDE BRACKET LOWER BUFFER GUIDE MOUNTING BRACKET UPPER GUIDE MOUNTING BLOCK EDGE GUIDE ADJUSTABLE BLOCK EDGE GUIDE POSITIONING PLATE ADJUST PLATE POSITIONING BLOCK BACKUP BRIDGE MEDIA INPUT PULLEY MODIFIED 65 GROOVE COLLAR PULLEY ASSY PULLEY OVERRUNNING CLUTCH ASSY BELT TENSIONER SHAFT BELT TENSIONER BRACKET IDLER SHAFT IDLER E RING 1 4 SHAFT PULLEY MODIFIED SCREW SHC 6 32 X 25 ASSY MOTOR MOUNT BRACKET BEARING SUPPORT WASHER FLAT STEEL 10 WASHER EXTERNAL LOCK 10 SCREW PHILLIPS PANHEAD 10 32 X 5 BEARING OIL LESS BRONZE SHAFT MARKER 5 BEARING MODIFIED SELF ALIGNING SPACER SHAFT INNER 1 2 LD X 1 16 SPACER 171 LD X 25 O D X 25 PULLEY DUAL CAPSTAN PIN DOWEL STAINLESS 125 X 5 SHAFT DRIVE LINKAGE HANGER UNLOAD SHAFT BUSHING GROMMET ASSY CUTTER 13 ASSY CAPSTAN GUIDE PLATESTREAM 13 BRACKET CABLE MOUNTING PLATE CLAMP BRACKET UNLOAD ROLLER FEED PLATE TORQUE SCREW SHC 448 32 X 38 WASHER NYLON 189 LD X A41 O D NUT HEX 48 173 177 178 181 182 184 185 186 187 188 189 192 193 194 195 197 198 201 206 209 210 211 212 213 235 236 237 238 250 251 254 255 262 263 264 265 266 271
47. 1 Startup the RIP a Connect the RIP to the network and turn it on b Press ctrl alt del on the RIP to log into Windows NT c Log in as Administrator with password printware d Double click on the Navigator icon to launch the RIP 2 Create appropriate page setup s in Page Setup Manager a Ensure that the Negative box is unchecked b Specify plate size and image positioning in the page layout menu c You can specify screens in the Screening menu or leave it at factory defaults Override fre quency and spot function Euclidean Spot Function 100 to 150 Ipi frequency depending on resolution the default Angles Use Harlequin Precision Screening and Rotate screens ac cording to Page Rotation 3 Publish the Page Setup on the network in Input Controller The name associated with the Page Setup in Input Controller will show up on the front end computer Note You may want to specify a name which incorporates resolution plate size or the target press e g Quickmaster2up2400dpr 4 Choose Start Inputs the green traffic light icon from the RIP menu 5 Set up the front end computer to print to the RIP For best results use the Adobe print driver and PlateStream PPD These are provided with the RIP If you don t have the Adobe driver the Linotype 630 driver can be used Note On Windows front ends specify the platesetter as a Local Printer not a Network Printer This allows selection of the correct spool folder
48. 2505 BEARING OIL LESS BRONZE RECEPTACLE CASSETTE TOP COND RING RETAINING 02 ASSEMBLY C2 Printware ASS Y ROLLER TRANSPORT DETAIL ASSEMBLY 807444 001 REVISION Sheet of 5 Printware Confidential Printware ASSY ROLLER TRANSPORT ASSEMBLY M ye ASSEMBLY F 807444 001 REVISION Sheet 2 of 5 Printware Confidential ASSEMBLY L Printware ASSY ROLLER TRANSPORT ASSEMBLY F 807444 001 REVISION Sheet 3 of 5 Printware Confidential ASSEMBLY ASSEMBLY ASSEMBLY S ASSEMBLY N 2 PLCS Printware Confidential 2 PLCS 263 x a J 62 in v 2 ASSEMBLY T ASSEMBLY 0 Printware ASSY ROLLER TRANSPORT 807444 001 REVISION F Sheet 4 of 5 ASSEMBLY N ASSEMBLY D MOTOR AND BELT ASSEMBLY Printware ASSY ROLLER TRANSPORT 807444 001 REVISION F Printware Confidential Sheet 5 of 5 Find Number 001 002 003 004 005 006 008 009 010 011 012 013 014 015 016 018 019 020 021 022 023 024 025 026 027 029 030 031 Quantity Component Used ON CO OO QN WA W A A U NNOO mme Ne RRR RR
49. 32 X 312 HOUSING SUPPLY CASSETTE ASSY END CAP LEFT HAND ASSY END CAP RIGHT HAND COVER SUPPLY CASSETTE SEAL EMI C FOLD SCREW SOCKET FLT HD UNC 4 40 X 5 8 STRIP RETAINING FLEECE 16 87 GASKET LIGHT SEAL BRACKET GROUND BRACKET GROUND ASSY GROUNDING SPRING WASHER EXTERNAL LOCK 6 SCREW B H TORX 6 32 X 375 NUT LOCKING 6 32 WASHER EXTERNAL LOCK 8 SCREW PAN PPH 8 32 X 38 FOAM SELF ADHESIVE WASHER FLAT STEEL 8 SCREW SET CUP POINT 6 32 X 375 SHEET PLASTIC ADHESIVE 16 72 Parts List Page 1 of 1 Printware Confidential Printware ASS Y SUPPLY CASSETTE 280 807467 001 REVISION E Sheet of PlateStream PD MH Platesetter MICROPLATE ILLUSTRATED PARTS MANUAL Printware LEADERS IN COMPUTER TO PLATE Rev A 700624 Find Number 001 002 002 003 003 004 005 010 010 011 012 Quantity Component Used ESB SB OC Re eS Se Assembly Number 807440 XXX PLATESTREAM MICROPLATE Number 807841 001 807245 001 807245 002 807046 001 807046 501 900047 000 900445 006 807117 001 807117 003 808 172 003 808 172 004 Revision D Component Description Parts List Page 1 of 1 ASSY IMAGER MICRO NO OPERATOR PANEL ASSY MARKER 13 IR ASSY MARKER 13 RED ASSY POWER SUPPLY INTEGRATED ASSY POWER SUPPLY INTEGRATED INTL WASHER EXTERNAL LOCK 8 SCREW B H TORX 8 32 UNC X 375 KIT FW PS LCD CONTROL PANEL KIT FW PS RIP CONTROL PANEL LABEL GUIDE METRIC LABE
50. 40 LBS PLATE LOCATING LATCH SEAL ROD LATCH ASSY PROBE ASSY TUBE ACTIVATOR 32 ASSY TUBE STABILIZER 24 ASSY TUBE ACTIVATOR 30 ASSY TUBE STABILIZER 30 SCREW B H TORX 8 32 X 5 TANK PLASTIC 5 GAL CLIP CORD ADHESIVE 19 CLIP CORD ADHESIVE 62 CABLE DB 9 PIN ASSY ADAPTER DB 9 TO DB 25 ASSY CABLE NAMEPLATE SPACER ROUND 10 X 1 2 CLIP CORD ADHESIVE 38 _ 5 ON TERMINAL N PROCESSOR 7 ON TERMINAL TS N PROCESSOR Printware Confidential Printware ASSY IMAGER 807841 001 REVISION Sheet of 2 MOUNTED ON DIVIDER PAN 96 INSIDE OF COVER GD OTHER SIDE ey OTHER SIDE UAL RE ss Printware ASSY IMAGER 807841 001 REVISION Printware Confidential Sheet 2 of 2 Find Number 001 002 003 004 005 006 007 008 009 010 011 012 013 014 015 019 027 028 029 030 031 035 036 037 038 039 050 052 053 054 055 056 058 059 060 061 063 064 067 068 Quantity Component Used e WN WY WN NY NN WR Re N N a nnn Q BR BR OR N NN Assembly Number 807527 001 KIT CHASSIS PLATESTREAM MICROPLATE W SOFTWARE OPERATOR PANEL Number 807449 001 807074 001 807447 001 807075 001 807078 001 807079 001 807212 001 807508 001
51. 68 IRE den 71 Press Related Problems 72 Wiring DI8gram i dede ur ette ea eddie i 73 SERVICE MANUAL CHAPTER 1 GENERAL INFORMATION This Platesetter has been certified as a Class 1 laser product under the U S Department of Health and Human Services DHHS Radiation Performance Standard This standard is in accordance with the Radiation Control for Health and Safety Act of 1968 A Class 1 certification means the Imager does not produce hazardous laser radiation Observe proper Electro Static Discharge ESD procedures at all times during maintenance of this equipment especially when servicing the RIP ESD can damage sensitive micro electronic circuitry leading to immediate failure or gradual degradation of performance over time Observing the fol lowing precautions will help to prevent ESD damage to components Always keep PCAs in anti static bags during transport or at any time when removed from the ma chine Never lay them down unprotected unless working at a static protected workstation Wear a ground strap attached to your wrist and to the frame of the machine Always keep ESD in mind when working on electronic equipment Use grounded or nonmetallic tools whenever possible Do not attempt to open the inner covers other than described in this manual Be especially careful when working on or around the following areas of the Plate
52. Backup Length Adj Adjusts the length of the leader there is a second set of values with the punch option installed 6 Punch Length Adj Only with the punch option installed Adjusts the punch position on the plate 7 Miniplate Backup Length Adj Only with the Miniplate or Cassette options installed Cali brates or eliminates the gap between jobs in Miniplate and Cassette modes 2 13 CONTROL PANEL Input Spool Manager Menu Input Spool Manager ESC to exit 1 Spool A 2 Spool B d Spool C Spool D ON ESC OFF ENTER 1 Spool A Sets the amount of material in spool A up to 280 or 85 m 2 Spool B Sets the amount of material in spool B 3 Spool C Sets the amount of material in spool C 4 Spool D Sets the amount of material in spool D Status Menu Status ESC to exit 1 Sensor Status 2 Takeup Cassette Remaining 0000 3 Current Plate Count 000000 Total Plate Count 000000 Material Used 000000 ESC ENTER 1 Sensor Status This selection provides access to the Sensor Status menu 2 Take up Cassette Remaining Shows the amount of media capacity remaining in the take up cassette in feet The maximum allowable amount of material is 26 The Take up Cassette Remaining value is automatically decreased from 26 as media is used When this value reaches 0 the Platesetter will stop running 2 14 CONTROL PANEL 3 Current Plate Count
53. Do not set the laser marker assembly down on a flat surface This can damage the resonant galvanometer on the side of the assembly kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk 5 Raise the top cover Remove tie straps and bubble pack from struts Remove the caps on the outside of each strut head 6 Locate the hinge shaft for attaching the marker assembly at the top inside left rear of the Platesetter 7 Have two people lift the marker assembly from the carton using the C shaped black handle located on the laser end of the marker Place the marker assembly in the Imager by placing the hinge brackets on the hinge shaft not on the brass bushings 8 Slide the marker assembly mounting clip onto the spring loaded brass bushing closest to the Processor 9 Lift the other end of the marker assembly and place it past the brass bushing Slide the brass bushing into place 10 Remove the 21 x 1 53 cm x 2 5 cm piece of black tape from the bottom of the marker assembly by gently pulling on the loose end of the tape Remove the C shaped black handle by removing the eight screws holding this handle 11 To attach the struts to the marker assembly Raise the marker assembly until the ball joints on the outside line up with the strut heads Firmly push the strut heads onto the ball joints and reattach the caps to lock the struts to the marker assembly 12 Gently lower the marker assembly and lock by
54. ESC key to clear the error message from the display If the solution s listed does not correct the error call your Printware authorized technician to service your Platesetter CAUSE The load knob is not pushed in SOLUTION Push knob in See chapter 3 in the sec tion Loading Plate Media CAUSE The Platesetter is out of media or the me dia not loaded properly SOLUTION See chapter 3 in the section Loading Plate Media media or not loaded far enough 43 OPERATING THE PLATESETTER CAUSE The Guide B sensor is blocked SOLUTION Clear media path See chapter 7 in the section Clearing Media Path CAUSE The leading edge of the media was not detected by the Guide B sensor within the expected amount of time SOLUTION Clear media path See chapter 7 in the section Clearing Media Path Media didn t enter Guide B CAUSE Imager Exit sensor is blocked SOLUTION Clear media path See chapter 7 in the section Clearing Media Path OPERATING THE PLATESETTER CAUSE The leading edge of the media was not detected by the Imager Exit sensor within the expected amount of time SOLUTION 1 Clear media path See chapter 7 in the section Clearing Media Path 2 Calibrate the processor See chapter 2 in the section Calibrate Menu CAUSE The sensor under cover G is blocked SOLUTION Clear media path See chapter 7 in section Clearing Media Path CAUSE
55. GND j 7510 70 araca INTREGND PANEL m MOLT PN Ds i maples wie AC 0 25A ADF GND 3 RED 5V BROWN PHOTODIODE 5 RA N 3 250V 522780 E BLACK GND 5 WHITE PRN D7 15 CIRCUIT BREAKER BLUE NEUTRAL 4 J6 4 YELLOW OP DV BLACK PRN DT E GREEN 1 13 BLUE 17 BROWN PRN RW 16 9 mE 900813 001 GREEN ROUND IE FUSE 0 12 BLACK GND RED PRNRIIW 35 5 aNd 3 GR G DRVO 1 ORANGE PRN STRB 17 GND 4 Ur GALVO ASSY WHITE G ET 2 STRB 3 5 3 PRN ACK ACKT 3T IN FUSE 5 PRN GND 9 15 G 6 00 807203 001 307049001 f sos c 1 SENSOR ASSY SOS SIG gt WHITE SOS REF 3 RED sor 1 WHITE SOT SIG 5 NU J16 GRAY SOT REF 5 S07151 001 PROCESSOR TORIP AC PLUG 1 6 807521 001 AC POWER WIRE COLOR VOLTAGE 807514 001 WIRE COLOR RED TSV AVIRECOLOR YELLOW TV x DOMESTIC INTERNATIONAL VOLTAGE BLUE TDV BLACK BROWN ORANGE 1 WHITE BLUE WHITE L GREEN GREEN YELLOW GROUND BLACK GROUND GREEN CHASISE GND 12 PIN ASSIGNMENTS CABLE 807530 001 FROM FRONT OF P S DRAWER
56. Introduction To avoid problems with the Platesetter maintain high print quality and to avoid unnecessary service calls follow the instructions in this chapter Keep all equipment clean and well maintained Perform regularly scheduled preventive maintenance Carefully follow instructions for the mix and use of chemistry Ink and press chemistry must be compatible Keep all solutions filled to the proper levels Handle plate media carefully Mount plates on the press properly Operator Maintenance Schedule Recommendations based on 8 hours per day use 5 days a week 1 Follow the Printware Recommended Periodic Maintenance Schedule in the Service manual 6 2 PREVENTIVE MAINTENANCE Maintenance Procedures Cleaning the Imager Rollers Clean all the Imager rollers when necessary to prevent plate slippage or plate skew It s easiest to clean the rollers just after the spool has run out of media To clean these rollers 1 Open the top cover Raise the marker by pulling marker lever towards the front of the Plateset ter until lever stops Lift up marker gently see Figure 6 1 Marker Lever Processor Working Tanks Cover E NN Activator v ape Y oa sh CUN YAY N 7 Processor e eM jd Exit Effluent Drain get life m c Optional Effluent Tank ch Replenishment Tanks Tank amp Cart Optional Cart Optional Figu
57. J11 SOS SOT sensors J15 Not Used J16 Not Used 30 SERVICE MANUAL Replacing the Controller PCA The non volatile SRAM on the controller PCA stores the total plate count image quality settings image position settings and marker assembly calibration values All of this information will be lost when the controller PCA is replaced If possible look through all the menus on the control panel before replacing the controller PCA and write down all the settings Image quality and position settings can be re entered from the control panel after the PCA is replaced The plate count and material used count will start over from zero so keep a record of the values read from the old controller PCA with the Platesetter The marker assembly calibration values will be regenerated during the marker assembly calibration procedure If the image settings and plate count values cannot be read due to a massive controller PCA failure use the information from the customer s operator log for resetting these values Before beginning the replacement procedure record the following information punch and 2400 dpi values are applicable only if those options are installed Resolution 900 1200 1800 2400 Cut Length Overlap Length Backup Length Punch off Backup Length Punch on Punch Length Punch on Miniplate Backup Length Image Power Processor amp Mini Plate Image Power Cassette MT Speed 1 Turn
58. Revision J Component Description Parts List Page 1 of 1 ASSY IMAGER W LCD CONTROL PANEL 13 ASSY IMAGER W SOFTWARE CONTROL PANEL 13 ASSY MARKER INFRARED LASER 13 ASSY MARKER RED LIGHT LASER 13 ASS Y POWER SUPPLY INTEGRATED DOMESTIC ASS Y POWER SUPPLY INTEGRATED INTERNATIONAL WASHER EXTERNAL LOCK 8 SCREW B H TORX 8 32 X 375 KIT FIRMWARE W LCD CONTROL PANEL KIT FIRMWARE W SOFTWARE CONTROL PANEL M Y Printware ASSY PLATESTREAM 807240 XXX REVJ Sheet of 1 Printware Confidential Find Number 001 002 005 006 007 008 009 010 011 012 014 015 016 017 018 018 019 020 021 022 023 024 025 026 027 028 029 030 031 032 033 034 036 039 042 043 045 047 050 052 053 056 Quantity Component Used NO e OK OO W N A m OO TONY A T Oo BR OR HN NY NN KS Assembly Number 807741 001 ASSY IMAGER PLATESTREAM W SOFTWARE OPERATOR PANEL 13 Number 807743 001 807244 001 807179 001 807514 001 900270 003 900257 900222 003 900223 007 523190 004 523060 001 900233 003 900047 000 900445 006 807222 001 806866 001 807223 001 900676 004 804569 003 900223 006 806843 001 803769 001 807652 001 900341 003 900222 007 900651 008 807431 001 900726 001 900726 005 900288 005 900652 007 900651 003 900233 001 900336 000 80717
59. TENSION MODIFIED ASSY CAPSTAN DRIVE ASSY UPPER PINCH TENSION NON OPERATOR SIDE ASSY UPPER PINCH TENSION OPERATOR SIDE ASSY CABLE CUTTER EXIT PLATE MARKER LOCATING LOWER ASSY PULLEY OVERRUNNING CLUTCH BRACKET CUTTER MOUNTING ASSY SWITCH MICRO ASSY LATCH COMPRESSION ROD HEX STAINLESS 5 16 HUB HANDLE SHAFT HANDLE KNOB OVAL TAPERD SCREW SET STAINLESS 10 32 X 188 PULLEY MODIFIED PULLEY MODIFIED 130 TOOTH WITH INSERT BELT TIMING 165 GROOVES 1 4 WIDE BELT TIMING 184 GROOVES 1 4 WIDE GUIDE LOWER SOLID GUIDE UPPER REMOVABLE GUIDE UPPER BUFFER GUIDE LOWER BUFFER GUIDE LOWER EXIT ASS Y GUIDE UPPER EXIT ASS Y GUIDE UPPER EXIT Parts List Page 1 of 4 077 079 080 081 083 084 085 086 087 088 090 091 092 093 094 119 120 121 122 123 124 125 128 131 132 134 135 136 137 142 151 152 154 155 156 157 158 160 161 162 165 167 171 172 N NY BN NN l2 e BRN NNN AN KF AWA eS pami N N N N RRR NO LP Assembly Number 807244 001 807062 001 806228 001 807063 001 808 193 001 806239 001 807215 001 807216 001 806352 002 806354 002 807064 001 807354 001 803713 001 807356 001 807363 001 807359 001 806347 001 806348 001 900229 001 806199 001 900235 013 803666 001 806393 001 900160 006 900047 003 900288 000 900406 006 806267 001 806585 001 900254 002 900039 001 804574 001 900582
60. TORX 8 32 X 375 TRAY STOP TRAY ADJUSTABLE GROMMET RUBBER TUBING SLIT 1 WASHER LOCK HELICAL SPRING 3 8 ASSY PUMP BRACKET PUMP MOUNTING BRACKET PUMP MOUNTING BUSHING SPACER NYLON 6 32 X 375 NUT HEX 3 8 16 WASHER FENDER 2 X 438 X 156 BOLT MODIFIED HEX ISOLATOR RING ISOLATOR BUSHING SCREW PHILLIPS PANHEAD 10 32 X 2 1 2 SPACER ROUND 10 X 5 8 WASHER FENDER 1 375 X 192 X 048 NUT LOCK 10 32 NUT SELF LOCKING HEX 6 32 PANEL PROCESSOR GUARD GUARD INTERFACE PCA ASSY CABLE INTERLOCK PROCESSOR SWITCH DOOR ASSY CABLE INTERLOCK JUMPER PANEL VAPOR BARRIER ISOLATOR RING ISOLATOR BUSHING STRAIN RELIEF CABLE BRACKET SHOCK MOUNTING LEFT 059 060 061 062 063 065 066 067 068 069 070 071 072 073 074 075 076 087 090 091 093 094 095 098 099 N NO N BN RRR N N e KF N e Assembly Number 807841 001 ASSY IMAGER MICROPLATE WITH SOFTWARE CONTROL PANEL 806474 001 806473 001 807096 001 807108 001 900660 008 900224 002 807167 001 807202 001 900270 006 806275 001 806400 001 806709 001 806719 009 807312 002 806719 008 807312 003 900445 007 901041 002 900040 900040 002 901255 001 807561 001 807563 001 900652 015 900040 001 Revision GUARD CAPSTAN DRIVE GUARD CAPSTAN PULLEY ASSY SPOOL 13 HOUSING INTERLOCK STANDOFF HEX MALE FEMALE 6 32 X 1 1 8 SCREW TAPTITE PHILLIPS PANHEAD 8 32 X 3 8 ASSY MARKER FAN GUIDE PANEL EXIT GAS CYLINDER
61. The leading edge of the me dia was not detected by the processor exit sensor within the expected amount of time SOLUTION 1 Clear media path See chapter 7 in section Clearing Media Path Media didn t exit processor 2 Calibrate the processor See chap ter 2 in the section Calibrate Menu 45 requesting to image plate Scan initialization time out OPERATING THE PLATESETTER CAUSE The Platesetter electronics have detected a problem with one of the power supply voltage levels SOLUTION Turn off the Imager and call for service CAUSE A print job was sent to the Platesetter while it was not in the On Line state SOLUTION From the Main Menu on the control panel press 3 to return the Platesetter to the On Line state Cause The marker unit did not power up cor rectly within the expected time SOLUTION 1 Turn the Platesetter off wait 30 seconds turn the Platesetter back on and wait for the power up to be completed 2 Call for service 46 OPERATING THE PLATESETTER CAUSE The marker is not ready to image SOLUTION 1 Turn the Platesetter off wait 30 seconds turn Marker not the Platesetter back on and wait for the power up y to be completed 2 Call for service CAUSE The take up cassette is not installed while the Platesetter is in the optional cassette mode SOLUTION Install the take up cassette See chapter 3 in t
62. View of the Processor 17 SERVICE MANUAL Heater Element PROC EXIT Switch P5 Drive Motor aa 9 Processor PCA Raz R43 PCA Screws Blower Figure S2 4 Right Side View of the PlateStream Platesetter 18 SERVICE MANUAL 19 This page intentionally left blank SERVICE MANUAL CHAPTER 3 COMPONENT REPAIR AND REPLACEMENT Replacing Rollers Belts Motors and Cutter Overview This section provides the procedures for removing and reinstalling the following 20 rollers see Figure 52 2 Two feed rollers upper and lower Two pinch rollers left and right One capstan roller Two imager exit rollers upper and lower Thirteen processor rollers NOTES 1 When removing rollers label all spacers in terms of front or rear 1f any and which roller they were used with For the Platesetter to function correctly all spacers must be placed back in their original positions 2 When replacing rollers note that the new roller shaft may not be precisely the same length as the old roller shaft Install the spacer s on the rear of the shaft with the required thickness to eliminate any front to rear play Spacers are available in four thicknesses 0 016 0 4 mm nominal Part 900254 006 Spacer Inner Shaft 3 8 ID x 016 Th 0 048 1 2 mm nominal Part 900359 Spacer 375 ID x 047 Th 0 063 1 6 mm nominal Part 900254 003 Spacer Inner Shaft
63. a Platesetter may cause interference to radio and television reception Printware Incorporated complies with the limits for a Class A computing device in accordance with the specifications in Subpart J of Part 15 of FCC rules These rules are designed to provide reasonable protection against radio and television interference in a commercial installation The user can determine if this equipment is causing interference to radio or television reception by turning the Platesetter off and on Listed below are measures the user can take to correct the interference a Reorient the receiving antenna b Relocate the Platesetter with respect to the receiver c Move the Platesetter away from the receiver d Plug the Platesetter into a different outlet so the Platesetter and receiver are on different circuits If these measures do not correct the interference problem the user should consult the dealer or an authorized technician for additional suggestions CONTENTS Chapter 1 General Information Introduction as au u ee dA i ed el es 1 2 Features Overview 2 2 2 0 0 1 5 Operator Safety ecce terne dcs 1 7 Chapter 2 Control Panel The Gontrol Panel 2 oa 2 umu na 0 ee nee dadas 2 2 Control Panel Menus and Functions 2 4 Chapter 3 Preparing for Operation Preparing to Make
64. a selected item press the numeric keys or press the ON to increase the number and press the OFF to decrease the number To exit a selected item without saving changes press the ESC key To save changes to a selected item press the ENTER key Ifa key is pressed that has no effect the control panel will emit a beep The PC keyboard may also be used directly to operate the Control Panel To minimize the Control Panel click on the lower right corner of the Control Panel This will leave the display but hide the keypad DO NOT close the Control Panel program upper right corner box while the imager is operating this will cause the interface to crash and the imager to malfunction CONTROL PANEL Printware PlateStream 1 Setup 5 Load 2 Test Plate 6 Cut Fd 3 On Off Line 4 More Information On Line Idle 0000 1800 DPI PROC Setup Test Plate More Information 5 n ae 1 Reading 1 Run 01 Plates i 1 Run Hardware 8 Punch OFF 3 Image Power 25 2 Choose Pattern Composite Pattern 2 Calibrate 9 Auto Load ON 4 Media Width 13 12 Spool Pos 13 3 Choose Length 13 3 Status 5 Input Spool A On Line Idle A0000 1800 DPI 4 Backup Feed Transport 6 Destination Processor 5 Miniplate Cut Length 12 7 Display Units English PROC 6 Miniplate Backup ON play Units Englisl 7 Guide B Sensor ON Calibrate Run Hardware Status 1 Calibrate Transport 1 Feed Motor
65. any initialization point for more than two minutes turn off the Platesetter and call for authorized service When the power sequence is successfully completed the display will show the Main Menu screen Main Menu Printware PlateStream 1 Setup 5 Load 2 Test Plate 6 Cut Fd 3 On Off Line 4 More Information On Line Transporting A0075 1800 DPI No Media Takeup Full PROC TEMP HIGH EFF LOW PROC ON ESC OFF ENTER 1 Setup Provides access to the Setup menu 2 Test Plate Provides access to the Test Plate menu 3 On Off LINE Sets the Platesetter to either on line or off line Platesetter must be on line in order to accept print jobs from the RIP The Platesetter cannot be set to On line if there is an error present Advancing the display to any of the sub menus automatically takes the Platesetter off line 2 4 CONTROL PANEL 4 More Information This selection provides access to several menus 5 Load This selection loads the media 6 Cut Fd This selection cuts and feeds the media into the processor for the Miniplate option This selection cuts and feeds the media into the takeup cassette for the film option 7 The bottom three lines lines 6 8 of the Main Menu and Test Plate Menu display the current state of the Platesetter and any error conditions Line 5 displays the marker state only if the marker is not ready to print Line 5 Scan point 1
66. as screen frequency and the screen angle as shown in Figure ApB 2 Se Screen angle Figure ApB 2 Screen Angle C3 HALFTONING AND SCREENING Recommended Settings The best halftone strategy depends on the type of work media resolution and press characteristics but Printware makes the following recommendations for PlateStream computer to plate systems as a starting point Euclidian dots Figure ApB 2 shows circular and elliptical dots but dots can have other shapes These are described in detail in the RIP manual Euclidian dot shapes vary with the screen to minimize perimeter to area ratio which make them a good general purpose dot for black amp white or color printing 133 to 150 line Screens Default Angles Silver halide plate materials support a maximum of 175 line screens but accuracy and calibration become more critical the higher the screen Enhanced AM screens also called supercell screens These screening algorithms allow more precise screen frequencies and angles e g if the application calls for a 150 line 45 screen the separation will be reproduced more exactly with supercell screening Without supercell screening selected the separation screens might be approximated with a variety of different screens and angles causing moir Supercell screening also reduces moir and smooths transi tions in gray levels Enhanced AM screens are called Spectracell Screens on the ZAPrip 200 Level 1 RI
67. enables you to fine tune the image length setting of the Platesetter to compensate for small mechanical variations in components such as the rollers or drive motors This adjustment is made on the Calibrate Transport Menu on the con trol panel This procedure should be com pleted for 900 1200 1800 and 2400 dpi NOTE Before adjusting image length clean all transport rollers inside the Plate setter 1 From the RIP JOBS directory on the RIP output the Grid12 ps file 2 Measure the distance between points A and B see Figure I 12 Use a preci sion steel ruler or digital measuring de vice to check this distance a digital mea suring device is more precise Leading Edge Operator Side front of Platesetter Figure I 12 Adjusting Image Length 3 If the distance between points A and B is gt 15 000 38 10 cm increase the Manual Length Adj value if the distance between A and B is lt 15 000 38 10 cm decrease Manual Length Adj To adjust this value From the Main Menu on the control panel press the 4 key More Information Press 427 Calibrate Press 1 Calibrate Transport e Press 2 Manual Length Adj Enter the amount to decrease or increase For example if the distance is 15 010 enter 010 Ifthe distance is 14 990 en
68. is fed from the feed cassette imaged and then fed into the take up cassette The take up cassette is easily re moved and taken to another area for processing The feed cassette will hold up to 280 of film The take up cassette will hold up to 25 of film The cut Fd Key 6 on the control panel Main Menu will cut and feed any print jobs remaining in the Platesetter plus a leader into the take up cassette 3 11 PREPARING FOR OPERATION Loading Optional Film Media 1 Open the top cover Raise the marker by pulling the marker lever towards the front of the Platesetter until the lever stops Lift up on the marker gently See figure 3 5 2 Open the load door and pull on the load knob Adjust the two rear edge guides inside the Platesetter by pulling the edge guide knobs up and sliding to the position closest to the film width 3 Adjust the two front edge guides by loosening the screws moving the guides all the way to the front 4 Open the feed cassette by lifting the back of the lid and sliding forward at the same time See figure 3 4 Remove the spool assembly Adjust the left hub to match the edge guide position by squeezing the clip and sliding on the shaft Remove the right hub from the shaft by lifting the clip and sliding it off the shaft Slide the film onto the shaft Slide the right hub onto the shaft by lifting the clip and pushing down on the spool until the spool is tight against the film see Figure 3 3 I
69. moisture control on the press to minimum 5 Replace the ink or add reducer 6 Change Processor chemistry 7 Call for service Toning Specking Background Smeared Images Tails on Charac ters Weak Image on Press CAUSE Plate media has abrasions The press ink is emulsified The press fountain solution is contaminated The Platesetter rollers are dirty Platesetter Processor chemistry is weak Plate media defective incom patible Too much press ink The press fountain solution is contaminated The roller pressure on the press is incorrect 1 2 CASE OF TROUBLE SOLUTION Handle plate media more carefully Change the fountain solution and the ink Change the fountain solution Use only distilled water for preparing solution Clean the rollers Change processor chemistry Change plate media Clean up press and reduce ink Replace the fountain solution Be sure to use distilled or deionized water for preparing the solution Check the stripes pressure be tween the press rollers 7 6 CASE OF TROUBLE General Troubleshooting PROBLEM The Platesetter will not Turn ON No Power Platesetter will not Start a Print Job Reload Media or Manually Reload Media message Platesetter will not Start a Print Job 7 7 1 2
70. necessary Calibrate the marker Replace the controller PCA Replace marker assembly Check galvo connector J14 on the controller PCA Check voltage across R267 or R266 on the controller PCA Calibrate marker Replace controller PCA Check galvo connector J14 on the controller PCA Calibrate the marker Replace the controller PCA Check the laser diode J1 and the safety interlock J7 connectors on the controller PCA Calibrate the marker Replace the controller PCA Check SOS SOT connectors on the controller PCA Check SOT sensor alignment Calibrate the marker Replace controller PCA Replace marker assembly Calibrate the marker Replace the controller PCA 50 SERVICE MANUAL MARKER GALVANOMETER PROBLEMS cont Marker hold error message 51 1 Turn up fogging circuit clockwise 1 4 turn maximum Note original potentiometer position If resetting does not alleviate problem return to original position 2 Realign SOS and SOT sensors Turn SOS screw 1 full turn clockwise Turn SOT screw 1 full turn counterclockwise Note original screw positions If realigning sensors does not alleviate problem return to original positions 3 Replace marker assembly GENERAL IMAGER PROBLEMS Platesetter spontaneously reboots Power out of spec message Platesetter is on line but will not start a job SERVIC
71. off the Platesetter and open the top cover 2 Replace the controller PCA as follows 31 SERVICE MANUAL CAUTION Follow ESD protective procedures carefully Refer to page 1 1 if neces sary a Remove the gold shield by unscrewing four screws and washers b Disconnect the laser diode connector first and immediately connect the cable to the brown grounding connector located underneath the PCA on the right side of the marker assembly frame See Figure 54 1 This prevents damage to the highly sensitive laser diode c Disconnect all cables from the controller PCA Note the correct orientation of each cable d Unscrew the four standoffs holding the controller PCA Carefully remove the controller PCA from the top of the marker assembly by squeezing the five plastic standoffs holding the controller PCA Note Always transport and store PCAs in anti static bags 3 Install the new PCA in reverse order 4 Recalibrate the marker assembly controller PCA as follows At the main menu move the cursor to position 4 or simply press 4 to access the More Information menu Once inside this menu move the cursor to 2 or simply press 2 to access the Calibrate menu In this menu move the cursor to 3 or simply press 3 to access the Calibrate Marker assembly menu The control panel will display are you sure Pressing ESC exits this menu without chang ing the marker assembly calibration Pressing ENTER will cause the control
72. on plates Ne 65 SERVICE MANUAL PROCESSOR MECHANICAL PROBLEMS Activator or Stabilizer rollers don t turn Processor drive motor jumping Processor noisy Replenishment pumps noisy Pull the rack out of the platesetter and check that the idler gears are meshing properly with the other gears Adjust gears if necessary Check the end play of rollers which should be approximately 0 010 to 0 020 0 25 to 0 5 mm Check for loose pulley or gear set screws Adjust worm gear drive to better mesh with other gears Check that the activator and stabilizer transport racks turn freely by hand Lower the drive motor to increase belt tension If motor cannot be moved lower shim the motor bracket away from the frame using the lock wash ers Order shim part 806741 001 Newer processor motor brackets have been redesigned and do not require the shim Squealing noise may be the pulley on the end of the worm gear Apply light oil or Teflon spray Motors generally make noise If too loud replace processor drive motor Check to see if the hoses coming from pumps are pinched Replace pumps 66 SERVICE MANUAL PROCESSOR SENSOR PROBLEMS Spurious low replenishment level error message Effluent probe not working Processor exit switch does not work 67 This problem is caused by faulty replenishment level probes 1 2 Check the probe connectors Check the cable Place one ohmmeter
73. panel to display Power Cycle which means to turn the machine off and then back on 5 Close the top cover Interface PCA Location and Function The interface PCA is located underneath the imager towards the front See Figure S4 1 The interface PCA acts as an interface between the controller PCA and the Platesetter engine assemblies The interface PCA also receives the signals from the various sensors within the Platesetter The interface PCA also sends control signals to the engine stepper PCA to activate the stepper motors 32 SERVICE MANUAL Voltages Supplied to Interface PCA 12 VDC 12 VDC 5 VDC 24 VDC Connector Assignments J1 Not used J2 Not used J3 Track change solenoid J4 Not used J5 Shutter solenoid J6 Micro stepping controller J7 Not used 18 Not used J9 Not used J10 Not used 111 Engine stepper PCA 2 Controller PCA control panel communication cable J13 Not used J14 Processor communication cable J15 Sensors J16 Power Supply 33 SERVICE MANUAL Replacing the Interface PCA 1 Turn off the Platesetter and remove the front panel 2 Replace the interface PCA as follows a Access the interface PCA from the front of the Platesetter Remove the plastic shield by unscrewing the four nuts and washers holding the shield b Disconnect all cables Note the correct orientation of each cable c Carefully remove the interface PCA by unscrewing the 4 standoffs which attach
74. print command if using set up with Mac chooser PREPARING FOR OPERATION MiniPlate Option With the MiniPlate option the Platesetter accommodates jobs shorter than the 12 minimum plate length by imposing several small jobs down the length of a plate To turn MiniPlate on change the destination to Processor MiniPlate in the Setup Menu see chapter 2 in the section Setup Menu The minimum job length is 1 MiniPlate accumulates shorter jobs until the combined length of the jobs exceeds an operator selected cut length e g 12 The plate material is then cut and run through the processor MiniPlate cut length can be set from 12 to 18 in the More Information Menu see chapter 2 The gap between jobs in MiniPlate Mode can be eliminated or set to a desired amount in the Calibrate Menu see the Physical Calibration section of the INSTALLATION GUIDE This calibration is enabled in the More Information Menu MiniPlate mode can also be used in cassette mode to eliminate the gap between nobs The CUT Fd key 6 operation will cut and feed into the processor any MiniPlates remaining in the Platesetter The extra material fed to bring the length up to the selected minimum length will be imaged black so as not to pick up ink on the press The word MINI in the lower right corner of the main menu indicates that the Platesetter contains MiniPlates that have not been cut or processed The following digit indicates the number of MiniPlates in th
75. pulling the edge guide knobs up and sliding to the position closest to the plate media width 3 Adjust the two front edge guides by loosening the screws and moving the guides all the way to the front 4 Adjust the left hub on the spool shaft to match the edge guide position by squeezing the clip and sliding on shaft Remove the right hub from the shaft by lifting clip and sliding off the shaft Slide media onto shaft Slide the right hub onto shaft by lifting clip and pushing down on spool until spool is tight against media see Figure QS 1 5 Place the spool assembly on the white receptacles in the Platesetter Feed media through rollers and four edge guides until media stops Adjust the two front edge guides by turning edge guide knobs counter clockwise and sliding edge guide until edge guide rests against plate media Lock edge guide by turning knobs clockwise 6 Gently lower the marker and lock down by pushing the marker lever towards the rear of the platesetter until the lever is horizontal Close the top cover 7 Set the plate width from the control panel setup menu 8 Push the load knob in This will automatically load the plate material Immediately close the load door 9 Image one test plate from the control panel Test Plate men Note Destination must be set to Processor see section Control Panel Set up menu 05 2 QUICK START GUIDE Control Panel Setup Menu EMULSION OUT MEDIA EMULSION IN_ MEDIA Spools Right Hu
76. s recommendations referto manufacturer s documentation or see the following table Optimal D Film of the quality of its laser spot the PlateStream can be set higher to yield better solids without sacrificing fine lines d Ifthe calibration of the densitometer is at all suspect a rough procedure is to 1 fully fog a piece of plate material and 11 set laser to yield 06 below the fully fogged density reading e If the density reading is ess than optimal 0 increase the laser power If the reading 15 greater than optimal reduce the laser power Tip as arough rule of thumb change the laser power by 1 for each 01 density change needed We ve found that D at 900 dpi is best set approximately 04 higher than the optimal f Repeat procedure for each resolution and media type You may prefer to calibrate only higher resolutions used for critical work B 3 CALIBRATION II Calibrating the ZAPrip HQ Harlequin RIP The goal of calibrating the RIP is to linearize the transfer curve Figure la shows a calibrated transfer curve and Figure 1b shows a non linear uncalibrated transfer curve Non Linear Output Linear Output g 100 g 100 o o m 50 m 50 2 2 096 0 0 50 100 0 50 100 REQUESTED REQUESTED Figure la Figure 1 The ZAPrip HO Harlequin RIP Print Calibration menu allows you to print test strips calibra tion targets Calibration Manager allows you to create a
77. the inter face PCA to the chassis d Install the new interface PCA in reverse order Replace the front panel Engine Stepper PCA Location The engine stepper PCA is located underneath the right side of the imager mounted on the side of the chassis see Figure 54 1 The engine stepper PCA provides power and control signals to the feed motor capstan motor exit motor and cutter motor Voltages Supplied to the Engine Stepper PCA 24 VDC stepper motor power 5 VDC signal logic 34 SERVICE MANUAL Connector Assignments J1 Cutter stepper motor J2 Exit stepper motor J3 Feed stepper motor J4 Not Used J5 Power in from power supply drawer J6 Not Used J7 Interface PCA Replacing the Engine Stepper PCA 1 Turn off the Platesetter 2 Remove the front panel 3 Access the Engine Stepper PCA from the front of the Platesetter Disconnect the six cables from the engine stepper PCA Note the correct orientation of each cable 4 Carefully remove the Engine Stepper PCA by removing the 4 nuts securing the engine stepper PCA to the chassis 5 Install the new PCA in reverse order Replace front panel 35 SERVICE MANUAL This page intentionally left blank 36 SERVICE MANUAL Power Supply Assembly Location The Power Supply assembly is located underneath the Imager See Figure S4 1 The power supply provides all DC power within the Platesetter and also provides AC power The circuit
78. the replenishment probes located underneath the processor and insert probes into the replenishment tanks by screwing on the white cap Remove the bubble pack from the optional effluent probe located underneath the processor and insert probe into the small hole on top of the optional effluent tank Attach one end of the 6 long 11 4 diameter 180 cm by 3 2 cm vinyl hose to the drain underneath the processor If there is an optional effluent tank place the other end in the optional effluent tank Gently push the cart s under the processor Close the bottom front doors Rotate the gears in the activator and stabilizer racks several times to free them up before operating the Platesetter Close the top cover Installing the Raster Image Processor RIP 1 Unpack the RIP central processing unit CPU and inspect it for obvious physical damage If any component appears damaged notify the carrier immediately Unpack the RIP keyboard Unpack the RIP monitor Plug the monitor cable into the back of the RIP CPU this cable should fit only one way Connect the keyboard cable to the keyboard connector on the back of the RIP CPU Attach the network cable to the network interface connector on the back of the RIP CPU Plug in the RIP electrical power cord s Connect the two interface cables between the RIP CPU and the Platesetter The Platesetter I O Panel is located on the top rear of the machine see Figu
79. 0 Current marker state displayed only during a marker error or while the marker is either calibrating or initializing Line 6 On Off Line Idle Current imager state the messages displayed as a single plate is fed through the Platesetter in processor mode are On Off Line Idle On Off Line Busy On Off Line Backing Up On Off Line Marker Hold On Off Line Imaging On Off Line Image Leader On Off Line Advancing On Off Line Cutting On Off Line Punching On Off Line Transporting On Off Line Loading On Off Line Feeding Imager ready to start imaging imager and processor are idle except possibly for the last several inches of the last plate exiting the processor Imager communicating with the RIP Backing up leader of plate from cutter to start of image point Marker getting ready to image Imaging current plate Imaging leader of next plate Advancing plate to cutter Cutting plate Punching Plate Moving media out of the imager Loading media Moving media into or through the imager CONTROL PANEL On Off Line Ready Pause 0 5 sec pause between plates On Off Line Ready Trans Imager ready to start imaging plate s still in imager On Off Line Ready Proc Imager ready to start imaging plate s in processor only A0075 Approximate number of feet of media left on input spool A if length of media on the spool was entered when the sp
80. 0 001 807177 001 806501 001 600292 001 804521 001 806913 001 900872 004 900872 008 600188 003 Revision C Component Description Parts List Page 1 of 2 ASSY CHASSIS PS WSOFTWARE OPERATOR PANEL ASSY ROLLER TRANSPORT 13 ASSY PROCESSOR ASSY INDICATOR LIGHT GAS CYLINDER 60 LBS STUD 10MM BALL 5 16 X 18 TPI NUT HEX 5 16 X 18 TPI WASHER LOCK HELICAL SPRING 5 16 PCA STEPPER SHEAR CUTTER PLATESTREAM PCA INTERFACE PLATESTREAM NUT LOCK 8 32 WASHER EXTERNAL LOCK 8 SCREW BACK HAND TORX 8 32 X 375 TRAY STOP TRAY ADJUSTABLE BLOCK TRAY ADJUSTABLE GROMMET RUBBER TUBING SLIT 1 WASHER LOCK HELICAL SPRING 3 8 ASSY PUMP BRACKET PUMP MOUNTING BRACKET PUMP MOUNTING BUSHING SPACER NYLON 6 32 X 375 NUT HEX 3 8 X 16 TPI WASHER FENDER 2 X 438 X 156 BOLT MODIFIED HEX ISOLATOR RING ISOLATOR BUSHING SCREW PHILLIPS PANHEAD 10 32 X 2 1 2 SPACER ROUND 10 X 5 8 WASHER FENDER 1 375 X 192 X 048 NUT LOCK HEX 10 32 NUT LOCK HEX 116 32 PANEL PROCESSOR GUARD GUARD INTERFACE PCA ASSY CABLE INTERLOCK PROCESSOR SWITCH DOOR ASSY CABLE INTERLOCK JUMPER PANEL VAPOR BARRIER ISOLATOR RING ISOLATOR BUSHING STRAIN RELIEF CABLE 058 059 060 061 062 063 065 066 067 068 069 070 071 072 073 074 075 076 087 090 093 094 095 098 099 N NO e N A N Ne e Ne Ne KF N e Assembly Number 807741 001 ASSY IMAGER PLATESTREAM
81. 001 900215 007 Revision Component Description Parts List Page 1 of 1 PLATE STABILIZER FRONT MICRO PLATE BEARING ROLLER GEAR ASSY GEAR SHAFT IDLER GEAR SPUR E RING SAE 25 STUD GEAR GEAR SPUR E RING SAE 312 PLATE STABILIZER REAR MICRO PLATE BRACKET DRIVE RACK ASSY CLUTCH WORM GEAR SHAFT DRIVE RACK ASSY STABILIZER ENTRANCE GUIDE ROLLER TRANSPORT HANDLE RACK ROLLER SQUEEGEE POLISHED ASSY RACK EXIT GUIDE SCREW STAINLESS 8 32 X 375 PHILLIPS PANHEAD WASHER LOCK STAINLESS 8 055X 040 WASHER FLAT STAINLESS 10 7 16X13 64X 062 SCREW STAINLESS 10 24 X 375 PHILLIPS PANHEAD WASHER LOCK STAINLESS SCREW STAINLESS TAP FORM 10 24 X 1 ROD SUPPORT 19 67 SPRING EXTENSION ROLLER PROCESSOR ASSIST SCREW SET STAINLESS 28 32 X 25 GEAR MOD BEARING NON METALLIC FLANGED LABEL GUIDE COVER GUIDE F COLLAR GEAR NUT STAINLESS 10 24 KEPS LOCKNUT COLLAR SHAFT WASHER NYLON 1 4 X 5 O D X 032 24 2 220 Ke ENDS PLACES BOTH Printware ASSY STABILIZER TRANSPORT 4 S C 807384 001 REVISION Sheet of 3 Printware Confidential AROUND 2 PLCS Printware ASS Y STABILIZER TRANSPORT 807384 001 REVISION C Sheet 2 of 3 Printware Confidential Printware ASSY STABILIZER TRANSPORT 807384 001 REVISION C Sheet 3 of 3 Printware Confidential Find Number 001 002 003 004 005 0
82. 002 003 005 006 007 008 009 010 011 012 013 015 016 019 020 021 022 023 024 025 026 028 030 032 033 034 035 037 038 039 040 Quantity Component Used 1 12 5 _ ow ONY NY NN NY YD BPN KW CO COR Bee Assembly Number 807328 001 ASSY STABILIZER TRANSPORT PLATESTREAM Number 807331 001 900960 004 900960 003 806752 001 900960 001 900229 017 806776 001 900960 020 900229 018 807332 001 806764 001 806852 001 806821 001 806837 001 806760 001 806278 001 806836 001 900967 001 901072 004 901071 013 900967 003 901072 005 901089 001 806822 001 806694 002 806510 001 901070 001 806819 001 900319 004 806695 001 900773 001 900968 005 900215 007 Revision Component Description PLATE STABILIZER FRONT BEARING ROLLER ASSY GEAR SHAFT IDLER ASSY GEAR SPUR E RING 25 SHAFT ASSY STUD GEAR ASSY GEAR SPUR E RING 312 SHAFT PLATE STABILIZER REAR BRACKET DRIVE RACK ASSY CLUTCH WORM GEAR SHAFT DRIVE RACK ASSY STABILIZER ENTRANCE GUIDE HANDLE RACK ROLLER SQUEEGEE POLISHED ASSY PROCESSOR GUIDE SCREW PHILLIPS PAN HEAD STAINLESS 8 32 X 375 WASHER SPRING LOCK STAINLESS 8 WASHER FLAT STAINLESS 10 SCREW PILLIPS PAN HEAD STAINLESS 10 24 X 375 WASHER SPRING LOCK STAINLESS SCREW TAP FORM STAINLESS 10 24 X 1 ROD SUPPORT SPRING EXTENSION ROLLER PROCESSOR ASSIST SCREW SET STAINLESS 8 32 X 25 GEAR MODI
83. 00359 001 807503 001 806099 002 806099 001 900236 003 Revision F WASHER FLAT STEEL 8 NUT LOCK 8 32 SCREW SHC 8 32 X 75 SPRING COMPRESSION 750X 360X 042 PLUNGER SPRING LOADED SCREW SOCKET HEAD SHOULDER 8 32 X 6255 SCREW TAPTITE PHILLIPS PANHHEAD 8 32 X 5 SCREW SHC 8 32 X 5 SCREW TAPTITE PHILLIPS PANHHEAD 6 32 X 3 8 NUT HEX JAM 1 4 X 28 SCREW SHC 8 32 X 5 8 WASHER FLAT STEEL 8 SCREW SHC 8 32 X 1 1 4 LABEL PLATE GUIDE POSITIONING LABEL PLATE GUIDE POSITIONING STUD 10MM BALL 5 16 18 THREAD WASHER LOCK HELICAL SPRING 5 16 REG NUT HEX UNC 5 16 18 WASHER FENDER 434 X 160 X 125 SCREW B H TORX 8 32 UNC X 750 SCREW PAN PPH 6 32 X 38 LABEL LOAD KNOB LABEL GUIDE COVER GUIDE A LABEL GUIDE COVER GUIDE B LABEL PLATE GUIDE POS EDGE GUIDE LABEL PLATE GUIDE POSITIONING EDGE GUIDE LABEL PLATE GUIDE POSITIONING EDGE GUIDE LABEL GUIDE C1 LABEL GUIDE C2 SHAFT 19 75 CLAMP FIXED DIA 25 LABEL GUIDE C1 ARROW UP LABEL GUIDE B ARROW DOWN ASSY SWITCH SHAFT IDLER ARM BEARING NUT SELF LOCKING HEX 6 32 SCREW PHILLIPS PANHEAD 6 32 X 7 16 WASHER FLAT STEEL 6 SPACER SHAFT INNER SPACER 375 ID X 093 THICK SPRING TRACTION CONTROL ASSY SOLENOID CAPSTAN GUIDE ASSY SOLENOID CAPSTAN GUIDE SCREW SOCKET HEAD SHLD 8 32X 125 338 339 340 341 N N Assembly Number 807444 001 ASSY ROLLER TRANSPORT PLATESTREAM MICRO PLATE 900236 008 900406 807457 001 807537 001 Revision F SCREW SOCKET HEAD SHOULDER 8 32 X
84. 01 806783 001 806826 001 806798 001 900967 004 900968 003 900967 005 901076 003 900338 002 900053 002 806827 001 806827 002 806830 001 806827 003 806827 004 ASSY ELECTRICAL PANEL PLATESTREAM Revision E Component Description PANEL ELECTRICAL LOWER ASSY CABLE HEATER CONTROL ASSY CABLE MOTOR CONTROL ASSY CABLE DRYER HEATER BUSHING GROMMET ASSY STRIP TS1 ASSY STRIP TS2 ASSY CABLE GROUND ASSY CABLE POWER CONTROL SCREW STAINLESS 4 40 X 375 NUT STAINLESS HEX LOCKNUT 4 40 SCREW STAINLESS PHILLIPS PANHEAD 8 32 X 5 WASHER LOCK STAINLESS EXTERNAL 8 MOUNT TIE TIE NYLON ASSY CABLE JUMPER 3 5 ASSY CABLE JUMPER 4 5 ASSY CABLE PROCESSOR MOTOR ASSY CABLE JUMPER 3 5 ASSY CABLE JUMPER 3 75 Parts List Page 1 of 1 FROM REFERENCE 51 1 P8 1 TS1 1 51 4 806827 003 ITEM 27 TS1 2 GNO 1 806826 001 ITEM 11 TS1 2 TS1 6 806827 001 ITEM 21 TS1 3 P8 3 TS1 3 P8 4 EHES TS1 4 TS2 3 806827 004 ITEM 28 TS1 4 DRIVE MOTOR 806830 001 ITEM 23 TS1 4 BLOWER FAN MOTOR BLACK TS1 5 5 1 TS1 5 BLOWER FAN MOTOR BLACK TS1 6 TS2 1 806827 002 ITEM 22 TS1 6 DRIVE MOTOR 806830 001 ITEM 23 TS1 6 BLOWER FAN MOTOR GREEN YELLOW 51 7 DRIVE MOTOR 806830 001 ITEM 23 TS2 1 2 TS2 1 TS2 6 806827 001 ITEM 21 TS2 2 P5 2 s TS2 3 TS2 8 806827 003 ITEM 27 TS2 3
85. 02 003 004 005 006 007 008 014 016 800 Quantity Component Used N A CO A A me Assembly Number 803666 001 ASSY MOTOR MOUNT Number 806098 002 803665 001 806199 001 900767 001 900652 014 900287 016 900160 004 900336 000 900160 011 900235 013 807439 001 Revision P Component Description ASSY MOTOR TAKEUP DRIVE BRACKET MOTOR MOUNT PULLEY MOD GROMMETS VIBRATION ISOLATOR SPACER ROUND 8 X 1 4 SCREW PAN PHILLIPS PANHEAD 6 32 X 1 WASHER FLAT STEEL 6 NUT SELF LOCKING HEX 6 32 WASHER FLAT STEEL 6 SCREW SHC 6 32 X 25 ASSY BLOCK MASS Parts List Page 1 of 1 Printware Confidential 600 IF REQUIRED e Printware ASSY MOTOR MOUNT 803666 001 REVISION P Sheet of 1 Find Number 001 002 003 008 009 010 011 012 013 014 015 017 018 019 020 021 024 Quantity Component Used BNO NY COW D RR Re N e Assembly Number 807050 001 ASSY CAPSTAN GUIDE PLATESTREAM MICRO PLATE Number 804241 001 804242 001 806324 001 806411 001 80641 1 002 806412 001 8064 12 002 900236 90087 1 001 900047 002 900236 008 807047 001 806658 001 900277 026 900233 003 90087 1 007 900230 005 Revision D Component Description GUIDE STATIONARY CAPSTAN SHUTTER CAPSTAN LINKAGE CAPSTAN BRACKET CAPSTAN GUIDE BRACKET CAPSTAN GUIDE BRACKET CAPSTAN SHUTTER BRACKET CAPSTAN SHUTTER SCREW SOCKET HEAD SHOULDER 8 32 X 188 SCREW S
86. 06 007 008 009 010 011 012 013 015 016 020 021 022 023 024 025 026 027 029 032 033 034 035 036 037 038 039 040 041 042 Quantity Component Used 1 16 8 5 N Nee 0 QN QN AO AO A e e e e N Assembly Number 807385 001 ASSY ACTIVATOR TRANSPORT PLATESTREAM MICRO PLATE Number 807380 001 900960 004 900960 003 806752 001 900960 001 900229 017 806776 001 900960 020 900229 018 807381 001 806694 001 806764 001 806852 001 806821 001 806836 001 806760 001 806762 001 806838 001 900967 001 901072 004 901071 013 900967 003 901072 005 901089 001 806278 001 806510 001 806506 001 806822 001 900319 004 901070 001 806819 001 806695 001 900773 001 900215 007 900968 005 807225 004 Revision Component Description Parts List Page 1 of 1 PLATE ACTIVATOR FRONT MICROPLATE BEARING ROLLER GEAR ASSY GEAR SHAFT IDLER GEAR SPUR E RING SAE 25 SHAFT STUD GEAR GEAR SPUR E RINGSAE 312 SHAFT PLATE ACTIVATOR REAR MICROPLATE SPRING EXTENSION BRACKET DRIVE RACK ASSY CLUTCH WORM GEAR SHAFT DRIVE RACK ASSY PROCESSOR GUIDE HANDLE RACK ROLLER TRANSPORT ASSY RACK EXIT GUIDE SCREW STAINLESS 8 32 X 375 PHILLIPS PANHEAD WASHER LOCK STAINLESS 8 055X 040 WASHER FLAT STAINLESS 10 7 16X13 64X 062 SCREW STAINLESS 10 24 X 375 PHILLIPS PANHEAD WASHER LOCK STAINLESS SCREW STAINLESS TAP FORM 10 24 X 1 ROLLER SQ
87. 06239 001 BRACKET UPPER GUIDE MOUNTING 076 1 807485 001 ASSY BOX VACUUM 078 1 900302 008 CLAMP HOSE Printware ASS Y PUNCH COMBO 807458 001 REVISION C Sheet of 1 Printware Confidential Find Number 001 002 003 004 A A Assembly Number 807085 001 ASSY CART REPLENISHMENT Quantity Component Used Number 807098 001 900832 003 900223 007 900222 003 Revision D Component Description Parts List Page 1 of 1 CART REPLENISHMENT CASTER TWIN WHEEL W O BRAKE WASHER LOCK HELICAL SPRING 5 16 NUT HEX UNC 5 16 18 Ut f Y EN X 9 Ww Su EN ET uu EN EN Xn SS NN NS 9 lt EN E uS EN EN EN EN Sy EN RM EN N SS foes 44 4 PLACES EN d Cu N Sy V x EM Printware ASSY REPLENISHMENT CART 807085 001 REVISION D Sheet of Printware Confidential Find Number 001 002 003 004 005 006 008 010 011 012 013 014 015 016 019 Quantity Component Used e N e eS 15 N NN NYFF Assembly Number 807152 002 ASSY FILM OPTION 13 Number 806912 001 807467 001 807072 001 807457 001 807115 001 807115 002 900047 000 807237 001 900229 010 807091 001 900235 020 900233 002 900160 010 90034 1 007 900445 007 Revision J Component Description ASSY CASSETTE TAKEUP ASSY SUPPLY CASSETTE 280 RECEPTACLE CASSETTE BOTTOM RECEPTACLE CASSETTE TOP COND
88. 0630 065 Th 0 092 2 3 mm nominal Part 900359 001 Spacer 375 ID x 093 Th 20 SERVICE MANUAL Replacing the Feed Rollers Lower and Upper Feed Stepper Motor and Feed Motor Belts See Figure S3 1 Capstan Roller Cutter p o PEA Imager Exit J a Feed Belts Moor Feed Rollers Imager Exit Belts Imager Exit Rollers Figure 83 1 Back View of the Imager NOTE The MicroPlate model will look slightly different than Figure S3 1 1 Open the top cover and raise the marker assembly Remove the back panel 2 Remove the bracket holding the pulley by unscrewing the three screws holding the bracket Remove the bracket holding the motor by unscrewing the four screws holding the bracket 3 Rotate the I shaped bracket located behind the pulley 90 and then slide the belts off of the gears 4 To replace the belts install the new belts in reverse order 5 To replace the motor disconnect the cable from the motor Remove the motor from the bracket Install the new motor in reverse order Adjust the drive belt tension by adjusting the set screw on the motor shaft and or pulley shaft 21 SERVICE MANUAL 6 To replace the rollers remove the pulley from the shaft by loosening the two set screws Remove the E clips and spacers if any from each end of the lower shaft Remove the bushings from each end of the roller shaft Access the rollers from the top of the Plate
89. 07338 001 807339 001 807340 001 806228 001 807063 001 806239 001 807215 001 807216 001 806352 002 806354 002 807064 001 807354 001 803713 001 807356 001 807363 001 807359 001 806347 001 806348 001 900229 001 806199 001 900235 013 803666 001 806393 001 900160 006 900047 003 900288 000 900406 006 806267 001 806585 001 900254 002 900039 001 804574 001 900582 006 807092 001 807065 001 900289 004 806127 001 807050 001 806360 001 80638 1 001 807066 001 807067 001 900235 005 ASSY ROLLER TRANSPORT PLATESTREAM MICRO PLATE Revision F GUIDE LOWER SWING GUIDE UPPER SOLID GUIDE UPPER EXIT GUIDE LOWER EXIT BRACKET LOWER SOLID MOUNTING BRACKET BUFFER GUIDE BRACKET UPPER GUIDE MOUNTING BLOCK EDGE GUIDE ADJUSTABLE BLOCK EDGE GUIDE POSITIONING PLATE ADJUST PLATE POSITIONING BLOCK BACKUP BRIDGE MEDIA INPUT PULLEY MOD 65 GR COLLAR PULLEY ASSY PULLEY OVERRUNNING CLUTCH ASSY BELT TENSIONER SHAFT BELT TENSIONER BRKT IDLER SHAFT IDLER E RING 1 4 SHAFT PULLEY MOD SCREW SHOULDER 6 32 X 25 ASSY MOTOR MOUNT BRKT BEARING SUPPORT WASHER FLAT STEEL 10 WASHER EXTERNAL LOCK 10 SCREW PHILLIPS PANHEAD 10 32 X 1 2 BEARING OIL LESS BRONZE DB1122 SHAFT MARKER 5 BEARING MODIFIED SELF ALIGNING SPACER SHAFT INNER 1 2ID X 1 16 SPACER 171 ID 25 OD 25 HT PULLEY DUAL CAPSTAN PIN DOWEL SST 1250 DIAMETER X 5 LONG SHAFT DRIVE LINKAGE HANGER UNLOAD SHAFT BUSHING GROMMET ASSY CUTTER 13 ASSY CAPSTAN GUIDE CTP 13 BRACKET C
90. 075 076 077 079 089 105 106 107 BPN WN 1r Assembly Number 807346 001 ASSY PROCESSOR PLATESTREAM MICRO PLATE 90027 1 003 806739 001 900967 010 806750 001 901089 004 900967 003 901072 005 900968 005 900967 006 901072 006 901092 001 900967 007 900967 001 901071 010 900967 005 900968 001 900967 019 901091 001 901071 012 807394 001 807313 002 808228 002 806848 001 806707 003 806657 002 806706 004 901100 002 807487 001 901072 004 Revision H BELT TIMING 1 5 PITCH 60 GROVES PANEL PCA BOARD SCREW STAINLESS 10 24 X 5 BLOCK SUPPORT SWITCH SCREW STAINLESS TAP FORM 10 32 X 5 SCREW STAINLESS 10 24 X 375 PHILLIPS PANHEAD WASHER SPRING LOCKING STAINLESS NUT STAINLESS 10 24 LOCKNUT SCREW STAINLESS 1 4 20 X 5 WASHER SPRING LOCKING STAINLESS GROMMET SCREW SCREW STAINLESS 4 40 X 625 SCREW STAINLESS 8 32 X 375 PHILLIPS PANHEAD WASHER FLAT STAINLESS 8 3 8X11 64X 031 SCREW STAINLESS 8 32 X 5 PILLIPS PANHEAD NUT STAINLESS 8 32 LOCKNUT SCREW STAINLESS 10 32 X 5 PHILLIPS PANHEAD STANDOFF TURN WASHER FLAT STAINLESS BRACKET RACK LOCATING ASSY AIR HOOD COVER G ASSY TRANSPORT DRYER ROLLER FOAM 11 ASSY CROSSOVER GUIDE GUIDE F ASSY ENTRANCE GUIDE GUIDE D ASSY RACK COVER COVER E ASSY TUBE OVERFLOW TUBING POLYVINYL CHLORIDE 1 1 4 X 1 BRACKET COVER ADJUST WASHER SPRING LOCK STAINLESS 8 055X 040 G N
91. 10 turn adjustment screw on each pump turn clockwise to increase the flow rate Sensors are in the replenishment tank see figure 52 2 14 SERVICE MANUAL NOTE If the effluent tank accessory is being used and the tank is full the replenisher pumps will not run Controls Prime Pump On the control panel Run Hardware Menu Used to activate the pumps They will run for 5 minutes and then stop Reset Used to clear all systems and prepare the processor section for a new job Quarterly Maintenance To run the processor with the top cover open use the Printware switch part number 807256 001 Insert flat edge of switch with finger locking into the hole on the side of the interlock bracket The black interlock bracket is located in the rear of the Platesetter above the processor dryer See Figure 52 2 1 Open the top cover See Figure 52 3 and 52 4 Inspect all gears and bearings for wear 2 Make sure that the dryer drive belt is tight If the dryer belt is jumping loose or is sagging it can be tightened by adjusting the bracket on the side rail Loosen the two screws in the bracket and move towards the solution racks to snug up the drive belt Tighten the two screws 3 Make sure that the dryer drive clutch is not slipping or the dryer rollers are rotating slower than the solution rack Tighten the dryer clutch by turning the nut at the end of the shaft clockwise 4 Check to see that there is a slight 0 01 to 0 03 0 0
92. 272 273 274 275 276 277 m L N N N ON 16 16 65 98 10 38 21 Assembly Number 807244 001 900236 900324 001 900235 035 803456 001 900406 002 803713 001 900235 001 900229 003 901024 001 804703 001 804704 002 807068 001 900319 002 803697 001 806304 001 807069 001 900235 007 900319 001 900223 000 900160 009 900958 001 900261 004 900875 002 900839 002 807116 001 807116 002 807116 003 807456 001 900233 900229 009 900236 008 900229 008 900287 019 900233 002 900445 006 900047 000 900445 007 900277 023 900047 002 900277 022 900566 003 900172 002 900160 005 900233 003 ASSY ROLLER TRANSPORT PLATESTREAM Revision 5 SCREW SOCKET HEAD SHOULDER 8 32X 188 WASHER CURVED SPRING 3 8 SCREW SHC 25 X 5 X 20 TPI PLATE IDLER BEARING OIL LESS BRONZE COLLAR PULLEY SCREW SHC 6 32 X 5 E RING 5 SHAFT KNOB PULL WASHER MODIFIED ROD PIVOT BRACKET CUTTER MOUNTING BEARING NON METALLIC FLANGED BAR UNLOADING LINKAGE PINCH ROLLER UNLOADING PLATE CUTTER MOUNTING SCREW SHC 4 40 X 5 BEARING NON METALLIC FLANGED WASHER LOCK HELICAL SPRING 1 4 WASHER FLAT STEEL 1 4 NUT RECEPTACLE RETAINING RECEPTACLE 1 4 TURN RING EXTERNAL RETAINING FASTENER 1 4 TURN PUSH BUTTON PLATE BACKING SPOOL 06 PLATE BACKING SPOOL 02 PLATE BACKING SPOOL 015 RECEPTACLE SPOOL CONDUCTIVE NUT LOCK 6 32 E RING 75 SHAFT SCREW SOCKET HE
93. 3 to 0 08 cm end play in the rack rollers To adjust for this play loosen the set screws in the gears moving the gears on the roller shafts and tighten set screws 5 Check the dryer belts for wear or cracks 6 If there is excessive vibration check for damaged motor mounts 7 Check to see that rack gears are properly seated into the drive shaft worm gear The teeth should be engaged at least half way but not be bottoming out The drive shaft can be adjusted by loosening the bearing block screws at each end adjusting the shaft position and tighten block screws 8 Check and tighten hose clamps 15 SERVICE MANUAL 9 Check drain and replenishment line for restrictions 10 The drive motor replenisher pump motor and the blower motor do not need to be lubricated 11 Drive motor assembly removal Remove the wire tray located on the right side of the Platesetter Remove the right exit panel by unscrewing the four screws holding this panel Remove drive motor by unscrewing the three screws holding the drive motor plate to the chassis Disconnect the 2 drive motor leads and unfasten the motor ground wire Take the drive belt off of the drive shaft by rotating the shaft and deflecting the belt off of the pulley 12 Check to verify that the solution is 86 F 30 C nominal activator temperature The activator temperature can be changed by adjusting a potentiometer R42 on the PC board Turning the screw clockwise increases the tempe
94. 4 001 806724 001 806727 001 807495 001 900289 004 806792 001 900338 001 900053 002 806715 001 900302 008 806769 001 600333 001 806731 001 807384 001 807385 001 806701 001 806702 001 806725 001 900338 002 806793 001 807204 001 900040 003 600330 001 806831 001 806704 001 806705 001 806788 001 806789 001 806790 001 523150 001 806708 001 806703 001 Revision H Component Description PANEL SUPPORT RACK ASSY CLUTCH SHAFT BEARING ROLLER BRACKET CLUTCH BEARING FLANGE MOD BUSHING GROMMET ASSY TEMPERATURE PROBE ACTIVATOR ASSY LEVEL SENSOR ASSY DRIVE SHAFT ASSY DRYER DRIVE SUPPORT UPPER DUCT RAIL RIGHT GUSSET RAIL DRIVE FRAME DRIVE DRYER BUSHING GROMMET ASSY CABLE P3 TO J14 MOUNT TIE ANCHOR NYLON TIE NYLON ASSY DRAIN CLAMP HOSE SWITCH WIRE FORM SWITCH SNAP LEVER DUCT VERTICAL ASSY STABILIZER TRANSPORT PS MICRO PLATE ASSY ACTIVATOR TRANSPORT PS MICRO PLATE ASSY ACTIVATOR TANK ASSY STABILIZER TANK RAIL LEFT MOUNT TIE ASSY CABLE ACTIVATOR STABILIZER LEVEL ASSY CABLE INTERFACE PCA TO PROCESSOR PCA CLIP CORD ADHESIVE SENSOR THERMISTOR DISK SHIM SUPPORT RACK PROCESSOR ASSY HEATER COVER ASSY HEATER BLOWER ASSY CABLE DRYER TEMPERATURE PROBE ASSY CABLE FILM SWITCH ASSY CABLE REPLENISHMENT LEVEL PCA PLATESTREAM PROCESSOR ASSY ELECTRICAL PANEL ASSY DRIVER MOTOR Parts List Page 1 of 2 046 047 048 050 052 053 054 055 056 057 059 060 061 062 064 065 067 068 069 074
95. 52 4 4 2 TS2 5 P13 3 Em TS2 5 P4 3 TS2 6 3 4 TS2 7 P4 EL TS2 7 ACT TANK HEATER Mere TS2 8 ACT TANK HEATER 2922 e N n n O oe 7 y o O m 806798 001 E Co s Af ae a Printware Confidential Printware ASSY ELECTRICAL PANEL 806708 001 Sheet 1 of 1 Find Number 001 002 003 004 005 007 008 Quantity Component Used Assembly Number 806816 002 ASSY TANK EFFLUENT WITH CART Number 900937 006 806718 001 806815 002 806803 001 806804 001 901118 001 807083 001 Revision F Component Description Parts List Page 1 of 1 15 GALLON ASSY DRAIN VALVE ASSY PROBE EFFLUENT PLATE TANK SUPPORT GASKET FITTING NUT PLASTIC ASSY CART EFFLUENT NOT PART OF THIS ASSEMBLY Sud j 20
96. 7 900236 008 900235 040 900233 003 900233 001 900288 006 900369 001 900287 029 900160 011 900005 002 900336 000 900287 025 900521 003 806127 002 900839 002 900875 002 900261 004 900958 001 Revision Description ASSY COMPRESSOR MODIFIED FITTING TUBE QUICK STRAIGHT ASSY PUNCH COMBO FITTING TUBE QUICK ELBOW FITTING TUBE QUICK STRAIGHT TUBING POLYURETHANE RED TUBING POLYURETHANE ORANGE TUBING POLY URETHANE GREEN BUSHING GROMMET MUFFLER PNEUMATIC SOLENOID AIR VALVE ASSY CABLE SOLENOID SCREW SHC 8 32 X 1 1 4 ASSY PLATE VACUUM BRACKET PUNCH MOUNTING NON OPERATOR SIDE BRACKET PUNCH MOUNTING OPERATOR SIDE GUIDE UPPER BUFFER GUIDE LOWER BUFFER BRACKET PUNCH PLATE SHAFT 19 75 WASHER FENDER 5 X 189 X 125 WASHER FENDER 749 X 203 X 156 WASHER EXTERNAL LOCK 8 SCREW B H TORX 8 32 X 375 SCREW B H TORX 8 32 X 5 SCREW SOCKET HEAD SHOULDER 8 32 X 2505 SCREW SHC 8 32 X 5 8 NUT LOCK 28 32 NUT LOCK 10 32 SCREW PHILLIPS PANHEAD 10 32 X 1 5 CLAMP FIXED DIAMETER 25 SCREW PHILLIPS PANHEAD 6 32 X 7 16 WASHER FLAT STEEL 6 RING GRIP NUT SELF LOCKING HEX 6 32 SCREW PHILLIPS PANHEAD 6 32 X 1 25 TUBING WIRE REINFORCED 1 ASSY CUTTER 13 FASTENER 1 4 TURN PUSH BUTTON RING EXTERNAL RETAINING RECEPTACLE 1 4 TURN NUT RECEPTACLE RETAINING Parts List Page 1 of 2 Assembly Number 807458 001 ASSY PUNCH COMBO PLATESTREAM MICROPLATE Revision C 075 1 8
97. 8 009 010 011 012 013 014 015 017 018 019 020 021 024 Quantity Component Used 0 Assembly Number 807050 001 ASSY CAPSTAN GUIDE PLATESTREAM Number 804241 001 804242 001 806324 001 806411 001 80641 1 002 806412 001 8064 12 002 900236 90087 1 001 900047 002 900236 008 807047 001 806658 001 900277 026 900233 003 90087 1 007 900230 005 Revision D Component Description GUIDE STATIONARY CAPSTAN SHUTTER CAPSTAN LINKAGE CAPSTAN BRACKET CAPSTAN GUIDE BRACKET CAPSTAN GUIDE BRACKET CAPSTAN SHUTTER BRACKET CAPSTAN SHUTTER SCREW SOCKET HEAD SHOULDER 8 32 X 188 SCREW SHC LOW HEAD 6 32 X 38 WASHER EXTERNAL LOCKING 6 SCREW SOCKET HEAD SHOULDER 8 32 X 2505 ASSY LIGHT SEAL 13 SPRING HOOKED CAPSTAN GUIDE SPRING COMPRESSION 25 X 240X 02 NUT LOCK 28 32 SCREW SHC LOW HEAD 46 32 X 25 BEARING NYLON SNAP IN 188 SHAFT Parts List Page 1 of 1 SEE DETAIL A Printware ASSY CAPSTAN GUIDE 807050 001 REVISION E Printware Confidential Sheet of DETAIL Note Assembly Number 807096 001 ASSY SPOOL PLATESTREAM 13 Revision D Find Quantity Component Component Number Used Number Description Parts List Page 1 of 1 001 1 806625 002 ASSY SPOOL PLATE ADJUSTABLE 002 1 806626 002 ASSY SPOOL PLATE FIXED 003 1 807109 001 AXLE SPOOL AN L4 f X S 1 3 3 1 es NS
98. 819 001 806695 001 900773 001 900968 005 900215 007 Revision Description PLATE ACTIVATOR FRONT BEARING ROLLER GEAR ASSY GEAR SHAFT IDLER GEAR SPUR E RING 25 SHAFT STUD GEAR GEAR SPUR E RING 312 SHAFT PLATE ACTIVATOR REAR SPRING EXTENSION BRACKET DRIVE RACK ASSY CLUTCH WORM GEAR SHAFT DRIVE RACK ASSY PROCESSOR GUIDE HANDLE RACK ROLLER TRANSPORT O RING SCREW PHILLIPS PANHEAD STAINLESS 8 32 X 375 WASHER SPRING LOCK STAINLESS 8 WASHER FLAT STAINLESS 10 SCREW PHILLIPS PANHEAD STAINLESS 10 24 X 375 WASHER SPRING LOCK STAINLESS SCREW TAP FORM STAINLESS 10 24 X 1 ROLLER SQUEEGEE POLISHED ROLLER PROCESSOR ASSIST GUARD PROCESSOR SPLASH ROD SUPPORT BEARING NON METALLIC FLANGED SCREW SET STAINLESS 8 32 X 25 GEAR MOD COLLAR GEAR COLLAR SHAFT NUT LOCK STAINLESS 10 24 WASHER NYLON 25 X 5 Parts List Page 1 of 1 24 2 2 5 Printware Confidential 2 PLCS Printware ASSY ACTIVATOR TRANSPORT 807327 001 REVISION C Sheet 1 of 3 Printware Confidential VA VON Printware ASSY ACTIVATOR TRANSPORT 807327 001 REVISION Sheet 2 of 3 WRAP ITEM 11 AROUND BOTH BEARINGS 2 PLCS WRAP ITEM 11 AROUND BOTH BEARINGS 2 PLES Printware ASS Y ACTIVATOR TRANSPORT EN 807327 001 REVISION C Printware Confidentia
99. 89 003 Revision C Component Description Parts List Page 1 of 1 TANK STABILIZER FITTING DRAIN O RING SCREW STAINLESS TAP FORM 10 24 X 75 Printware ASSY STABILIZER TANK 806702 001 REVISION C Printware Confidential Sheet of Find Number 001 002 004 008 009 010 012 013 014 016 017 018 Quantity Component Used BRN N BRK ORR oo Assembly Number 808228 002 ASSY TRANSPORT DRYER ROLLER FOAM PLATESTREAM MICRO PLATE Number 808229 001 806751 001 901077 001 900230 002 806747 001 900229 019 901079 001 806649 001 806649 002 807352 001 807351 001 900005 002 Revision C Component Description RACK PANEL ROLLER FOAM ROLLER DRYER LOWER BELT ENDLESS ROUND BEARING NYLON SNAP IN 25 SHAFT ROLLER DRYER UPPER E RING SAE 375 SHAFT PIN SPIRAL ASSY FLANGED BEARING ASSY FLANGED BEARING SHAFT 19 75 ROLLER FOAM RING GRIP Parts List Page 1 of 1 PLACES 4 E Printware ASSY DRYER TRANSPORT 808228 002 REVISION C Printware Confidential Sheet Number 001 003 004 005 006 008 009 011 012 013 014 017 018 019 020 021 022 023 027 028 Quantity Component Used N N CO OR A e Assembly Number 806708 001 ASSY ELECTRICAL PANEL PLATESTREAM MICROPLATE Number 806736 001 806795 001 806796 001 806797 001
100. ABLE MOUNTING PLATE CLAMP BRKT UNLOAD ROLLER FEED PLATE TORQUE SCREW SHC 8 32 X 38 171 172 173 177 178 181 182 184 185 186 187 188 189 192 193 194 195 197 198 201 206 209 210 211 212 213 235 236 237 238 250 251 254 255 262 263 264 265 266 271 272 273 274 275 NN NK Q G tA tA 1 Assembly Number 807444 001 ASSY ROLLER TRANSPORT PLATESTREAM MICRO PLATE 900276 007 900222 002 900236 900324 001 900235 035 803456 001 900406 002 803713 001 900235 001 900229 003 901024 001 804703 001 804704 002 807068 001 9003 19 002 803697 001 806304 001 807069 001 900235 007 900319 001 900223 000 900160 009 900958 001 90026 1 004 900875 002 900839 002 807116 001 807116 002 807116 003 807456 001 900233 900229 009 900236 008 900229 008 900287 019 900233 002 900445 006 900047 000 900445 007 900277 023 900047 002 900277 022 900566 003 900172 002 Revision F WASHER NYLON WEAR 189 ID X 41 OD NUT HEX 8 SCREW SOCKET HEAD SHOULDER 8 32 X 188 WASHER CURVED SPRING 3 8 SCREW SHC 1 4 20 X 1 2 PLATE FI IDLER BEARING OIL LESS BRONZE COLLAR PULLEY SCREW SHC 6 32 X 5 E RING 1 2 SHAFT KNOB PULL WASHER MOD ROD PIVOT BRACKET CUTTER MOUNTING BEARING NON METALLIC FLANGED BAR UNLOADING LINK PINCH UNLOADING PLATE CUTTER MOUNTING SCREW SHC 4 40 X 5 BEARING NON METALLIC FLANGED WASHER LOCK HELICAL SPRING 1 4 WASHER FLAT STEEL
101. AD SHOULDER 8 32X 2505 E RING 625 SHAFT SCREW PHILLIPS PANHEAD 4 40 X 75 NUT LOCK 4 40 SCREW B H TORX 8 32 X 375 WASHER EXTERNAL LOCK 8 SCREW B H TORX 8 32 X 5 SPRING COMPRESSION 75 X 360 X 038 WASHER EXTERNAL LOCK 6 SPRING COMPRESSION 1 X 660 X 072 KNOB KNURLED SHC 8 SCREW FLAT HEAD 6 32 X 38 WASHER FLAT STEEL 8 NUT LOCK 8 32 278 280 281 282 283 287 290 294 295 297 298 305 306 307 308 309 310 319 320 321 322 323 325 326 327 328 NF N NR e e P2 F2 t2 9 9 DAN OO OO NO N tA Assembly Number 807244 001 900235 000 900277 004 900963 002 900236 005 900224 005 900235 002 900224 001 900928 003 900235 040 900160 012 900235 041 900257 900223 007 900222 003 900651 019 900445 009 900287 008 807503 001 807091 008 806099 002 806099 001 900236 003 900236 008 900406 807457 001 807537 001 ASSY ROLLER TRANSPORT PLATESTREAM Revision S SCREW SHC 8 32 X 75 SPRING COMPRESSION 75 X 360X 042 PLUNGER SPRING LOADED SCREW SOCKET HEAD SHOULDER 88 32 X 6255 SCREW TAPTITE PHILLIPS PANHEAD 48 32 X 5 SCREW SHC 8 32 X 5 SCREW TAPTITE PHILLIPS PANHEAD 46 32 X 3 8 NUT HEX JAM 1 4 X 28 TPI SCREW SHC 48 32 X 5 8 WASHER FLAT STEEL 8 SCREW SHC 8 32 X 1 1 4 STUD 10MM BALL 5 16 X 18 TPI WASHER LOCK HELICAL SPRING 5 16 NUT HEX 5 16 X 18 TPI WASHER FENDER 434 X 16 X 125 SCREW B H TOR
102. Adjustment I 17 Adjusting Image Length 1 18 Adjusting Overlap 1 19 Adjusting Cut Length 1 19 Adjusting Backup Length 1 20 Adjusting Fogging Edge LED 1 20 Adjusting Miniplate Backup Length 1 21 Punch Alignment Skew 1 22 Adjusting Punch Length 1 24 Density Dot Calibration 1 25 De Installing the Platesetter 1 26 Serial Numbers and Factory Settings 1 29 PLATESTREAM PLATESETTER INSTALLATION GUIDE Pre Installation Checklist 1 Confirm Electrical Requirements Verify that the electrical power of the required voltage and current is available at the machine location Verify an Ethernet network drop is available at the RIP location The RIP requires a 10 Base T or thin coaxial cable The Platesetter requires a dedicated 200 240 VAC 20 amp 50 60Hz three wire single phase electrical line A 100 120 VAC 15 amp 50 60Hz line with a power strip is required for the Raster Image Processor RIP The RIP can be switched to 200 240 VAC operation The Platesetter is shipped without a power plug The Platesetter power cord length is approximately 9 The power plug used with the Platesetter must be rated for 20 amp 250 volt power and should have the proper safety certification for the country of use The electrical wiring color codes are North America International Line Black Brown Neutral White Blue Ground Green Green Yellow Verify that an electrician is available if needed 2 Confirm Supply of Recommended Consumables Have at l
103. BLUE WH INTERFACE PCA 25 GND GREEN 25 2 YELLOW 2 RED 26 PLG OP BLUE 26 JA 3 3 GREEN 27 PLG OP VIOLET 27 BLACK 28 GND GRAY 28 29 STEP SYNC WHITE 29 EXIT STEPPER 30 STEP SYNC BLACK 30 803666 001 31 GND BROWN 31 32 SPARE3 RED 32 GR 33 SPARE3 ORANGE 33 34 GND YELLOW 34 DECURL EXIT 1 1 1 WHITE BLU 35 FD TR DIR GREEN 35 2 YELLOW 2 2 RED 36 FD TR DIR BLUE 36 J2 3 3 YELLOW 37 GND VIOLET 37 4 4 BLACK 38 SPAREI GRAY _ 38 39 SPAREI WHITE 39 40 GND BLACK 40 41 SPAREO BROWN 41 CUTTER ASSY 42 SPAREO RED 42 43 GND ORANGE 43 44 EX DIR YELLOW 44 SHEAR CUTTER 1 1 BLACK CUTTER SWITCH 45 EX DIR GREEN 45 WHITE 46 GND BLUE 46 78 3 3 47 SPARE2 VIOLET 47 4 RED 4 RED CUTTER MOTOR 48 SPARE2 GRAY 48 49 GND WHITE 49 50 GND BLACK 50 806127 001 1 2 3 4 5 J6 NU 5 7 8 9 CABLE 803321 001 10 11 12 POWER AES ORANGE 3 SUPPLY 24V_ ORANGE pu DAS 06 21 00 DRAWER 5 GND BLACK i s ENG PRINTWARE INC 6 GND BLACK 3 ss APPVL 7 GND BLACK 5 2 MEG ST PAUL MN QA MATERIAL d TOLERANCE UNLESS OTHERWISE SPECIFIED Q ANGLES 5 DEG 1 PLACE DECIMALS ae FINISH 2 PLACE DECIMALS 02 lt 3 PLACE DECIMALS 010 Z Title WIRING DIAGRAM PlateStream Z COMM CODE Size INSP VERSION REV 5 FIRST USED ON B 700629 001 A This document and the information it contains is the property of Printware Inc and may not be y E SCHEM ATIC P AGE 5 reproduced copi
104. CK ELBOW FITTING TUBE QUICK STRAIGHT TUBING POLYURETHANE RED TUBING POLYURETHANE ORANGE TUBING POLYURETHANE GREEN BUSHING GROMMET SOLENOID AIR VALVE ASSY CABLE SOLENOID SCREW SHC 8 32 X 1 1 4 ASSY PLATE VACUUM BRACKET PUNCH MOUNTING NON OPERTOR SIDE BRACKET PUNCH MOUNTING OPERATOR SIDE GUIDE UPPER BUFFER GUIDE LOWER BUFFER BRACKET LOWER SOLID MOUNTING PUNCH BRACKE PUNCH PLATE WASHER FENDER 5 X 189 X 125 WASHER FENDER 749 X 203 X 156 WASHER EXTERNAL LOCK 8 SCREW B H TORX 8 32 X 375 SCREW B H TORX 8 32 X 5 SCREW SOCKET HEAD SHOULDER 8 32 X 2505 5 5 8 32 X 5 8 NUT LOCK 8 32 NUT LOCK 10 32 SCREW PHILLIPS PANHEAD 10 32 X 1 5 SCREW PHILLIPS PANHEAD 6 32 X 1 25 TUBING WIRE REINFORCED 5 8 TUBING POLY URETHANE BLACK FITTING TUBE QUICK DISCONNECT UNION TEE BAG COLLECTOR CHIP TIE NYLON ASSY CUTTER 13 Parts List Page 1 of 1 SNAP IN PLACE IN HOLE CHASSIS Printware ASS Y PUNCH PINBAR 806927 001 REVISION J Printware Confidential Sheet of 1 Find Number 001 002 003 004 005 006 007 008 009 011 012 013 017 019 020 021 022 023 027 028 040 041 042 043 044 045 047 048 049 050 051 052 053 054 055 059 064 070 071 072 073 074 Quantity Component Used N e e 4 4 N Q N N N oo NFP P RFR Q Assembly Number 807458 001 ASSY PUNC
105. DE B 45V Title E 2 NM WIRING DIAGRAM PlateStream 39 WHITE GUIDE B GND NU J13 40 BLACK NU 807091 001 9 COMM CODE Size 700629 001 INSP VERSION REV 5 nnsruspos B This document and the information it contains isthe property of Printware Inc and may not be BER SCHEMATIC PAGE 1 S Sz mm w maaa SCALE NONE tion from Printware Inc Both the document and its contents are to be treated as confidential amp ctc 1 op 6 proprietary and may not be used in any manner not consistent with the rights of Printware Inc Sheet of 1 2 3 4 5 6 7 1 2 3 4 5 6 TAB BLOCK PART NO DESCRIPTION 807046 001 NORTH AMERICAN 807046 501 INTERNATIONAL POWER SUPPLY INTEGRATED ASSY 806420 003 FOR NORTH AMERICAN USE BLACK WHITE GREEN WIRE 807046 806420 004 FOR INTERNATIONAL USE BROWN BLUE GREEN YELLOW WIRE D POWER DISTRIBUTION PCA VENT FAN gis 900894 001 DC POWER SUPPLY 901142 001 ALL FUSES 250V 7A 600322 001 600267 002 AC IN BLACK T SWITCH 45V FUSE s E EMI FILTER E 50 60 HZ E an 30VK6 1 LINE Po 806420 TAB gt 25A 40F e 522780 ae BLUE f2 NEUTRAL CFOWER Taan L pes WIRE COLOR DOMESTIC INTERNATIONAL VOLTAGE BLACK BROWN AC WHITE BLUE GREEN GREEN YELLOW GROUND
106. E MANUAL Check AC voltage The specification is 200 264 Volts 50 60 Hz Protect against AC power glitches 2 1 Check for correct AC power wiring especially grounding 2 2 Install AC power conditioner To diagnose intermittent DC problems track platesetter state at time of reboot e g was cutter cutting punch punching processor starting Check fuses in power supply Check voltages at controller PCA Specifications are 5 5 25V 12 0 6V and 24 1 2V Check the I O cable from the RIP Power cycle the Platesetter Reset the RIP Replace the controller PCA 52 SERVICE MANUAL GENERAL IMAGER PROBLEMS cont All silver plates Shutter problems Run Hardware 1 Feed Motor OFF 7 Reset Proc 2 Transport Motor OFF 8 Start Pr 3 Exit Motor OFF P 4 D Shutter Close ON OFF 53 All silver plates usually indicates the shutter isn t opening properly 1 Check to make sure the correct media is used for printing and the emulsion side is up 2 Check that the shutter spring is in place and operating 3 Verify that the shutter plate isn t hitting the capstan roller To adjust loosen screws on the outside of the transport on the operator and non operator side Adjust the shutter plate to 1 32 to 1 16 0 8 to 1 6 mm from the capstan roller ESC to exit OC Prime Pump ESC ENTER interface PCA 4 Open and close the shutter from the Operator Panel ha
107. EAM BRACKET HINGE MOUNTING LATCH PULL FLUSH LATCH VISE ACTION LATCH VISE ACTION PANEL SKIN BOTTOM BRACKET CATCH MOUNTING BRACKET INTERLOCK CATCH SNAP IN BRACKET DOOR HINGE BRACKET DOOR HINGE ASSY POCKET PULL 4 84 X 1 84 04 07 CASTER SWIVEL W O STEM W BRAKE CASTER SWIVEL STEM W O BRAKE BRACKET DOOR HINGE MIDDLE BOLT HEX HEAD 5 16 X 5 WASHER LOCK HELICAL SPRING 5 16 BRACKET DAMPER MOUNTING DAMPER SCREW B H TORX 8 32 X 375 WASHER EXTERNAL LOCK 8 NUT LOCK 8 32 STUD 10MM BALL 5 16 18 TPI WASHER LOCK HELICAL SPRING 5 16 NUT HEX 5 16 18 TPI SPACER THREADED HEX NUT LOCK 4 40 WASHER FLAT STEEL 4 SCREW PAN PHILLIPS PANHEAD 4 40 X 5 NUT LOCK 26 32 PANEL FRONT ACCESS MAGNET STRIP 06 X 75 SCREW B H TORX 48 32 X 5 WASHER FLAT STEEL 8 SPACER 171 LD X 25 O D X25 Parts List Page 1 of 2 071 Assembly Number 807527 001 KIT CHASSIS PLATESTREAM W SOFTWARE OPERATOR PANEL Revision B 1 807473 001 PANEL REAR LOWER PLATESTREAM Printware Confidential Printware KIT CHASSIS PLATESTREAM 807527 001 REVISION B Sheet of 3 gt lt eo w cC cn Cu lt Y b B 807527 001 REVISION Sheet 2 of 3 Printware Confidential Printware KIT CHASSIS PLATESTREAM
108. EDIA Identifies the amount of media in the spool as okay or none 0 indicates that the media supply is empty 1 indicates that the amount is sufficient 2 15 CONTROL PANEL LOAD OK Indicates the status of media loading A 1 indicates the media is loaded a 0 indicates the media is not loaded GUIDE B Indicates the presence of media at Guide A 1 indicates that media is present e g during imaging A 0 indicates the sensor is clear This is the normal idle condition WRKNG TANK LOW This sensor monitors the solution level in the working tanks in the processor A 0 indicates the current level is okay a 1 indicates a low solution level in one or both of the tanks REPLN TANK LOW This sensor monitors the solution level in the replenishment tanks underneath the processor A 0 indicates the current level is okay a 1 indicates a low solution level in one or both of the tanks EFL TANK HIGH This sensor monitors the level of spent solution in the optional effluent tank underneath the processor A 0 indicates the current level is okay a 1 indicates the tank needs to be emptied PROC TEMP OK The processor Activator Temperature sensor monitors the temperature of the Activator bath A 0 indicates that the current temperature is okay a 1 indicates that the bath is still warming up or that there is a problem with the heater PROC E
109. EDs do not go on replace the processor PCA 3 2 If Heater Up To Temperature light is on set temperature by adjusting potentiometer R43 Clockwise turns heat up on most PCAs instructions are on the inside of the processor panel 3 3 If Heater Up To Temperature light is always on regardless of the R43 setting replace the thermistor Check heater element 4 1 Remove dryer heater assembly from processor 4 2 Check heater element resistance with an ohmmeter Normal values are Pin to Pin 2 450 Pin to Pin 3 45Q Pin 2 to Pin 3 88Q Pin to Pin 4 Open 68 SERVICE MANUAL PROCESSOR ELECTRICAL PROBLEMS cont Replenishment pumps not turning Pumps turning but fluid output is inadequate Activator bath is too hot 69 Check the effluent tank If it is full the pumps will not come on If the replenishment tanks are low the pump will not come on Check the Check Pump prime light on processor PCA If the light does not come on when the pumps should be on replace the processor PCA Measure the voltage across the pumps at TS2 2 brown and TS2 3 blue If220V is present replace pump assembly If220V isn t present the replace the processor PCA Verify that there is chemistry in the replen ishment tanks Check for leaking hoses Check for air in the hoses If there is unplug the hose from tank and hold the end over the tank as it pumps until the air is cleared Check for pinch
110. EMP LOW PROC EXIT TAKEUP CASSETTE ON OFF status menu ESC ENTER status to be sure the switch is not sticking 3 If Sensor Status does not toggle between 1 and 0 7 the switch should be replaced The replace ment part includes detailed replacement instructions 0 1 1 0 0 0 58 SERVICE MANUAL CUTTER PROBLEMS Cutter won t cycle Cutter won t stop cycling Cutter cycles but doesn t cut 59 Check and re seat cutter connector Check for loose wires on the cutter switch non operator side of machine See if the cutter motor shaft spins by hand the shaft coming out of the back of the motor Check for any media stuck in cutter Check motor winding resistance normally 10 to 1000 If motor is shorted or open replace the cutter Switch misadjusted 1 1 If switch is open the cutter wheel should turn one third of a revolution 1 2 If switch 16 activated the wheel should turn 2 to 4 revolutions without stopping Switch failed 2 1 Turn the shaft on the back of motor by hand you should be able to hear the switch click 2 2 Check the switch with an ohmmeter in the open and closed positions Remove cutter assembly so cutting blade can be adjusted Lay cutter on a table with cutter blade facing up Turn blade by spinning silver shaft on back of motor by hand clockwise until blade comes down to lowest point in its rotation Loosen set screws on
111. ER EXTERNAL LOCK 6 SCREW B H TORX 6 32 X 375 NUT LOCKING 6 32 WASHER EXTERNAL LOCK 8 SCREW PAN PPH 8 32 X 38 FOAM SELF ADHESIVE WASHER FLAT STEEL 8 SCREW SET CUP POINT 6 32 X 375 SHEET PLASTIC ADHESIVE 16 72 Parts List Page 1 of 1 Printware Confidential Printware ASS Y SUPPLY CASSETTE 280 807467 001 REVISION E Sheet of
112. ER TRANSPORT WELDMENT ROLLER TRANSPORT MICRO PLATE ROLLER FEED WASHER PRELOAD SPRING M T BEARING BALL RETAINER BEARING BRACKET CAPSTAN DRIVE MOUNTING ROLLER SUPPLY TAKE UP SEGMENTED ROLLER PINCH TRACTION ROLLER ALUMINUM CAPSTAN E RING SAE 3 8 SHAFT WASHER WAVE SPRING 22MM OD X 01 NUT HEX JAM 5 8 18 BUTTON LOCATING ADJUSTABLE SCREW SHC LOW HEAD 1 4 28 X 1 5 ASSY LOWER PINCH TENSION ASSY LOWER PINCH TENSION SPRING TENSION MOD ASSY CAPSTAN DRIVE ASSY UPPER PINCH TENSION R H ASSY UPPER PINCH TENSION L H ASSY CABLE CUTTER EXIT PLATE MARKER LOCATING LOWER ASSY PULLEY OVERRUNNING CLUTCH BRACKET CUTTER MOUNTING ASSY SWITCH LATCH COMPRESSION ASSEMBLY ROD 5 16 HEX 8 80 HUB HANDLE SHAFT HANDLE KNOB OVAL TAPERD SCREW SET STAINLESS 10 32 X 188 PULLEY MOD PULLEY MOD 130 TOOTH W INSERT BELT TIMING 216 GROOVES BELT TIMING 165 GROOVES 1 4 W BELT TIMING 184 GROOVES 1 4 W BELT TIMING 336 GROOVES GUIDE LOWER SOLID GUIDE UPPER REMOVABLE GUIDE UPPER CUTTER EXIT 8 5 GUIDE LOWER CUTTER EXIT 8 5 Parts List Page 1 of 5 075 076 077 078 079 080 083 084 085 086 087 088 090 091 092 093 094 119 120 121 122 123 124 125 128 131 132 134 135 136 137 142 151 152 154 155 156 157 158 160 161 162 165 167 t2 l2 ON 9 9 F2 NN OK N N N N RRR RR NO BK N Assembly Number 807444 001 807337 001 8
113. FIED BEARING NON METALLIC FLANGED COLLAR GEAR COLLAR SHAFT NUT LOCK STAINLESS 10 24 WASHER NYLON 25 LD X 5 O D X 032 Parts List Page 1 of 1 2 5 PLACES BOTH ENDS Aet BOTH ENDS M Printware ASSY STABILIZER TRANSPORT 807328 001 REVISION C Sheet 1 of 3 Printware Confidential SETS 3 PLACES WRAP IT AROUND BOTH BEARINGS 2 PLCS WRAP ITEM 31 AROUND BOTH BEARINGS 2 PLCS Printware ASSY STABILIZER TRANSPORT 807328 001 REVISION C Sheet 2 of 3 Printware ASS Y STABILIZER TRANSPORT C 807328 001 REVISION Sheet 3 of 3 Printware Confidential Number Find 001 002 003 004 005 006 007 008 009 010 011 012 013 015 016 020 021 022 023 024 025 026 027 029 032 033 034 035 036 037 038 039 040 041 Quantity Component Used 1 12 6 _ ow N NY NNN NFP NN WA WN OO ON FN Ke _ Assembly Number 807327 001 ASSY ACTIVATOR TRANSPORT PLATESTREAM Number 807329 001 900960 004 900960 003 806752 001 900960 001 900229 017 806776 001 900960 020 900229 018 807330 001 806694 001 806764 001 806852 001 806821 001 806836 001 806760 001 806762 001 900291 010 900967 001 901072 004 901071 013 900967 003 901072 005 901089 001 806278 001 806510 001 806506 001 806822 001 900319 004 901070 001 806
114. FR100 SPEC820 SPECS20R SDP 175 SPEC820 SPEC820R INSTALLATION GUIDE 4 Verify Final Location Select a suitable place for installation Avoid excessive dust vibration and direct sunlight The Platesetter is designed for use in a prepress environment Acceptable ambient temperature range is 65 F to 80 F 18 C to 27 C and acceptable relative humidity is 45 to 70 Check the necessary dimensions at the physical installation site e g width of doors etc with the Plateset ter dimensions To ensure optimal operation allow clearances of at least 30 75 cm on the left 24 60 cm on the right 30 75 cm in front and 12 30 cm in the rear see Figure I 1 on page 8 After uncrating the depth of the Platesetter which is on casters is approximately 31 79 cm If the optional effluent tank is not ordered a method for plumbing to remove chemical effluence is required This method must meet local environmental codes The drain for the chemicals provided with the Plateset ter is a vinyl flexible hose 6 long 1 outer diameter and 1 inner diameter Precautions 1 Due to the 700 Ib 318 kg weight ofthe Platesetter use caution when removing Platesetter from pallet 2 Follow electrostatic discharge ESD protective procedures when connecting cables or working near Platesetter PCAs including Ground yourself by touching the metal chassis of the Platesetter before connecting or disconnecting any cable Use a wrist
115. GENERAL INFORMATION Right processor 47 119 cm 24 60 cm clearance rt 55 22 cm 30 75 cm clearance front Figure 1 4 Features of PlateStream Platesetter 1 6 GENERAL INFORMATION Operator Safety The Printware Platesetter has been certified as a Class 1 laser product under the U S Department of Health and Human Services DHHS Radiation Performance Standard This standard is in accordance with the Radiation Control for Health and Safety Act of 1968 A Class 1 certification means the Platesetter does not produce hazardous laser radiation The laser light produced inside the Platesetter is completely confined within protective housings and external covers The laser beam cannot escape from the Platesetter during any phase of user operation provided the user follows the operating instructions specified in this manual A warning label is attached to the bottom of the laser marker unit This label is visible whenever the media path hood is open The Center of Devices and Radiological Health CDRH of the U S Food and Drug Administration implemented regulations for laser products on August 2 1976 Compliance is mandatory for prod ucts marketed in the United States Always follow these basic safety rules when using the Printware Platesetter 1 Read this manual before using the Platesetter 2 Do not remove protective housings or external covers except as specified in this manual 3 Do not disassemble
116. H COMBO PLATESTREAM MICROPLATE Number 807415 001 901051 005 807460 004 901051 007 901051 008 900940 003 900940 004 900940 005 900289 003 901053 001 901052 003 807301 001 900235 041 807461 001 806935 001 806934 001 807335 001 807336 001 806936 001 807352 001 900651 022 900651 020 900047 000 900445 006 900445 007 900236 008 900235 040 900233 003 900233 001 900288 006 900369 001 900287 029 900160 011 900005 002 900336 000 900287 025 900521 003 806127 002 900839 002 900875 002 90026 1 004 900958 001 Revision C Component Description ASSY COMPRESSOR MODIFIED FITTING TUBE QUICK STRAIGHT ASSY PUNCH COMBO FITTING TUBE QUICK ELBOW FITTING TUBE QUICK STRAIGHT TUBING POLYURETHANE RED TUBING POLYURETHANE ORANGE TUBING POLY URETHANE GREEN BUSHING GROMMET MUFFLER PNEUMATIC SOLENOID AIR VALVE ASSY CABLE SOLENOID SCREW SHC 8 32 X 1 1 4 ASSY PLATE VACUUM BRACKET PUNCH MOUNTING NON OPERATOR SIDE BRACKET PUNCH MOUNTING OPERATOR SIDE GUIDE UPPER BUFFER GUIDE LOWER BUFFER BRACKET PUNCH PLATE SHAFT 19 75 WASHER FENDER 5 X 189 X 125 WASHER FENDER 749 X 203 X 156 WASHER EXTERNAL LOCK 8 SCREW B H TORX 8 32 X 375 SCREW B H TORX 8 32 X 5 SCREW SOCKET HEAD SHOULDER 8 32 X 2505 SCREW SHC 8 32 X 5 8 NUT LOCK 28 32 NUT LOCK 10 32 SCREW PHILLIPS PANHEAD 10 32 X 1 5 CLAMP FIXED DIAMETER 25 SCREW PHILLIPS PANHEAD 6 32 X 7 16 WASHER FLAT STEEL 6 RING GRIP NUT SE
117. HC LOW HEAD 6 32 X 38 WASHER EXTERNAL LOCK 6 SCREW SOCKET HEAD SHOULD 8 32 X 2505 ASSY LIGHT SEAL 13 SPRING HOOKED CAPSTAN GUIDE SPRING COMPRESSION 250 X 240X 020 NUT LOCK K 8 32 SCREW SHC LOW HEAD 6 32 X 25 BEARING NYLON SNAP IN 188 SHAFT Parts List Page 1 of 1 SEE DETAIL A Printware ASSY CAPSTAN GUIDE 807050 001 REVISION E Printware Confidential Sheet of DETAIL Note Assembly Number 807096 001 ASSY SPOOL 13 Revision D Find Quantity Component Component Number Used Number Description Parts List Page 1 of 1 001 1 806625 002 ASSY SPOOL PLATE ADJUSTABLE 002 1 806626 002 ASSY SPOOL PLATE FIXED 003 1 807109 001 AXLE SPOOL AN L4 f X S 1 3 3 1 es NS Printware ASS Y SPOOL 807096 001 REVISION D Printware Confidential Sheet 1 of 1 Find Number 001 002 003 004 005 006 007 009 010 011 012 013 014 015 016 017 018 019 020 021 022 023 024 025 026 029 030 031 032 033 034 035 036 037 038 039 040 041 042 043 044 Quantity Component Used OF N e N e e e N e N 4 Lk e CN Assembly Number 807346 001 ASSY PROCESSOR PLATESTREAM MICRO PLATE Number 806743 001 806713 001 900960 005 806733 001 806824 001 900289 003 806786 001 807497 001 806710 001 806714 001 80749
118. L GUIDE METRIC Printware Confidential Printware ASS Y PlateStream Microplate 807440 REVD Sheet 1 of Find Number 001 002 005 006 007 008 009 010 011 012 014 015 016 017 018 019 020 021 022 023 024 025 026 027 028 029 030 031 032 033 034 036 039 042 043 045 047 050 052 Quantity Component Used NO e OK OO UJ o 3 CO Q n Q T HR AOM HNN Assembly Number 807841 001 ASSY IMAGER MICROPLATE WITH SOFTWARE CONTROL PANEL Number 807743 001 807444 001 807346 001 807514 001 900270 003 900257 900222 003 900223 007 523190 004 523060 001 900233 003 900047 000 900445 006 807222 001 806866 001 900676 004 804569 003 900223 006 806843 001 803769 001 807652 001 900341 003 900222 007 900651 008 807431 001 900726 001 900726 005 900288 005 900652 007 900651 003 900233 001 900336 000 807170 001 807177 001 806501 001 600292 001 804521 001 806913 001 900872 004 900872 008 600188 003 807095 001 Revision C Component Description Parts List Page 1 of 2 ASSY CHASSIS W SOFTWARE OPERATOR PANEL ASSY ROLLER TRANSPORT ASSY PROCESSOR ASSY INDICATOR LIGHT GAS CYLINDER 60 LBS STUD 10MM BALL 5 16 18 NUT HEX 5 16 18 WASHER LOCK HELICAL SPRING 5 16 PCA STEPPER SHEAR CUTTER PCA INTERFACE NUT LOCK 8 32 WASHER EXTERNAL LOCK 8 SCREW B H
119. LAMP HOSE SWITCH WIRE FORM SWITCH SNAP LEVER DUCT VERTICAL ASSY STABILIZER TRANSPORT ASSY ACTIVATOR TRANSPORT ASSY ACTIVATOR TANK ASSY STABILIZER TANK RAIL LEFT MOUNT TIE ASSY CABLE ACTIVATOR amp STABILIZER LEVEL ASSY CABLE INTERFACE 13 CLIP CORD ADHESIVE BACK SENSOR THERMISTOR DISK SHIM SUPPORT RACK PROCESSOR ASSY HEATER COVER ASSY HEATER BLOWER ASSY CABLE DRYER TEMPEATURE PROBE ASSY CABLE FILM SWITCH FILM OPTION ONLY ASSY CABLE REPLENISHMENT LEVEL PCA INTERFACE PROCESSOR ASSY ELECTRICAL PANEL ASSY DRYER MOTOR Parts List Page 1 of 2 046 047 048 050 052 053 054 055 056 057 059 060 061 062 064 065 067 068 069 074 075 076 077 079 089 105 106 107 BPN DWN 000 O RO L Assembly Number 807179 001 ASSY PROCESSOR PLATESTREAM 900271 003 806739 001 900967 010 806750 001 901089 004 900967 003 901072 005 900968 005 900967 006 901072 006 901092 001 900967 007 900967 001 901071 010 900967 005 900968 001 900967 019 901091 001 901071 012 807394 001 807313 002 808228 002 806848 001 806707 003 806657 002 806706 004 901100 002 807487 001 901072 004 Revision U BELT TIMING 1 5 PITCH 60 GROVES PANEL PCA BOARD SCREW STAINLESS 10 24 X 5 BLOCK SUPPORT SWITCH SCREW STAINLESS TAP FORM 10 32 X 5 SCREW STAINLESS 10 24 X 375 WASHER LOCK SPRING STAINLESS NUT LOCK STAINLESS 10 24 SCREW STAINLESS 1 4 X 20 TPI X 5 WASHE
120. LF LOCKING HEX 6 32 SCREW PHILLIPS PANHEAD 6 32 X 1 25 TUBING WIRE REINFORCED 1 ASSY CUTTER 13 FASTENER 1 4 TURN PUSH BUTTON RING EXTERNAL RETAINING RECEPTACLE 1 4 TURN NUT RECEPTACLE RETAINING Parts List Page 1 of 2 Assembly Number 807458 001 ASSY PUNCH COMBO PLATESTREAM MICROPLATE Revision C 075 1 806239 001 BRACKET UPPER GUIDE MOUNTING 076 1 807485 001 ASSY BOX VACUUM 078 1 900302 008 CLAMP HOSE Printware ASS Y PUNCH COMBO 807458 001 REVISION C Sheet of 1 Printware Confidential Find Number 001 002 003 004 A A Assembly Number 807085 001 ASSY CART REPLENISHMENT Quantity Component Used Number 807098 001 900832 003 900223 007 900222 003 Revision D Component Description Parts List Page 1 of 1 CART REPLENISHMENT CASTER TWIN WHEEL W O BRAKE WASHER LOCK HELICAL SPRING 5 16 NUT HEX UNC 5 16 18 Ut f Y EN X 9 Ww Su EN ET uu EN EN Xn SS NN NS 9 lt EN E uS EN EN EN EN Sy EN RM EN N SS foes 44 4 PLACES EN d Cu N Sy V x EM Printware ASSY REPLENISHMENT CART 807085 001 REVISION D Sheet of Printware Confidential Find Number 001 002 003 004 005 006 008 010 011 012 013 014 015 016 019 Quantity Component Used e N e eS 15 N NN NYFF Assembly Number 807152 002 ASSY FILM OPTION 13 Number
121. LOWER BELT ENDLESS ROUND BEARING NYLON SNAP IN 25 SHAFT ROLLER DRYER UPPER E RING 375 SHAFT PIN SPIRAL ASSY BEARING FLANGED ASSY BEARING FLANGED SHAFT 19 75 ROLLER FOAM RING GRIP Parts List Page 1 of 1 AFTER ITEM 13 IS INSTALLED 17 44 PLACES Printware ASSY DRYER TRANSPORT 808228 002 REVISION C Printware Confidential Sheet Find Number 001 002 003 004 005 007 008 Quantity Component Used Assembly Number 806816 002 ASSY TANK EFFLUENT WITH CART Number 900937 006 806718 001 806815 002 806803 001 806804 001 901118 001 807083 001 Revision F Component Description Parts List Page 1 of 1 15 GALLON ASSY DRAIN VALVE ASSY PROBE EFFLUENT PLATE TANK SUPPORT GASKET FITTING NUT PLASTIC ASSY CART EFFLUENT NOT PART OF THIS ASSEMBLY Sud j 20 Printware 2 2 ASSY TANK EFFLUENT WITH CART ud asd 806816 002 REVISION F oe Printware Confidential Sheet 1 of Find Number 001 002 003 004 005 006 007 008 009 010 011 012 013 017 020 021 022 023 024 027 030 040 041 042 043 044 045 048 049 050 051 052 053 054 055 056 057 058 059 Quantity Component Used N N NN N NN Ke R PB N BB N Q Q N N N Assembly Number 806925 001 Num
122. N CABLE 807204 001 z RANCE zr WORKING TANKS LOW A ROSE 1 15 GREEN NU GND RED 2 16 BLUE NU REPLN TANKS LOW ORANGE 3 17 VIOLET EXIT LOOP 45V EXIKEOOP GND YELLOW 4 18 GRAY EXIT LOOP SIG SENSOR EFF TANK HIGH GREEN 5 36709 1 001 GND BLUE 6 J15 20 BLACK FEED LOOP 5 N PROC TEMP VIOLET 7 SENSOR NO GND GRAY 8 SENSORS 22 RED FEED LOOP GND FILM EXIT WHITE 9 23 ORANGE NU GND BLACK 10 24 YELLOW NU PY S DAS 06 21 00 SPARE BROWN 11 25 GREEN NU TO GND RED 12 26 BLUE NU ENG PRINTWARE INC PROCESSOR 45V PULL UP ORANGE 13 27 VIOLET NU E f SOJ YELLOW 14 28 GRAY NU ST PAUL MN 5 PULL UP GREEN 15 29 WHITE NU gt DRIVE INH BLUE 16 30 BLACK NU QA MATERIAL 5V_PULL UP VIOLET 17 3L BROWN IMAGER EXIT 1 5V IMAGER EXIT d TOLER ANGE UNLESS OTHERWISE SPECIHIED RESET GRAY 18 SENSOR NO D ANGLES 5 DEG 5V PULL UP WHITE 19 ROTOS TOO 1 PLACE DECIMALS FINISH PUMP PRIME BLACK 20 34 YELLOW NU L S ELACBDROIMALS 45V PULL UP BROWN 21 35 GREEN NU ef Ss peace wasapay SPARE RED 22 36 BLUE NU 9 NU ORANGE 23 37 VIOLET GUIDE B 45V NU YELLOW 24 SENSOR NO WIRING DIAGRAM PlateStream N O NU GREEN 25 807091 061 Size NC BLUES 6 NU J13 do BLACK NU COMM CODE 700629 001 INSP VERSION REV FIRST USED ON B A SCHEMATIC PAGE 4 Tepsoduced copied disclosed to others or disposed of cay or indrectly without autoriza SCALE TTA ATE AL
123. N GND 9 GALVO ASSY WHITE G SENSE 2 38 NC GREEN G DRVI 3 39 NC RED G DRV0 4 40 NC BLACK G SENSE 5 RED G DRVI 6 807049 001 RED 505 C 1 A SENSOR ASSY GREEN SOS SIG 2 2 WHITE SOS REF 3 3 RED SOT C NU J16 4 WHITE SOT SIG 5 5 GRAY SOT REF 6 6 807151 001 1 2 J3 NU NU J2 4 5 807521 001 6 of em 20 o SJ HPAP SY S s RY SPAY A GY ALAS ca RS SESS ALS SY SST SIS S CABLE 807530 001 DRAWN Das 06 21 00 ENG PRINTWARE INC ENG APPVL 9 ST PAUL MN z QA MATERIAL d TOLERANCE UNLESS OTHERWISE SPECIFIED Q ANGLES m 5 DEG PLACE DECIMALS 5 FINISH m 2 PLACE DECIMALS 02 PDECAT 2 5 Z 5 Z 5 Z 5 Z 5 lt 3 PLACE DECIMALS 010 RE Zn 9 9 1 9 o WIRING DIAGRAM PlateStream N O Z COMM CODE Sue 700629 001 INSEE NERSION REY 5 FIRST USED ON B i A This document and the information it contains is the property of Printware Inc and may not be SCALE NONE reproduced 1 disclosed to others or disposed of directly drectly witho
124. Novell network utility Log on to your Novell file server an mount a volume directory The directory will be mounted on the RIP as the I drive Exit NET e Change directory to I and enter MD RIP to create the hot folder This is the folder the RIP will monitor for incoming PostScript jobs Postscript files placed here will be processed automatically when the RIP is running The spool directory is set in the RIP setup under the Configure Edit Setups Spooling menu item f Reboot the RIP Adobe PostScript ZAPrip a Loginas Administrator with password printware b Double click on ZAPrip icon to launch the RIP c Hit F6 to start the RIP output queue PREPARING FOR OPERATION 3 9 ZAPripHQ Harlequin Xitron RIP a Press ctrl alt del to log on b Log in as Administrator with password printware c Double click on the ZAPrip icon d Choose Start Inputs from the Xitron RIP menu to start the RIP Print a Job a Be sure your front end computer can see the network hot folder b The Adobe and ZAPrip HQ Harlequin RIPs can use the Mac chooser as well as a hot folder To set this up use the chooser to select the desired PlateStream output device and resolution c Ifa print driver is required use Adobe 4 2 for WIN95 Adobe 5 for NT d Create a test job whose document size 1s equal to the desired plate size e Print the job saving it as a PostScript file in the spool hot folder or using the
125. OE Bani Bani Bani Bani Bani Bani Bani IN tion from Printware Inc Both the document and its contents are to be treated as confidential amp Sheet 4 of 6 proprietary and may not be used any manner not consistent with the rights of Printware Inc 6 1 2 3 5 6 WHEEL CUTTER r H NU SHEAR CUTTER 5 18 DECURL EXIT STEPPER BOARD 9 n CABLE 803318 002 PAPER FEED 1 GND BROWN 8273 2 FD STEP RED 2 3 STEP ORANGE 3 4 GND YELLOW 4 WHEEL CUTTER 1 5 ED RESET GREEN 5 2 MARKER TRANS 6 FD RESET BLUE 6 J1 NU 3 7 GND VIOLET 7 4 n 5 X sia ENGINE STEPPER PCA FEED STEPPER 10 GND BLACK 10 523190 004 803666 001 POWER 11 TR RESET BROWN 11 12 TR RESET RED 12 13 GND ORANGE 13 14 EX STEP YELLOW 14 PAPER FEED 1 1 BLU 15 EX STEP GREEN 15 2 YELLOW 2 2 RED 16 GND BLUE 16 J3 3 RED 3 3 YELLOW Ha 17 EX RESET VIOLET 17 4 4 BLACK 18 EX RESET GRAY 18 19 GND WHITE 19 CAPSTAN STEPPER CUT 20 CUT STEP BLACK 20 804628 001 DERE 21 CUT STEP BROWN 21 22 GND RED 22 7 23 RESET ORANGE 23 MT J 1 24 CUT RESET YELLOW 24 MARKER TRANS 1 323
126. OFF ENTER 1 Image This selection sets the type of imaging for the different types of media The choices are Positive or Negative Wrong Reading and Positive or Negative Right Reading These attributes can be set separately for Cassette mode and Processor Miniplate mode For example cassette mode could be set for Positive Wrong Reading the destination could be changed see item 6 below and Processor set for Negative Right Reading Cassette mode would remain Positive Wrong Read ing in this example 2 7 CONTROL PANEL 2 Resolution Sets the resolution of plates imaged from the control panel The choices are 900 1200 1800 or 2400 dpi Note that this menu only affects test plates sent from the control panel the resolution of plates sent from the front end or RIP are set by the RIP The message Not allowed Imager and or RIP busy appears if jobs are running while attempting to change resolution 3 Image Power Sets the image power laser intensity Increasing image power increases D or Density while decreasing image power reduces D Image power be set separately for each combination of destination see item 6 and resolution see item 1 Thus up to eight image power settings can be stored for the possible combinations of two destinations Processor Miniplate or Cassette and four resolutions This allows a different image power to be set for film in the Cassette mode compared to plate material in the Proces
127. ON ESC OFF ENTER 1 Calibrate Processor Runs a plate which calibrates the processor exit sensor for the current resolution dpi setting Since Platesetter speed varies with resolution the processor exit sensor must be calibrated at the factory If the control panel error displays Media didn t exit imager or Media didn t exit processor calibrating the processor is one of the possible solutions Ensure that destination is set to Processor then Calibrate the processor by pressing ENTER The Plateseetter must be in Processor mode not cassette or Miniplate mode to calibrate the processor The calibrate operation must be performed for each resolution For more details on menu items 2 7 see Physical Calibration in the INSTALLATION GUIDE 2 Manual Length Adj Incremental corrections to obtain the correct plate length The length change displayed is reset to 0 after pressing enter There are independent adjustments for each resolution At 900 dpi the manual length is adjustable in 0 006 0 015 cm increments at 1200 dpi in 0 004 0 01 cm increments 1800 dpi in 0 003 0 08 cm increments and at 2400 dpi in 0 002 0 005 cm increments The length will not be changed if the increment entered is less than the minimum increment size 3 Cut Length Adj Sets the length of the trailing edge of the plate 4 Overlap Length Adj Sets the length of plate that is double exposed on the leading edge 5
128. OWER BUFFER BRACKET LOWER SOLID MOUNTING PUNCH BRACKE PUNCH PLATE WASHER FENDER 5 X 189 X 125 WASHER FENDER 749 X 203 X 156 WASHER EXTERNAL LOCK 8 SCREW B H TORX 8 32 X 375 SCREW B H TORX 8 32 X 5 SCREW SOCKET HEAD SHOULDER 8 32 X 2505 5 5 8 32 X 5 8 NUT LOCK 8 32 NUT LOCK 10 32 SCREW PHILLIPS PANHEAD 10 32 X 1 5 SCREW PHILLIPS PANHEAD 6 32 X 1 25 TUBING WIRE REINFORCED 5 8 TUBING POLY URETHANE BLACK FITTING TUBE QUICK DISCONNECT UNION TEE BAG COLLECTOR CHIP TIE NYLON ASSY CUTTER 13 Parts List Page 1 of 1 SNAP IN PLACE IN HOLE CHASSIS Printware ASS Y PUNCH PINBAR 806927 001 REVISION J Printware Confidential Sheet of 1 Find Number 001 002 003 004 005 006 007 008 009 011 012 013 017 019 020 021 022 023 027 028 040 041 042 043 044 045 047 048 049 050 051 052 053 054 055 059 064 070 071 072 073 Quantity Component Used N e e 4 4 N Q N N N oo NF L FN NF RFR We Assembly Number 807458 001 ASSY PUNCH COMBO PLATESTREAM MICROPLATE Number 807415 001 90105 1 005 807460 004 90105 1 007 90105 1 008 900940 003 900940 004 900940 005 900289 003 901053 001 901052 003 807301 001 900235 041 807461 001 806935 001 806934 001 807335 001 807336 001 806936 001 807352 001 900651 022 900651 020 900047 000 900445 006 900445 00
129. P Accurate Screens on the Adobe PostScript ZAPrip and Harlequin Precision Screens HPS on the ZAPrip HQ Harlequin Xitron RIP C4 PlateStream Platesetter Service Manual Printware LEADERS IN COMPUTER TO PLATE 700570 Rev E PlateStream Platesetter Service Manual Printware LEADERS IN COMPUTER TO PLATE 700570 Rev E CONTENTS Chapter 1 General Information INTFOCUCTION s 2 u uu Su So S us Dakun 2 Construction of the Platesetter 4 Chapter 2 Maintenance Approved 6 Cleaning asss 6 Platesetter Maintenance 7 Procedures to Raise and Lower the 8 Inspecting and Cleaning Marker Assembly Unit 9 Marker Focus Adjustment Procedure 13 Processor SOCIO u u 14 Chapter 3 Component Repair Replacement Replacing Rollers Belts Motors and Cutter 20 Replacing Marker Unit eese 27 Chapter 4 Replacing Electronic Components emn nennen nenne 28 Controller 1 6
130. PlateStream Lr abs Platesetter 3 Click on desired manual Quick Start Guide Installation Guide Operator Manual Service Manual Illustrated Parts List Illustrated Parts List PlateStream MicroPlate Model Printware LEADERS IN COMPUTER TO PLATE 1270 Eagan Industrial Road St Paul MN 55121 Phone 800 456 1400 Fax 651 454 3684 http PrintwareInc com PlateStream eee wees Platesetter Quick Start Guide Printware LEADERS IN COMPUTER TO PLATE 700546 Rev H QUICK START GUIDE Contents Introduction Loading Plate Material Control Panel Setup Menu RIP Setup amp Imaging Plates QS 2 QS 2 QS 3 08 4 QUICK START GUIDE Introduction For detailed procedures on the control panel plate media and chemistry preventive maintenance and trouble shooting see the PlateStream Platesetter Operator Manual Before making a plate the Platesetter must be Connected to the RIP the I O panel is located on the top rear of the machine Ready to accept a job Main Menu displayed on the control panel On Line state no error conditions The processing tanks must be filled to proper levels Loading Plate Material 1 Open the top cover Raise marker by pulling marker lever towards the front of the Platesetter until lever stops Lift up marker gently 2 Open the load door and pull on the load knob Remove the spool assembly from the Platesetter Adjust the two rear edge guides inside the Platesetter by
131. R LOCK SPRING STAINLESS GROMMET SCREW SCREW STAINLESS 4 40 X 625 SCREW PHILLIPS PANHEAD STAINLESS 8 32 X 375 WASHER FLAT STAINLESS 8 3 8 X 11 64 X 031 SCREW PHILLIPS PANHEAD STAINLESS 8 32 X 5 NUT STAINLESS LOCK 8 32 SCREW PHILLIPS PANHEAD STAINLESS 10 32 X 5 STANDOFF TURN WASHER FLAT STAINLESS BRACKET RACK LOCATING ASSY DRYER AIR HOOD COVER G ASSY TRANSPORT DRYER ROLLER FOAM 11 ASSY CROSSOVER GUIDE GUIDE F ASSY ENTRANCE GUIDE GUIDE D ASSY RACK COVER COVER E ASSY TUBE OVERFLOW TUBING POLY VINYL CHLORIDE PVC 1 1 4 X 1 BRACKET DRYER COVER ADJUST WASHER SPRING LOCK STAINLESS 8 X 055 X 04 FROM 0 0 REPLENISH PUMP 152 GREEN YELLOW VISH PUMP 152 3 iul ISH PUMP 1522 ROW HEATER 1 2 8 RI 2 ET HEATER 152 7 RI I TERLOCK 151 5 BROW TERLOCK 151 7 BLUE 7 2 S1 CDM BLAC 51 CLR Printware Gd ASSY PROCESSOR I 807179 001 REVISION U Sheetl of 5 Printware Confidential Printware ASSY PROCESSOR 80731 79 001 REVISION U Sheet 2 of 5 DEEP GROOVE THIS SIDI Printware ASSY PROCESSOR 8071 79 001 REVISION U Printware Confidential Sheet 3 of 5 y GROUND WIRE Printware Confidential
132. TROLLER PCA ASSY CABLE INTERFACE PCA INDICATOR LIGHT ASSY CABLE RIP CONTROLLER PCA ASSY CABLE SCSI ENGINE ASSY CABLE POWER CONTROLLER FAN ASSY CABLE ENGINE POWER ASSY CABLE INTERFACE PCA SENSORS ASSY CABLE ENGINE STEPPER PCA ASSY CABLE MARKER FAN Parts List Page 1 of 1 Ns I IA Printware KIT CABLES PLATESTREAM MICROPLATE 807535 001 REVISION A Sheet of 1 Printware Confidential Find Number 001 001 002 003 005 006 007 009 010 011 012 013 014 015 016 017 018 019 020 022 023 030 031 042 049 050 051 054 055 056 057 058 064 065 066 067 069 070 071 072 073 Quantity Component Used N N N e Ne N e e e N N e ON ON DD kL Assembly Number 807444 001 ASSY ROLLER TRANSPORT PLATESTREAM MICRO PLATE Number 807343 001 807345 001 807169 001 822307 900297 001 803305 001 806308 001 804621 001 807350 001 804604 001 900229 002 900360 000 900928 002 901023 001 900871 008 803418 002 803418 001 806870 001 804627 001 803463 001 803466 001 807236 001 806327 001 803744 001 806309 001 807091 001 901026 001 806623 002 806617 001 806618 001 901102 001 901070 003 803741 002 803772 001 900569 035 900569 001 900569 008 900569 036 807175 001 807176 001 806887 001 806888 001 Revision F Component Description KIT REWORK MARK
133. UEEGEE POLISHED ROLLER PROCESSOR ASSIST GUARD PROCESSOR SPLASH ROD SUPPORT 19 67 BEARING NON METALLIC FLANGED SCREW SET STAINLESS 8 32 X 25 GEAR MOD COLLAR GEAR COLLAR SHAFT WASHER NYLON 1 4 X 5 OD X 032 NUT STAINLESS 10 24 LOCKNUT LABEL ACT ASS Y ACTIVATOR TRANSPORT D 807385 001 REVISION Sheet 1 of 3 Printware Confidential Printware Confidential Printware ASSY ACTIVATOR TRANSPORT 807385 001 REVISION D Sheet 2 of 3 WRAP ITEM 11 AROUND BOTH BEARINGS 2 F Printware ASSY ACTIVATOR TRANSPORT 807385 001 REVISION D Printware Confidential Sheet 3 of 3 Find Number 001 002 003 004 005 007 Quantity Component Used e Assembly Number 806701 001 ASSY ACTIVATOR TANK Number 806735 001 806774 001 900291 009 901089 003 901083 001 600335 001 Revision D Component Description Parts List Page 1 of 1 TANK ACTIVATOR FITTING DRAIN O RING SCREW STAINLESS TAP FORM 10 24 X 75 FITTING COMPRESSION HEATER BLANKET Printware Confidential Printware ASSY ACTIVATOR TANK 806701 001 REVISION D Sheet of Find Number 001 002 003 004 e m Assembly Number 806702 001 ASSY STABILIZER TANK Quantity Component Used Number 806734 001 806774 001 90029 1 009 9010
134. X 48 32 X 75 SCREW PAN PPH 6 32 X 38 SPRING TRACTION CONTROL PLATESTREAM ASSY SWITCH ASSY SOLENOID CAPSTAN GUIDE OPERATOR SIDE ASSY SOLENOID CAPSTAN GUIDE NONOPERATOR SIDE SCREW SOCKET HEAD SHOULDER 8 32X 125 SCREW SOCKET HEAD SHLOUDER 48 32 X 2505 BEARING OIL LESS BRONZE RECEPTACLE CASSETTE TOP CONDUCTIVE RING RETAINING 02 ASSEMBLY AIL DET tware Prin ASSY ROLLER TRANSPORT NUR 2 uA MBLY I ASSE ASSEMBLY A ASSEMBLY B S 807244 001 REVISION Sheet of 5 Printware Confidential ASSEMBLY F ASSEMBLY E 1 PLC ASSEMBLY ASSEMBLY SEE SHEET Printware ASS Y ROLLER TRANSPORT 807244 001 REVISION S Printware Confidential Sheet 2 of 5 N 5 264 2 _ ASSEMBLY L Printware ASSY ROLLER TRANSPORT SHEE ASSEMBLY 5 807244 001 REVISION Sheet 3 of 5 Printware Confidential 57 ASSEMBLY 5 a y C ASSEMBLY Q 2 PLCS des D 4 27 ASSEMBLY p aN 4 32 024 _ ASSEMBLY N 2 PLCS 263 2 d 5 2 IN B m JL pe ASSEMBLY T Printware Confidential Printware ASSY ROLLER TRANSPORT 807244 001 REVISION S Sheet 4 of 5
135. XIT Indicates the presence or absence of media at the processor exit sensor A 1 indicates that media is present e g during imaging A 0 indicates the sensor is clear This is the normal operating condition TAKE UP CASSETTE Identifies the presence of an optional film takeup cassette 1 indicates the film takeup cassette is present 0 indicates that the film takeup cassette is not present 2 16 PREPARING FOR OPERATION CHAPTER 3 Preparing to Make Plates Overview The following information explains how to prepare the Platesetter for a print job Refer to your host computer operator manual and the RIP operator manual for further detail on connecting and operating these devices with the Platesetter Introduction Before making a plate the Platesetter must be Loaded with the correct type of plate media see chapter 3 in the section Loading Plate Media Connected to the RIP I O panel is located on the top rear of the machine Ready to accept a print job Main Menu displayed on the control panel On Line state no error conditions The integrated processor must be filled to proper levels see chapter 3 in the section Filling the Processor Tanks 32 PREPARING FOR OPERATION Filling the Processor Tanks Overview Fill the processor working tanks and replenishment tanks as needed Follow manufacturer s safety instructions The message LOW REPL will appear o
136. arm with a metric Allen wrench Rotate cutter blade shaft on opposite end with pliers until blade is of the way through the silver plate on the inside Tighten set screws on arm and test the cutter before reinstalling cutter in machine PUNCH PROBLEMS Punch does not operate or does not punch all the way through SERVICE MANUAL 1 At the Operator Panel verify that the punch option is turned on 2 At the regulator on the compressor check the air pressure should be approx 80 psi 2 1 If no air pressure Check that the compressor is plugged in and turned on If you can hear the compressor try adjusting the regulator control on the air compressor Check for leaks around air hosefittings on the punch the punch solenoid and the air compres Sor If air pressure is still inadequate replace the compressor 2 2 If air pressure is adequate Check the cable from the punch solenoid to the interface PCA and re seat the cable Check that the air compressor gauge is not stuck Purge the air by opening the valve on the bottom of the glass regulator tube Then let it come back up to 80 psi Turn off the platesetter plug the punch solenoid wire into the shutter connector on the interface PCA Turn the Platesetter power back on and then at the Operator Panel run the shutter to see if the punch operates If so replace the interface PCA If the punch doesn t work when plugged into the s
137. aser marker assembly too high in front diagonal D E lt diagonal C F Turn adjustment screw clockwise to correct Leading Edge UJ lt EN N Open Top Cover Laser Marker Assembly Fixed point Capstan Roller i Media E Frame Rear Side Front Operator Side T Operator Side front of Platesetter G Figure I 10 Image Skew Laser marker assembly too low in front diagonal D E gt diagonal C F Turn adjustment screw counterclockwise to correct INSTALLATION GUIDE Scan Width and Linearity Adjustment Leading Edge This procedure enables you to fine tune the imaging accuracy and the positioning of the laser beam The B overall width of the image on the plate is determined by the positions of two sensors accessible from the front operator side of the laser marker assembly These sensors are called the Start of Trace SOT and Start of Scan SOS sensors The SOT sensor controls the total width of the laser scan which is wider than the maximum media width SOS provides the timing reference which starts the active portion of the laser scan across the media Adjusting these two sensors controls the scan width and linearity of the laser marker assembly The sensors are accessed through a small hole in the front of the laser marker assembly Use a 3 32 Allen key for adjustments Operator Side front of Platesetter
138. at 1 800 456 1400 be fore adjusting this boltto avoid warranty issues To locate this bolt Stand in front of the Platesetter operator side facing the Platesetter Open the Imager unit top cover Leading Edge UJ D i D c D c 2 lt 2 Q O H Figure I 8 No Image Skew diagonal D E diagonal C F e Look down at the point where the laser marker assembly rests on the Imager module metal frame Locate the laser marker assembly Imager cover locking clamps e The adjustment bolt is just to the right toward the Processor module of the right locking clamp 3 Figure 8 shows no image skew Ifthe image skew condition shown in Figure 1 9 is present turn the adjustment screw clockwise to lower the front of the laser marker assembly 4 Ifthe image skew condition shown in Figure I 10 is present turn the adjustment screw counterclock wise to raise the front of the laser marker assembly 5 After each adjustment close the platesetter top cover Run two test plates and measure the second plate for image skew Continue until the image is square on the plate l 15 INSTALLATION GUIDE Leading Edge UJ x N s Open Top Cover p Assembly Fixed point Capstan Roller N Media E Frame Rear Side Front Operator Side T Operator Side front of Platesetter Figure 1 9 Image Skew L
139. at print time 6 Print the Job a On Mac front ends ensure that the appropriate device name has been selected in Chooser and print normally from the application Do not specify screens or resolution in the application b On Windows front ends print to file from the application using the printer set up in step 3 the default printer name is PlateStream when using the PlateStream PPD Select the ZAPrip HQ and the appropriate hot folder Quickmaster2up2400dpi in our example as the destination by browsing Network Neighborhood Select the PlateStream PPD if the application supports PPDs Do not specify screens or resolution in the application 05 4 PlateStream eee wees Platesetter Installation Manual Printware LEADERS IN COMPUTER TO PLATE 700547 Rev L INSTALLATION GUIDE Contents Pre Installation Checklist 1 2 Confirm Electrical Requirements 1 2 Confirm Supply of Recommended Consumables 1 2 Confirm Arrival of Platesetter 1 2 Verify Final Location 1 4 Precautions 4 Unpacking and Inspection 1 4 Assembling the Platesetter 1 5 Assembling the Processor 1 6 Installing the Raster Image Processor RIP 1 7 Turning the Platesetter 1 8 Loading Plate Material 1 9 Setting Replenishment Rates 1 10 Changing Processor 50 60 HZ I 11 Calibrate Processor I 12 Physical Calibration 1 13 Overview 1 13 Cutter Skew 1 13 Transport Skew 1 14 Image Skew 1 15 Scan Width Linearity Adjustment 1 17 Marker Position
140. b Right Hub Position 13 Figure QS 1 Loading Plate Media on Spool The control panel Setup Menu below lists six options for changing various Platesetter parameters Setup ESC to exit 1 Image Negative Right Reading 2 Resolution 1800 DPI 3 ms Power 5596 4 Media Width 13 12 Spool Pos 13 5 Input Spool A 6 Destination Processor Display Units English ON ESC OFF ENTER 1 Image Sets the type of imaging The choices are Positive or Negative Wrong Reading and Positive or Negative Right Reading The default is Negative Right reading for plate media 2 Resolution Sets the resolution The choices are 900 1200 1800 or 2400 dpi 3 Image Power Sets the image power laser intensity 4 Media Width xx xx Spool Pos yy Media Width is the exact width entered by the operator from 7 00 to 13 40 17 78 cm to 34 00 cm Spool Pos indicates the position to set the spool or cassette Spool position 15 set at the media width in inches rounded to the nearest inch from 7 to 13 5 Input Spool Specifies the input spool The choices are A C D 6 Destination Sets output destination for the imaged media The choices are Processor Processor Miniplate with Miniplate option or Cassette with film option 7 Display Units Toggles between English and Metric display units QS 3 QUICK START GUIDE ZAPrip HQ Harlequin RIP Setup Imaging Plates
141. bassemblies within the Platesetter require lubrication details the procedures for lubricating the assemblies and shows the recommended frequency for performing each procedure This chapter also includes information on other preventive maintenance proce dures Performance of lubrication and preventive maintenance procedures is essential to keep the Plate setter in proper operating condition and to maintain optimal image quality Keeping the Platesetter and its surrounding area clean is also important Wipe excess oil from all parts after performing lubrication procedures Perform these procedures at the time intervals shown in the Platesetter Maintenance Schedule section to keep the Platesetter operating properly and avoid unnecessary repairs For detailed drawings and Printware replacement part numbers see the PlateStream Platesetter Parts Manual Approved Lubricants The following lubricants are the only ones approved for use on the PlateStream Mobilith SHC 460 Silicone Stick Lubricant Cleaning Supplies Marker Mirrors Compressed air recommend type in Ultrajet E Series Precision Dust Remover Acetone 100 pure cotton non woven lintless non scratching fabric such as Webril Wipes Imager rollers Non linting soft cotton cloth Cleaning refreshing solvent Recommended type is D Ink Processor Rollers Non linting soft cotton cloth Warm soapy water SERVICE MANUAL Printware Recommended Periodic Maintenance S
142. been imaged and processed measure the angle E see Figure I 6 Adjust roller pressure to eliminate transport skew as follows see Figure I 7 f angle E 15 gt 90 tighten the roller pressure on the front operator end of the second pinch roller INSTALLATION GUIDE Leading Edge UJ D 2 9 gt I Figure I 6 Checking for Transport Skew If angle E is lt 90 tighten the roller pressure on the rear end of the second pinch roller Marker Lever o VERO Marker lt Pinch Roller Y Media Path Imager Exit Rollers EY Imager Exit Figure I 7 Location of the Pinch Rollers I 14 INSTALLATION GUIDE Image Skew Image skew is caused by the laser marker assembly being tilted relative to the capstan roller Image skew is present when the material is square but the image on the media is measurably skewed 1 Check for image skew by comparing the two di agonal image measurements Measure the distance from point C to point F see Figure 1 8 and compare this to the distance from point D to point E If the two diagonal measurements are equal no image skew is present skip the remainder of this procedure and go on to the next section Scan Width and Linearity Adjustment 2 To correct image skew adjust the laser marker assembly position bolt Notify Printware s Cus tomer Service Department
143. ber 807415 002 901051 005 901051 002 901051 004 901051 008 900940 003 900940 004 900940 005 900289 003 901053 001 807460 001 901052 003 807301 001 900235 040 806935 002 806957 001 807309 001 807310 001 807361 001 806936 001 806806 001 900651 022 900651 020 900047 000 900445 006 900445 007 900236 008 900233 003 900233 001 900288 006 900369 001 900287 029 900160 004 900005 002 900336 000 806915 001 807352 001 900287 025 806891 002 806127 002 900235 041 ASSY PUNCH PLATESTREAM BACHER 220 Revision G Component Description ASSY COMPRESSOR MODIFIED FITTING TUBE QUICK RELEASE STRAIGHT FITTING TUBE QUICK RELEASE UNION TEE FITTING TUBE QUICK RELEASE STRAIGHT FITTING TUBE QUICK RELEASE STRAIGHT TUBING POLYURETHANE RED TUBING POLYURETHANE ORANGE TUBING POLYURETHANE GREEN BUSHING GROMMET MUFFLER PNEUMATIC ASSY PUNCH BACHER 220 SOLENOID AIR VALVE ASSY CABLE SOLENOID SCREW SOCKETHEAD CAP 8 32 X 5 8 BRACKET PUNCH MOUNTING NON OPERATOR SIDE BRACKET PUNCH MOUNTING OPERATOR SIDE GUIDE UPPER BUFFER PUNCH GUIDE LOWER BUFFER PUNCH ASSY FOG LAMP LED BRACKET PUNCH PLATE ASSY CROSSOVER GUIDE WASHER FENDER 5 X 189 X 125 WASHER FENDER 749 X 203 X 156 WASHER EXTERNAL LOCK 8 SCREW B H TORX 8 32 X 375 SCREW B H TORX 48 32 X 5 SCREW SOCKETHEAD SHOULDER 8 32 X 2505 NUT LOCK 8 32 NUT LOCK 10 32 SCREW PHILLIPS PANHEAD 10 32 X 1 5 CLAMP FIXED DIAMETER
144. breaker prevents high current from damaging the Platesetter electronics Components The power supply contains a PCA which is responsible for distributing the correct signals within the Platesetter The connectors and other items on the external portion of the power supply drawer are described below Power on off switch Circuit Breaker 20 amp Outlet incoming power connection Connector 11 engine stepper PCA Connector J4 controller microstepper fan Connector J5 interface and operator panel PCA s Replacing the Power Supply Assembly 1 Turn the Platesetter off and unplug Remove the rear panel 2 Disconnect the cables from the power supply Note the orientation of each cable 3 Access the power supply screws by opening the bottom front doors Remove power supply by unscrewing the nine screws and pull power supply out of the Platesetter from the rear 4 Install the new power supply in reverse order Replace the rear panel and close bottom front doors 37 SERVICE MANUAL Sensors The sensor Status menu indicates the current digital status of all Platesetter sensors Explanation of all the sensor indications are shown below LOAD KNOB This sensor is activated when the load knob is pushed A 0 indicates the knob is pushed in 1 indicates the load knob is pulled out FEED LOOP Indicates the status of the service loop sensor in the feed area of the Platesetter T indicates that a loop i
145. chedule Recommendations based on 8 hours per day use 5 days a week 1 Imager section maintenance Weekly 1 Roller cleaning damp cloth light D ink no alcohol or solvents Q Clean or replace fan filter Q General cleaning of dust dirt from imager area Q Clean out any punch chips from punch area or machine Check oil level in punch compressor 2 Processor section maintenance Weekly Remove Activator and Stabilizer racks Clean racks and guides with warm soapy water Do not use alcohol or solvents Clean any splashed chemistry from processor and dryer area Inspect racks for worn or damaged components gears and replace as necessary U At 4 000 plates or 4 weeks whichever comes first completely drain Activator and Stabilizer tanks and clean tanks and racks Refill with fresh chemistry Note Replenishment rates are to be set to Printware recommendations See Setting Replenishment Rates in the Installation Guide C Check the temperature of the Activator bath 86 F 2 3 Semi annual Preventive Maintenance Ll Performed by Printware authorized service technician Includes check and adjustment replacement as necessary of sensors and belts all bearings gears rollers and clutches pumps blowers motors O rings heater tem peratures marker focus calibration etc SERVICE MANUAL Procedures to Raise and Lower the Marker Open the top cover and raise the marker by pulling marker
146. crew Note 1 full turn ofthe adjustment screw moves the cutter approximately 020 Tighten the two 9 64 Allen cap screws After adjustment run two plates and check the second plate for skew Operator Side front of Platesetter I NOTE You must run two plates before checking the results as the first plate will have one cut made at the previous setting Figure 1 3 Checking Cutter Squareness 6 Continue adjusting cutter position and inspecting test plates until the plate is cut square Reattach the rear cover to the Imager unit l 13 Transport Skew Transport skew results when the media is not feeding through the rollers perpendicular to the capstan roller Before making any other adjustments check the four edge guides to ensure they are securely in place Also check the adjustable guides toward the front of the Platesetter they should be flush with the media but not so tight that they cause the media to buckle as it moves If you are unsure of whether or not the media is being transported properly open the Platesetter top cover press the load key 5 on the Platesetter control panel Main Menu and watch the media Once you have determined that the edge guides are properly in place follow the procedure below to optimize trans port skew 1 To determine whether or not the image is square on the plate print either a grid pattern or a solid pattern from the RIP 2 Once the plate has
147. d adjust the marker focus screw using a 7 32 allen wrench Turn the focus screw 3 full turns clockwise see Figure S2 1 Close the top cover Run another 4 pixel on focus test plate 4 Compare to previous plate If the focus pattern looks better you are turning the focus screw in the right direction Continue turning the focus screw 2 full turns at a time and re imaging another focus pattern and observe the results again 5 If the pattern looks worse turn the focus screw 6 full turns CCW close the cover and run another focus pattern 6 Repeat whatever parts of steps 3 4 amp 5 that are necessary until test plates are in focus Note that there is approximately an 8 to 10 focus screw turn range where the marker is in focus The best focus will be obtained in the middle of that range 12 SERVICE MANUAL 13 Note the sharp clean focused pattern above vertical and horizontal lines approximately the same width full sharp dots in both the positive and negative modes 4 pixel on focus patterns Note the fuzzy un focused pattern below vertical and horizontal lines are fuzzy and may not be the same width dots are fuzzy and small or even non existent SERVICE MANUAL Processor Section Operation Safeguards 1 Do not spill liquids into the electrical compartment or on other electrical components Do not operate the processor if electrical components have been dama
148. d vinyl hose into the optional effluent tank Reinstall the optional effluent tank and close the tank cover Gently push the cart s under the processor and replace the bottom front panel PREPARING FOR OPERATION Kc Marker Lever Processor Working Tanks Cover E Activator v Stabilizer 7 Processor JJ Exit D Effluent Drain 7 Optional Effluent Tank gt Tank amp Cart Optional Replenishment Tanks Cart Optional Figure 3 1 Side View of the PlateStream Platesetter Processor Note If the processor has not been in use for several days the racks can freeze up due to evapo ration causing rollers to stick together The racks should be removed and rinsed with water and rotate the gears to free them up Failure to do so can result gear breakage 34 PREPARING FOR OPERATION Loading Plate Media 1 Open the top cover Raise the marker by pulling the marker lever towards the front of the Platesetter until the lever stops Lift up on the marker gently See Figure 3 1 Open load door and pull on the load knob see Figure 3 2 Remove the spool assembly from the Platesetter Adjust the two rear edge guides inside the Platesetter by pulling the edge guide knobs up and sliding to the position closest to the plate media width Adjust the two front edge guides by loosening the screws moving the guides all the way to the front Adjust the left hub
149. dia Jam cut the media from the operator panel Run Hardware Menu 4 Remove all loose media in the Platesetter 4 If media is wrapped around the capstan roller push the load knob in and back up the feed transport rollers from the operator panel More Information Menu 4 To stop the transport roller press the ESC or OFF key 5 Replace all guides to the original positions Gently close the marker and lock it by pushing down the marker lever Reload the plate media 7 10 CASE OF TROUBLE LOAD _ _ DOOR GUIDE B PINS CAPSTAN GUIDE C PIN 7 A MARKER LEVER COVER E GUIDE D PINS GUIDE E PINS COVER G Figure 7 la Clearing Media Path standard model 7 11 CASE OF TROUBLE Clearing Media Path MicroPlate Model 1 Open the load door and pull on the load knob Raise marker by pulling marker lever fully toward the front of the Platesetter Gently lift up the marker see Figure 7 1b 2 Inspect media path for jammed media in the areas described below Access the media path through the top and front covers of the Platesetter Guide A Press down on the three or four pins and remove Capstan Inspect capstan roller for media wrapped around it Open the shutter if necessary The shutter is located on top of the capstan roller Guide B Remove the front cover of the P
150. e loaded with no tears or wrinkles Cut off any punched area of plate before reloading to ensure a reliable load Remove leader from daylight load media before loading media Media must be loaded with no tears or wrinkles Media must be reloaded after jams or other fault conditions In this case a message will appear on the operator panel to Reload Media or Manually Reload Media The Optional Edge LED should be ON for plate widths more than 13 3 allowing a fully exposed 13 4 plate see chapter 2 in the section More Information Menu PREPARING FOR OPERATION Receptacle Spool Assembly Load Door Load Knob Figure 3 2 Location of Spool Assembly EMULSION OUT MEDIA EMULSION IN MEDIA Right Hub Position 13 Figure 3 3 Loading Plate Media on Spool PREPARING FOR OPERATION Imaging Plates 1 Configure RIP Connect to the Network ZAPrip 200 Level 1 ZAPrip a Exit RIP and watch for the reboot warning The RIP will reboot in 15 seconds b Hit ctrl c when you see the message c Answer Y to Terminate batch job d Set up network connection For AppleShare networks At the DOS prompt enter CD PHONENET Enter DA to start Phonenet desk accessory Use DA to log on to your AppleShare file server and mount a folder directory The directory will be mounted on the RIP as the I drive Exit DA For Novell networks At the DOS prompt enter CD NWCLIENT Enter NET to start
151. e Platesetter and if more than 9 MiniPlates are present the digit will be replaced by a Printware PlateStream 1 Setu 5 Load 2 Test Plate 3 On Off Line 4 More Information On Line Transporting A0075 1800 DPI 6 Cut Fd MINI3 ON ESC OFF ENTER 3 10 PREPARING FOR OPERATION MicroPlate Model The PlateStream MicroPlate makes plates of less than 60 in dramatically reducing waste in social printing and similar applications which use small format Waste Waste PlateStream MicroPlate 7 x 8 5 No Waste Figure 3 3a PlateStream MicroPlate plate format PlateStream MicroPlate minimum plate size is 8 5 long by 7 wide The MicroPlate version is also compatible with the MiniPlate option for the ultimate in platemaking economy The PlateStream MicroPlate Platesetter has a slightly different plate path than the standard PlateStream including a number of additional rollers and different guides The operator panel menus are the same as the standard model except of course that plate lengths as small as 8 5 can be entered minimum plate length for the standard PlateStream is 12 Film Option With this option the Platesetter will image film media any width from 7 to 13 4 To turn the film option on change the destination to cassette in the Setup Menu see chapter 2 in the section Setup Menu This option is supplied with light tight feed and take up cassettes The film
152. e cutter The cutter cuts the media to a specified plate length After the media is cut it is fed between the upper and lower imager exit rollers and into the integrated processor 2 Activating Developing a base chemical process which etches the image on the media This is done by the activator on silver halide plate material 3 Stabilizing Fixing a slightly acidic chemical process which stops the developing This is done by the stabilizer on silver halide plate material 4 Drying air drying of the processed media Unless another file is sent immediately the Platesetter returns to idle mode The feed capstan and imager exit motors are shut off The processor transport motor and dryer are also shut off _ Marker Lever 5 lt Pinch Roller 1 Capstan Roller Rollers Cutter e 4 Punch S Imager Exit Rollers Tank amp Cart E Optional CJ CO Cart Optional Figure 1 3 Media Path of the PlateStream Platesetter 14 GENERAL INFORMATION Panel High Speed Load Door Control Panel Power Switch Options Features Overview The I O panel is located on the top rear of the Platesetter This I O panel is used to connect the Platesetter to an external RIP The Platesetter images plates up to a rate of 120 plates per hour and up to 36 inches per minute Plates emerge right reading for easy proof
153. e the plate material 7 8 IN CASE OF TROUBLE PROBLEM SOLUTION White Black or Silver 1 Clean processor and replace chemistry Streaks on the Plates Brown Haze on Plates 1 Clean processor and replace chemistry 2 Clean the processor rollers Wet Plates 1 Clean the dryer 2 Clean the processor and replace the chemistry 7 9 CASE OF TROUBLE Clearing Media Path standard model see pp 7 12 to 7 13 for MicroPlate procedure 1 Open the load door and pull on the load knob Raise marker by pulling marker lever fully toward the front of the Platesetter Gently lift up the marker see Figure 7 1a 2 Inspect media path for jammed media in the areas described below Access the media path through the top and front covers of the Platesetter Guide A Press down on the four pins and remove Capstan Inspect capstan roller for media wrapped around it Open the shutter 1f necessary The shutter is located on top of the capstan roller GuideB Remove the front cover of the Platesetter Push the two mounting pins and swing the guide to the left Guide C Press down on the two mounting pins Remove the guide by rotating upward Guide D Slide the guide toward the front of the Platesetter Lift the rear of the guide and remove Guide F Remove cover E Slide Guide F toward the rear of the Platesetter Lift the front end of the guide and remove Cover G Use the handle to remove 3 After locating the area of the me
154. e the value Note that Miniplate Backup creates a non imageable area equal to the Backup Length on the trailing edge of each job 6 If necessary follow the procedure for all resolutions to be used with the Miniplate mode Miniplate Backup Length is set independently for each resolution The default Miniplate Backup Length for each resolution is Default Miniplate Resolution Backup Length 900 dpi 0 134 1200 dpi 0 084 1800 dpi 0 021 2400 dpi 0 010 l 21 INSTALLATION GUIDE Punch Alignment and Skew Plates must be punched accurately to align in the press There are two physical calibration adjustments for the punch lateral side to side alignment and skew parallelism to the cut edge Additionally the punch depth longitudinal position can be adjusted in the Operator Panel see Cut Length Backup Length and Overlap Adjustment Adjusting Punch Length in this guide NOTE Before adjusting the punch ensure that the cutter has been adjusted correctly see Physical cali bration Cutter Skew in this guide Because the punch adjustment uses the cut edge as a reference the cutter must be adjusted first Punch Alignment 1 To enable the punch from the Main Menu on the control panel Press 4 More Information Press 8 Punch Press ON to turn the punch on 2 Run a test plate with the punch on see Cutter Skew procedure above NOTE Use the intended plate width for these adjustments Lateral a
155. e three halftone parameters to be specified are 1 The shape of the dots created 2 The frequency and angle of the dot pattern 3 The screening algorithm i e conventional AM or enhanced supercell screening HALFTONING AND SCREENING Dots Halftone Cells and Screens Dots are the visible part of halftoning and most halftoning can be described in terms of patterns of these dots The industry standard terms used to describe the organization of these dots into manage able structures are halftone cells and screens Each dot is considered to occupy a halftone cell Figure ApB 1 shows two groups of four halftone cells Every halftone cell is used to represent a gray level or color intensity A dot can have any area in the range 0 of the area of the halftone cell a completely white cell through 100 of the area of the halftone cell a completely black cell Dots of intermediate areas create the illusion of gray levels The number of pixels in the halftone cell defines how many intermediate areas of dot are possible and in most systems this defines the number of reproducible grays Cell spacing related to line screen rY Figure ApB 1 Halftone cells Screen Frequency and Dot Shapes A screen is an invisible grid that is superimposed on the image each square in the grid is a halftone cell For a particular dot shape the important characteristics of a screen are its spatial resolution referred to
156. east 16 gallons of working Activator on hand Have at least 16 gallons of working Stabilizer available Have plate media available as required Plate media may be either paper or polyester based Roll width may be from 7 to 13 4 17 8 cm to 34 0 cm The maximum roll length is 280 85 m See table on following page for recommended media 3 Confirm Arrival of the Platesetter Verify the machine will be at the installation site final location loading dock storage area etc before scheduling installation The Platesetter should be initially installed by an authorized service technician Recommended Supplies RECOMMENDED CONSUMABLES FOR PLATESTREAM PRINTWARE SILVERSTREAM RED LIGHT PLATE MEDIA Emulsion In 5 mil polyester 808555 XXX 280 FT ROLLS 8 mil polyester 808666 XXX 280 FT ROLLS CHEMISTRY ACTIVATOR 808777 001 STABILIZER 808777 002 AGFA SETPRINT PLUS RED LIGHT PLATE MEDIA Emulsion In 5 mil polyester SET R 0 13 8 mil polyester SET R 0 20 CHEMISTRY ACTIVATOR G5200 STABILIZER 55400 MITSUBISHI SILVER DIGIPLATE INFRA RED PLATE MEDIA Emulsion In Emulsion Out 5 mil paper SDP RD125 SPEC28 SPEC28R 7 mil paper SDP RD175 SPEC 28 SPEC28R 4 mil polyester SDP FD100 SPEC 820 SPEC820R 7 mil polyester SDP FD175 SPEC 820 SPEC820R CHEMISTRY ACTIVATOR SLM AC STABILIZER SLM ST RED LIGHT PLATE MEDIA Emulsion In Emulsion Out SDP RR125 SPEC28 SPEC28R SDP RR175 SPEC28 SPEC28R SDP
157. ed di losed to others or disposed of directly or indrectly without authoriza SCALE NONE tion from Printware Inc Both the document and its content are to be treated as confidential amp Sheet 5 of 6 proprietary and may not be used in any manner not consistent with the rights of Printware Inc 6 EXIT SWITCH 600333 001 RIBBON CABLE TO INTERFACE BOARD WORKING TANK SENSORS PS46 806794 001 806800 001 EN PS 807204 001 806792 001 MOUNTING SCREW BEEDUENT TANE EE VEL 228 SS DRIER TEMP SENSOR PS46 806815 001 5 806815 002 600330 001 806786 001 806790 001 REPLENISHMENT TANK SENSORS 806709 001 p alls z a 2 II 5 806703 001 2 B 5 1 1 IS BROWN PIN 26 IS GREEN ACT BLANKET HEATER 600335 001 TRANSFORMER WIRING DIAGRAM PS46 808155 001 523150 001 PS 807179001 523200 001 806705 001 EMI FILTER 2A 250V m 5A 250V 22 21 F3 12 32 31 Bl 11 5A 250V 5 HOOD INTERLOCK 2A 250V 31 2 600292 001 F5 of a SSS HHHH
158. ed hoses Adjust pump rate see Installation Guide chapter 1 for adjustment procedures Turn heat down on processor PCA by adjusting potentiometer R42 the tempera ture specification is 86 2 F or 30 1 C Replace temperature probe SERVICE MANUAL PROCESSOR ELECTRICAL PROBLEMS cont Processor drive motor does not work 95 Make sure the processor interlock switch is being activated If not adjust the switch bracket Remove both racks and turn on the proces sor If the motor comes on with the racks removed replace one rack at a time If adding a rack causes the motor to stop check the meshing of the gears and the roller end play of that rack Check the worm drive Remove the right side end panel and measure the voltage across motor Ifvoltage reads 220V with motor on but the motor is not spinning replace motor is no voltage across the motor check fuse F5 on the PCA If the fuse is good replace the PCA Turn the white motor fan blade by hand If it doesn t turn easily disconnect the drive belt and try again If it still does not turn easily replace the motor assembly 70 SERVICE MANUAL MEDIA PROBLEMS Media has excessive curl 71 Check for excessive curl in media Lay a 12 length of material on a flat surface and hold down one end If curl the is more than 2 replace media it does not meet the manufacturer s specifications Decrease drye
159. enu The platesetter is now ready to image 15 To remove imaged film for processing press the Cut Fd 6 on the control panel Main Menu Open the top cover and remove the take up cassette by lifting the cassette off the two take up receptacles 16 To remove film from the feed cassette open the load door and pull on the load knob Remove the feed cassette by lifting the cassette off the four receptacles Open the feed cassette by lifting the back of the lid and sliding forward at the same time Remove the spool assembly from the cassette Remove the right hub from the shaft by lifting the clip and sliding it off ofthe shaft Slide film off of the shaft To load another roll of film follow steps outlined above Note The take up cassette will hold up to 25 of printed jobs however the cassette will hold only one piece of film ata time After imaging and cutting one piece of film the load button on the op panel must be pressed before imaging another piece of film Emulsion out Emulsion in T Side View of Supply Cassette Top Front View of Supply Cassette Figure 3 4 Loading Film on Spool 3 13 PREPARING FOR OPERATION we Marker Lever 1 Feed Cassette Take up Cassette Receptacles Take up Cassette Media Path Guide D Feed Cassette WA Pins _ Receptacles Imager Exit Guide Tank amp Cart Optional Cart Optional Figure 3 5 Location of Opti
160. ff any punched area of plate before reloading to ensure a reliable load Media must be reloaded after jams or other fault conditions In this case a message will appear on the operator panel to Reload Media or Manually Reload Media Media must be loaded with no tears or wrinkles EMULSION OUT MEDIA EMULSION IN MEDIA Right Hub Right Hub Left Hub S LA Media Roll a Position 13 59 Position 13 Figure 1 2 Loading Plate Media on Spool INSTALLATION GUIDE Setting Replenishment Rates 1 Open top cover and remove replenishment hoses from the working tanks inside the processor Place the replenishment hoses in measurement containers 2 From the control panel run a test plate that represents the average plate size that will be run on this Platesetter 3 Compare the measured volume to the table outlined below Recommended replenishment rates are as follows Printware SilverStream Activator or Stabilizer 0 37 ounces ft 120 mI M Agfa Setprint Plus Activator or Stabilizer 0 37 ounces f 120 ml M Mitsubishi Silver DigiPlate Activator 0 47 ounces ft 150 ml M Stabilizer 0 63 ounces f 200 ml M Average Plate Size 0 6 f 0 8 1 0 f 1212 1412 1 6 f 1 8 f 2 0 f 2 5 ft 0 06M 0 07M 0 09 M 0 11 M 0 13 M 0 15 M 0 17 M 0 19 M 023 M Printware SilverStream Activator amp Stabilizer oz Activator amp Stabilizer ml Agfa Setprint Plus Activator amp Stabilizer oz Activa
161. ged 2 Disconnect electrical power before servicing the processor 3 Before handling photographic chemicals read the manufacturer s handling procedures including the material safety data sheets Chemicals used in processing are hazardous if handled carelessly Systems Transport When the leading edge of the plate exits the imager the processor transport system also starts Opposed rollers guides and belts will move the media through the activator and stabilizer racks dryer and into the receiver tray Heating The solution in the activator tank is heated by a blanket heater attached to the underside of the tank The heater energizes when power is applied to the processor providing that there is solution in contact with the working tank level sensor The solution temperature is maintained by a working tank temperature sensor Over temperature protection is provided for by means of a thermostat in the blanket heater The dryer heater energizes when imaging starts and de energizes a few seconds after the last plate falls into the receiver The dryer temperature is maintained at the set point by means of a sensor in the dryer chamber Over temperature protection is provided for by a thermostat in the heater assembly Replenishing Replenishment occurs when the media is depressing the switch in the dryer The media travels at 37 inches minute 94 cm minute and the pump can be adjusted to replenish a certain amount for each plate There is a
162. he section Film Option CAUSE The take up cassette for the film option is full SOLUTION Empty take up cassette See chapter 3 in section Film Option Takeup Full 47 SUPPLIES CHAPTER 5 SUPPLIES Introduction Using recommended supplies ensures high quality printing plates and printed output The Plateset ter is designed to image silver halide coated plate material Silver halide material is normally imaged negative right reading see chapter 2 in the section Setup Menu Plate media may be either paper or polyester based Roll width may be from 7 to 13 4 17 8 cm to 34 cm The maximum roll length is 280 85 M SUPPLIES PRINTWARE SILVERSTREAM RED LIGHT PLATE MEDIA Emulsion In 5 mil polyester 808555 XXX 280 FT ROLLS 8 mil polyester 808666 XXX 280 FT ROLLS CHEMISTRY ACTIVATOR 808777 001 STABILIZER 808777 002 AGFA SETPRINT PLUS RED LIGHT PLATE MEDIA Emulsion In 5 mil polyester SET R 0 13 8 mil polyester SET R 0 20 CHEMISTRY ACTIVATOR G5200 STABILIZER 55400 MITSUBISHI SILVER DIGIPLATE INFRA RED PLATE MEDIA RED LIGHT PLATE MEDIA Emulsion In Emulsion Out Emulsion In Emulsion Out 5 mil paper SDP RD125 SPEC28 SPEC28R SDP RR125 SPEC28 SPEC28R 7 mil paper SDP RD175 SPEC 28 SPEC28R SDP RR175 SPEC28 SPEC28R 4 mil polyester SDP FD100 SPEC 820 SPEC820R SDP FR100 SPEC820 SPEC820R 7 mil polyester SDP FD175 SPEC 820 SPEC820R SDP FR175 SPEC820 SPEC820R CHEMISTRY
163. her side of the roller pairs to set correct tension Correct roller tensions are as follows Infeed rollers approx 4 Ibs 18 N First pinch rollers approx 4 5 lbs 20 Second pinch rollers 8 14 Ibs 50 note tensioner on operator side may look tighter due to the traction control on the back of this roller Exit rollers approx 4 Ibs 18 N If unable to resolve the problem send sample plates to Printware Send four maximum width grid pattern plates We can measure and advise on adjustments 48 SERVICE MANUAL OPERATOR PANEL PROBLEMS Operator Panel does not function 49 1 The operator panel is an applet on the RIP Check that both the RIP and the Platesetter are plugged in and turned on 2 Check the cable connections between the RIP and the Platesetter Note The machine is designed to beep continuously every 5 seconds if a job is sent with an unsupported resolution SERVICE MANUAL MARKER GALVANOMETER PROBLEMS For all galvanometer errors recycle the platesetter to clear spurious errors If errors persist use the following steps before replacing the marker assembly Galvo initialization stops at 00 02 03 05 07 10 OQ Check cables between controller PCA and marker assembly Check controller PCA and power supply voltages Check voltages at power supply Check fuses and replace if necessary Replace Power Supply if
164. hutter connector on the interface PCA replace the punch solenoid cable assembly order both and have them wired together at the factory before shipment 60 SERVICE MANUAL PUNCH PROBLEMS cont Media gets stuck in punch 1 Clear chips from the system 1 1 Ifa vacuum cleaner is available attach it to the punch plate plumbing to extract any build up of chips this may be operator or non operator side depending on the chip collec tor configuration 1 2 If a vacuum cleaner is unavailable or step above doesn t clear the chips completely remove upper infeed Guide A the lower infeed guide with brackets left on the guide and the plate on the back of the punch to clear the remaining chips Be sure to reinstall the guide in the correct position 2 For older systems consider a vacuum chip clearing assist upgrade 2 1 The current design has the chip collection bag on operator side no upgrade neces sary 2 2 Systems with a vacuum assist upgrade have a fitting on operator side of the punch back plate to blow chips towards the non operator side vacuum tube Double punch with twisted plate 1 This problem is caused by a hooked edge of the punch pattern snagging the plate 1 1 Adjust punch side to side so that only complete holes are being punched This may require a press adjustment 1 2 Use wider or narrower media so that only complete holes are being punched Overheated compressor 1 Checkoi
165. i S23060 001 16 BLUE GND 16 INTERFACE 5 17 VIOLET EX RESET 17 BOARD LAY OUT 5 18 GRAY EX RESET 18 19 WHITE GND 19 NU 20__ CUT STEP 20 e 21 BROWN CUT STEP 21 o i 22 RED GND 22 ofl 23 ORANGE CUT RESET 23 TO 24 YELLOW CUT RESET 24 55 GREEN GND 2s ENGINE STEPPER 26 BLUE PLG OP 26 PCA J7 27 VIOLET PLG OP 27 5 28 GRAY GND 28 29 WHITE STEP 5 29 i J6 NU 30 BLACK STEP SYNC 30 z 31 BROWN GND 31 32 RED SPARE3 32 33 ORANGE SPARE3 33 34 YELLOW GND 34 35 GREEN FD TR DIR 35 i 36 BLUE FD TR DIR 36 5 37 VIOLET GND 37 38 GRAY SPARE 38 Canin J4 NU 39 WHITE SPARE 1 39 806306 002 40 BLACK GND 40 4 BROWN SPARE 0 21 42 RED SPARE 0 42 43 ORANGE GND 43 44 YELLOW EX DIR 44 RED 1 324V ORANGE 1 45 GREEN EX DIR 45 sex 2 FAN DEV WHITE 46 BLUE GND 46 47 VIOLET SPARE 2 47 COOLING FAN 48 GRAY SPARE2 48 49 WHITE GND 49 CABLE 50 BLACK GND 50 804140 002 WHITE 1 PREIS RENE NER 3 3 1 BROWN NO MEDIA 45V V sion ORANGE SENSOR NO CABLE 4 YELLOW LOAD OK 55V See 806059 001 807226 001 SENSOR NO SHUTTER 807091 001 SOLENOID ware 24V ORANGE 7 VIOLET LOAD KNOB 45V TOAD ENOR SHUTTER DRV WHITE SENSOR NO WHITE 24 ORANGE 807091 001 sae surm Dav wars SHUTTER DRV WHITE 10 BLACK EXIT CASSETTE 45V GRIT CASSETTE SED ONLY 09 001 1l BROWN EXIT CASSETTE SIG SENSOR NO WITH FILM 12 RED EXIT CASSETTE GND 30209 5001 OPTIO
166. i x ON POWER SUPPLY INTEGRATED ASSY n 803319 002 Ll o 807046 TAB POWER 0 Ed ENG STP 45V ORANGE No 215 0 37 ORANGE ENG STP 424V YELLOW PRN GND 2190 VENT FAN 5 6 7 BLACK ENG STP GND ENG STEPPER RED 1 GREEN NC 2555 900894 001 d m POWER SUPPLY BLACK 2 BLUE PRN GND 22 2 E DRAWER RED 3 VIOLET NC 4 BLACK 3 BLACK 3 GRAY TRN GND B 2 note on YELLOW s WHITE NC FERES CABLE 80539002 BLACK 6 CONTROLLER PCA BLACK PRN GND En 5 n BLUE T BROWN PIX ENBL CIN RED CONT 45V BLACK s 522980 001 IR RED PIX ENBL 25 Gy YELLOW CONT 12V ORANGE ORANG PIX CLE 7 T a CONT 12 4 oe i 522980 002 RED ORANGE mar to z CONTROLLER J a AES H o ORANGE CONT 24V BLUE PRN DOT 37 19 Elle 2 589 10 Brack CONT GND SCHEMATIC PAGE 3 VIOLET PRN DI 7 2 a ORANGE VENT FAN 24 ENTIS ire OC Pv a 1 ye t y Ee GRAY FEN Di DC POWER SUPPLY BLACK VENTEANEIN INTERLOCK ASSY m mE TO RIP 901142 001 a CABLE 803312 003 806307 002 BROWN PRN D3 11 600322 001 M RED S ac RED INTRE 5V dE E H BLACK SWITCH YELLOW INTRF 12V 4 45V EUSE RAN RED 1 YELLOW PRN Di m X ACIN Li ace 2 sown ew E BLUR INTRE 12 BEACK GRI PRN DS 13 COREOM E sv u ORANGE INTRE 92V INTERFACE IK BLUE m 2 50 60 HZ BLUE 30VK6 BROWN
167. ial Find Number 001 002 003 004 005 006 007 008 Quantity Component Used 2 rm Assembly Number 806714 001 Number 900960 004 900271 004 900960 002 900582 007 900268 008 806770 001 900229 017 806729 001 ASSY DRYER DRIVE Revision F Component Description Parts List Page 1 of 1 BEARING ROLLER BELT TIMING 1 5 PITCH 100 GROOVES GEAR WORM SINGLE PIN DOWEL 1250 DIA X 625 PULLEY TIMING BELT 1 5 PITCH SHAFT DRIVE BELT E RING SAE 25 SHAFT CHANNEL DRIVE DRYER Printware Confidential Printware ASSY DRYER DRIVE 80671 4 001 REVISION Sheet 1 of 1 Find Number 001 002 003 005 006 007 008 009 010 011 012 013 015 016 018 019 020 021 022 023 024 025 026 028 030 031 032 033 034 035 036 037 038 039 040 Quantity Component Used 1 N N NO PRN CN CO COR BR NOR Assembly Number 807384 001 ASSY STABILIZER TRANSPORT PLATESTREAM MICRO PLATE Number 807382 001 900960 004 900960 003 806752 001 900960 001 900229 017 806776 001 900960 020 900229 018 807383 001 806764 001 806852 001 806821 001 806837 001 806762 001 806760 001 806278 001 806838 001 900967 001 901072 004 901071 013 900967 003 901072 005 901089 001 806822 001 806694 002 806510 001 901070 001 806819 001 900319 004 807231 007 806695 001 900968 005 900773
168. ibration Pressing ENTER will cause the control panel to display Power Cycle which means to turn the machine off then back on 27 SERVICE MANUAL CHAPTER 4 REPLACING ELECTRONIC COMPONENTS Introduction Signals output by the RIP are received by the controller PCA mounted on top of the marker In structions and acknowledgments are acted on accordingly The controller PCA controls power to the laser and drive current sent to the galvanometer The data signals sent to the controller PCA cause the circuitry to turn the laser on and off while the galvanometer sweeps the laser light back and forth across the plate surface to selectively expose portions of the plate material passing under the aperture The engine stepper PCA precisely controls the timing of drive signals sent to the various motors within the Imager section to coordinate the feeding imaging and cutting of the plate material The control panel PCA accepts signals from the interface PCA controller PCA and from the hu man operator via the keys on the control panel to control and report Platesetter functions and conditions There are four PCAs and one power supply assembly within the imager half of the Platesetter These are PCA Interface PCA Engine Stepper PCA Power Supply Assembly This chapter provides the following information for each PCA location voltages connector and pin assignments replacement instructions Th
169. ide frame must rest on the foam Attach all four wood blocks to the crate by using two wood screws in each block Close the bottom front doors 4 Plastic wrap the entire Platesetter Place cardboard sides and cover over the Platesetter Place ramp on top of the cardboard cover Strap ramp to crate Make sure the ramp top cover and sides are very secure 1 28 INSTALLATION GUIDE This page should be filled out on Installation Serial Numbers and Factory Settings Installation Date Location Serial Numbers Component Serial Model Imager Unit Laser Marker Assy RIP CPU RIP Monitor Setup punch and 2400 dpi values are applicable only if those options are installed Resolution 900 1200 1800 2400 Cut Length Overlap Length Backup Length Punch off Backup Length Punch on Punch Length Punch on Miniplate Backup Length Image Power Processor amp Mini Plate Image Power Cassette MT Speed 1 29 PlateStream eee wees Platesetter Operator Manual Printware LEADERS IN COMPUTER TO PLATE 700550 Rev H COPYRIGHT NOTICE This manual is copyrighted and all rights are reserved Under copyright law this manual may not be copied by any means or in any form in whole or in part without the written consent of Printware Printware Inc makes no representations or warranties with respect to the contents hereof and specifically disclaims any im
170. ift guide from the back of the Platesetter and remove Wash cover E guide F and guide D in warm soapy water and dry using a soft cloth Remove Activator and Stabilizer racks Clean the processor working tanks using warm soapy water and dry with soft cloth Clean Activator and Stabilizer racks using warm soapy water Rotate the rollers and clean them using a soft cloth and warm soapy water Replace the Activator and Stabilizer racks to original positions Replace guides and cover to original position 4 Remove cover G Remove dryer rack by holding the metal edge in the center of the dryer rack lift to clear the two bottom pins and remove Wash cover G and dryer rack in warm soapy water and dry using a soft cloth Replace dryer rack and cover G to original position 5 Close top cover 65 CASE OF TROUBLE CHAPTER 7 TROUBLESHOOTING Print Quality Troubleshooting PROBLEM CAUSE SOLUTION Scumming ghost 1 The press ink fountain Correct the balance images smudges or balance is incorrect blotches on prints due to poor plate surface 2 The press fountain mix 2 Use the recommended fountain solution ture is incorrect or too properly mixed weak 3 The press ink is not com 3 Use the recommended ink patible with the other chemicals 4 The press dampener 4 Adjust the pressure form roll pressure is out of adjustment The press Moleton PONE 5 Replace the cover or sleeve or sleeve is contami
171. ing and final plate checks The Platesetter can image any width from 9 to 13 3 and any length from 12 to 22 The maximum roll length is 280 The media load door is located on the left side of the Platesetter providing quick easy loading of plate material The control panel is an applet on the RIP The control panel keys allow you to perform a number of adjustment and diagnostic func tions and the 8 x 40 character display shows status error mes sages and function menus The power switch is located in the rear of the Platesetter Film With this option the Platesetter can image film and load a take up cassette for processing MiniPlate With this option the Platesetter will impose multiple jobs shorter than the minimum plate length MicroPlate The MicroPlate version of the PlateStream allows plates as short as 8 5 long eliminating plate waste in small format applications Punch With the PunchStream integrated punch option the Platesetter will automatically punch the plate 2400 dpi The high resolution option allows imaging 2400 dpi especially useful for imaging film Infrared With this option the Platesetter will image Infrared 780 nm plate material Effluent Tank This option eliminates the need for direct plumbing of chemical effluence Rear I O panel 12 30 a clearance rear Load Door 30 75 cm clearance left Power Switch EN 31 79 cm k
172. is chapter also includes information about the sensors 28 SERVICE MANUAL NOTE There are no procedures for replacing the SOS and SOT sensors The SOS and SOT sensors are part of the marker assembly and are not replaced separately Controller PCA Grounding Connector PCA A Interface PCA Power Supply Figure S4 1 Location of the PCAs Controller PCA Location and Function The controller PCA is attached to the top of the marker See Figure S4 1 Controller PCA elec tronics perform the following functions control data transmission from RIP to Platesetter control laser intensity 29 SERVICE MANUAL control laser data rate monitor all sensors control galvo control motors The non volatile SRAM memory ofthe controller PCA stores the total plate count the image quality settings specified using the Manual Setup menu on the control panel for both polyester and paper plate material the image position settings and the calibration settings Voltages Supplied to Controller PCA 5 VDC to power all integrated logic chips 24 VDC 12 VDC 12 VDC Connector Assignments J1 Laser power and control J2 Not used J3 Not used J4 Not used J5 Not used J6 Power J7 Laser safety interlock switch 18 Imager Processor Interface J9 Interface PCA control panel communication cable J10 Galvanometer control
173. l Press 4 More Information Press 2 Calibrate Press 1 Calibrate Transport Adjusting Cut Length 1 Measure the distance between points C and D see Figure I 13 2 If the distance between C and D is gt 0 5 1 27 cm decrease the value for Cut Length Adj on the control panel by the difference for example if the measured value is 0 505 and Cut Length Adj is set at 1 955 then decrease Cut Length Adj to 1 950 3 If the distance between C and D is lt 0 5 1 27 cm increase Cut Length Adj by the difference 1 19 Leading Edge Operator Side front of Platesetter Figure 1 13 Adjusting Cut Length and Backup Length INSTALLATION GUIDE Adjusting Backup Length 1 Measure the distance between points A and B see Figure I 13 2 If the distance between A and B is gt 1 200 3 05 cm increase the value for Backup Length Adj on the control panel by the difference for example ifthe distance between A and B is 1 250 and Backup Length Adj is set at 1 350 increase Backup Length Adj to 1 400 3 If the distance between A and B is lt 1 200 3 05 cm decrease Backup Length Adj by the difference 4 Recheck overlap by measuring the width of the black band at the leading edge of the plate 5 The width should be at least 0 050 0 13 cm 6 Ifa silver line a
174. l Sheet 3 of 3 Find Number 001 002 003 004 005 007 Quantity Component Used e Assembly Number 806701 001 ASSY ACTIVATOR TANK Number 806735 001 806774 001 900291 009 901089 003 901083 001 600335 001 Revision D Component Description Parts List Page 1 of 1 TANK ACTIVATOR FITTING DRAIN O RING SCREW TAP FORM STAINLESS 10 24 X 75 FITTING COMPRESSION HEATER BLANKET q Printware Confidential Printware ASSY ACTIVATOR TANK 806701 001 REVISION D Sheet of Find Number 001 002 003 004 e m Assembly Number 806702 001 ASSY STABILIZER TANK Quantity Component Used Number 806734 001 806774 001 90029 1 009 901089 003 Revision C Component Description Parts List Page 1 of 1 TANK STABILIZER FITTING DRAIN O RING SCREW TAP FORM STAINLESS 10 24 X 75 Printware Confidential Printware ASSY STABILIZER TANK 806702 001 REVISION Sheet of Number Find 001 003 004 005 006 008 009 011 012 013 014 017 018 019 020 021 022 023 027 028 Quantity Component Used N N CO OR A e Assembly Number 806708 001 Number 806736 001 806795 001 806796 001 806797 001 900289 003 806782 0
175. latesetter Push the two mounting pins and swing the guide to the left Guide Press up on the two mounting pins Remove the guide by rotating downward Guide D Slide the guide toward the front of the Platesetter Lift the rear of the guide and remove Guide F Remove cover E Slide Guide F toward the rear of the Platesetter Lift the front end of the guide and remove Cover G Use the handle to remove 3 After locating the area of the media jam cut the media from the operator panel Run Hardware Menu 4 Remove all loose media in the Platesetter 4 If media is wrapped around the capstan roller push the load knob in and back up the feed transport rollers from the operator panel More Information Menu 4 To stop the transport roller press the ESC or OFF key 5 Replace all guides to the original positions Gently close the marker and lock it by pushing down the marker lever Reload the plate media 7 12 CASE OF TROUBLE MARKER 7 MARKER LEVER G CAPSTAN LOAD DOOR GUIDE A PINS COVER E GUIDE D GUIDE F MEDIA PATH GUIDE B PINS GUIDE C1 PINS IMAGER EXIT Figure 7 1 Clearing MicroPlate Model Media Path 7 13 CASE OF TROUBLE Calling For Service Overview To avoid most problems keep equipment clean and follow directions on all imaging and printing supplies Attempt to resolve the problem before calling for ser
176. lever towards the front of the Platesetter until lever stops Lift up marker gently Lower marker by gently lowering the marker and lock by pushing marker lever towards the rear of the Platesetter until lever is horizontal See Figure S2 1 Assembly 4 Focus Screw P m m Reversing Mirror Mirror Marker Lever l Folding Lower Cover 4 Lower Cover gt Mirror Screws Galvanometer Screws Figure S2 1 Side View of the Marker SERVICE MANUAL Inspecting and Cleaning Marker Assembly Unit Mirrors CAUTION Marker Assembly mirrors should be inspected and cleaned only if absolutely necessary The marker unit mirrors have a sensitive surface coating and are easily scratched Once a mirror is scratched it is ruined and the entire Marker assembly unit must be returned to Printware for mirror replacement and realignment Overview Under certain conditions it may be necessary to inspect and clean the Marker assembly mirrors Carefully check the condition of the marker Clean only when necessary Normally only the folding mirror the mirror visible through the aperture requires cleaning The laser beam is focused down to a small point when it strikes this mirror and is therefore susceptible to interference from dust or other surface dirt Procedures to Determine if the Mirrors Need Cleaning Ensure that all Platesetter Recommended Periodic Maintenance has been performed
177. lignment depends on the plate width 3 With a 9 64 Allen wrench loosen the two screws on the Operator side and one screw on the Non operator side of the punch assembly see Fig 1 4 4 Centerthe punch pattern on the plate by adjusting the Lateral Adjustment Screw both adjustment screws require a 9 64 Allen wrench Tightening the phillips screw clockwise moves the punch pattern toward the operator side Each turn moves the punch approximately 0 030 0 08 cm Non operator side S o Q N Lateral Adjustmen Skew Adjustment Figure I 4 Lateral and Skew Punch Adjustments 1 22 INSTALLATION GUIDE Punch Skew 1 Refer to Fig I 5 or I 5a for plate measurements If A lt B loosen the 2 locking screws on the Operator side and turn the Skew Adjustment Screw counterclockwise Each turn moves the punch approximately 0 030 0 08 cm If A gt B turn the Skew Adjustment Screw clockwise 2 After adjustment run another plate to check for punch skew 3 Continue adjusting punch skew until the punch pattern is sufficiently parallel to the image 4 Tighten the two locking screws on either side of the punch assembly Operator side notch arid Pattern Non operator side notch lt Lateral Punch Alignment Figure I 5 Punch Alignment and Skew
178. llected in a basket Figure 1 1 Flowchart of the Platemaker Process GENERAL INFORMATION SS 00 Workstation Job stream character codes pluscommand codes gt C QS External RIP File reconfigured commandsinterpreted Workstation Figure 1 2 Interface Between the Host Computer RIP and PlateStream GENERAL INFORMATION Figure 1 3 illustrates the Platesetter media path It uses a four step photographic process 1 Imaging The laser light beam sweeps across the emulsion side of the plate material as it passes the laser marker unit The data generated by the RIP turns the laser on and off When the laser is turned on the portion of the plate exposed to the laser sweep is imaged black the portions of the media not exposed to the laser remain clear or silver During imaging the Start Of Scan SOS sensor on the marker unit counts the number of scan lines being imaged on the plate at the user selected resolution 900 1200 1800 or 2400 scan lines per inch Once the correct number of scan lines have been imaged the marker unit keeps the laser turned on to expose the trailing edge of the plate Once the entire page is imaged the media advances to th
179. llevel oil could have leaked out if the compressor had been tipped 2 Check for air leaks 61 PROCESSOR JAMS Plates jamming at processor entrance SERVICE MANUAL Check that the processor tanks are fully seated Check that the infeed rollers on the activator rack are turning Check that Guide D is properly installed Check that the imager exit switch engages to turn the processor on Adjust the imager exit switch arm COVER E 4 PLACES Correct processor guide placement Media is being bent in processor Verify the wire guides are installed properly they are easy to put in backwards Verify that the media is coming out of imager module straight Check to see if media comes out of the activator rack straight under the crossover guide Adjust activator stop bracket 62 SERVICE MANUAL Short plates jamming in the activator rack One plate comes out of processor and then the messages media did not exit processor and load media both come up 63 N Verify that plate length is within platesetter limita tions 8 5 or 21 cm minimum for PlateStream MicroPlate 12 or 30 cm minimum for all other models Check that the processor wire guides are correctly installed see diagram above for correct proces sor guide placement Verify that the rollers in the activator and stabilizer racks are turning Check processor exit switch in Sensor Status menu Calibrate
180. load door and pull on the load knob Remove the spool assembly from the Platesetter Adjust the two rear edge guides inside the Platesetter by pulling the edge guide knobs up and sliding to the position closest to the plate media width 3 Adjust the two front edge guides by loosening the screws and moving the guides all the way to the front 4 Adjust the left hub on the spool shaft to match the edge guide position by squeezing the clip and sliding on shaft Remove the right hub from the shaft by lifting clip and sliding off the shaft Slide media onto shaft Slide the right hub onto shaft by lifting clip and pushing down on spool until spool is tight against media see Figure 1 2 5 Place the spool assembly on the white receptacles in the Platesetter Feed media through rollers and four edge guides until media stops Adjust the two front edge guides by turning edge guide knobs counterclock wise and sliding edge guide until edge guide rests against plate media Lock edge guide by turning knobs clockwise 6 Push load knob in Gently lower the marker and lock by pushing marker lever towards the rear of the Platesetter until lever is horizontal Close the load door and the top cover 7 Press the load key 5 on the control panel Main menu and wait for plate Set the plate width from the control panel setup menu Image one test plate from the control panel Test Plate menu NOTES Destination must be set to Processor Cut o
181. loth and D Ink Press the OFF key to turn off the exit motor then press the ESC key 6 Press the ESC key again to return to the Main Menu then press the 3 key to return the Platesetter to the on line mode c Replace the front panel Gently lower the marker and lock by pushing marker lever towards the rear of the Platesetter until lever is horizontal Close the top cover 6 4 PREVENTIVE MAINTENANCE Cleaning the Processor Module For optimum performance of the processor module it is important to keep all chemistry filled to the proper levels and clean the machine weekly to prevent a buildup of chemistry on the rollers The processor should be cleaned more frequently if needed to maintain plate quality For Mitsubishi Silver Digiplate the processor should be cleaned if the pH of the chemicals fall outside the recom mended range Activator pH gt 12 8 Stabilizer pH lt 6 8 To clean the processor see figure 6 1 1 Open the top cover Place 6 long 11 4 diameter 182 cm by 3 2 cm vinyl hose from underneath the processor in the optional effluent tank Drain the processor working tanks by removing the overflow tubes located in the rear of the processor tanks inside the Platesetter Removecover E Remove guide F by pressing guide towards the back ofthe Platesetter lift guide from the front ofthe Platesetter and remove Remove guide D by pressing guide towards the front of the Platesetter l
182. ment Electrical Requirements 220 240V 50 60Hz 4400 VA Temperature 65 F 80 F 18 C 27 C operating 40 F 150 F 40 C 65 C non operating A 4 APPENDIX CALIBRATION CALIBRATION Introduction This appendix provides tips for calibrating the PlateStream Following these procedures will provide the bestresults especially when printing screens Calibration has two major steps I Setting maximum density D in solid black areas by adjusting the laser power II Linearization ofthe dot percentage transfer curve by calibrating the RIP PlateStream users doing critical screens have found it helpful to calibrate the platesetter weekly or more often if required and replace the processing chemistry every two weeks or more often if required I Setting Maximum Density Before calibrating dot density maximum density D is set by adjusting laser power from the PlateStream operator panel There are several ways to do this A Using an exposure file l From the RIP run file 805346 1 ps using the lowest resolution that your PlateStream is set up for i e 900 or 1200 DPI Use a page setup from the RIP that corresponds to this lowest resolution 2 With the unaided eye look at the 1x1 2x2 3x3 4x4 and 8x8 checkerboard patterns 3 Ifall 5 patterns look the same density the same grey level the image power is correct 4 Ifthe patterns get lighter grey going from 8x8 to 1x1 with 1x1 being the lighte
183. n the PCA Bubble wrap the ends of the disconnected cables Prepare to remove marker a Raise marker by pulling marker lever towards the front of the Platesetter until lever stops and lift the front of the marker Place a 21 by 1 53 cm by 2 5 cm piece of tape on the bottom of the laser marker over the slot for the laser light Detach the strut on the laser end while holding the marker in the upright position and removing the cap and pulling strut off the ball joint d Fasten C shaped black handle to the laser right end of the marker with eight screws Detach the strut from the galvo left end of the marker Reattach cap to struts 3 Remove marker 1 27 Place blue plastic bag and two DESI PAK bags the marker assembly carton with the bag laid open Remove the marker from the Platesetter using two people Slide the marker assembly off the brass pivot bushing located furthest from the processor section left without moving the bushing Slide the marker assembly off the brass pivot bushing located closest to the processor right without moving the bushing INSTALLATION GUIDE 4 Place marker in carton a Place the marker assembly in the blue plastic bag with the laser end placed in the location shown on the drawing that is attached to the bottom of the carton b Fold the blue plastic bag around marker and tie wrap shut 4 Place flat cardboard cover with the four S
184. n the lower half of the control panel Main Menu when one or both of the replenishment tanks are low on chemistry The message LOW WORKING will appear on the lower half of the control panel Main Menu when one or both of the processor working tanks are low on chemistry The message HIGH EFF will appear on the lower half of the control panel Main Menu when the optional effluent tanks is full Once per week remove all chemistry and clean the processor section as described in Chapter 6 Preventive Main tenance Procedure 1 Open the top cover and remove bottom front panel Remove cover E Gently roll out cart s from underneath the processor See figure 3 1 If necessary prepare the Activator and Stabilizer solutions in the plastic replenishment tanks following the manufacturer s instructions Remove probes from the replenishment tanks by unscrewing the white cap Fill the processor working tanks inside the Platesetter and the replenishment tanks with the proper chemistry Reinstall the probes into the replenishment tanks Make sure the activator tanks are filled with activator and the stabilizer tanks are filled with stabilizer Place cover E over processor working tanks Close the top cover Remove the probe and vinyl hose from the optional effluent tank Remove the optional effluent tank and empty it Be sure to dispose of or recycle the spent chemistry in accordance with local regulations Reinstall the probe an
185. n the processor working tanks using warm soapy water Drain and clean the hoses 1 26 INSTALLATION GUIDE 4 Package inside of processor a ugs Place 2 plated metal or plastic Styrofoam pieces in the front operator side of the processor working tanks Place 2 non plated Styrofoam pieces in the rear non operator side of the working tanks Replace the activator and stabilizer racks and tape them down Replace Guide D Bubble wrap cover E guide F and overflow tubes and tape to the top of the working tanks Package Carts a b f Roll out the replenishment cart and the optional effluent cart Remove probes from plastic replenishment tanks and optional effluent tank air blow dry and place them in the plastic clip located up underneath the processor section Empty tanks per local environmental codes Individually bubble wrap the cart s and tanks Place cart s in accessory box 1 and tanks in accessory box 2 Seal accessory box 2 Remove 6 long 1 4 diameter 180 cm by 3 2 cm vinyl hose from underneath the processor Place in accessory box 1 Close the bottom front doors B Package the marker 1 Disconnect cables a b 4 b Disconnect the grounding strap from the imager section frame Disconnect the 10 wire connector from J6 on the printed circuit assembly PCA located on top of the laser marker assembly Disconnect the ribbon cable s from J8 on the PCA and J9 o
186. nal Features of the PlateStream Platesetter Construction of the Platesetter The five major component areas of the Platesetter are Imager Assembly Marker Power Supply Assembly Cables and Electronics Processor Imager Assembly The Imager Assembly consists of the following Spool Assembly Feed Rollers and Stepper Motor Drive System Capstan Roller Left and Right Pinch Rollers Capstan Pinch Roller Stepper Motor Drive System Cutter Upper and Lower Imager Exit Rollers and Stepper Motor Drive System SERVICE MANUAL Marker This section consists of the following Marker Assembly Includes Laser Diode Laser Lens Assembly Galvanometer Mirrors SOS and SOT Sensors Power Supply Assembly The power supply assembly consists of the following Power On Off Switch 20 Amp Circuit Breaker Electromagnetic Interference EMI Filter Power Distribution PCA Cooling Fan Multi output Power Supply External Connectors J1 J5 Cables and Electronics This group of components consist of the following Controller PCA nterface PCA Processor PCA Stepper Motor PCA Processor This group of components consist of the following Activator Tanks and Rack With Rollers Stabilizer Tanks and Rack With Rollers Dryer Drive System SERVICE MANUAL CHAPTER 2 MAINTENANCE For physical calibration procedures see the PlateStream Platesetter Installation Guide This chapter identifies which su
187. nd edit calibration sets and to enable or disable particular sets Xitron RIP xiton Edit Preview Color Output Fonts Eire Ie psc s Calibration Dot Gain Manager displays calibration sets grouped by device When you select from the Device drop down list all ofthe existing calibration sets for that device are displayed The basic calibration steps are as follows see the RIP manual for detailed procedures 1 Select Print Calibration to print an uncalibrated target see Figure 2 B4 CALIBRATION tus ruptor areo rtr emt Y Tie di 3 m Fei May 55556 120522 Figure 2 Calibration Target 2 Measure the density of each square ofthe target with the densitometer Note that the densities marked on the target are reversed e g the 10 square will be marked 90 Tip Some densitometers require special procedures to measure densities of less than 10 consult your densitometer manual 3 Click New to create a new calibration set for the first time The RIP manual describes how to useall the items in the Edit Calibration dialog box but the essential items are as follows a Set the PlateStream for negative right reading b Set Measurements as negative dot c Check Negative media for film plate material is positive media d Check Force solid colors indicating that the PlateStream is a halftone device e Enter the dot percentages from the densitome
188. nner covers other than described in this manual Construction and Function of the Marker Assembly Unit The marker assembly unit consists of a frame top cover lower cover laser lens assembly galva nometer reversing mirror spherical mirror folding mirror SOS sensor and SOT sensor The laser diode produces infrared light and is highly sensitive to ESD damage The galvanometer resonates at 540 Hz in a sealed vacuum chamber The marker assembly unit is mounted in an outer frame which is attached by two hinge assemblies to the Imager section chassis The controller PCA is mounted on the top of the marker assembly unit There is a lithium battery backup RAM on the controller printed circuit board U178 on 522980 XXX located on the top of the assembly This RAM lithium battery is not field replaceable Refer to the PlateStream Platesetter Installation Guide for the installation of a new marker When new marker assembly unit is installed in a Platesetter the new marker assembly unit calibration settings must be stored in the non volatile SRAM memory by the controller PCA This section describes the calibration setting storing procedures Recalibrating the Marker Controller PCA At the main menu press 4 to access the More Information menu Press 2 to access the Calibrate menu Press 2 to calibrate Marker The control panel will display are you sure Pressing ESC exists this menu without changing the marker cal
189. nsert the loaded spool assembly back into the feed cassette with 12 of film remaining outside the cassette 5 Place the feed cassette onto the platesetter cassette mounting brackets 6 Feed film through the 1 set of rollers and two edge guides 7 From inside the platesetter push the film up through the next edge guide and into the nip of the pinch roller 8 Set the front edge guides up against the film and tighten the screws 9 Remove guide D by pressing the guide towards the front of the Platesetter Lift the guide from the back of the Platesetter and remove 10 Install the takeup cassette and align cassette pins to receptacles locking cassette into place See figure 3 5 11 Gently lower the marker and lock down by pushing the marker lever towards the rear of the Platesetter until the lever is horizontal Close the top cover 3 12 PREPARING FOR OPERATION 12 Set destination in set up menu to cassette mode Set the plate width from the control panel setup menu Optional Adjust the feet remaining feature on the control panel input spool manager menu 13 Pushthe load knob in This will automatically load the film materia Immediately close the load door The control panel must be in the main menu or the test plate menu for this automatic feature to work NOTE Pressing the load key 5 on the control panel Main menu will also start the load film process 14 Image one test plate from the ctrl panel Test Plate m
190. nsult the recommended supplies list that came with your Platesetter system All supplies should be stored in a cool dry area The use of low grade or improperly stored media will result in print quality problems 12 There is a lithium battery in the battery backup RAM on the laser controller board U17 on 522980 XXX mounted to the top of the laser marker unit This lithium battery is not replaceable Dispose of or recycle all printed circuit boards properly WARNING Performing procedures adjustments or using controls in a way other than those specified in this manual can cause hazardous laser radiation exposure electrical hazards or damage to the Platesetter 1 8 CONTROL PANEL CHAPTER 2 The Control Panel The control panel is an applet that runs on the RIP The control panel program starts automati cally when the RIP is powered up Figure 2 1 illustrates a flowchart of the control panel menus The panel consists of an 8 x 40 character display which shows status messages and menu options and the following 18 keys an ON key e an OFF key an ESC key an ENTER key 4 arrow keys 10 numeric keys numbered 0 9 These keys allow you to perform a variety of functions To select an item move the cursor over the corresponding numeric key with the mouse and push the left mouse button to press the key To scroll through the choices of the selected item press the ON or OFF keys To change numbers in
191. nt and rear panels 24 SERVICE MANUAL Replacing the Imager Exit Rollers Imager Exit Motors and Imager Exit Belts See Figure S3 1 1 Open the top cover and raise the marker assembly Remove the back panel 2 Remove the bracket holding the pulley by unscrewing the three screws holding the bracket Remove the bracket holding the motor by unscrewing the four screws holding the bracket 3 Rotate the I shaped bracket located behind the pulley 90 and then slide the belts off of the gear 4 To replace belts install new belts in reverse order 5 To replace motor disconnect the cable from the motor Remove the motor from the bracket Install new motor in reverse order Adjust drive belt tension by adjusting set screw on the motor shaft and or pulley shaft 6 To replace rollers remove the pulley from the roller shaft by removing E clip Remove the E clips and spacers if any from each end of the lower shaft Remove the bushings from each end of the roller shaft Access the upper roller from the top of the Platesetter Remove Guide C by pressing down on the four pins Remove the upper roller by sliding towards the rear of the Platesetter until it clears the frame Access the lower roller from the front side of the PlateStream Press down on the two Guide B pins and swing Guide B to the left Remove the lower roller by sliding towards the front of the Platesetter until it clears the frame 7 Install the new rollers in reverse o
192. oPlate model 6 Miniplate Backup Enables calibration or elimination of the gap between jobs in Miniplate mode see Physical Calibration in the INSTALLATION GUIDE It also adjusts the gap between jobs in Cassette Mode 7 Guide B Turns the Guide B sensor On OFF The sensor should be ON to detect jams unless the sensor is damaged 8 Punch Only if punch option installed turns the punch on and off 9 Auto Load When ON the media will automatically start to load about 2 seconds after the LOAD knob is push in only if the main menu is selected 2 10 CONTROL PANEL Run Hardware Menu Run Hardware ESC to exit Feed Motor OFF 7 Reset Proc Transport Motor OFF 8 Start Proc Exit Motor OFF 9 Prime Pump Cut Plate Shutter Close Punch Plate ON ESC OFF 1 Feed motor Turns on or off the feed stepper motor 2 Transport motor Turns on or off the capstan motor 3 Exit motor Turns on or off the Imager Exit motor 4 Cut Plate Cycles the cutter 5 Shutter Opens and closes the shutter 6 Punch Plate Cycles the Punch 7 Reset Proc Stops the processor and resets all of the counters 8 Start Proc Starts the processor to test for functionality of this section 9 Prime pump Turns on the processor pump for approximately five minutes 2 11 CONTROL PANEL Calibrate Menu Calibrate ESC to exit 1 Calibrate Transport Calib
193. ocedures detailed in this section to calibrate Platesetter for production at the customer site Be sure to follow these procedures in the order presented Before performing these calibration procedures make sure the Platesetter is in its final location and that it has been properly leveled Once set these calibrations should not have to be repeated unless a problem is noticed If any of the orange torque seals on the screws are broken the Platesetter warranty is void Cutter Skew Plates must be cut square in order to avoid problems with image position straightness and registration when mounted on the press The cutter will pivot at the front of the Imager and can be moved toward or away from the capstan roller at the rear of the unit 1 To determine plate cut squareness print either a grid pattern or a solid pattern from the RIP 2 Once the plate has been imaged and processed measure and compare the diagonal distance of opposite corners of the cut plate see Figure I 3 3 If the plate is square within specification skip the remaining steps and go on to the Transport Skew procedure UJ Leading Edge 4 Remove the back cover from the Platesetter Locate the cutter bracket and note the current position of the cutter a reference line will be inscribed on the bracket at the factory 5 Loosen the two 9 64 Allen cap screws If angle A is lt 90 tighten adjustment screw If angle A is gt 90 loosen adjustment s
194. on the spool shaft to match the edge guide position by squeezing the clip and sliding on shaft Remove the right hub from the shaft by lifting clip and sliding off the shaft Slide media onto shaft Slide the right hub onto shaft by lifting clip and pushing down on spool until spool is tight against media see Figure 3 3 Place the spool assembly on the white receptacles in the Platesetter Feed media through rollers and four edge guides until media stops Adjust the two front edge guides by turning edge guide knobs counterclockwise and sliding edge guide until edge guide rests against plate media Lock edge guide by turning knobs clockwise Gently lower the marker and lock down by pushing the marker lever towards the rear of the platesetter until the lever is horizontal Close the top cover Set the plate width from the control panel setup menu Push the load knob in This will automatically load the plate material Immediately close the load door The control panel must be in the main menu or the test plate menu for this auto matic feature to work NOTE Pressing the load key 5 on the control panel Main menu will also start the load film process 9 Image one test plate from the control panel Test Plate men Note Destination must be set to Processor see section Control Panel Set up menu PREPARING FOR OPERATION NOTES Destination must be set to Processor see chapter 2 in the section Setup Menu Media must b
195. onal Feed and Take up Film Cassettes 3 14 4 OPERATING THE Making a Plate Controlling Image Quality To maintain optimum print quality use only recommended media and processing chemistry and store all supplies properly Also perform the preventive maintenance procedures detailed in Chap ter 6 to keep the Platesetter clean and in proper operating condition Be sure all Platesetter covers are completely closed when making plates Once per week or more often if conditions require print a test plate and inspect the print quality If image quality problems are noticed perform the following adjustments Image quality problems may include slight changes in character stroke width image density or background density Refer to your RIP reference guide for instructions on printing a test plate Inspect the plate If image quality problems are found adjust the exposure as described in the next section Adjusting Exposure Laser Intensity See CALIBRATION in Appendix B 42 OPERATING THE PLATESETTER Responding to Control Panel Error Messages This section shows the different error messages which may be displayed on the Platesetter control panel Next to each error message is the cause and the most probable solutions When more than one solution is listed try the first solution first if it does not correct the problem then try the next solution Once the problem is corrected press the
196. ool was loaded 1800 dpi Current resolution Line 7 NO MEDIA No media detected at sensor closest to input spool LOW WORKING Either or both of the processor working tanks low TAKEUP FULL The takeup cassette counter has counted down to 0 starts at 26 or 8 m when media is loaded may also be manually set INTERLOCK OPEN The marker is in the raised position LOW PROC TEMP The processor is not up to specified temperature yet HIGH EFF The effluent tank is full LOW REPL Either or both of the replenisher tanks are empty CONTROL PANE L PROC Imager destination lower right corner of operator panel PROC MINI MINI3 CAS 500 CAS21 Setup Menu Imager is in processor mode Imager is in miniplate mode there are No accumulated miniplates in the imager Imager is in miniplate mode there are 3 accumulated miniplates in the imager if there are more than 9 accumulated miniplates the digit changes to a Imager is in cassette mode and the media has not yet been loaded Imager is in cassette mode the media has been loaded but no plates have been imaged yet Imager is in cassette mode and 21 plates have been imaged so far Setup ESC to exit 2 Input Spool A Destination Processor Display Units English 1 Image Negative Right Reading 2 Resolution 800 DPI 1 Image Power 2 5 6 yi 5 Media Width 13 12 Spool Pos 13 ON ESC
197. ower cord located in the rear of the machine per electrical wiring codes Assembling the Processor 1 Remove black tape holding the activator and stabilizer racks Remove the four styrofoam pieces located in the front and rear of the processor working tanks inside the Platesetter Remove bubble pack wrapped around Cover E Guide F and overflow tubes 2 Place the overflow tubes in the large holes located in the rear of the processor working tanks inside the Platesetter Press down until overflow tubes stop Place the spring pin from Guide F into the hole located in the rear of the activator tank while placing the other pin into the hole located in the rear of the stabilizer tank Slide Guide F towards the rear of the Platesetter while placing pins on the other side of Guide F into the holes located in the front of the activator and stabilizer racks INSTALLATION GUIDE Place the two replenishment tanks the optional smaller cart Place the optional effluent tank on the optional larger cart Ifnecessary prepare the Activator and the Stabilizer solutions in the replenishment tanks following the manufacturers instructions Fill the processor working tanks inside the Platesetter and the replenishment tanks with the solutions Make sure the activator tank is filled with activator and the stabilizer tank is filled with stabilizer Place Cover E over processor working tanks Open the bottom front doors Remove the bubble pack from
198. pendently for each resolution NOTE The 900 dpi values must be set even if 900 dpi is not used in order for the first plate after loading media to be accurately punched 900 dpi settings are used to speed loading Density Dot Calibration See the OPERATOR S GUIDE Appendix B for Density Dot Calibration procedures 1 25 INSTALLATION GUIDE De Installing the Platesetter These instructions are provided in the event you ever need to repackage the Platesetter 1 Turn off the Platesetter and RIP 2 Disconnect video interface cable from the rear of the Platesetter Packaging the Platesetter A Package the processor section 1 Open the top cover and remove the optional film take up cassette Bubble wrap the cassette and place in accessory box 1 2 Drain processor a b Open the bottom front doors and place the 6 long 1 diameter 180 cm by 3 2 cm vinyl hose from underneath the processor in the optional effluent tank Drain the processor working tanks by removing the overflow tubes located inside the Platesetter top section to the rear of the processor tanks 3 Clean processor a b Remove cover E Remove guide D Press guide towards the front of the Platesetter lift guide from the rear of the Platesetter and remove Remove guide F Press guide towards the rear of the Platesetter lift guide from the front of the Platesetter and remove d Remove Activator and Stabilizer racks Clea
199. plate Mode ON from the Main Menu on the control panel Press 1 Setup Press 6 Destination Select Processor Miniplate as the output destination 2 To enable Miniplate Backup from the Main Menu on the control panel Press 4 More Information Press 6 Miniplate Backup Press ON to turn Miniplate Backup ON enabling calibration of the gap between Miniplate jobs Press 5 to select Miniplate Cut Length Set to the intended plate length e g 12 then press ENTER to save 3 To run a test plate from control panel Main Menu e Press 2 Test Plate e Press 3 Choose Length Set to the approximate intended length of the Miniplate jobs e g 4 then press ENTER to save e Press 2 Choose Pattern Use the ON key or the OFF key to scroll through the patterns Select the Screen pattern then press ENTER to save e Press 1 Run XX Plates Enter the number of jobs per miniplate Press ENTER to image a Miniplate test plate Press ESC to return to the Main Menu 4 To calibrate the gap between Miniplate jobs from the More Information Menu Press 2 to go to the Calibrate Menu Press 1 Calibrate Transport Press 7 Miniplate Backup Length Adj 5 To decrease the gap between jobs increase the value for Miniplate Backup Length Adj on the control panel To increase the gap decreas
200. plied warranties of merchantability or fitness for any particular purpose In addition Printware reserves the right to revise this publication and to make changes from time to time in the content hereof without obligation of Printware to notify any person of such revisions or changes 1998 by Printware Inc IBM and PC are registered trademarks of International Business Machines Corporation ZipRip ZAPrip and Printstyle are trademarks of Printware Inc Macintosh and AppleTalk are registered trademarks of Apple Computer Inc PostScript is a registered trademark of Adobe Systems Incorporated Futura is a registered trademark of the Fundicion Typografica Neufville SA Times is a registered trademark of the Linotype Company Printstyle is licensed to make use of the PostScript page description language copyrighted by Adobe Systems Inc PRINTWARE INC 1270 Eagan Industrial Road St Paul MN 55121 Phone 651 456 1400 Part Number 700550 Rev June 29 1999 The camera ready master for this manual was generated on a Printware Laser Imaging System and an IBM compatible PC CAUTION electronic circuitry inside the Platesetter is very sensitive to damage from electrostatic discharge ESD Always follow the ESD protective procedures described in this manual when working on the Platesetter FEDERAL COMMUNICATIONS COMMISSION FCC NOTICE Printware Platesetters generate and use radio frequency If not installed properly
201. ppears increase the value for Overlap Length Adj on the control panel Adjusting Fogging Edge LED The Edge Fogging LED accompanies the punch option It fogs approximately 0 2 on the operator side of the plate allowing a fully fogged 13 4 plate The intensity of the Edge Fogging LED determines the width of the fogging The Edge Fogging LED is located on the operator side guide the Edge Fogging LED intensity adjustment is located on the operator side of the chassis The procedure to adjust the intensity is as follows 1 To enable Edge Fogging from the Main Menu on the control panel Press 4 More Information Press 8 Edge LED Press ON to turn the Edge Fogging LED ON 2 Run a 13 4 wide plate and check the operator side plate edge to see if it is fully fogged black 3 Ifthe fogging band width is too wide or too narrow locate the Edge Fogging LED intensity adjustment see Fig I 14 4 To increase the fogging band width increase the LED intensity by turning the adjustment clockwise To decrease the fogging band turn the adjustment counterclockwise Edge Fogging Intensity Adj Figure I 14 Edge Fogging LED intensity adjustment operator side of chassis 1 20 INSTALLATION GUIDE Adjusting Miniplate Backup Length Miniplate Backup Length can be used to adjust or eliminate the gap between Miniplate jobs It also adjusts the gap between jobs in the Cassette Mode 1 To turn Mini
202. pport by tele phone or FAX message Toll free U S A only 1 800 456 1400 FAX Number 612 454 3684 Be prepared to provide Technical Support with the following information Customer name Platesetter serial number Marker serial number Description of print quality problems you are having Description of Folding Mirror surface cleanliness Steps you have taken Request to remove Marker lower cover to inspect and possibly clean the other mirrors If appropriate Technical Support will authorize you by telephone or FAX message to remove the marker assembly unit lower cover to examine the other mirrors and to clean these mirrors if neces sary Technical Support may also offer suggestions to correct the print quality problem other than mirror cleaning 10 SERVICE MANUAL Inspecting the Galvanometer Window Reversing Mirror Spherical Mirror and the Folding Mirror Get authorization to remove the marker lower cover See the previous procedure Open the top cover and raise the marker Remove the marker lower cover by unscrewing the 4 Allen head screws with flat washers located underneath the marker Refer to Figure 52 1 This will break the warranty void seals Inspect the surfaces of the galvanometer window the reversing mirror the spherical mirror and the folding mirror Refer to Figure 52 1 If no dust particles or other particles are present on the mirror surfaces reinstall the marker assembly unit lower cover
203. pring around one additional turn 3 2 Temporarily disable traction control to see if this solves the problem 4 Noisy capstan motor causes high frequency horizon tal banding down the whole length of plate 4 1 Check capstan motor mounting 4 2 Replace capstan motor 5 Noisy power supply fan Artifact will be a constant frequency down the page 5 1 Check fan motor mounting 5 2 Replace power supply fan motor 6 Ifunable to diagnose the problem send two plate samples to Printware for analysis Vertical artifacts 1 Wavy vertical lines throughout media or more severe on the non operator side of plate generally low frequency on the order of 10 artifacts per inch Usually a faulty galvanometer Replace marker assembly 2 Wavy high frequency on the order of 100 artifacts per inch vertical lines concentrated in the middle of the plate Usually a faulty controller PCA 3 Well defined straight vertical lines Usually a faulty controller PCA 45 SERVICE MANUAL IMAGE QUALITY PROBLEMS ARTIFACTS cont Fuzzy or Blurry Image 1 Clean processor and replace chemistry see Operator Manual S 2 Inspect marker mirrors and clean if necessary see 3 Chapter 2 SZ 3 Adjust laser focus see Chapter 2 White black or silver streaks 1 Set Density Dot calibration see Installation Guide 2 Increase exposure control panel setup menu 3 Inspect marker mirrors and clean if necessary see Chapter 2
204. pts the user just to back up and not cut after certain errors 1 Adjustthe cutter infeed guides 2 Adjust the cutter blade see procedures under Cutter cycles but doesn t cut SERVICE MANUAL IMAGER MODULE SENSOR PROBLEMS Guide B Sensor blocked Guide B Sensor faulty Ensure that the cable harness under Guide A is plugged into the switch Check for any pieces of media that may be stuck in the punch Remove the rear panel and use a flashlight to see if there are any scraps of media in the punch cutter path If there is no media blocking the guide B sensor the switch may be damaged From the Operator Panel go to the Sensor Status menu to test the switch Open top cover Lift capstan guide arm and separate the capstan roller from the pinch roller on the exit side of the imager Push a piece of paper through these rollers and the center of the punch assembly over the switch The Sensor Status should toggle between 1 and 0 as you activated and deactivate the switch Current firmware will show a 1 when engaged and a 0 when disengaged Older firmware may show the opposite status numbers but will still toggle between them Move the paper over the switch several times while watching the sensor SENSOR STATUS LOAD KNOB 0 FEED LOOP 00 EXIT LOOP 0 IMAGER EXIT 0 NO MEDIA 00 LOAD OK 00 x GUIDE B Sensor ESC to exit WRKNG TANK LOW REPLN TANK LOW EFFL TANK HIGH PROC T
205. pushing the marker lever towards the rear of the Platesetter until lever is horizontal INSTALLATION GUIDE 13 Remove bubble pack from cables Connect the cables to the marker assembly as follows Connect the grounding strap from the rear of the marker assembly to the Imager unit frame Connect the 10 wire connector to connector J6 on the printed circuit card PCA assembly located top of the marker assembly Connect the ribbon cable from the rear I O panel to connector J8 on the PCA Connect the ribbon cable from the harness assembly to J9 on the PCA 14 Align the bottom front doors by adjusting the buckle located inside the doors Turn the buckle clockwise to move door in and turn the buckle counterclockwise to move door out Make sure all casters are touching the floor If not adjust the front right casters as necessary so that they do touch the floor 15 Open accessory boxes and remove bubble pack from contents The contents should include The and PlateStream manuals on CD s Two plastic replenishment tanks and optional small replenishment cart A wire tray Two media spools and one media shaft Optional large effluent cart and optional effluent tank Optional take up and feed cassettes Drain hose with clamp Tube with plate samples So 16 Insert wire tray into slots located on the top right side of the Platesetter Attach customer supplied power plug to Platesetter p
206. r hood temperature potenti ometer R43 instructions on end panel SERVICE MANUAL PRESS RELATED PROBLEMS refer to troubleshooting guides for supplies for most press problems Short run length 1 Check press roller settings Recommended settings for most presses are Form to Plate stripe 1 8 3 mm Plate to Blanket stripe 3 16 5 mm 2 Verify that exposure is set correctly by checking D Laser power too high can cause short run lengths 3 Reduce laser power 72 CABLE 807150 001 CABLE 803321 001 CABLE J1 NU
207. rate Marker Tapit Spool Manager arker Position 00 00 Save Imager Setup to Load Imager Setup from RIP Edge LED OFF ON ESC OFF ENTER 1 Calibrate Transport Provides access to the Calibrate Transport menu 2 Calibrate Marker Sets the marker to perform a full calibration the next time the machine is powered up 3 Input Spool Manager Provides access to the Spool Manager menu 4 Marker Position Adjusts the side to side image position up to 0 05 0 13 cm Increas ing the value moves the imager away from the operator side decreasing the value moves the imager towards the operator side to accommodate the physical position of the marker 5 Save Imager Setup to RIP Saves the imager setup data to the RIP hard drive 6 Load Imager Setup from RIP Reloads the imager setup data from the RIP hard drive 7 Edge LED Only if 34cm option installed turns on the Edge Fogging LED which exposes approximately 0 2 on the operator side of the plate The Edge LED should normally be OFF for plate widths of 13 3 or less and ON for plate widths more than 13 3 allowing a fully exposed 13 4 plate CONTROL PANEL Calibrate Transport Menu Calibrate Transport ESC to exit Calibrate Processor Manual Length Adj 0 000 Cut Length Ad 1 950 Backup Length Adj 1 350 Punch Length Adj 1 500 Miniplate Backup Len Adj 0 134 1 2 3 j Overlap th Adj 0 750 6 7
208. rature if the potentiometer is blue Turning the screw coun terclockwise increases the temperature if the potentiometer is grey 13 Check to verify that the dryer temperature is 115 F 46 C nominal The dryer temperature can be changed by adjusting a potentiometer R43 on the PC board Turning the screw clockwise increases the temperature if the potentiometer is blue Turning the screw counterclockwise in creases the temperature if the potentiometer is grey 14 Printed circuit board removal Remove the wire tray located on the right side of the Platesetter Remove the right exit panel by unscrewing the four screws holding this panel Disconnect all the connectors There are nine quarter turn plastic standoff screws that hold the board on the printed circuit board bracket Rotate these screws 1 4 turn to free the board 15 Dryer heater element removal Remove the wire tray located on the right side of the Platesetter Remove the right exit panel by unscrewing the four screws holding this panel Remove the blower and mounting bracket There are 4 rubber isolators used to mount this assembly Remove the vertical cover panel that forms a part of the dryer plenum The heater is mounted on the inside of this cover 16 SERVICE MANUAL _ Marker Lever Interlock Bracket Activator Rack x 3 Dryer Belts a Dryer Drive Clutch Rack Drive Gear Drive Motor Belt Drive Shaft Worm Gear Figure S2 3
209. rder 25 SERVICE MANUAL Cutter Assembly Construction of the Cutter Assembly See Figure S3 1 The cutter assembly consists of a frame DC motor and position sensor 1 Open the top cover and raise the marker 2 Disconnect the cutter cable assembly 3 Remove the 4 Allen head screws which hold the cutter to the plate 4 Access the cutter assembly from the top of the Platesetter and remove 5 Install the new cutter in reverse order Replace the rear panel Lower the marker and close the top cover Replacing the Processor Rollers See Figure S2 2 S2 3 There are thirteen rollers six in the activator rack and seven in the stabilizer rack 1 Open the top cover 2 Remove Cover E Remove Guide F by pressing guide towards the rear of the Platesetter lift guide from the front of the Platesetter and remove Remove Guide D by pressing the guide towards the front of the Platesetter lift the guide from the back of the Platesetter and remove 3 Remove the rack from the Platesetter 4 Remove the gear from roller by loosening one set screw Remove the spring if any and the bearing if any 5 Remove the roller by sliding the roller towards the front of the rack until it clears the frame 6 Install the new roller in reverse order Close the top cover 26 SERVICE MANUAL Replacing the Marker Unit CAUTION The Marker Housing contains potentially harmful invisible laser energy Do not attempt to open the i
210. rdware menu 4 1 If the shutter solenoid isn t operating check the solenoid with an ohmmeter for a short or open its resistance should be approximately 55 ohms If the solenoid is open or shorted replace the solenoid 4 2 If the solenoid is OK but not being actuated replace the 4 3 If the solenoid is actuating but the shutter isn t fully opening check that the moveable arm moves freely 4 4 If the moveable arm doesn t move freely loosen the screws that control the arm until it moves freely SERVICE MANUAL GENERAL IMAGER PROBLEMS cont Light leaks On models with a load door the door is the most common source of light leaks Open the load door and look down to the bottom of the chassis Shine a flashlight into the gap between the load door and the bottom skirt If light is visible seal the gap between the load door and the bottom skirt with black electrical tape On models without a load door check the light seals around the panels and cassettes with a flashlight Move the platesetter away from bright light sources such as windows If this is not possible orient the platesetter with the processor end is away from light sources If unable to resolve the problem send sample plates to Printware Send 22 long plate with a gray test pattern 54 SERVICE MANUAL GENERAL IMAGER PROBLEMS cont No media or Media not loaded far enough messages 55 Verify that
211. re 6 1 Side View of the PlateStream Platesetter 6 3 PREVENTIVE MAINTENANCE CAUTION Be very careful when working on or around the Imager rollers with the machine running especially when wearing a tie or loose fitting sleeves to avoid getting anything caught between the rollers oe oe oe oe oe oe oe oe oe oe oe oe oe 2 From the Main Menu display on the control panel press 4 and then 1 to access the Run Hardware Menu 3 Turn on the feed motor by pressing the 1 key and then the ON key Access the feed rollers from the top ofthe Platesetter As the feed rollers are rotating clean them using a soft cloth and D Ink See Figure 6 1 Press the OFF key to turn off the feed motor then press ESC 4 Turn on the capstan motor by pressing the 2 key and then the ON key Access the rollers from the top ofthe Platesetter and open the shutter As the pinch and capstan roller are rotating clean them using a soft cloth and D Ink Press the OFF key to turn off the transport motor then press ESC 5 Turn on the imager exit motor by pressing the 3 key and then the ON key Access the upper roller from top of the Platesetter Remove the front panel to access lower roller from the side of the Platesetter As the imager exit rollers are rotating clean them using a soft c
212. re I 1 INSTALLATION GUIDE Turning On the Platesetter 1 The power switch for the Platesetter is located on the rear of the machine To turn on the Platesetter flip the switch up see Figure I 1 Each time the Platesetter power switch is turned on the Platesetter performs a series of tests of its internal components If an error message appears on the control panel see the section Responding to Control Panel Error Messages in the PlateStream Operator Manual If the display stops at any initialization point for more than five minutes turn off the Platesetter and call for authorized service Platesetter boot up procedure takes approximately four minutes If best absolute accuracy is re quired allow six hours for the Platesetter to reach operating temperature Once the power up sequence is successfully completed the control panel screen will show the main menu with On Line mode indicated and no error messages displayed Right processor Rear I O panel 12 30 cm clearance rear Load Door 47 119 cm 30 75 cm 24 60 clearance left 60 cm clearance rt al Power Switch 31 79 em 59 30 75 clearance front Figure 1 1 Location of the Power Switch the Platesetter INSTALLATION GUIDE Loading Plate Media 1 Open the top cover Raise marker by pulling marker lever towards the front of the Platesetter until lever stops Lift up marker gently 2 Open
213. rfaces that have particles attached to them Be sure that only the webril wipes comes in contact with mirror surface Wipe the mirror with a steady slow pace in one direction Use the same method on the galvanometer window Do not clean mirror surfaces or the galvanometer window surface unnecessarily If a surface is clean leave it alone The mirrors and the galvanometer window have thin fragile surface coatings that can be very easily rubbed off Once the surface is rubbed off the mirror is ruined and the entire marker assembly will have to be returned to Printware for repair If spots other than dust particles are present apply only enough pressure to remove these spots It is better to under clean than to over clean a mirror surface If the tissue becomes dirty use a new piece of tissue soaked with acetone 2 Examine each surface with a flashlight to ensure that the entire surface is clean 3 Reinstall the Marker lower cover Do not operate the Platesetter with the lower cover removed Lower the marker and close the top cover Print plates to determine if print quality has improved Marker Focus adjustment Procedure 1 At 1200 DPI image a 12 long 4 pixel on focus test plate from the control panel Test Plate Menu 2 Inspect the plate under an eye loop at least 15 power Observe the cross hairs and the small dots Note that there are 2 patterns one is the negative of the other 3 Open the top imager s top cover an
214. s formed 0 indicates that a loop is not present EXIT LOOP Indicates the status of the exit loop sensor in the exit section of the Imager 1 indicates that a loop is formed 0 indicates that a loop is not present IMAGER EXIT Indicates the presence of media at the imager exit A 1 indicates the media is present e g during imaging A 0 means the sensor is clear this is the normal idle condition NO MEDIA Identifies the amount of media in the spool as okay or none A 0 indicates that the media supply is empty 1 indicates that the amount is sufficient LOAD OK Indicates the status of media loading A 1 indicates the media is loaded a 0 indicates the media is not loaded GUIDE Indicates the presence of media at Guide A 1 indicates that media is present e g during imaging A 0 indicates the sensor is clear This is the normal idle condition WRKNG TANK LOW This sensor monitors the solution level in the working tanks within the processor A 0 indicates the current level is okay a 1 indicates low solution level in one or both of the tanks REPLN TANK LOW This sensor monitors the solution level in the replenishment tanks under neath the processor A 0 indicates the current level is okay a 1 indicates a low solution level in one or both or the tanks 38 SERVICE MANUAL EFL TANK HIGH This sensor monitor
215. s the level of spent solution in the optional effluent tank underneath the processor A 0 indicates the current level is okay a 1 indicates the tank needs to be emptied PROC TEMP OK The processor Activator temperature sensor monitors the temperature of the Activator bath A 0 indicates that the current temperature is okay 0 indicates that the bath is still warming up or that there is a problem with the heater PROC EXIT Indicates the presence or absence of media at the processor exit sensor A 1 indicates that media is present e g during imaging A 0 indicates the sensor is clear This is the normal operating condition EXIT CASSETTE Identifies the presence of an optional film takeup cassette A 1 indicates the film takeup cassette is present A 0 indicates that the film takeup cassette is not present 39 SERVICE MANUAL Replacing the Imager Sensors See Figure S4 2 1 Remove the front panel 2 Access sensors from the front of the Platesetter Disconnect the three pin connector from the sensor 3 Remove the sensor by removing the two screws holding the sensor in place 4 Install new sensor in reverse order Replace the front panel and close top cover NOTE The PROC EXIT sensor is located above the processor PCA See Figure 52 4 Load OK Loop DE uide No Media Imager Exit b Ww E Load Knob Exit Loop
216. setter Marker Power Supply Assembly Processor SERVICE MANUAL The Platesetter is controlled by a Raster Image Processor RIP several different RIP options are available depending on the most common type of work to be done The system is driven by the host computer on which the operator composes the text and graphics to be imaged Once the print job has been composed on the host computer it is sent to the RIP where it is prepared for imaging The rasterized file is then sent to the Platesetter where the file is imaged onto a plate Figure S1 1 illustrates the basic system setup Figure S1 2 illustrates the dimensions and external features of the Platesetter Workstation Job stream character codes plus command codes SS Extemal RIP File reconfigured commands interpreted SS Workstation Figure 81 1 Interface Between the Host Computer RIP and PlateStream SERVICE MANUAL Right processor Rear I O panel 12 30 cm clearance rear Load Door 47 119 cm 30 75 cm 24 60 clearance left 60 cm clearance rt Power Switch 31 79cm 30 75 clearance front Figure 81 2 Exter
217. setter Remove the upper roller by sliding the roller towards the rear of the Platesetter until it clears the frame Remove the lower roller by sliding the roller towards the front of the Platesetter until it clears the frame Install the new rollers in reverse order 7 Replace the back panel lower the marker assembly and close the top cover Removing the Pinch Rollers Left and Right See Figure S3 1 1 Open the top cover and raise the marker Remove the front and rear panel 2 Remove the E clips spacers if any and bushings from each end of the pinch roller shaft 3 Remove the spring loaded tensioner from each end of the roller shaft by removing the hex nut 4 Access the shutter from the top of the Platesetter Loosen the four screws on the shutter to access the roller Remove the roller by sliding the roller towards the rear of the frame until it clears the frame 5 Install the new roller in reverse order Lower marker assembly and close the top cover 22 SERVICE MANUAL Removing the Capstan roller and Capstan Drive Assembly See Figure S3 1 S3 2 2 Marker Lever Marker Capstan Drive Motor Figure S3 2 Location of the Capstan Drive Motor 1 Open the top cover and raise the marker Remove the front and rear panels 2 Remove the pinch rollers Refer to the previous procedure 3 Access the capstan drive assembly from the front of the Platesetter Remo
218. sor mode for example Optimal image power settings also change with resolution 4 Media Width xx xx Spool Pos yy Media Width is the exact width entered by the operator from 7 00 to 13 40 17 78 cm to 34 00 cm Spool Pos is automatically calculated from Media Width and indicates the position to set the spool or cassette Spool position is set at the media width in inches rounded to the nearest inch from 7 to 13 Media Width is set independently for each of the Input Spools see 5 below eliminating the need to reset image width every time the spool is changed 5 Input Spool Selects the input spool The choices are A B C or D A different default spool can be set for Processor Miniplate and Cassette modes For example Spool A could be set as the default in Processor Miniplate mode to be used for plate material and Spool B as default in Cassette mode to be used for film If the destination is switched back from Cassette to Processor or Miniplate the Input Spool would automatically default back to Spool A The media remaining for the selected cassette decreases as media is imaged see Spool Manager later in this chapter Each spool can hold up to 280 85 m each spool s counter can be reset after reloading Input spool selection will be displayed in front of the feet remaining in the main menu 6 Destination Sets the output destination for the imaged media Choices are Processor Processor Miniplate
219. st the image power is set too low Increase the image power and run the file again Again look at the patterns to determine if the grey level is acceptable This image power is made from the op panel main menu as follows 1 Setup enter Verify that the resolution shown after 2 is the same as you ran the file at 3 Image Power type in a higher or lower image power setting number enter Then re run the file B 2 CALIBRATION 5 Ifthe patterns get darker grey going from 8x8 to 1x1 with 1x1 being the darkest the laser power is set too high Decrease the laser power and run the file again and again look at the patterns to determine if the grey level is acceptable 6 Repeat this procedure with the next highest resolution with the following exceptions At 1800 DPI ignore the 1x1 pattern as it will nearly always be too dark At 2400 DPI ignore the 1x1 and 2x2 patterns as they both will nearly always be too dark NOTE When changing image power at low resolutions it may take several power level changes before a change in grey level on the printed patterns is visible At higher resolution often times a change of 1 power level will result in a visible change in grey level on the printed patterns B Measuring Solid Black Areas a Runa calibration target or a test plate and measure the density ofa solid black areausing areflective densitormeter transmissive densitometer for film b Setthe D according to the media manufacturer
220. strap and an antistatic work surface 1f possible when handling PCAs or other electronic components Always store and transport PCAs in antistatic bags Unpacking and Inspection Keep all the shipping boxes braces crates and packing pieces in case the Platesetter needs to be repackaged 1 Inspect the Platesetter crate for signs of shipping damage Report any damage discovered to the carrier immediately 2 Remove the strapping ramp and the top cover from the crate 3 Remove the cardboard sides 4 Attach the ramp to bottom of the crate using the two pegs located on either short side of the crate 5 Remove the plastic wrapping from the unit INSTALLATION GUIDE 6 Remove screws from the four wood blocks mounted to the bottom of the crate Remove blocks by slightly lifting the Platesetter 7 Roll the Platesetter down the ramp and on to the floor carefully 8 Open the bottom front doors Remove metal shipping brace at the bottom of the unit by removing the screws located above the front casters Assembling the Platesetter 1 Carefully open the carton containing the marker assembly 2 Remove the second cardboard cover from the marker assembly 3 Cut tie strap 4 Identify the front and rear of the marker assembly the front has a warning label and serial number the rear has a grounding strap and welded hinge brackets kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk CAUTION
221. t be used in any manner not consistent with the rights of Printware Inc 6 2 3 4 5 6 807150 001 1 2 1 BROWN 1 O Ji NU 2 RED PRN_GND 20 CABLE 3 ORANGE NC 2 803319 002 KIT 807117 001 IR 4 YELLOW PRN GND 21 KIT 807117 002 RED 5 GREEN NC 3 RED V 45V 1 6 BLUE GND 22 POWER SUPPLY BLACK GND 2 7 NC 4 DRAWER RED 45V 3 8 GRAY PRN GND 23 BLACK GND 4 9 WHITE NC 5 807046 001 YELLOW 12V 5 CONTROLLER PCA 10 BLACK PRN GND 24 BLACK GND 6 11 BROWN PIX 6 BLUE 12V 7 522980 001 IR 12 RED PIX ENBL 25 BLACK GND 8 522980 002 RED 13 ORANGE PIX CLK 7 ORANGE 324 9 14 YELLOW PIX 26 JA BLACK GND 10 15 GREEN PRN DO 8 16 BLUE PRN DO 27 17 VIOLET PRN DI 9 18 GRAY PRN DI 28 19 WHITE PRN D2 0 INTERLOCK PWR 1 20 BLACK PRN D2 29 TO RIP INTERLOCK ASSY 12V 2 21 BROWN PRN D3 I NC 3 22 RED PRN D3 30 806307 002 23 ORANGE PRN D4 2 24 YELLOW PRN D4 31 25 GREEN PRN D5 3 26 BLUE PRN D5 32 RED LASER 1 27 VIOLET PRN 4 PASE AS oa BLACK GND 2 28 GRAY PRN D6 33 803280 001 IR BLUE 12V 3 29 WHITE PRN D7 5 807220 TAB RED BLACK GND 4 30 BLACK PRN D7 34 BROWN PHOTODIODE 5 FIRMWARE CONTROL HARDWARE 31 BROWN R W 6 BLACK GND 6 PIXEL RATE 32 RED PRN R W 35 ENGINE PROCESSOR 33 ORANGE PRN STRB 7 SCAN PROCESSOR 34 YELLOW STRB 36 35 GREEN PRN ACK 8 36 BLUE ACK 37 G DRV0 1 37 VIOLET PR
222. t the two drive motor leads and unfasten the motor ground wire Take the drive belt off of the drive shaft by rotating the shaft and deflecting the belt off of the pulley Take care not to damage the wiring Remove the drive gear from the drive motor by loosening the two hex set screws in the gear 4 Open the top right cover Remove the driven gear from the drive shaft worm gear by loosening the two hex set screws in the gear Slide the gear off of the drive shaft worm gear while pushing the shaft to the left This allows the gear to clear the opening in the sheet metal 5 For 60 Hz installation the smaller gear 18 Teeth goes on the drive motor and the larger gear 20 Teeth goes on the drive shaft worm gear For 50 Hz installation the larger gear 20 Teeth goes on the drive motor and the smaller gear 18 Teeth goes on the drive shaft worm gear 6 When installing the gear on the drive shaft worm gear move the shaft all the way to the right Center the gear in the sheet metal slot Tighten the two set screws Make sure that of the screws is on the flat of the shaft 7 Wheninstalling the gear on the drive motor push the gear onto the shaft leaving 0 04 1 mm between the gear and the motor housing Tighten the two set screws Make sure that one of the screws 1s on the flat ofthe shaft Seat the belt onto the driven gear and motor gear while twisting the motor into position Reinstall the two drive motor leads motor ground wire
223. ter 010 The length change displayed is reset to 0 after pressing enter Print the Grid ps file again and measure the distance between points A and B 4 Repeat steps 1 through 3 until length is within specification 5 At 900 dpi the manual length is adjustable in 0 006 0 015 cm increments at 1200 dpi in 0 004 0 01 cm increments 1800 dpi in 0 003 0 08 cm increments and at 2400 dpi in 0 002 0 005 cm increments NOTES It is best to make small incremental changes Once you enter a new value for Manual Length Adj it is immediately copied to the battery backup Be careful not to make big adjustments as this could result in corrupt data in the firmware specification for image length accuracy is 0 003 75 microns l 18 INSTALLATION GUIDE Overlap Adjustment In waste reduction mode the Platesetter scans the leading and trailing edges of the plate causing a black area to appear This black area is the unimageable area of the plate At the leading edge of each plate is a double exposed area visible as a black band where the media was exposed on the trailing edge of the previous plate backed up and re exposed on the leading edge of the current plate If a silver line appears in this lead area then the overlap adjust is set too low 1 From the RIP JOBS directory on the RIP output the Grid 12 ps file 2 To make the adjustments described below from the Main Menu on the control pane
224. ter readings f In the Warning criteria panel enter the settings used to create the target resolution dot shape and the range of screen frequencies for which this calibration set be used 4 Save the set by clicking the OK button in the Calibration Manager dialog If you click the Cancel button in the Calibration Manager dialog you lose the changes 5 Selecta calibration set from the Calibration drop down list in the Page Setup dialog box in order to associate it with a page set up 6 Printa calibrated target to check calibration A single pass new calibration should be accurate to within about 2 For greater accuracy you can do a second calibration iteration by editing the values in the calibration set with the densitometer readings from the calibrated target Edit from calibrated target 7 Repeat this process for each resolution screen and media combination to be calibrated You may need to calibrate only those combinations you use for critical work B 5 HALFTONING AND SCREENING APPENDIX Halftoning Printware RIPs provide a number of options to control halftone generation Using them appropriately can improve the quality of your image This section gives an overview of halftoning see the RIP manual for more details Halftoning is the process of approximating gray levels or color shades with a pattern of dots In many halftoning systems the dots can have only one color value but can vary in size to alter the ra
225. the Platesetter or try to repair it yourself other than as specified in the Preventive Maintenance and Troubleshooting sections of this manual Call an authorized service technician for necessary repair 4 Plug the power cord into a 3 conductor grounded earthed outlet only Never ground the cord to a gas pipe or a water pipe Keep the cord away from hot surfaces Avoid using an extension cord 5 Use caution when disconnecting any electrical connector within the Platesetter Do not disconnect electrical components with the Platesetter turned on 6 Be extremely careful when working on the Platesetter with the machine turned on and the top cover open Notice the warning label attached to the underside of the laser marker unit 7 Always read and follow all label instructions on supplies carefully Dispose of used supplies and containers appropriately 8 Use caution when working on or around rollers within the Platesetter with the power on Be especially careful when wearing loose fitting sleeves or a tie Follow similar precautions when working on or around the cutter 1 7 GENERAL INFORMATION 9 Do not operate the Platesetter if any part of it is damaged or if any part has been dropped until you have it checked by an authorized service technician 10 When turning OFF the Power switch be sure to do it after the machine cycling has come to a complete stop 11 Use only supplies designated by Printware with your Platesetter Co
226. the processor from Operator Panel SERVICE MANUAL PROCESSING QUALITY PROBLEMS ARTIFACTS Media trailing edge wet Some residual chemistry on the media trailing edge is normal If excessive however follow these steps 1 Verify that the stabilizer tank level is not too high and that the stabilizer tube is pushed all the way down Check the springs on stabilizer rack squee gee rollers Replace if stretched out Clean squeegee rollers with D Ink and rinse with water Increase dryer hood temperature potenti ometer R43 instructions on end panel Recommended temperatures are as follows setting dryer hood temperature too low can result in wet plates too high a temperature can result in media curl Thin paper 100 F 38 C Thin poly or thick paper 110 F 43 C Thick polyester 120 F 49 C PCA Screws Blower Heater Element Drive 2225 Motor 39 9 Processor 2 N PROC EXIT Switch R42 R43 B H Processor adjustments right side panel 64 SERVICE MANUAL PROCESSING QUALITY PROBLEMS ARTIFACTS cont Brownish looking plates 1 Check the activator and in silver areas dryer temperatures 2 Clean the rollers 3 Change processor chemistry 4 Increase the replenishment rate Yellow stabilizer stains 1 Decrease dryer temperature Clean the rollers Change processor chemistry Dirty roller marks
227. there is media in the machine Manually feed the media up to the capstan roller Check for faulty Load OK switch 3 1 Remove media 3 2 View Sensor Status on Operator Panel 1 means media present 3 3 Manually actuate the Load OK switch Ifit the status does not toggle check the cable by unplugging the Load OK and No Media switches and plugging the Load OK cable into the No Media switch Manually actuate the No Media switch If the Sensor Status does not toggle with the Load OK cable replace the cable Ifthe status does toggle with the Load OK cable the cable is good Replace the switch If the Load switch and cable test good but there are still spurious No media or Media not loaded far enough messages bend the Load OK switch lever back toward the left of the machine slightly to increase its sensitivity switch No Media Load OK efe Yo Capstan Roller i NI opt Guide 9 Imager Exit 4 switch ff 4 switch Feed Loop switch Exit Loop switch Imager module sensor locations SERVICE MANUAL GENERAL IMAGER PROBLEMS cont Imaging seems to First plates take longer than other plates General guidelines for take too long first plate total times are as follows Resolution No punch With Punch 900 DPI 2 min 2 min 30 sec 1200 DPI 2 min 30 sec 3 min 1800 DPI 3 min 3 min 30 sec 2400 DPI 3 min 30 sec 4 min
228. tio of dot color to background color The simplest use of this technique is approximating gray levels with a pattern of black dots against a white background as illustrated in Figure ApB 1 Here the size of the dots varies to represent different shades of gray You see an area of small dots as a light gray while an area of larger dots each nearly filling its allowed space in the pattern of dots is seen as dark gray More strictly it is not the size of the dots but the resultant ratio of black area to white area that represents the gray value Color shades are approximated with three patterns of dots each in a primary color cyan ma genta and yellow used with or without a fourth pattern of black dots This description of halftoning assumes three patterns in fact the fourth pattern of black dots is almost always used for technical reasons that do not affect the principles of halftoning Within each color separation the size of the dots in relation to their background is proportional to the amount of the primary color in the compos ite shade When the separations are combined typically by overprinting in registration they create the illusion of shades of color The cyan magenta and yellow dots cannot be distinguished when viewed from a distance instead the pattern of color dots appears to be an area of a shade of color Halftoning can be specified in the front end application or can be overridden and specified in the RIP Th
229. tor amp Stabilizer ml Mitsubishi Silver DigiPlate Activator ounces Stabilizer ounces Activator milliliters Stabilizer milliliters 4 If more replenishment is required turn the screw on the pump clockwise if less replenishment is required turn the screw counterclockwise The screw for the stabilizer replenishment is located towards the front of the pump the screw for the activator is located towards the back of the pump The adjustment screw has a ten turn range 5 If the average plate size changes the replenishment rate should be adjusted 1 10 INSTALLATION GUIDE Changing Processor for 50 60 HZ Operation Note The processor should be properly configured at the factory This procedure is included for refer ence only Refer to figures I 3 and I 4 The AC motor that runs the Processor will run 5 6 of the speed at 50 Hz than at 60 Hz The Processor speed can be adjusted by changing the drive and driven gears in the processor The motors in the imaging section are microprocessor controlled and are not affected by the AC line frequency 1 Unplug the power cord 2 Remove the wire tray located on the right side of the Platesetter Remove the right exit panel by unscrewing the four screws holding this panel Remove the front right cover Remove the gear access plate by unscrewing the six screws holding this panel 3 Remove the drive motor by unscrewing the three screws holding the drive motor to the chassis Discon nec
230. tyrofoam pieces facing up over the plastic bag Seal the carton Bubble wrap and tie wrap the struts inside the Platesetter C Package Platesetter 1 Remove Accessories a Remove wire tray located on the right side of the Platesetter Bubble wrap tray and place in accessory box 1 Remove customer supplied power plug Bubble wrap the end of the power cord Open the left load door and remove the media spool assembly or the optional feed cassette Bubble wrap the media spools media shaft and the optional feed cassette individually Place items in accessory box 1 Close left load door Bubble wrap the two black binders containing the manuals place items in accessory box 1 and seal it shut 2 Close the Platesetter top cover Place two DESI PAK bags on the Platesetter crate Roll the Platesetter up the ramp onto the Platesetter crate 3 Support Platesetter off from wheels a b f Open the bottom front doors and attach metal shipping brace to the inside bottom of the front with two screws one above each front caster Place the 36 by 6 3 4 90 cm by 17 cm wood block underneath the shipping brace The shipping brace must rest on the foam Place the 36 by 6 90 cm by 15 cm wood block underneath the bottom back of the Platesetter The inside frame of the Platesetter must rest on the foam Place the two 20 by 6 50 cm by 15 cm wood blocks underneath the bottom sides of the Platesetter The ins
231. ut authoriza TO INTERFACE PCA J12 SCHEMATIC PAGE 3 daly riety viou SCALE NOME proprietary and may not be used in any manner not consistent with the rights of Printware Inc eet 0 2 3 4 3 6 1 2 3 4 5 6 TO CONTROLLER PCA J9 a aa cof se sa of m m m m m o9 5 2 CABLE PQ cof tpg Of SP kani kani kanl kani ban kani kani LSN LAN KA KA AP QP A AY cn cof ca af ea ba ba caf caf SF tf ey 803318 002 amp Sl 807520 002 WURDE M MM MIELE IMMER EL IDE Sel 1 BROWN GND 1 ius i 2 RED FD STEP 2 POWER 3 ORANGE FD STEP 3 e SUPPLY VELON GND 7 2 i YELLOW 6 BLUE FD RESET 6 E e III r PLACK i 9 WHITE TR STEP 9 ME AD m i 0 1l BROWN TR RESET 11 12 RED TR RESET 12 INTERFACE PCA 13 ORANGE GND 13 14 YELLOW EX STEP 14 15 GREEN EX STEP 15
232. ve the bracket covering the capstan drive assembly by unscrewing five screws Disconnect the cable from the capstan drive assembly Remove the capstan drive assembly by removing the three screws holding the bracket Slide the belts off of the capstan roller These screws are located underneath the capstan drive assembly 23 SERVICE MANUAL 4 To replace the belts remove the E clip and bearing from the capstan drive assembly Install the new belts in reverse order 5 To replace the motor remove the three screws holding the motor Install in reverse order 6 To replace the capstan roller remove the shutter assembly located above the capstan roller by removing four screws two on each side attached to the Imager and removing two shoulder screws located on solenoid underneath the shutter assembly Remove the following parts from the rear end of the Capstan roller shaft jam nut 2 wave washers Spacer roller bearing bearing removing two hex nuts Remove the following parts from the front end of the capstan roller shaft pulley removing Allen screw bearing clip removing two hex nuts Access the Capstan roller from the top of the Platesetter Remove the five E clips Remove the roller by sliding the capstan roller toward the front of the frame until the rear of the roller shaft clears the frame Install the new Capstan roller in reverse order Lower the marker and close the top cover Replace the fro
233. vice Use the procedures and troubleshooting guidelines outlined in this manual Ifthe problem still cannot be resolved then follow the procedure outlined below Also call on an authorized service technician to perform preventive maintenance as required Steps for Calling for Service 1 Observe and write down the control panel error display if applicable 2 Turn off the Platesetter 3 Write down the Platesetter model number and serial number located on the rear cover 4 Be prepared to provide the service technician with a complete description of the problem 5 Only an authorized service technician should be allowed to service the Platesetter If you are unsure of whom to call to arrange for servicing then call Printware s Customer Service Department at 800 456 1400 7 14 APPENDIX A SPECIFICATIONS SPECIFICATIONS Resolution Throughput Image Width Plate Size Standard model MicroPlate Plate Cutter Waste Reduction Mode Miniplate Option Exposure Laser Spot Size Repeatability Image to Edge Accuracy 900 1200 1800 dpi 2400 dpi optional Up to 175 line per inch 70 line per cm screen rulings 36 in min 91 cm min at 900 dpi 27 in min 69 cm min at 1200 dpi 18 in min 46 cm min at 1800 dpi 14 in min 34 cm min at 2400 dpi 13 4 34 cm 81 picas 13 4 x 22 max 7 x 12 min 34 x 56 cm max 17 8 x 30 5 cm min 13 4 x 22 max 7 x 8 5 min 34
234. with the Miniplate option and Cassette with the film option For a standard PlateStream with no options installed Processor is the only destination 7 Display Units Toggles between English and Metric display units NOTE This manual generally refers to English display units with Metric units in parentheses where applicable CONTROL PANEL Test Plate Menu ESC to exit Choose Pattern Composite Pattern 13 Transporting 0000 1800 DPI PROC ON ESC OFF ENTER Run nn Plates Sets the number of plates from 1 to 99 Pressing ENTER sets the specified number of plates to be printed Pressing ENTER again causes the specified number of plates to be printed As each plate is printed the displayed number will decrement by 1 Printing can be interrupted by pressing the ESC key If printing is interrupted the current plate will be imaged the Platesetter will not print the remaining plates the displayed number will return to its selected value If printing is not interrupted then once the specified number of plates have been imaged the displayed value will return to its selected value 2 Choose Pattern This selection sets the pattern The choices are Composite Pttrn White Plate Black Plate Half Blk Wht Thin Vert Lines Wide Vert Lines Thin Horiz Wide Horiz Small Black Sqs Small White Sqs Large Black Sqs Large White Sqs Light Gray Tone Dary Gray Tone Horz Line Res Press Pattern
235. x 56 cm max 17 8 x 21 6 cm min Automatically cuts to size Reduces leader to 0 7 1 8 cm Integrated imposition software allows up to 5 images per plate 650 nm red laser diode 780 nm infrared optional 25 micron nominal diameter 0 001 25 microns typical 4 consecutive plates 0 003 75 microns typical A 2 SPECIFICATIONS User Settings Right wrong reading and reverse Laser intensity 0 100 Resolution 900 1200 1800 2400 dpi Variable Image offsets Recommended Media Silver halide polyester or paper plates 0 004 to 0 008 thick Imagesetting film with film handling option Integrated Processor Adjustable area based automatic replenishment 40 per minute Two bath design Adjustable developer bath temperature 75 F 95 F 24 C 35 C Adjustable dryer temperature 75 F 140 F 24 C 60 C PunchStream Option Integrated punch option for Bacher C2000 or pin bar patterns others available on request Punching repeatability 40 001 25 microns Film handling Option Input cassette for daylight film loading Processor bypass take up cassette for up to 25 8M ZAPrip Raster Image Processor Options Adobe PostScript ZAPrip ZAPrip HQ Harlequin interpreter ZAPrip 200 HyWay interpreter A 3 SPECIFICATIONS RIP Interface Options Novell NetWare Mac AppleShare TCP IP PAP NetBEUI Physical Dimensions Dimensions 47 hx 55 wx31 d 119 cm x 140 cm x 79 cm Weight so 3 Environ

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