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Platestream 46 Dual manual

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2. 1 AB BROWN NC 1 POWER SUPPLY BOX CARLE J1 NU RED PRN GND 20 5 CABLE 803321001 803319 002 ORANGE NC 2 15 P YELLOW PRN GND 21 o RED ENG STP 45V Y 3l V 3 ENERO ING STEPPER GND To ORANGE ENGST WER SUPPLY 2 E E 22 BLACK ENGSTPGND E VIOLET NC 715 BLACK X3 BLACK ENG STP GND BLACK 4 GRAY PRN GND 25 5 ORANGE 807046001 YELLOW 5 WHITE NC 51 Seas ety BLACK BLACK CONTROLLER PCA BLACK PEN END ao BLUE T NBL S lo CABLE 805319402 BLACK 522980 001 RED PIX ENGL 25 m ORANGE 9 ORANGE PIX F o NG y 5 BLACK 10 522980 002 RED YELLOW PIX CLK 26 o o BED D J4 GREEN PRN DO 3 To Yellow CONT DV CONTR
3. 52 Media Jams Imager Module 57 Imager Module Sensor Problems 58 Cutter Problems esses 59 Punch Problems nu EISE 60 Processor d ay 62 Processing Quality Problems Artifacts 64 Processor Mechanical Problems 66 Processor Sensor Problems 67 Processor Electrical Problems 68 Media Problems tete 71 Press Related Problems 72 Wiring BIagralm ee Det las 73 SERVICE MANUAL 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 t
4. Host Cornputer Figure 51 1 Interface Between the Host Computer RIP and PlateStream 46 SERVICE MANUAL 12 30 cm d Rear clearance Processor Module 24 60 cm m d Left clearance Imager Module Marker Lever Load Knob 47 119 cm Power Switch TES ie P as 24 60 cm Upper Cassette Right clearance mounting brackets Lower Cassette mounting brackets pr ser sm 7 132 em 24 60 cm Front clearance Figure 51 2 External Features of the PlateStream 46 Platesetter Construction of the Platesetter The five major component areas of the Platesetter are eImager Assembly The Marker The Power Supply Assembly Cables and Electronics Processor Imager Assembly The Imager Assembly consists of the following eSpool 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 PC
5. 7 Procedures to Raise and Lower the 8 Inspecting and Cleaning Marker Assembly Unit 9 Marker Focus Adjustment Procedure 13 Processor SOC sitas 14 Chapter 3 Component Repair and Replacement Replacing Rollers Belts Motors and Cutter 20 Replacing Marker 1 27 Chapter 4 Replacing Electronic Components e nennen 28 Controller PGA i ie ete e c eee 29 Interface PORA ttc e eite den 32 Engine Stepper 34 Control Panel 0 00 040 1 35 Power Supply 37 38 Chapter 5 Troubleshooting Introduction sense nen in 42 Exposure Problems usa 43 Image Quality 44 SERVICE MANUAL SERVICE MANUAL Registration and 5 47 Operator Panel Problems 49 Marker Galvanometer 50 General Imager Problems
6. 1 2 3 4 5 6 TAB BLOCK POWER SUPPLY INTEGRATED ASSY PART NO DESCRIPTION 807046 TAB 807046 001 NORTH AMERICAN 807046 501 INTERNATIONAL 806420 003 FOR NORTH AMERICAN USE BLACK WHITE GREEN WIRE 806420 004 FOR INTERNATIONAL USE BROWN BLUE GREEN YELLOW WIRE BOWER SUEPLY BOX CABLE 803321 001 DEINDE POWER RED ENG STP 5V_ ENG STEPPER DISTRIBUTION ORANGE ENG STP 424V BLACK PCA BLACK ENG STP GND ORANGE 24V FAN MOUNTS TO BLACK GND FRONT OF POWER SUPPLY CABLE 803319 002 RED CONT 5V YELLOW CONT 12V CONTROLLER BLUE CONT 12V ORANGE CONT 24V BLACK CONT GND ORANGE VENTFAN 24 BLACK VENT FAN RTN DC POWER SUPPLY 901142 001 ALL FUSES CABLE 803312 003 PIN ASSIGNMENTS 250V 7A 600322 001 FROM BACK OF P S DRAWER RED INTRE 5V YELLOW INTRF 12V OP PANEL BLUE INTRF 12V ORANGE INTRF 24V BLACK GND RED OP 5 PLUG FOR POWER SUPPLY 522780 THO BLUE OP 12V BLACK OP GND POWER CORD AC POWER COVER WIRE COLOR VOLTAGE a 4 PLUG MOUNTS TO BACK OF POWER SUPPLY 8 8 i s amp VENT FAN 5 900894 001 2 a 806504 001 ASSY CABLE FAN FILTER BRKT CONNECTOR MOUNTING 807493 001 FAN MOUNTS TO FRAME 600307 001 NOT TO COVER OUTLET ACCESSORY DRAWS BY WMS 7 17 99 i ENG c PRINTWARE INC APPVL E AB ST PAUL MN ACIN en z CIRCUIT BREAKER m 600320 001 QA MATERIAL 240 VAC CORCOM a OUTLET 16 20A IEC 320 TOLERANCE UNLESS OTHERWISE SPECIFIEII 5
7. Heater Element Drive pu Motor eS PROC EXIT Switch o R42 R43 o U H Processor gt TER 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 Decrease dryer temperature Dirty roller marks on plates 1 Clean the rollers Change processor chemistry 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
8. N y x 2 E gt d e C E S IN N n a EN N _ o EN N gt SER co J 5 N E ae P d E Sr Tos I Sel AM Saca I Pd A N 2 N T peg E A P A p A Pe 2 2 cw p A SN kalt N A Ss AM EN Pd ES ES EY EORNM 17 TN S Sia FEN MAL ee EUN IA M 4 2 e A a ASSY TANK EFFLUENT 806816 001 REVISION E Sheet 1 of 1 Printware Confidential Find Number 001 005 006 008 010 011 012 013 014 015 017 018 019 020 021 Quantity Component Used N N N Ne NY NO RR NOR ke Assembly Number 808154 001 Number 808149 001 808203 001 808203 002 900047 000 807237 001 900229 010 600092 000 900287 019 900233 002 808192 001 900725 001 901089 007 900160 010 900233 003 900445 007 ASSY FILM OPTION Revision B Component Description ASSY CASSETTE TAKEUP BLOCK TAKE UP CASSETTE 46 BLOCK TAKE UP CASSETTE 46 WASHER EXTERNAL LOCK 8 PIN SWITCH ACTIVATOR E RINGSAE 125 SHAFT SWITCH SLD ST MICRO N O L LEVER SCREW PAN PPH 4 40 X 75 NUT LOCKK 74 40 BRKT SWITCH MTG FEET ROUND 8 ROUND HEAD SCREW STNLSS TAP FORM 6 32X 75 WASHER FLAT STEEL 4 NARROW NUT LOCK K 48 32 SCREW B H TORX 8 32 UNC X 500 Parts List Page 1 of 1 Printware Confidential EFERENCE ONL DWN FOR Ri S IS m FOR REFERENC
9. Replenishment Tanks Figure 6 1 Side View of the PlateStream 46 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 k k k 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 of the 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 of the 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 cloth and D Ink Press the key to turn off the exit motor then press the ESC
10. 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 Nh WN Ra 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 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 1 Turn up fogging circuit clockwise turn maximum Note original potentiometer
11. Ground yourself by touching the metal chassis of the Platesetter before connecting or disconnecting any cable Use a wrist strap and an antistatic work surface if possible when handling PCAs or other electronic components Always store and transport PCAs in antistatic bags INSTALLATION GUIDE Unpacking and Inspection 1 2 Keep all the shipping boxes braces crates and packing pieces in case the Platesetter needs to be repackaged Inspect the Imager and Processor crates for signs of shipping damage Report any damage discovered to the carrier immediately NOTE Procedures refer to wooden crates used for international shipments Procedures are similar for cardboard crates used for domestic shipments Unpacking the Imager 1 2 Remove the screws holding the top and sides of the crate labeled Imaging Module Remove the ramp from the foam cap and attach the ramp to the bottom of the crate using the two nails located in the front of the crate Remove the top cover sides and the foam cap Remove the plastic wrapping from the unit Remove the screws from the four wood blocks mounted to the bottom of the crate Remove blocks by slightly lifting the imager Roll the imager down the ramp and onto the floor carefully Unpacking the Processor 1 2 Remove the screws holding the top and sides of the crate labeled Processor Module Remove the top cover sides and the foam cap Remove th
12. 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 CONTROL PANEL 3 Current Plate Count 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 LOADKNOB 0 WRKNG TANK LOW 0 FEED LOOP 00 REPLN TANK LOW 1 EXIT LOOP 0 EFFLTANK HIGH 1 IMAGER EXIT 0 PROCTEMPLOW 0 NO MEDIA 00 PROC EXIT 0 LOAD OK 00 TAKEUPCASSETTE 0 GUIDE B 0 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 NOTE There are two FEED LOOP NO MEDIA and LOAD OK sensors on Dual Casette machines In these cases the first status number refers to the upper cassette the second to the lower cassette LOAD KNOB This sensor is activated when the load knob is pushed A 0 indicates the load knob is pushed in
13. 1 2 3 4 5 6 TO CONTROLLER PCA J9 alalta SESSIE RRR S SA A Al HI J16 IEEE 22 az 1812 lel Sa zl II ES Sl amp lz EL m CABLE 803311003 4 3 8 qo 3 414 e l o e amp ez o o a o2 a a e o o m o 2 a a a o o a 9 2 a a a o o a o 2 a a a o o m o 2 a CABE AE ele ele 2o 2 7 53 2 3 5 sala asas RRS 803118 001 a 2 amp 803312 003 245 AAA 1 BROWN V GND 1 i 2 RED FD STEP 2 POWER 3 ORANGE FD STEP 3 e v SUPPLY YELTOW GND 1 _ DRAWER RED 3 gt gt 6 FD RESET 6 n YELLOW 5 2 5 RA T eel Y BLACK s 9 WHITE TR STEP 9 P m m ll BROWN TR RESET n INTERFACE PCA 12 RED TR RESET 12 A 13 ORANGE GND 13 14 YELLOW EX STEP 14 15 GREEN EX STEP 15 523060 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 i J1 NU 20 BLACK CUT STEP 20 E ee 21 BROWN CUT STEP 21 22 RED GND 22 23 ORANGE CUT RESET 23 TO 24 YELLOW CUT RESET 24 SS GREEN GND 55 ENGINE STEPPER i 26 BLUE PLG OP 26 PCA J7 gt 27 VIOLET PLG OP 27 E 28 GRAY GND 28 29 WHITE STEP SYNC 29 i J6 NU 30 BLACK STEP SYNC 30 e 31__ BROWN GND 31 32 RED SPARE3 3
14. 2 Check the balance and correct if neces sary 3 Deglaze the rollers or blanket 4 Check the pressure and adjust if neces p sary Adjust the exposure in the Platesetter Setup menu on the control panel per plate Media Manufacturer s instruc tions Clean processor and replace processor chemistry 2 Call for service 1 Clean the Platesetter rollers 2 Replace the plate material 3 Replace processor chemistry 74 IN CASE OF TROUBLE PROBLEM CAUSE SOLUTION 1 The exposure is set too 1 Adjust the exposure using the high Platesetter Setup menu on the control panel Plugged Images or Excessive Back ground 2 Bad plate material 2 Replace plate material Wrinkled Cracked 1 The press plate clamp is 1 Check handling techniques Plates improperly set when mounting plates and check the uniformity of the plate clamp bsa 1 Press pressure is exces 1 Adjust the pressure Plates have Short Press Life are 2 Press blanket surface 15 too 2 Change toa softer smoother harsh blanket 3 There are abrasive particles in the press ink WwW Replace the ink 4 The press ink fountain 4 Adjust the moisture control on balance is incorrect the press to minimum o 5 Replace the ink or add reducer 6 Platesetter Processor 6 Change Processor chemistry chemistry is depleted 7 Marker out of focus 7 Call for service 75 PROBLEM Toning Specking Ba
15. 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 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 that media is present e g during imaging A 0 means the sensor is clear this is the normal idle condi tion 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 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 B 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 under
16. 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 GENERAL INFORMATION 12 30 cm p Rear clearance lt 24 60 cm we Left clearance Marker Lever Load Knob S 47 119 cm 24 60 cm Power Switch Upper Cassette mounting brackets Lower Cassette mounting brackets p 52 A 132 cm 24 60 cm Front clearance Figure 1 4 Features of PlateStream 46 Dual Cassette Platesetter 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
17. SOLUTION See chapter 3 in the section Loading Plate Media media or not loaded far enough 4 3 OPERATING THE PLATESETTER CAUSE The Guide B sensor is blocked SOLUTION Clear media path See chapter 7 in the section Clearing Media Path CE Guide B sensor blocked 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 tenter Guide B CAUSE The Imager Exit sensor is blocked SOLUTION Clear media path See chapter 7 in the section Clearing Media Path OPERATING THE PLATESETTER 45 Processor exit sensor blocked RR ARE PPP q a PIE TES Media didn t exit processor 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 1s blocked SOLUTION Clear media path See chapter 7 in section Clearing Media Path CAUSE 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 2 Calibrate the processor See chap ter
18. 26 SERVICE MANUAL Replacing the Marker Unit CAUTION The Marker Housing contains potentially harmful invisible laser energy Do not attempt to open the inner 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 46 Platesetter Installation Guide for the installation of a new marker When a 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 acces
19. 38 px 53 5 ANDA CC f SN 52 5 ASSY PROCESSOR 18 DUAL CASSETTE 808155 001 REVISION E Sheet 2 of 5 Printware Confidential Printware Confidential 2 pac Do 22 F DEEP GROOVE THIS SIDE ON AY SS 7 N EN et Sar i P d gt P Printware ASSY PROCESSOR 18 DUAL CASSETTE 808155 001 REVISION E Sheet 3 of 5 Es zm m 32 2 ASSY PROCESSOR 18 DUAL CASSETTE s 808155 001 REVISION E Sheet 4 of 5 Printware Confidential ES 28 PLAC NES 7 SX S SEN E 808155 001 REVISION Sheet 5 of 5 Printware Confidential Find Number 001 002 003 004 005 006 007 008 Quantity Component Used O Oc Q e e 9 Assembly Number 806710 001 Number 806775 001 900960 019 901090 001 806824 001 900268 005 901079 001 900087 002 900016 000 ASSY DRIVE SHAFT 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 LUBE SYNTHETIC SHC460 14 5 OZ LOCKTITE SMALL SCREW Printware Confidential Printware ASSY DRIVE SHAFT 806710 001 REVISION E Sheet1 of 1 Printware Confidential Find Number 001 002 003 004 005 006 007
20. 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 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 Back
21. ON to turn the punch on 2 Run a test plate with the punch on 3 Return to the Calibrate Transport menu 4 Measure the depth or position of the punch notch see Figure I 16 5 Forthe Bacher punch pattern the notch depth should be 0 433 11 mm Forthe pin bar pattern the center of the holes should be 0 3125 7 94 mm from the edge 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 If necessary follow the procedure for all resolutions to be used with the punch mode Punch length is set independently for each resolution Punch Notches Larger punch length produces deeper notches Figure I 16 Adjusting Punch Length 1 27 INSTALLATION GUIDE De Installing the Platesetter These instructions are provided in the event you ever need to repackage the Platesetter Turn off the Platesetter and RIP 2 Disconnect the Imager cable from the rear of the Platesetter Packaging the Platesetter A Package the processor section 1 Open the top right cover and remove the optional film take up cassette Bubble wrap the cassette and place in accessory box 2 Drain processor a Remove the right front panel and gently roll out the effluent cart Drain the effluent cart Reinstall the effluent tank and place the 6 long 114 diameter
22. PI3 1 2 P4 2 P13 3 P4 3 P13 4 4 1 TANK HEATER O 2 J P 805798 001 C2 FEN AS C CY A ACT TANK HEATER TO BLOWER FAN MOTOR Printware ASS Y ELECTRICAL PANEL 806708 001 REVISION E Sheet 1 of 1 Printware Confidential Find Number 001 002 004 008 009 010 012 013 014 016 017 018 Assembly Number 808228 001 ASSY TRANSPORT DRYER ROLLER FOAM 15 Revision B Quantity Component Component Used Number Description Parts List Page 1 of 1 1 808229 001 RACK PANEL ROLLER FOAM 1 806751 001 ROLLER DRYER LOWER 15 901077 001 BELT ENDLESS ROUND 8 900230 002 BEARING NYLON SNAP IN 250 SHFT 1 806747 001 ROLLER DRYER UPPER 4 900229 019 E RING 5 375 SHAFT 1 901079 001 PIN SPIRAL 2 806649 001 ASSY FLANGED BEARING 2 806649 002 ASSY FLANGED BEARING 4 807352 001 SHAFT 19 75 56 807351 001 ROLLER FOAM 8 900005 002 RING GRIP Printware C
23. Power Supply Assembly This chapter provides the following information for each PCA elocation voltages connector and pin assignments replacement instructions This 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 n Engine Stepper PCA Interface PCA Pover 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 of the 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 Laser power and control J2 Not used J3 Not used
24. Set to the approximate intended length of the Miniplate jobs e g 4 then press ENTER to save 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 Press 17 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 1 23 INSTALLATION GUIDE 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 decrease 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 1200 dpi 1800 dpi 2400 dpi 24 INSTALLATION GUIDE Punch Set up with optional punch installed The punch is an electronically actuated pneumatic system There is a compressed air connection on the lower rear panel of the p
25. 123 124 125 126 128 129 130 131 132 134 135 136 137 142 151 152 Se eS oh 02 42 Q gt N po N N DS WD Ww 24 12 12 12 12 N N Assembly Number 808444 XX X 900569 037 806955 001 807371 001 807421 001 806953 001 807372 001 807422 001 806228 001 806239 001 806950 001 806951 001 806958 001 806959 001 900336 001 807354 001 803713 001 807356 001 807363 001 807359 001 807091 001 808197 001 808197 002 807091 004 806330 001 806347 001 806348 001 900229 001 806199 001 900235 013 803666 001 806393 001 806389 001 900160 006 900225 001 900236 012 900047 003 900288 000 900406 006 806267 001 806585 001 900254 002 900039 001 804574 001 900582 007 ASSY XPORT ROLLER 46 DUAL CASSETTE Revision G BELT TIMING 434 GROOVES GUIDE UPPER SET TOP GUIDE UPPERSET BOTTOM INTERNATIONAL GUIDE UPPERSET BOTTOM DOMESTIC GUIDE LOWER SET TOP GUIDE LOWERSET BOTTOM INTERNATIONAL GUIDE LOWERSET BOTTOM DOMESTIC BRACKET LOWER SOLID MTG BRKT UPPER GUIDE MTG BLOCK EDGE GUIDE ADJUSTABLE UPPER SET BLOCK EDGE GUIDE POSITION UPPER SET BLOCK EDGE GUIDE ADJUSTABLE LOWER SET BLOCK EDGE GUIDE POSITION LOWER SET NUT SELF LOCKING HEX 8 32 UNC 3B PULLEY MOD 65 GR COLLAR PULLEY ASSY PULLEY OVERRUNNING CLUTCH ASSY BELT TENSIONER SHAFT BELT TENSIONER ASSY SWITCH ASSY CABLE EXTENSION LOAD OK ASSY CABLE EXTENSION E
26. 5 Media Width 13 12 Spool Pos 13 Media Upper Spool Input Spool A Destination Processor Display Units English ON ESC 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 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 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 aax or Density while decreasing image power reduces Image power can 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 re
27. 8 32 X 50 PANEL ACCESS 54 CATCH SNAP IN SCREW PAN PPH 4 40 X 38 WASHER FLAT STEEL 4 REGULAR NUT LOCKK 44 40 SCREW PPH 10 32 X 3 8 WASHER EXTERNAL LOCK 710 SPACER THREADED HEX LOCKTITE SMALL SCREW HINGE PROCESSOR DOOR HINGE PROCESSOR DOOR BRKT DOOR HINGE BRKT DOOR HINGE WASHER FLAT STEEL 8 NARROW Parts List Page 1 of 1 Printware Confidential C KIT CHASSIS 18 808153 001 REVISION Printware Sheet 1 of 2 Printware Confidential u on SEE SHEET 1 KIT CHASSIS 18 808153 001 REVISION C Sheet 2 of 2 Printware Confidential Find Number 002 003 004 005 006 007 009 010 011 012 014 015 017 018 019 020 022 023 024 025 029 031 032 033 038 042 043 047 048 049 050 051 052 053 054 055 056 060 064 065 067 068 Quantity Component Used N N N N N N 599 N N Re N 22 BON DH Assembly Number 808444 XXX ASSY XPORT ROLLER 46 DUAL CASSETTE Number 806919 001 804288 001 808220 001 900297 001 803305 001 808218 001 900871 008 900928 002 822307 900229 002 807350 002 901023 001 900360 000 803418 001 803419 001 804627 001 803463 001 803466 001 808208 001 808215 001 808
28. 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 12 SPECIFICATIONS A 1 SPECIFICATIONS APPENDIX A SPECIFICATIONS General Resolution Throughput Image Width Plate Size Plate Cutter Waste Reduction Mode Dual Cassette 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 18 1 46 cm 108 picas 18 1 x 22 max 9 x 12 min 46 x 56 cm max 22 9 x 30 5 cm min Automatically cuts to size Reduces leader to 0 7 1 8 cm Two independent input cassettes Special imposition software allows up to 5 separate 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 i SPECIFICATIONS User Settings Right wrong reading and reverse Laser intensity 0 100946 Resolution 900 1200 1800 2400 dpi Variable Image offsets Recommended M
29. 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 55 65 50 60 1200 DPI 45 55 40 50 1800 DPI 35 45 30 40 2400 DPI 25 35 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 Feed loop Intermittent artifacts beginning approximately 2 down the plate Adjust the Feed Loop switch 2 2 Exit loop Intermittent artifacts beginning approximately 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 spring around one additional turn 3 2 Temporarily disable traction control to see if this solves the problem 4 Noisy capstan motor causes high frequency horizontal banding down the whole length of plate 4 1 Check capstan motor
30. 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 Consult 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 2 1 CONTROL PANEL CHAPTER 2 The Control Panel The control panel is located in the upper left corner of the front of the Platesetter Figure 2 1 illustrates a fl
31. 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 7 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 12 8 Stabilizer pH 6 8 To clean the processor see figure 6 1 1 Open the processor top cover Place 6 long 114 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 Remove cover E Remove guide F by pressing guide towards the back of the Platesetter lift guide from the front of the Platesetter and remove Remove guide D by pressing guide towards the front of the Platesetter lift guide from the back of the Platesetter and remove Wash cover E guide F and guide
32. 008 Quantity Component Used 2 A 2 Se eS Ln 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 SST 1250 DIA X 625 LG PULLEY TIMING BELT 1 5 PITCH SHAFT DRIVE BELT E RING SAE 250 SHAFT CHANNEL DRIVE DRYER Printware Confidential gt Printware k ASSY DRYER DRIVE 806714 001 REVISION F Sheet 1 of 1 Printware Confidential Find Number 001 001 002 003 003 004 005 006 007 Assembly Number 806715 001 Quantity Component Used 2 oO ON Ruy 0 25 Number 900960 052 901119 001 806818 001 900960 057 901119 002 900302 008 901082 001 901085 001 901100 002 ASSY DRAIN Revision E Component Description Parts List Page 1 of 1 ELBOW 90 FITTING PVC PIPE ELBOW 90 DEGREE PIPE PVC TEE FITTING PVC PIPE TEE 3 4 CLAMP HOSE ADHESIVE PLASTIC PIPE CLEANER PLASTIC PIPE TUBING POLYVINYL CHLORIDE 1 1 4 X 1 Printware Confidential HE L7 J1 5 p EN SP ONUS SN PEN 21516 41 d E EE ULA uU N SAY Y y l 1 5 A NN N 21546 ES Printware ASSY DRAIN 806715 001 REVISION E Sheet1 of 1 Printware Confidential Find Number 001 002 003 005 006 007 008 00
33. 11 12 13 14 15 16 17 18 19 20 SCHEMATIC PAGE 7 TO CONTROLLER PCA J9 AND TO INTERFACE PCA J12 DRAWN ay WMS 7 17 99 ENG PRINTWARE INC ENG sm ST PAUL MN QA MATERIAL TOLERANCE UNLESS OTHERWISE SPECIFIEI ANGLES 5 DEG FINISH 02 010 1 PLACE DECIMALS 2 PLACE DECIMALS 3 PLACE DECIMALS Title WIRING DIAGRAM PlateStream DC46 COMM CODE Size INSP VERSION REV FIRST USED ON B 700607 001 B DO NOT SCALE DRAWING This document and the information it contains is the property of Printware Inc and may not b E reproduced copied disclosed to others or disposed of directly or indrectly without authoriza SCALE NONE tion from Printware Inc Both the document and its contents are to be treated as confidential amp Sheet 7 of 7 proprietary and may not be used in any manner not consistent with the rights of Printware Inc N w 3 6 PlateStream 46 Platesetter Dual Cassette Illustrated Parts List Printware LEADERS IN COMPUTER TO PLATE Manual 700612 Rev A Find Number 001 001 002 002 003 003 007 007 Quantity Component Used Lm kaa Assembly Number 808440 ASSY PlateStream 46 DUAL CASSETTE Number 808441 001 808441 002 808145 001 808145 002 806420 001 806420 002 808447 001 808447 002 Revision C Component Descript
34. 34 cm x 17 cm wood block with lip underneath bottom front of the Imager The frame must rest on the foam b Placing the 18 by 6 3 4 34 cm x 17 cm wood block underneath the bottom back of the Imager The frame must rest on the foam c Placing the two 24 by 6 3 4 61 cm x 17 cm wood blocks underneath the bottom sides of the Imager The frame must rest on the foam Attaching all four wood blocks to the crate by using two wood screws in each block e Replace the front and rear panels 6 Plastic wrap the entire Imager Place the foam cap over the Imager Place the ramp inside the foam cap Place the 33 84 cm wide plywood with notches on the front of the crate with the boards facing inside the crate and the notches on the bottom Place the 33 84 cm wide plywood on the back of the crate with the boards facing inside the crate Place the two 50 127 em wide plywood on the sides of the crate with the boards facing inside the crate and flush with the bottom Screw the top and the sides together Make sure the top cover and the sides are very secure D Package the Accessories 1 Place the accessory box marker box and RIP boxes on the crate 2 Place sides and top on the crate Screw the top and sides together Make sure the top and sides are secure 1 31 INSTALLATION GUIDE This page should be filled out on Installation Serial Numbers and Factory Settings Installation Date Location Serial Numbers Component
35. 900967 005 900337 000 900968 001 901091 001 901071 012 807394 001 807313 001 808228 001 806848 001 806707 003 806657 002 806706 004 900058 001 806410 002 806410 001 901100 002 807487 001 901072 004 700603 001 ASSY PROCESSOR Revision E PCA DIGIPLATE PROCESSOR ASSY ELECTRICAL PANEL ASSY DRIVER MOTOR BELT TIMING 1 5 PITCH 60 GROVES PANEL PCA BOARD SCREW STAINLESS 10 24 X 500 TAPE FOAM SINGLE COATED 4317 X 5 BLOCK SUPPORT SWITCH SCREW STNLSS TAP FORM 10 32 X 50 SCREW STAINLESS 10 24 X 375 PPH WASHER SPR LK STNLES NUT STAINLESS 10 24 KEPS LOCKNUT SCREW STAINLESS 1 4 20 X 500 WASHER SPR LK STAINLESS GROMMET SCREW SCREW STAINLESS 4 40 X 625 SCREW STAINLESS 8 32 X 375 PPH WASHER FLT STNLS 8 3 8X11 64X 031 SCREW STAINLESS 8 32 X 500 PPH GROMMET EDGE SLOTTED NUT STAINLESS 8 32 KEPS LOCKNUT STANDOFF TURN WASHER FLT STNLS BRKT RACK LOCATING ASSY AIR HOOD ASSY TRNSRT DRYER ROLLER FOAM 15 ASSY CROSSOVER GUIDE ASSY ENTRANCE GUIDE ASSY RACK COVER ASSY TUBE OVERFLOW ADHESIVE 3M CA8 PRONTO 1 OZ BTL BRKT PROC HEATER HEIGHT BRKT PROC HEATER HEIGHT TUBING POLYVINYL CHLORIDE 1 1 4X 1 BRKT COVER ADJUST WASHER SPR LK STNLES 78 055X 040 WIRING DIAGRAM PROCESSOR Printware Confidential ASSY PROCESSOR 18 DUAL CASSETTE 808155 001 REVISION E Sheet 1 of 5 Printware Confidential 27 APPLY ALONG ENTIRE LENGTH DF SEAM 27 o SS 7 ZA 22 A D EN
36. 900968 005 900215 007 807225 004 Revision C Component Description PLATE ACTIVATOR FRONT BEARING ROLLER GEAR ASSY GEAR D SHAFT IDLER GEAR SPUR E RING SAE 250 SHAFT STUD GEAR GEAR SPUR E RINGSAE 312 SHAFT PLATE ACTIVATOR REAR SPRING EXTENSION 022 BRKT DRIVE RACK ASSY CLUTCH WORM GEAR SHAFT DRIVE RACK ASSY PROCESSOR GUIDE HANDLE RACK ROLLER TRANSPORT O RING SCREW STAINLESS 8 32 X 375 PPH WASHER SPRING LOCK STAINLESS 8 055X 040 WASHER FLAT STNL 710 7 16X13 64X 062 SCREW STAINLESS 10 24 X 375 PPH WASHER SPRING LOCK STAINLESS SCREW STAINLESS TAP FORM 10 24 X 1 00 ROLLER SQUEEGEE POLISHED ROLLER PROCESSOR ASSIST GUARD PROCESSOR SPLASH ROD SUPPORT 19 67 BEARING NON METALLIC FLANGED SCREW SET STAINLESS 8 32 X 250 GEAR MOD COLLAR GEAR COLLAR SHAFT NUT STAINLESS 10 24 KEPS LOCKNUT WASHER NYLON 1 4 X 50D X 032 THK LABEL ACTIVATOR Parts List Page 1 of 1 Printware Confidential ASSY ACTIVATOR TRANSPORT C 807327 001 REVISION Sheet of 3 Printware Confidential Printware ASSY ACTIVATOR TRANSPORT 807327 001 REVISION C Sheet 2 0f 3 Printware Confidential ITEM 11 AROUNO INGS 2 PLCS NS WRAP ITEM 11 AROUND BOTH BEARINGS 2 PLCS Printware ASSY ACTIVATOR TRANSPORT 807327 001 REVISION C Sheet 3 of 3 Printware Confidential Find Number 001 002 003 004 005 006 007 Quant
37. BLACK Ey NU J2 H GRE GND 10 E El vo 11 6 VENTFAN PLUG MOUNTS 2 VLCD 12 900894 001 5 2 ASSY LCD 802533 806504 001 ASSY CABLE FAN FILTER 5 o 1 BROWN il 2 RED 2 1 GREEN 3 ORANGE 3 KEYPAD x D BROWN 503180001 X67 7 YELLOW BLUE Xs 3 GREEN 5 1 xis 6 BLUE 5 yyy BROWN Xi 5 7 VIOLET 7 4 FAN MOUNTS TO FRAME GRAY GREEN GRAY XT 3 H GRAY s 1 NOT TO COVER z s 7 T 9 mg xi CABLE 803311 003 3 tirti e z BLACK 4 E la Yo 9 BROWN n 4 za 10 y r 10 12 RED 12 4 3 yi m B ORANGE 13 sa s 5 8 X n YELLOW 14 ACIN w SWITCH El 15 GREEN 15 1 BLACK CIRCUIT BREAKER PIN 8516 16 BLUE 16 240 VAC AC CORCOM BROWN oS a FROM BACK OF P S DRAWER 17 VIOLET y GREEN 30VK6 i 9 18 GRAY 1 4 25 40 o BLUE mE i 806420 TAB AC SUV BLUE 7 7 70 BLACK m 4 600267 002 900813 001 261 002 SABLE a PLUG FOR POWER SUPPLY GROUNDS TO MOUNTING SCREW kou ni GREEN GROUND STUD IN BOTTOM OF CHASSIE CABLE 806462 001 ee Z 2 5 z 1915 zi IS z 9 E aseo ERES ERE Es S SEM S ESI EIE RISE del ERE CABLE 803312 003 SIE SPREE EES 5602355265612 ap leper fo fofefec senex e ele gjallese CABLE 803118 001 LOWER FEED STEPPER 803666001 BROWN 1 GND BROWN 1 idi RED FD STEP
38. DUAL CASSETTE 80844 XXX REVISION C Sheet 3 of 3 Printware Confidential Find Number 001 003 004 005 006 007 008 010 011 012 013 014 015 016 017 018 019 020 021 022 023 032 033 034 035 036 038 039 089 093 094 095 096 112 115 116 117 127 136 137 138 139 Quantity Component Used N BRR a BR POR N Ne BR NOR h Nme c oo GC C me me e me e e Assembly Number 808143 001 Number 8033 14 001 804217 001 807226 002 8033 11 003 8033 12 002 806306 001 8033 18 001 803334 001 804149 001 803319 002 803321 001 901020 002 901029 002 900040 001 900040 002 900040 806376 001 900318 003 806475 001 821521 001 900224 001 900813 001 600267 002 600320 001 900237 002 600307 001 803323 002 806366 001 90082 1 002 600272 000 600272 003 600272 004 900233 002 900445 004 901022 001 806275 001 806400 001 900445 006 806504 001 806461 001 806462 001 600188 003 ASSY CHASSIS Revision B Component Description ASSY CABLE CON RIP ASSY CABLE BLK PROC ASSY CABLE INTF SOLENOID ASSY CABLE INT CON OP ASSY CABLE PWR OP INT ASSY CABLE MARKER FAN ASSY CABLE SCSI ENG ASSY CABLE BRK BLK ASSY CABLE FIL BRK ASSY CABLE PWR4 CON6 FAN A48 B43 ASSY CABLE 5 PWRI WRAP SPIRAL 500 EA BOX STANDOFF WIRE TWIST LOK CLIP CORD ADHESIVE 38 CLIP CORD ADHESIVE 62 CLIP CORD ADHESIVE 19 ASSY CABLE PROC I O SLEEVING EXPANDABLE 2 1 2 BL
39. 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 Spherical Mirror and the Folding Mirror if Compressed Air Does Not Remove the Particles Spots 1 Soak a clean piece of webril wipe with acetone 2 Very carefully and gently wipe the mirror surfaces 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 sur
40. OK switch lever back toward the left of the machine slightly to increase its sensitivity A switch No Media switch switch Feed 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 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 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
41. 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 J1 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 NOTE There are two FEED LOOP NO MEDIA and LOAD OK sensors on Dual Casette machines In these cases the first status number refers to the upper cassette the second to the lower cassette 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 0 indicates that a lo
42. Slide the marker assembly off the brass pivot bushing located on the right without moving the bushing 4 Place the marker in the 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 c Install foam block in the location shown on the drawing in the marker box d Place flat cardboard cover with the four Styrofoam pieces facing up over the plastic bag Seal the carton e Bubble wrap and tie wrap the marker struts inside the Platesetter f Reattach the right cover strut by firmly pushing the strut head onto the ball joints and reattach ing the caps to lock the strut C Package the Imager 1 Remove customer supplied power plug Bubble wrap the end of the power cord 2 Remove the supply cassette Bubble wrap the media spools and place in the supply cassette Secure the shaft to the inside of the supply cassette with tape Bubble wrap and place in the accessory box 1 30 INSTALLATION GUIDE 3 Bubble wrap the two binders containing the manuals place items in accessory box and seal it shut 4 Close the Imager top cover Place three strips of bubble wrap on top of the front panel Place two DESI PAK bags on the Imager crate Roll the Imager up the ramp onto the Imager crate 5 Support the Imager up off of the wheels by a Placing the 18 by 6 3 4
43. VIOLET 45V PULL UP VIOLET 17 HITE M RT S BLACK 806786 001 GRAY RESET GRAY IS 30 BLACK 1 RED QA MATERIAL NENE SUPERE T 31 BROWN IMAGERENEDLGSV IMAGER EXIT 6 BLACK TOLERANCE UNLESS OTHERWISE SPECIFIED BLACK PUMP PRIME BAR 32 RED IMAGER EXIT SIG SENSOR NO 7 BLACK a ANGLES 5 DEG BROWN 45V PULL UP BROWN 21 33 ORANGE IMAGEREXIT T GND m PLACED MALS FINISH RED SPARE RED 2 3i YELLOW LOWER FEED LOOP 45V BE i 2 PLACE DECIMALS m ORANGE NU ORANGE 23 35 GREEN LOWER FEED LOOP SIG x 3 PLACEDECIMALS YELLOW NU YELLOW 24 BLUE LOWER FEED LOOP GND Pen Sa GREEN NU GREEN 25 37 VIOLET GUIDE B 45V BLUE NC BLUE S GRAY GUIDES SIG ER WIRING DIAGRAM PlateStream DC46 IECT R NU J13 LE 807091001 2 COMM CODE Size 700607 001 INSP VERSION REV 806794 001 DB25 CONNECT FIRSTUSEDON B B CABLE MOUNTS TO SIDE OF IMAGER is document and ie avon cons he propery lnc andmay SCALE NONE 21515 14141 reproduced copied disclosed to others or disposed of directly or indrectly without authoriza E tion from Printware Inc Both the document and its contents are to be treated as confidential amp Sheet 1 f 7 proprietary and may not be used in any manner not consistent with the rights of Printware Inc Sheet 2 s s 1
44. between A and B is 21 200 3 05 cm increase the value for Backup Length Adj on the control panel by the difference for example if the 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 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 If a silver line appears increase the value for Overlap Length Adj on the control panel 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 Miniplate 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 Press 2 Test Plate Press 3 Choose Length
45. directly or indrectly without authoriza SCALE NONE tion from Printware Inc Both the document and its contents are to be treated as confidential amp Sheet 5 f 7 proprietary and may not be used in any manner not consistent with the rights of Printware Inc eel 9 1 2 3 4 5 6 DB25 PIN CONNECTOR MOUNTS ON SIDE OF IMAGER EXIT SWITCH 600333 001 RIBBON CABLE TO INTERFACE BOARD PS46 806794 001 WORKING TANK SENSORS 806800 001 EM PS 807204 001 EFFLUENT TANK LEVEL 806792001 n DRIER TEMP SENSOR C MOUNTING SCREW PS46 806815 001 Ny PS 806815 002 600330 001 ACT TEMP PROBE 806786 001 REPLEN Ra K SENSORS x UID ESE BE c DRIVE MOTOR al lt 3E a II 806703 001 z T m 5 1 IS BROWN 26 IS GREEN 4 DRYER Y mew Y TEMP ACT BLANKET HEATER ICAL o CAL 600335 001 TRANSFORMER WIRING DIAGRAM PS46 808155 001 PSMP 807346001 223150 001 PS 807179 001 806705 001 32 31 11 EMI FILTER 2A 250V SA 250V 5A 250V HOOD INTERLOCK 2A 250V 600292 001 COOR 1 ITIN DR
46. 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 10 turn adjustment screw on each pump turn clockwise to increase the flow rate Sensors are in the replenishment tank see figure S2 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 S2 2 1 Open the top cover 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 be tightened by adjusting the bracket on the side rail Loosen
47. 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 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 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 option installed Calibrates or elimi nates the gap between jobs in Miniplate mode 2 13 CONTROL PANEL Input Spool Manager Menu 3 Input Spool Manager ESC to exit Spool A 1 2 Spool B i 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 Spools A and B are upper cassettes Spools C and Dare upper cassettes 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 ON ESC OFF ENTER
48. 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 The 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 g
49. 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 4 2 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 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
50. 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 I 10 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 at 1 800 456 1400 be fore adjusting this boltto avoid warranty issues To locate this bolt Figure I 10 No Image Skew diagonal D E diagonal C F D D c O a O c 9 Q O H e Stand in front of the Platesetter operator side facing the Platesetter e Open the Imager unit top cover 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 I 10 shows no image skew If the image skew condition shown in Figure I 11 is present turn the adjustment screw clockwise to lower the front of the laser marker assembly 4 If the image skew condition shown in Figure I 12 is present turn the adjustment screw counterclock wise
51. 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 Black Line 1 Brown Line White Line 2 Blue Neutral Green Ground Green Yellow Ground Verify that an electrician is available if needed 2 Confirm Supply of Recommended Consumables Have at least 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 9 to 18 1 22 9 cm to 46 0 cm The maximum roll length is 280 85 m INSTALLATION GUIDE RECOMMENDED CONSUMABLES FOR PLATESTREAM 46 MITSUBISHI SILVER DIGIPLATE INFRA RED PLATE MEDIA RED LIGHT PLATE MEDIA Emulsion In Emulsion Out Emulsion In Emulsion Out 5 mil paper SDPRD125 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 SPECS20R 7 mil polyester SDP FD175 SPEC 820 SPEC820R SDP FR175 5 820 SPECS20R CHEMISTRY ACTIVATOR SLM AC STABILIZER SLM ST AGFA SETPRINT RED LIGHT PLATE MEDIA Emulsion In 5 mil polyester SET HN LL 13 8 mil polyester SET HN LL 20 CHEMISTRY ACTIVATOR G260b STABILIZER G360b INSTALLATION GUIDE 3 Scheduling Installation Verify preparations that the mach
52. 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 51 GENERAL IMAGER PROBLEMS Platesetter spontaneously reboots Power out of spec message Platesetter is on line but will not start a job On Dual Cassette model Lower cassette unload does not stop after switching to upper cas sette Supp SERVICE MANUAL Check AC voltage The specification is 200 264 Volts 50 60 Hz Protect against AC power glitches 2 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 Verify that the lower cassette is properly loaded Check lower Load OK switch and cable Adjust lower Load OK switch 52 SERVICE MANUAL GENERAL IMAGER PROBLEMS cont All silver plates All silver plates usually indicates
53. 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 Marker v Lever Marker jas SN Capstan Drive Motor Figure 53 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 Remove 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 Toreplace 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
54. right side of the Platesetter Attach customer supplied power plug to Platesetter power cord located in the rear of the machine per electrical wiring codes Assembling the Processor NOTE Follow manufacturer s safety instructions for Activator and Stabilizer and do not contaminate the Activator pieces with Stabilizer solution Open the top right cover Remove black tape holding Cover G 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 overflow tubes and Cover G 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 Place the two replenishment tanks on the smaller cart Place the optional effluent tank on the optional larger cart If necessary prepare the Activator and the Stabilizer solutions in the replenishment tanks following the manufacturer s instructions Fill the processor working tanks inside the Platesetter and the replenishment tanks wit
55. 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 0 sensor status to be sure the switch is not stick ing 1 1 0 0 0 3 If Sensor Status does not toggle between 1 and 0 the switch should be replaced The replacement part includes detailed re placement instructions ESC Sensor status menu 58 SERVICE MANUAL CUTTER PROBLEMS Cutter won t cycle Cutter won t stop cycling Cutter cycles but doesn t cut 59 1 Check and re seat cutter connector Check for loose wires on the cutter switch non operator side of machine 3 Seeifthe cutter motor shaft spins by hand the shaft coming out of the back of the motor 4 Checkforany media stuck in cutter 5 Check motor winding resistance normally 10 to 1000 If motor is shorted or open replace the cutter 1 Switch misadjusted 1 1 If switch is open the cutter wheel should turn one t
56. 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 N e Check the probe connectors Check the cable Place one ohmmeter 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 no
57. the top cover The control panel PCA is connected to the signal lines running between the controller PCA and the interface PCA The control panel PCA reads signals from the control panel keypad and writes information to the display These signal lines also control the activation of motors and read data in from the sensors 35 SERVICE MANUAL Voltages Supplied to Control Panel PCA 12 VDC 12 VDC 5 VDC Connector Assignments 12 13 J4 J5 J6 Power from power supply drawer Controller PCA interface PCA communication line Not used Display connector Not used Keyboard Matrix Replacing the Control Panel PCA Turn off the Platesetter 2 Remove the control panel assembly as follows a Open the top cover b Disconnect the power J1 and controller interface J2 cables from the control panel assembly c Carefully remove the Control Panel PCA by removing the four hex nuts securing the assembly to the front panel d Install the new control panel assembly in reverse order 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 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
58. 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 03 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 m
59. 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 18 ps file 2 To make the adjustments described below from the Main Menu on the control panel Leading Edge 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 15 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 Operator Side front of Platesetter D Figure I 15 Adjusting Cut Length and Backup Length 1 22 INSTALLATION GUIDE Adjusting Backup Length 1 Measure the distance between points A and B see Figure I 15 2 If the distance
60. 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 17 Activator Rack 1 1 N Dryer Belts gt I 4 Dryer Drive Clutch Rack Drive Gear E am Drive Motor Belt p Drive Shaft Worm Gear Figure S2 3 View of the Processor SERVICE MANUAL x Heater Element PROC EAT Switch Drive 42 R43 a Motor Processor PCA PCA Screws Z Blower Figure S2 4 Right Side View of the PlateStream 46 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 S2 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 if 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
61. 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 o Clean the processor working tanks using warm soapy water Drain and clean the hoses 4 Package inside of processor a Place 4 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 Place bubble wrap over Cover G and tape down 5 Package Carts a b Roll out the replenishment cart and the optional effluent cart Remove probes from the replenishment tanks and the optional effluent tank air blow dry and place them in the plastic clip located underneath the right side of the processor section Empty tanks per local en
62. 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 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 ora water pipe Keep the cord away from hot surfaces Avoid using an extension cord 5 Usecaution when disconnecting any electrical connector within the Platesetter Do not disconnect electrical components with the Platesetter turned on 6 Beextremely 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
63. 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 one of the screws is on the flat of the shaft 7 When installing 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 is on the flat of the 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 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 2 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 retur
64. wrap from struts Remove the caps on the outside of each strut head Detach the right cover strut on the marker end by removing the cap and pulling off the ball joint Locate the hinge shaft for attaching the marker assembly at the top inside left rear of the Imager Have two people lift the marker assembly from the carton Place the marker assembly in the Imager by placing the hinge brackets on the hinge shaft not on the brass bushings Slide the marker assembly mounting clip onto the right spring loaded brass bushing Lift the other end of the marker assembly and place it past the brass bushing Slide the brass bushing into place Remove the shipping brace located on the laser end of the marker by removing eight screws Save the brace and screws in case the platesetter or marker need to be returned to the factory Remove the 26 by 1 66 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 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 Gently lower the marker assembly and lock by pushing the marker lever towards the rear of the Platesetter until lever is horizontal Reattach the right cover strut by firmly pushing the strut head onto the ball joints and reattac
65. 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 C4 HALFTONING AND SCREENING APPENDIX C 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 ratio 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
66. 0 60HZ lt A 30VK6 U 5 DEG 806420 TAB 25A 40F m 250V 02 TO PROCESSOR met DECIMALS 010 Y itle GEOUNDSTO MOUNTINGSCHEW E WIRING DIAGRAM PlateStream DC46 GREEN Z COMM CODE Size INSP VERSION REV CABLE 806462 001 HIRST USED ON B 700607 001 B This 4 t and the inf tion it contains is thx ty of Printware Inc and may not bi SCHEMATIC PAGE 2 reproduced copied disclosed to others or disposed of directly or indrecly without authoriza SCALE NONE tion from Printware Inc Both the document and its contents are to be treated as confidential amp Sheet 2 of 7 proprietary and may not be used in any manner not consistent with the rights of Printware Inc 1 2 3 4 6 1 2 3 4 5 6 CABLE 803314 001 1 2 1 BROWN NC V 1 J1 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 PRN GND 22 POWER SUPPLY BLACK GND 2 7 VIOLET 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 1l BROWN PIX ENBL 6 BLUE 12V 7 522980 001 IR 12 RED PIX ENBL 25 BLACK GND 8 522980 002 RED 13 ORANGE PIX CLK 7 ORANGE 424V 9 14 YELLOW PIX CLK 26 JA BLACK GND 10 15 GREEN PRN DO 8 16 BLUE D0 27 17 VIOLET PRN DI 9 18 GRAY PRN DI 28 19 WHITE PRN D2 0 INTERLOCK PWR 1 20 BLACK PRN D
67. 01 900726 001 900726 005 807157 001 806409 001 806409 004 700287 001 808185 001 808185 002 806474 001 806473 001 900224 002 806501 001 600188 003 600292 001 804521 001 600306 002 806719 007 807312 001 806719 008 807312 003 807524 001 807525 001 808447 001 Revision C ISOLATOR WR4 060 ISOLATOR WB4 060 SCREW PPH 10 32 X 2 SPACER ROUND 10 X 5 8 WASHER FENDER 1 375 X 192 X 048 NUT LOCK 710 32 ISOLATOR WR3 030 RING ISOLATOR WB3 030 BUSHING ASSY CART REPLENISHMENT LABEL OPERATION SYSTEM LABEL OPERATION SYSTEM WIRING DIAG STRIP TRIM STRIP TRIM GUARD CAPSTAN DRIVE GUARD CAPSTAN PULLEY SCREW TAPTITE PPH 8 32 X 3 8 ASSY CABLE INTERLOCK PROCESSOR STRAIN RELIEF CABLE SWITCH DOOR ASSY CABLE INTERLOCK JUMPER CABLE ACCESSORY MALE IEC ASSY TUBE ACT 18 ASSY TUBE STAB 11 ASSY TUBE ACT 30 ASSY TUBE STAB 30 LABEL MEDIA LOADING LABEL MEDIA CLEARING ASSY SHROUD DUAL CASS Printware Confidential Printware ASSY IMAGER PS46 DUAL CASSETTE C 808441 XXX REVISION Sheet of 3 Printware Confidential IMAGER IS SSEMBLY ATTACH THIS IMAGER ERMINAL TSI ESSOR INTERLOCK WIRING Printware ASSY IMAGER PS46 DUAL CASSETTE 808441 XXX REVISIONC Sheet 2 of 3 Printware Confidential Printware ASSY IMAGER PS46
68. 2 29 TO RIP INTERLOCK ASSY I2V 2 21 BROWN PRN D3 I NC 3 22 RED PRN D3 30 806307 002 23 ORANGE PRN D4 2 24 YELLOW PRN D4 3l 25 GREEN PRN D5 3 26__ BLUE D5 32 RED LASER 1 27 VIOLET PRN D6 4 TASER ASSY 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 U76 CONTROL HARDWARE 31 BROWN PRN R W 6 BLACK GND 6 U43 PIXEL RATE 32 PRN R W 35 Ul96 ENGINE PROCESSOR 33 ORANGE PRN STRB 7 U199 SCAN PROCESSOR 34 YELLOW PRN STRB 36 35 GREEN PRN ACK 8 36 BLUE 37 G DRV0 1 37 VIOLET PRN GND 9 GALVO ASSY WHITE G SENSE 2 38 NC GREEN G DRVI 3 39 NC RED G DRVO0 4 40 NC BLACK G SENSE 5 RED G DRVI 6 807049 001 RED SOS C 1 1 SENSOR ASSY GREEN SOS SIG 2 2 WHITE SOS REF 3 3 RED SOT C 4 NU J16 1 WHITE SOT SIG 5 5 GRAY SOT REF 6 6 807151 001 1 1 2 2 3 3 3 J3 NU NU J2 3 5 5 6 6 TO OPERATOR PANEL PCA J2 BROWN RED ORANGE YELLOW GREEN BLUE VIOLET GRAY WHITE 10 BLACK 11 BROWN 12 RED 13 ORANGE 14 YELLOW 15 GREEN 16 BLUE 17 VIOLET 18 GRAY 19 WHITE 20 BLACK 1 2 3 4 5 6 7 8 9 z mz z El lols Dez Dez S fas EIS FM S MEE Z 4 2 BIG ISIS S S EISIS 8 sia 2 AISISIEIS S1Q SI SIEIAISISIEZIS ja 14 5 e A gt O BO gt 0 F B a olema o eo Ie m wro celvlolisi icimiivpis cejejeisi I icolj
69. 2 33 ORANGE SPARE3 33 34 YELLOW GND 34 35 GREEN FD TR DIR 35 i 36 BLUE FD TR DIR 36 gt 37 VIOLET GND 37 38 GRAY SPARE 38 CARTE i J4 NU 39 WHITE SPARE 1 39 NT 806306 002 40 BLACK GND 40 41 BROWN SPARE 0 41 42 RED SPAREO 42 43 ORANGE GND 43 ids dE A 44 YELLOW EX DIR 44 24V BLACK 2 FAN Day wur 2 aD ae 47 VIOLET SPARE2 47 COOLING FAN 48 GRAY SPARE2 48 49 WHITE GND 49 50 BLACK GND 50 CABLE 804140 004 WHITE 1 2 NU WHITE 3 1 BROWN UPPER NO MEDIA 45V V UPPER NO MEDIA 807301 001 ORANGE 3 SENSOR NO 3 ORANGE UPPER NO MEDIA GND 8070912001 CABLE 4 YELLOW UPPER LOAD OK 5V PERNA 807226 001 SENSOR mo SAUTER suL 807091 001 24V ORANGE 1 7 LOAD KNOB 45V TOAD KNOB SHUTTER DRV WHITE 2 8 GRAY LOAD KNOB SIG SENSOR NO WHITE 324v ORANGE 9 WHITE LOAD KNOB GND Sc Lnd SHUT ER wan smurmR Dav warme 4 SHUTTER DRV WHITE 4 4 10 BLACK EXIT CASSETTE 5 EXI CASSETE USED ONLY ll BROWN EXIT CASSETTE SIG SENSOR NO 12 RED EXIT CASSETTE GND 307001001 OPTION CABLE 806376 001 ORANGE TOWER NO MEDIA SSV LOWER NO 22 50 YELLOW LOWERNOMEDIA SG T MEDIA NO 1 WORKING TANKS LOW V BROWN 1 GREEN LOWER LOAD OK SIG m 807091 001 BLUE LOWER NO MEDIA GND 2 __REPLN TANKS LOW ORANGE 3 17 VIOLET EX LOOP 45V LOWER LOAD OK 5V I5 an YELLOW 4 Pm LOWERLOADOK SIG HOWE AD O 3 EFF TANK HIGH GREEN 5 19 WHITE EX LOOP GND LOWER LOAD OK GND 80
70. 2 in the section Calibrate Menu RIP requesting to image plate IAS 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 Medi 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 the 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 4 7 SUPPLIES 5 1 SUPPLIES CHAPTER 5 SUPPLIES Introduction Using recommended supplies
71. 209 001 808214 001 808213 001 808212 001 804477 001 803744 001 806327 001 808227 001 807068 001 806309 001 808199 001 901026 001 806623 001 806617 001 806618 001 901102 001 901070 003 803557 001 803741 002 803772 001 900569 001 900569 008 Revision G Component Description Parts List Page 1 of 5 WELDMENT ROLLER TRANSPORT ROLLER SEGMENTED ROLLER FEED BEARING BALL RETAINER BEARING BRACKET CAPSTAN DRIVE MTG SCREW SHC LOW HEAD 1 4 28 X 1 5 NUT HEX JAM 5 8 18 WASHER PRELOAD SPRING M T E RING SAE 3 8 SHAFT ROLLER PINCH TRACTION BUTTON LOCATING ADJUSTMENT WASHER WAVE SPRING 22MM OD X 010 ASSY LOWER PINCH TENSION ASSY DRIVE EXIT ROLLER TENSION ASSY CAPSTAN DRIVE ASSY UPPER PINCH TENSION RIGHT HAND ASSY UPPER PINCH TENSION LEFT HAND GUIDE LOWER BUFFER GUIDE UPPER EXIT GUIDE UPPER BUFFER GUIDE LOWER EXIT GUIDE UPPER CUTTER GUIDE LOWER CUTTER ROLLER ALUMINUM IMAGE ASSY PULLEY OVERRUNNING CLUTCH PLATE MARKER LOCATING LOWER BRKT CUTTER MTG BRKT CUTTER MTG BRKT CUTTER MTG ASSY CUTTER LATCH COMPRESSION ASSEMBLY ROD 5 16 HEX SST 20 90 HUB HANDLE SHAFT HANDLE KNOB OVAL TAPERD SCREW SET STAINLESS 10 32 X 188 SHAFT IDLER ARM BEARING PULLEY MOD PULLEY MOD 130 TOOTH W INSERT BELT TIMING 165 GROOVES 1 4 W BELT TIMING 184 GROOVES 1 4 W Printware Confidential 069 071 072 072 073 074 074 079 083 084 085 086 087 089 090 091 092 093 094 106 107 108 110 118 119 120 121 122
72. 25 2 YELLOW 2 2 RED 26 PLG OP BLUE 26 JA 3 RED 3 3 GREEN qu o o H 27 PLG OP VIOLET 27 4 WHITE 4 4 Back 28 GND GRAY 28 29 STEP SYNC WHITE 29 EXIT STEPPER 30 STEP SYNC BLACK 30 803666 001 31 GND BROWN 31 32 SPARE 3 RED 32 33 SPARE 3 ORANGE 33 34 GND YELLOW 34 DECURL EXIT 1 BLACK 803323 002 1 ln WHITE 35 FD TR DIR GREEN 35 2 YELLOW 2 2 RED 36 FD TR DIR BLUE 36 J2 3 3 3 YELLOW H 37 GND VIOLET 37 4 WHITE 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 BLACK CUTTER SWITCH 45 EX DIR GREEN 45 46 GND BLUE 46 8 3 BLACK 47 SPARE2 VIOLET 47 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 E 7 8 9 CABLE 803321 001 10 11 12 2 424V ORANGE 4 SUPPLY 3 24V ORANGE 6 PRAWN WMS 7 17 99 DRAWER 5 GND BLACK 1 I v RED 2 ENG PRINTWARE INC 6 GND BLACK 3 o ES 7 GND BLACK 5 AB ST PAUL MN 2 QA MATERIAL TOLERANCE UNLESS OTHERWISE SPECIFIEI A ANGLES 5 DEG 1 PLACE DECIMALS E FINISH 2 PLACE DECIMAL 02 S 3 PLACE DECIMALS 010 n E WIRING DIAGRAM PlateStream DC46 Z COMM CODE Size 7 6 07 1 INSP VERSION REV FIRST USED ON B 00 00 B This document and the information it contains is the property of Printware Inc and may not b E SCHEMATIC PAGE 5 reproduced copied disclosed to others or disposed of
73. 5 036 037 038 039 040 041 042 043 044 Quantity Component Used ON ON ON GO GO N Rh Ra gt gt pa pap N N tA co 0 A N N m m NN FP oO 16 Assembly Number 808153 001 Number 807498 001 806619 001 806556 001 806557 001 808164 001 806608 001 806607 001 806607 002 808183 001 808184 001 901019 001 901019 002 900222 008 900223 009 900173 004 900223 006 900160 007 900287 003 900823 002 900594 004 900594 005 900047 000 806627 001 808186 001 806615 001 806634 001 900233 900224 005 806415 001 901103 002 900287 005 900160 008 900233 002 900288 003 900047 003 900904 002 900016 000 806646 001 806646 002 806635 001 806635 002 900160 012 KIT CHASSIS 46 CM Revision C Component Description CHASSIS IMAGER CHASSIS PROCESSOR PANEL IMAGER FRONT 96 PANEL ACCESS PROC 96 INTERFACE CHASSIS PANEL IMAGER REAR 96 HINGE CONTINUOUS IMAGER HINGE CONTINUOUS PROCESSOR COVER PROCESSOR COVER IMAGER CASTER SWIVEL STEM W BRAKE CASTER SWIVEL STEM W O BRAKE NUT HEX UNC 1 2 13 WASHER LOCK HELICAL SPRING 1 2 REG BOLT HEX HD UNC THREAD 3 8 X 1 WASHER LOCK HELICAL SPRING 3 8 REG WASHER FLAT STEEL 3 8 SCREW PAN PPH 8 32 X 38 LATCH PULL FLUSH LATCH VISE ACTION LATCH VISE ACTION WASHER EXTERNAL LOCK 8 BRKT CATCH MTG PANEL ACCESS PROC PUMP BRKT INTERLOCK BRKT INTERLOCK MTG NUT LOCK 6 32 SCREW TAPTITE PPH
74. 5 005 806835 006 808197 004 ASSY CHASSIS Revision B PLUG PLASTIC KIT CHASSIS 46 CM BUSHING GROMMET LABEL GROUND SYMBOL COVER FILTER FAN ASSY CABLE FI GRD TUBING SHRINK 2 PLATE CABLE RETAINING FAN GUARD ONLY FAN S P N 09362 G FAN RETAINER ONLY FAN S P N 09362 R MEDIA 3 5 8 FAN FILTER FAN AC 3610PS 23T B30 230V SCREW FLAT HD 6 32 X 2 NUT SELF LOCKING HEX 6 32 UNC 3B WASHER FLAT STEEL 76 GROMMETS VIBRATION ISOLATOR ADHESIVE EPOXY HYSOL 608 NUT LOCK 6 32 BRKT PUMP MTG 232 WASHER FLAT STEEL 78 NUT LOCK K 78 32 SEAL EMI CFOLD SEAL EMI CFOLD SEAL EMI 039 X 394 TAPE FOAM SINGLE COATED 4714 X 5 SEAL EMI 125 X 500 TAPE FOAM SINGLE COATED 4317 X 5 TAPE FOAM SINGLE PSA 4317 X 3 4 TAPE FOAM SELF ADHESIVE 1 X1X9 WASHER EXTERNAL LOCK 6 WASHER EXTERNAL LOCK 78 SCREW TAPTITE PPH 8 32 X 3 8 SCREW PAN PPH 4 40 X 50 SCREW LOCK KIT 312 SCREW BRKT CONNECTOR MOUNTING LABEL HEATER POT BLUE ARROW LABEL HEATER POT GRAY ARROW LABEL HEATER POT BLUE INST LABEL HEATER POT GRAY INST LABEL HEATER POT ACT TEMP LABEL HEATER POT DRY TEMP ASSY CABLE EXTENSION EXIT 1 Printware Confidential gj 2 Printware ASSY CHASSIS 1 8081 43 001 REVISION B ROM OF CHASSIS CUTOUT F REAR op INSIDE MACHINE INSTALL FROM Sheet 1 of 7 Printware
75. 6947 001 900237 000 900235 041 807191 001 900566 003 900236 005 900277 004 807513 001 900774 005 900963 002 900160 005 900039 001 900445 006 900445 007 900047 000 900445 008 807191 002 806321 001 807093 003 807093 004 807391 001 806930 001 807093 008 808172 002 807193 001 807193 003 807193 004 900225 001 900160 012 806883 002 806883 003 900155 001 Revision C Component Description SHROUD FAB STRIP NOISE SUPPRESSION BRACKET INPUT MEDIA ALIGNMENT DOMESTIC BRACKET INPUT MEDIA ALIGNMENT INTERNATIONAL BLOCK EDGE GUIDE ADJUSTABLE BLOCK EDGE GUIDE POSITIONING BRIDGE MEDIA INPUT PLATE ADJUST PLATE POSITIONING BLOCK BACKUP BRACKET BOTTOM BRACKET TOP SCREW SOCKET FLAT HEAD UNC 6 32 X 3 8 SCREW SHC 8 32 X 1 1 4 BLOCK LOCATING UPPER FRONT KNOB KNURLED SHC 8 SCREW SOCKET HEAD SHOULDER 8 32 X 6255 SPRING COMPRESSION 750X 360X 042 FOAM LIGHT BAFFLE SEAL EMI C FOLD ASTRAGAL PLUNGER SPRING LOADED WASHER FLAT STEEL 8 SPACER 171 ID 25 OD 25 HT SCREW B H TORX 8 32 UNC X 375 SCREW B H TORX 8 32 UNC X 500 WASHER EXTERNAL LOCK 8 SCREW B H TORX 8 32 UNC X 625 BLOCK LOCATING UPPER REAR PLATE BLOCK LOCATING LABEL PLATE GUIDE POSITIONING EDGE GUIDE LABEL PLATE GUIDE POSITIONING EDGE GUIDE RECEPTACLE CASSETTE FRONT PLATE BLOCK LOWER LOCATING LABEL GUIDE DOWN DOMESTIC LABEL GUIDE DOWN INTERNATIONAL SPACER LOCATING BLOCK UPPER 807191 SPACER LOCATING BLOCK 020 SPACER LOCATING BLOCK 015 WA
76. 7091 001 807091 001 16 BLUE 6 20 BLACK UPPER FD LOOP 5 4 PROC TEMP VIOLET 7 rl 17 GND GRAY 8 22 RED UPPER FD LOOP GND BE 5 FILM EXIT WHITE 9 23 ORANGE NU TO 18 GND BLACK 10 24 YELLOW NU PRAWN WMS 7 17 99 PROCESSOR 6 SPARE BROWN 11 25 GREEN NU ENG PRINTWARE INC 19 GND RED 12 26 BLUE NU i 7 5 PULL UP ORANGE 13 27 VIOLET NU olx 20 SOJ YELLOW 14 28 GRAY NU gt i ST PAUL MN 8 5 PULL UP GREEN 15 29 WHITE NU ES 21 DRIVE INH BLUE 16 30 BLACK NU z QA MATERIAE 0 15V PULL UP VIOLET 17 31 BROWN IMAGER EXIT 1 45V AGREE S TOLRRANGETUNERSSOTHERWISESPEGIEIEN 22 RESET GRAY 18 SENSOR NO A ANGLES s DEG BEES WHITE l 807091 001 1 PLACE DECIMALS us FINISH 23 PUMP PRIME BLACK 20 34 YELLOW LOWER FEED LOOP 45V TOWERTEZEDIGORI Ed P EDACHDEGMALS 11 5V PULL UP BROWN 21 35 GREEN LOWER FEED LOOP SIG NO lt S ar ACH DECIMALS 16 24 SPARE RED 22 36 BLUE LOWER FEED LOOP GND So 9 Title 37 VIOLET GUIDE B 45V 25 LOW QUE GUDE B SIC wm E WIRING DIAGRAM PlateStream DC46 13 GREEN 25 39 WHITE GUIDE B GND z VE NU J13 202 BLACK SI 807091 001 COMM CODE Size 7 0 0 6 07 0 0 1 INSP VERSION REV A FIRST USED ON B B SCHEMATIC PAGE 4 Teproduced copied disclosed to others or disposed SCALE NONE tla elol S MMMM MMMA tion from Printware Inc Both the document and its contents are to be treated as confidential amp Sheet 4 of 7 proprietary and may not be used in any manner not c
77. 9 010 011 012 013 015 016 019 020 021 022 023 024 025 026 028 030 031 032 033 034 035 036 037 038 039 040 041 Quantity Component Used 1 12 5 4 2 h2 NON BN DK WN CO CO A me e gt gt UA Assembly Number 807328 001 ASSY STABILIZER TRANSPORT 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 807231 007 806695 001 900773 001 900968 005 900215 007 807225 005 Revision C Component Description PLATE STABILIZER FRONT BEARING ROLLER GEAR ASSY GEAR SHAFT IDLER GEAR SPUR E RING SAE 250 SHAFT STUD GEAR GEAR SPUR E RINGSAE 312 SHAFT PLATE STABILIZER REAR BRKT DRIVE RACK ASSY CLUTCH WORM GEAR SHAFT DRIVE RACK ASSY STABILIZER ENTRANCE GUIDE HANDLE RACK ROLLER SQUEEGEE POLISHED ASSY PROCESSOR GUIDE SCREW STAINLESS 8 32 X 375 PPH WASHER SPRING LOCK STAINLESS 8 055X 040 WASHER FLT STAINLESS 10 7 16X13 64X 062 SCREW STAINLESS 10 24 X 375 PPH WASHER SPRING LOCK STAINLESS SCREW STAINLESS TAP FORM 10 24 X 1 00 ROD SUPPORT 19 67 SPRING EXTENSION 028 ROLLER PROCESSOR ASSIST SCREW SET STAINLESS 8 32 X 250 GEAR MOD BEARING
78. A Cooling Fan Multi output Power Supply External Connectors J1 J5 Cables and Electronics This group of components consist of the following Controller PCA Interface PCA Control Panel PCA Processor PCA eStepper Motor PCA Processor This group of components consist of the following Activator Tanks and Rack With Rollers eStabilizer Tanks and Rack With Rollers eDryer Drive System SERVICE MANUAL CHAPTER 2 MAINTENANCE For physical calibration procedures see the PlateStream 46 Platesetter Installation Guide This chapter identifies which subassemblies 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 Plateset ter 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 lubrica tion 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 46 Platesetter Parts Manual Approved Lubr
79. ACK GUARD CIRCUIT BREAKER ASSY CABLE GROUND STRAP 6 50 SCREW TAPTITE PPH 6 32 X 3 8 FILTER RFI K SERIES 30VK6 CIRCUIT BREAKER DOUBLE POLE 20A OUTLET 16 20A IEC 320 SCREW SOCKET FLT HD UNC 4 40 X 3 8 OUTLET ACCESSORY PUSH IN ASSY CABLE ENG STEPPER ASSY CABLE CUT STEPPER POCKET PULL 4 84 X 1 84 040 070 TERMINAL BLOCK GREY 4 CONDUCTOR TERMINAL BLOCK GRN YLW 4 CONDUCTOR TERMINAL BLOCK END PLATE NUT LOCKK 44 40 SCREW B H TORX 6 32 UNC X 375 BEARING FLANGE ALIGN PLATE LOCATING LATCH SEAL ROD LATCH SCREW B H TORX 8 32 UNC X 375 ASSY CABLE FAN FILTER ASSY CABLE OUTLET PROC ASSY CABLE GND STRAIN RELIEF CABLE Parts List Page 1 of 2 Printware Confidential 141 142 143 144 150 151 156 157 161 162 163 164 165 166 167 168 169 170 171 173 179 184 185 186 187 188 189 190 191 192 193 194 198 200 201 202 203 204 205 206 207 208 no 5 2 5 o Rh N N Assembly Number 808143 001 900891 007 808153 001 900289 003 901121 001 806614 001 806503 001 901063 002 806507 001 900429 001 900429 002 804677 001 900894 001 900172 017 900336 000 900160 004 900767 003 900015 000 900233 803795 001 900160 005 900233 003 900774 002 900774 003 900774 006 900214 001 900774 008 900214 004 900214 009 900835 003 900047 002 900047 000 900224 002 900287 004 900069 002 807493 001 806835 001 806835 002 806835 003 806835 004 80683
80. ASSETTE Revision G SHAFT DRIVE LINKAGE ASSY CAPSTAN GUIDE BRACKET CABLE MOUNTING PLATE CLAMP BRKT UNLOAD ROLLER FEED PLATE TORQUE WASHER LOCK HELICAL SPRING 28 REG SCREW SHC 8 32 X 38 SCREW SOCKET HEAD SHOULDER 10 32 X 626 PLATE ARM UNLOAD WASHER NYLON WEAR 189 ID X 410 OD SCREW SOCKET HEAD SHOULDER 10 32 X 1880 SCREW SOCKET HEAD SHOULDER 8 32 X 188 SPRING TORSION LT045H 4L NUT HEX UNC 8 WASHER CURVED SPRING 3 8 SCREW SHC 1 4 20 X 1 2 PLATE FI IDLER BEARING OIL LESS BRONZE DB119 SCREW SHC 6 32 X 50 E RING SAE 1 2 SHAFT KNOB PULL WASHER MOD ROD PIVOT BEARING NON METALLIC FLANGED BAR UNLOADING LINK PINCH UNLOADING SCREW SHC 4 40 X 50 WASHER LOCK HELICAL SPRING 1 4 REG WASHER FLAT STEEL 1 4 REGULAR NUT LOCK K 6 32 E RING SAE 750 SHAFT E RING SAE 625 SHAFT SCREW SOCKET HEAD SHOULDER 8 32 X 2505 SCREW PAN PPH 4 40 X 50 SCREW PAN PPH 4 40 X 63 NUT LOCKK 44 40 SCREW B H TORX 8 32 UNC X 375 WASHER EXTERNAL LOCK 8 RECEPTACLE 1 4 TURN RING EXTERNAL RETAINING NUT RECEPTACLE RETAINING FASTENER 1 4 TURN PUSH BUTTON SPRING COMPRESSION 75X 360X 038 Printware Confidential 272 273 274 275 276 2T 278 279 281 282 283 287 288 289 290 291 292 293 294 295 296 297 298 301 302 303 304 306 307 308 309 310 311 312 313 314 314 317 318 319 320 321 322 323 ON NY cO 5 N NV L N NN BRN WW C OO OND Assembly
81. CK K 8 32 SCREW SHC LOW HEAD 6 32 X 250 BEARING NYLON SNAP IN 188 SHAFT TAPE TEFLON 6 5 MIL X 1 IN Parts List Page 1 of 1 Printware Confidential PPOSITE SIDE D SEE NOTE ASSY CAPSTAN GUIDE B 808152 001 REVISION Sheet of 1 Printware Confidential Find Number 001 001 002 003 004 005 007 Quantity Component Used O N N e Assembly Number 807363 001 ASSY BELT TENSIONER Number 807358 001 808238 001 900406 002 900236 021 901187 002 807433 001 900016 000 Revision D Component Description Parts List Page 1 of 1 BRKT BELT TENSIONER XPO BRKT BELT TENSIONER BEARING OIL LESS BRONZE DB119 SCREW SOCKET HD SHLD 10 32 X 312 BELT TIMING DOUBLE SIDED 190 GRV PULLEY IDLER LOCKTITE SMALL SCREW Printware Confidential ASSY BELT TENSIONER 807363 001 REVISION D Sheet of 1 Printware Confidential Find Number 001 002 003 003 004 005 006 007 008 009 010 011 012 013 014 015 016 017 019 020 021 022 025 026 027 028 029 030 032 033 035 036 037 037 038 039 040 041 042 043 044 045 Quantity Component Used ON NY 9 NNN DR NNN NY 9 29 N N N YO A UANO OO ON NY FS ANNAN Assembly Number 808447 XXX ASSY SHROUD DUAL CASSETTE Number 806918 001 806883 001 806353 001 807373 001 807215 001 807216 001 806954 001 806352 002 806354 002 806944 001 80
82. Clean processor and replace chemistry 2 Clean the processor rollers Wet Plates 1 Clean the dryer 2 Clean the processor and replace the chemistry 79 IN CASE OF TROUBLE Clearing Media Path 1 Pull the load knob and gently lift up the top cover and MARKER see Fig 7 1 2 Inspect the MEDIA PATH for jammed media in the areas described below Access the MEDIA PATH through the top and front covers of the Platesetter GUIDE Al CAPSTAN GUIDE B GUIDE C1 GUIDE C2 GUIDE D GUIDE F COVER G Press down on the four mounting pins to release guide A1 move guide to the left Remove cables from the three switches on the underside of guide and remove guide Al Inspect theCAPSTAN ROLLER for media wrapped around it Open the shutter if necessary The shutter is located on top of CAPSTAN roller Remove the front cover of the Platesetter Push the two mounting pins and swing the guide to the left Remove the front cover of the Platesetter Push the two mounting pins and swing the guide to the right Press down on the two mounting pins Slide the guide toward the front of the Platesetter Lift the rear of the guide and remove Remove COVER E Slide GUIDE F toward the rear of the Platesetter Lift the front end of the guide and remove 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 Plates
83. Confidential Printware ASSY CHASSIS 18 8081 43 001 REVISION B Sheet 2 of 7 Printware Confidential Printware ASSY CHASSIS 18 808143 001 REVISION B Sheet 3 of 7 Printware Confidential PZN gt MISSA SEE JETAIL B SEE DETAI X Printware Confidential DETAIL fal v SEE DETAI 188 ALL AROUND s SEE SHEET 1 Printware ASSY CHASSIS 18 8081 43 001 REVISION B Sheet 4 of 7 N 142 A ON 2 185 55 Ps ALL AROUND Kr IMAGER DOOR REAR PROCESSOR DOOR Printware ASSY CHASSIS 18 8081 43 001 REVISION B Sheet 5 of 7 Printware Confidential Printware ASSY CHASSIS 18 808143 001 REVISION B Sheet 6 of 7 Printware Confidential 4 yt CUNNECTIUN PLATE AS VIEWED 807493 001 BRKT CONNECTOR MOUNTING GoD FROM INSI
84. D for bottom enter Select 6 to choose destination you must choose processor if using plate material and must choose cassette if using film Select enter esc 3 Load media into capstan roller by selecting 5 load from the op panel main menu enter PREPARING FOR OPERATION Emulsion out Emulsion in Side View of Supply Cassette Figure 3 2 Loading Cassettes ES LOADING TIPS When selecting 5 load from the main menu the media will backup the op panel will display unloading for a few seconds to correctly position the media This is normal Both cassettes must be present on the left side of the machine even if only using one cassette Otherwise light leaks will fog the media f loading film in one cassette and plate material in the other the plate material must be loaded first without any film in the imager Complete the loading of the plate material before attempting to load the film in cassette mode Cut off 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 3 7 PREPARING FOR OPERATION Imaging Plates with the ZAPrip HQ Harlequin RIP 1 Startup the RIP a Connect the RIP to the network and turn it on b Press ctrl alt del on the RIP to
85. 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 liftto 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 IN CASE OF TROUBLE 7 1 IN CASE OF TROUBLE CHAPTER 7 TROUBLESHOOTING Print Quality Troubleshooting PROBLEM CAUSE SOLUTION Scumming ghost The press ink fountain I 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 cover 5 Replace the cover or sleeve or sleeve is contami nated 6 The Platesetter Processor Replace Platesetter
86. DE DF COVER FILTER FAN P ug 600307 001 DUTLET ACCESSORY 806461 001 ASSY CABLE DUTLET PWQ SUPPLY NL POWER SUPPLY em gt Z e 3 803334 001 ASSY CABLE BRK BLK 10 SS 8 B a M gp PROCESSOR I L1 71 95 WA 93 I I ex 94 Here Nur pr 804149 001 CASSY CABLE FIL BRO 1 D FOE GRAY I I I BROWN GREEN 600267 002 CIRCUIT BREAKER DOLBLE POLE BLUE po lt 800320 001 DUTLET 16 204 IEC 320 34 f all 1 BROWN z GREEN o xc E a 806461 001 ASSY CABLE QUTLET PROC 37 lt 2 4 y M 3 i GROUND TD 1 001 CFAN AC 162 NL I BROWN 900813 001 creen ELLE FILTER RFI K SERIES GND MARKER TRANSPORT FRAME 806919 001 UR 808205 001 3 806462 001 CASSY CABLE GND 138 OE 808503 001 ASSY CABLE FIL GND 151 BROWN N N E 806504 001 ASSY CABLE FAN FILTER 13 EN 170 200233 000 6 32 K NUT 2 GREEN GREEN Print W are LINE BLACK BROWN NEUTRAL WHITECBLUE GNO GREEN GREEN YELLDW ASSY CHASSIS 1 8 GROUND STUD IN BOTTOM m ee OF CHASSIS 808153 001 8081 43 001 REVISION B 806420 TAB ASSY CABLE P NER Sheet T of 7 Printware Confidential Find Number 001 002 003 004 005 006 007 008 009 010 011 012 013 014 015 016 017 020 021 022 023 024 025 026 027 028 029 030 031 032 033 034 03
87. E ART IS SH PA ASS Y FILM OPTION PS46DC B 8081 54 001 REVISION Sheet of Printware Confidential Find Number 001 002 006 012 013 014 015 021 022 023 024 025 026 028 029 030 031 032 033 034 035 036 037 038 039 040 041 042 Quantity Component Used N dA N PD 4 oc RR Assembly Number 808243 XXX ASSY CASSETTE SUPPLY 280 Number 806625 002 806626 002 806342 001 807464 002 807466 001 807466 002 807463 002 806416 001 901028 001 900155 900237 004 901128 001 900016 000 807437 001 900774 002 900236 015 807472 001 900233 807454 001 807454 002 900047 000 900287 003 900047 002 900445 004 900060 002 901244 001 900160 005 900157 006 Revision F Component Description ASSY SPOOL PLATE ADJUSTABLE ASSY SPOOL PLATE FIXED AXLE SPOOL HOUSING SUPPLY CASSETTE ASSY END CAP LEFT HAND ASSY END CAP RIGHT HAND COVER SUPPLY CASSETTE STRIP RETAINING FLEECE 21 25 FLEECE EA YARD TAPE BONDING 1 2 WIDE CLEAR SCREW SOCKET FLAT HEAD UNC 4 40 X 5 8 TAPE PALLETIZING LOCKTITE SMALL SCREW GASKET LIGHT SEAL SEAL EMI CFOLD SCREW SOCKET HD SHLD 8 32 X 312 ASSY GROUNDING SPRING NUT LOCK 6 32 BRACKET GROUND BRACKET GROUND WASHER EXTERNAL LOCK 8 SCREW PAN PPH 8 32 X 38 WASHER EXTERNAL LOCK 6 SCREW B H TORX 6 32 UNC X 375 ADHESIVE RTV BLACK 5223 FOAM SELF ADHESIVE WASHER FLA
88. E3 ORANGE 3 UR DER us 4 YELLOW GND YELLOW 1 18 35 GREEN DIR GREEN 35 PEE 3 YELOW T ww 36 BLUE FD TR DIRT BLUE 3 RED 3 Evo 806792 001 gt 37 VIOLET 37 4 WHITE 4 4 BLACK 38 GRAY SPARETT A E PROCESSOR gt J4 NU 39 WHITE SPARET WHITE 3 EFFLUENT TANK LEVEL 50 01 CABLE 806306 002 BROWN SPAREO PS 806815 002 INED LE SCHEMATIC PAGE 6 43 ORANGE GND ORANGE 43 CUTTER ASSY 806790 001 44 YELLOW EX DIR Y 44 RED p End ORANGE 45 GREEN EX DIR GREEN 45 STAB WHITE BLACK 2 FAN DRV WHITE 2 BLUE GND BLUE 46 Li PARETS 7 BLACK 1 BLACK EPLENISHMENT TANK ACD burn 47 VIOLET SPARE VIOLET 47 1 CUTTER SWITCH STAR BLACK COOLING FAN 48 GRAY SPARE 2 GRAY 48 SHEAR CUTTER 2 WHITE 2 2 wE SENSORS 806709 001 Lus BLACK 49 WHITE GND WHITE 4 3 BLACK 3 G BLACK te 30 BLACK GND BLACK 50 I RED 1 cUrrER MOTOR 1 PUNCH gt 7 ORANGE 2 CABLE 804140 004 BLACK SEND i WORKING TANK WHITE CABLE 807301 001 MM ux EH BEN UPPER NO MEDIA 806127 001 2 MEDIA SIG P SENSORS 806800 001 807226 001 3 ORANGE UPPER NO MEDIA GND p 3 YELLOW UPPER LOAD OK 45V t UPPERLOAD OK 30099000 WHITE m 5 GREEN UPPER LOAD OK SIG SENSOR NO 1 806789 001 SS WHITE V ORANGE 1 6 BLUE UPPER LOAD OK GND BEN WHITE U SHUTTERDRV WHHE 2 Ed LOAD KNOB 43V BLACK WHITE 24 ORANGE 3 3 GRAY LOAD KNOB SIG SENSOR NO 3 EXIT SWITCH WHITE res ware SHUTTE
89. ELF LOCKING HEX 6 32 UNC 3B WASHER FLAT STEEL 6 NARROW SCREW SHC 6 32 X 25 WRAP SPIRAL 375 ASSY BLOCK MASS Parts List Page 1 of 1 EA BOX Printware Confidential 800 IF REQUIRED S S Mo N v lt Y Ss 1 V Z _ ND x N I D THIS SIDE SEE NOTE 2 Printware ASSY MOTOR MOUNT 803666 001 REVISION N Sheet of 1 Printware Confidential Find Number 001 002 003 008 008 009 009 010 010 011 011 012 013 014 015 017 018 018 019 020 021 024 025 Quantity Component Used N BR N e 2 N OO OO N me m m m a N e Ln Assembly Number 808152 001 ASSY CAPSTAN GUIDE N Number 806320 001 806323 001 806324 001 806325 001 806411 001 806325 002 80641 1 002 806317 001 806412 001 806317 002 806412 002 900236 900871 001 900047 002 900236 008 806283 001 806517 001 806658 001 900277 026 900233 003 900871 007 900230 005 900448 Revision B Component Description GUIDE STATIONARY CAPSTAN APERTURE CAPSTAN LINK CAPSTAN BRKT CAPSTAN SHUTTER BRKT CAPSTAN GUIDE BRKT CAPSTAN SHUTTER BRKT CAPSTAN GUIDE BRKT CAPSTAN GUIDE BRKT CAPSTAN SHUTTER BRKT CAPSTAN GUIDE BRKT CAPSTAN SHUTTER SCREW SOCKET HD SHLD 8 32 X 188 SCREW SHC LOW HEAD 6 32 X 38 WASHER EXTERNAL LOCK 6 SCREW SOCKET HD SHLD 8 32 X 2505 ASSY CAPSTAN LIGHT SEAL 18 SPRING CAPSTAN GUIDE SPRING HOOKED CAPSTAN GUIDE SPRING COMPRESSION 250 X 240X 020 NUT LO
90. I 5 3 Ifthe 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 90 tighten adjustment screw f angle A is gt 90 loosen adjustment screw 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 T 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 5 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 1 16 INSTALLATION GUIDE Transport Skew Transport skew results when the media is not feeding Leading Edge 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
91. 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 Platesetter 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 traction control belt from the pinch and capstan rollers by pushing the belt tensioner to your right 3 Remove the E clips spacers if any and bushings from each end of the pinch roller shaft 4 Remove the spring loaded tensioner from each end of the roller shaft by removing the hex nut 5 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 6 Install the new roller in
92. LABEL PLATE GUIDE POSITION EDGE GUIDE LABEL PLATE GUIDE POSITION EDGE GUIDE LABEL GUIDE DOMESTIC UP LABEL GUIDE METRIC UP LABEL GUIDE COVER GUIDE A2 LABEL GUIDE COVER GUIDE B LABEL GUIDE Cl LABEL GUIDE Cl LABEL GUIDE C2 LABEL GUIDE B PLATE ADJUST Printware Confidential 324 325 326 328 329 330 331 332 337 338 339 340 341 342 343 344 345 346 347 348 349 350 351 352 353 363 364 365 366 367 368 369 370 371 372 O N A e mememe N NN NN e N T N N HN Assembly Number 808444 XX X 806354 002 806870 001 803418 002 807396 002 807398 001 807392 001 807393 001 900569 038 900660 002 900287 001 900660 007 900287 008 900871 007 900566 001 900324 001 807238 007 807238 008 807091 006 807649 001 900288 006 900277 017 807438 001 900277 004 806099 002 806099 001 807502 001 807131 004 807131 005 807131 006 807131 007 807131 008 807131 009 900445 011 900236 003 901094 001 ASSY XPORT ROLLER 46 DUAL CASSETTE Revision G PLATE POSITIONING BLOCK BACKUP SPRING TENSION MOD ASSY LOWER PINCH TENSION SCREW BLOCK MOD POSITIONING BRACKET SOLID MOUNT BRIDGE MEDIA UPPER SET BRIDGE MEDIA LOWER SET BELT TIMING 250 GROOVES STANDOFF HEX MALE FEMALE 6 32 X 1 SCREW PAN PPH 6 32 X 25 STANDOFF HEX MALE FEM 6 32 X 3 8 SCREW PAN PPH 6 32 X 38 SCREW SHC LOW HEAD 6 32 X 250 KNOB KNURLED SHC 4 WASHER CURVED SPRING 3 8 LABEL GUIDE A1 LABEL G
93. LLER DC INTERNATIONAL ASSY TRANSPORT ROLLER DC DOMESTIC ASSY MANUAL PLATESTREAM 46 DUAL CASSETTE ASSY POWER SUPPLY 110 220V ASSY CABLE INTERFACE SENSORS ASSY PROCESSOR ASSY CASSETTE SUPPLY DOMESTIC ASSY CASSETTE SUPPLY INTERNATIONAL ASSY OPERATOR PANEL FOAM LIGHTSEAL CASSETTE GAS CYLINDER 30 LBS GAS CYLINDER 75 LBS GAS CYLINDER 50 LBS STUD 10MM BALL 5 16 18 THREAD NUT HEX UNC 5 16 18 WASHER LOCK HELICAL SPRING 5 16 REG GUIDE PROCESSOR EXIT PCA STEPPER SHEAR CUTTER DUAL PF PCA INTERFACE 3240 RECEPTACLE 1 4 TURN NUT RECEPTACLE RETAINING ASSY PUMP BRKT PUMP MOUNTING ASSY PROBE WASHER EXTERNAL LOCK 8 SCREW B H TORX 8 32 UNC X 375 NUT LOCK K 48 32 TRAY STOP TRAY ADJUSTABLE TUBING SLIT 1 00 WASHER LOCK HELICAL SPRING 3 8 REG FEET ROUND 8 ROUND HEAD SCREW PAN PPH 6 32 X 75 WASHER NYLON 6 X 062 THK BUSHING SPACER NYLON 6 32 X 375 PANEL FLAT GUARD I O CABLE COVER POWER SWITCH NUT HEX UNC 3 8 16 WASHER FENDER 2 000 X 438 X 156 BOLT HEX HD UNC THREAD 3 8 16X2 3 4 Parts List Page 1 of 2 Printware Confidential 049 050 051 052 053 054 055 056 062 069 071 072 075 076 083 084 085 087 088 091 093 094 095 096 097 098 107 108 701 gt C pb T gt O gt Assembly Number 808441 XX X ASSY IMAGER PS46 DUAL CASSETTE 900872 004 900872 008 900288 002 900652 007 900651 003 900233 0
94. NON METALLIC FLANGED LABEL GUIDE COVER GUIDE F COLLAR GEAR COLLAR SHAFT NUT STAINLESS 10 24 KEPS LOCKNUT WASHER NYLON 1 4 X 50D X 032 THK LABEL STABILIZER Parts List Page 1 of 1 Printware Confidential TH ENDS Printware ASSY STABILIZER TRANSPORT 807328 001 REVISION C Sheet 1 of 3 Printware Confidential WRAP ITEM AROUND BOTH BEARINGS 2 PLCS Printware ASSY STABILIZER TRANSPORT 807328 001 REVISION C Sheet 2 of 3 Printware Confidential rs 1 0 OP SIDE 3 36 AT SEE NOTE 1 ASSY STABILIZER TRANSPORT 807328 001 REVISION C Sheet 3 of 3 Printware Confidential Find Number 001 002 003 004 005 006 007 008 009 010 011 012 013 015 016 020 021 022 023 024 025 026 027 029 031 032 033 034 035 036 037 038 039 040 041 042 Quantity Component Used 1 12 6 4 2 NO N N NY FN NY ON WN O OO OO Ne N e e e c Assembly Number 807327 001 ASSY ACTIVATOR TRANSPORT 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 806819 001 806695 001 900773 001
95. Number 808444 XX X 900047 002 900277 029 900566 003 900172 002 900160 005 900233 003 900235 000 900235 005 900963 002 900236 005 900224 005 900235 002 900172 003 900236 001 900224 002 900319 001 900254 003 900276 006 900928 003 900235 040 900445 004 900160 012 900235 003 900160 004 900235 032 900257 900016 000 900223 007 900222 003 900651 019 900445 009 900359 001 900520 001 807093 003 807093 004 807093 006 808172 001 807231 009 807231 002 807238 003 807238 004 807238 005 807238 006 806352 002 ASSY XPORT ROLLER 46 DUAL CASSETTE Revision G WASHER EXTERNAL LOCK 6 SPRING COMPRESSION 2 00 X 660X 072 KNOB KNURLED SHC 8 SCREW FLAT HD 6 32 X 38 WASHER FLAT STEEL 8 NUT LOCK K 78 32 SCREW SHC 8 32 X 75 SCREW SHC 8 32 X 38 PLUNGER SPRING LOADED SCREW SOCKET HEAD SHOULDER 8 32 X 6255 SCREW TAPTITE PPH 8 32 X 50 SCREW SHC 8 32 X 50 SCREW FLAT HEAD 6 32X 5 SCREW SOCKET HEAD SHOULDER 10 32 X 500 SCREW TAPTITE PPH 8 32 X 3 8 BEARING NON METALLIC FLANGED SPACER SHAFT INNER WASHER NYLON WEAR 253 ID X 568 OD NUT HEXJAM 1 4 X28 SCREW SHC 8 32 X 5 8 SCREW B H TORX 6 32 UNC X 375 WASHER FLAT STEEL 8 NARROW SCREW SHC 8 32 X 1 00 WASHER FLAT STEEL 6 SCREW SHC 6 32 X 3 4 STUD 10MM BALL 5 16 18 THREAD LOCKTITE SMALL SCREW 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 SPACER 375 ID X 093 THICK TORQUE SEAL BLUE
96. OLLER BLUE PRN DO 27 o BLUE SCHEMATIC PAGE 3 VIOLET PRN DI 915 ORANGE INTERLOCK PWR GRAY PRN DIT 2 o BLACK IN 2 WHITE PRN D2 10 ORANGE INTERLOCK ASSY 2 UAE TRAD gt T TO RIP BLACK VENTFANRIN 806302 BROWN PRN D3 mo DC POWER SUPPLY E RED PRN DST 30 2 901142 001 ALLFUSES ABLE 803312003 ORANGE PRN D4 215 EA 15 RED YELLOW PRN D47 31 322 Amis LASER ASSY ES GREEN PRN D5 13 o RED INTERFACE BLACK GND E E Iu B To SEE YELLOW INTRF 2V PANEL 305280001 IR BLUE DV 3 BLUE PRN D x 4 Ne 807220 TAB RED BLACK GND 4 EM 4 Io ORANGE INTRE 32V BROWN PHOTODIODE 5 GRAY m 5190 uu HERE BLACK GND CABLE 803312 003 OPERATOR PANEL ASSY BLACK PRN D77 om RED OP 45V C ELI 807148 001 BROWN 6 ence 22 or RED PRN RYW BLUE 12V POWER i BU 1 GREEN G DRVO 1 ORANGE PRN STRE ma 424V FUSE BLACK GND SUPPLY Bl 2 GALVO ASSY G SENSE 2 YELLOW STRE 36 GROUND DAA gt DRAWER A SCMEMATIC PAGE 7 GREEN GDRVI 3 GREEN PRN ACK 18 D m i RED G DRVO E BLUE ACK 31 9 12V FUSE BLUR 4 SENSE 5 VIOLET PRN GND 19 2 x o L T DRVI 807049 001 NC 12V FUSE m J5 E L AC POWER COVER RED sos c GREEN SOS SIG 2 DC POWER E WEE 09 REL SCHEMATIC PAGE 2 rr m BED Sore 4 NU J16 WIRE COLOR xx i WHITE SOT SIG 5 SDE GRAY SOT REF 6 TT E LIQUID CRYSTAL DISPLAY E 807151 001 YELLOW 522540 4 r YD 5 E WE e 7 8 8 5 XSCL Y
97. PlateStream CENE Platesetter 9 Click on desired manual Quick Start Guide Installation Guide Operator Manual Service Manual Illustrated Parts List Printware LEADERS IN COMPUTER TO PLATE 1270 Eagan Industrial Road St Paul MN 55121 Phone 800 456 1400 gt Fax 651 454 3684 http PrintwareInc com PlateStream 46 Platesetter Dual Cassette Quick Start Guide Printware LEADERS IN COMPUTER TO PLATE Manual 700608 Rev B QUICK START GUIDE Contents Introduction Loading Plate Material Control Panel Setup Menu RIP Setup amp Imaging Plates QS 2 QS 2 QS 4 QS 5 QUICK START GUIDE Introduction For detailed procedures see the PlateStream 46 Operator Manual Before making a plate the Platesetter must be Connected to the RIP the I O panel is located on the bottom 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 PREPARING TO LOAD 1 Open the platesetter top cover Raise the marker by pulling the marker lever towards the front of the platesetter until the lever stops Gently lift up the marker 2 Pull out the load knob on the left side of the platesetter CHANGING BOTTOM CASSETTE MEDIA WIDTH if necessary 1 Unload top cassette before adjusting the rear edge guides 2 From inside of the platesetter carefully remove th
98. Processor chemistry chemistry is depleted 7 2 IN CASE OF TROUBLE PROBLEM Image Blinding faint printing 73 CAUSE 1 The press ink fountain bal ance is incorrect 2 The press pressure is insuf ficient 3 The press ink rollers are glazed 4 The paper is clinging to the press blanket 5 The press fountain concen tration is too strong 6 The press blanket was not dry on roll up 7 The press blanket is glazed SOLUTION 1 Check the balance and correct if 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 PROBLEM 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 CAUSE 1 The press fountain concentra tion or ink is incorrect 2 The press ink fountain balance is incorrect 3 The press rollers or blanket is glazed 4 Press pressure is insufficient Exposure laser intensity is set too high 1 Platesetter processor chemistry 1s dirty 2 Laser is out of focus 1 The Platesetter rollers are dirty 2 Bad plate material 3 Platesetter processor chemistry is dirty IN CASE OF TROUBLE SOLUTION 1 Check and replace if necessary
99. R DEV WHITE 4 9 WHITE LOAD KNOB GND 5 600333 001 NU CABLE SX 1 BLACK DOT 6 oT EXIT CASSETTE USED ONLY J6 NU 806376 001 11 BROWN SENSOR NO WITH FILM 7 a 1 12 RED s 807091001 OPTION 8 806788 001 BROWN WORKING TANKS LOW BROWN 1 13 ORANGE LOWER NO MEDIA 45V A Wea 9 WHITE RED GND RED 2 14 YELLOW LOWER NO MEDIA SIG MEDIA NO 10 DRIER TEMP SENSOR BLACK ORANGE REPLN TANKS LOW ORANGE 3 15 GREEN LOWER LOAD OK SIG 807091001 TL WHITE YELLOW GND YELLOW 4 16 BLUE LOWER NO MEDIA GND I 17 600330 001 GREEN EFF TANK HIGH GREEN 5 17 VIOLET EX LOOP 5V EXITLOOP LOWER LOAD OK 45V IOWERIOADOK BLUE GND BLUE 18 GRAY EX LOOP SIG SENSOR NO LOWERLOAD OK SIG NOS VIOLET PROC TEMP VIOLET 7 19 WHITE LOOP GND Y LOWER LOAD OK GND yx 4 7 5 3E gt E GRAY GND GRAY y X BLACK UPPER FD LOOP TSV 307091 001 m D T 307091 001 B 06534 WIRING CHANGE PAGE 6 J8 W M S 9 1 99 WHITE FILM EXITS WHITE 9 3I BROWN UPPER FD LOOP SIG IPERE RED LOO A 06490 INITAL RELEASE WMS 7 9 99 BLACK GND BLACK 00 22 RED UPPER FD LOOP GND T s 7 n 7 TEL BROWN SPARET BROWN il ORANGE 801091001 DESCRIPTION DRAWNBY DATE APPVL DATE RED GND RED 12 YELLOW uv WMS 7 2 99 ORANGE 5V POLLUP ORANGE 13 GREEN YELLOW Sor YELLOW it BLUE a PRINTWARE INC GREEN 35V PULLUP GREEN IS VIOLET ORANGE AL ACT TEMP PROBE RED BLUE DRIVE INH BLUE 16 GRAY POWER 3 ORANGE c ST PAUL MN BLACK
100. RED 2 NGINE STEPPER PCA ce ORANGE 3 POWER ORANGE FD STEP g J SUPPLY 10 BLACK 2 YELLOW au 523190 004 1 BLACK 80323002 1 1 WHITE BLU DRAWER 2 RED S GREEN FD RESET GREEN 5 WHEEL CUTTER 2 YELLOW 2 2 RED 3 BLACK 3 BLUE DRETS BLUE 6 3 veo YELLOW 5 VIOLET GND VIOLET 7 3 WHITE BLACK 5 BLACK 6 GRAY TR STEP GRAY 6 BLUE WHITE TR STEP WHITE 9 UPPER FEED STEPPER 1 BLACK x 803666001 BLACK GND BLACK 10 J5 1 ORANGE ra BROWN TR RESET BROWN Il SCHEMATIC PAGE 5 es ON PlateStream DC46 ONLY T 3 a RED TR RESET RED 1 INTERFACE PCA ORANGE GND ORANGE 13 80332300 y 523060 001 YELLOW EX STEP YELLOW 14 L BLACK wm BLU TS2 TS1 E GREEN EX STEP Y GREEN 15 PAPER FEED 2 YELLOW 2 2 RED BLUE GND BLUE 16 3 3 RED 3 Soma 1 y VI WHITE 4 4 BLACK VIOLET EX RESET VIOLET 17 3 GND 2 SCHEMATIC PAGE 4 GRAY EX RESET GRAY 18 ri r1 WHITE GND WHITE 19 CAPSTAN STEPPER L2 J1 NU BLACK CUT STEP BLACK 20 YEL 304628001 BROWN CUT STEPS BROWN 21 RED GND RED 7 ORANGE CUT RESET ORANGE 23 YELLOW CUT RESET YELLOW MARKER TRANS 1 BLACK 80333002 1 Buz aa 25 GREEN GND GREEN 5 2 YELLOW 2 2 RED H 37 VIOLET PLGTOP VIOLET 27 I WHITE z 3 BLACK 28 GRAY GND GRAY 28 8 3 Jemo Se ag WHITE EXIT STEPPER I S BLACK STEP SYNET BLACK 3 St 31 BROWN GND BROWN 414 les od 32 RED 5 RED 32 7 NGE 35 33 ORANGE SPAR
101. SHER FLAT STEEL 25 DIAMETER WASHER FLAT STEEL 8 NARROW STRIP NOISE SUPPRESSION STRIP NOISE SUPPRESSION TAPE BONDING 4 WIDE EA 1 ROLL Parts List Page 1 of 1 Printware Confidential FON ne 54 fixe J 0 0 0 NE Ha 1 op E HIS SIDE NOTE o o FOUR PIECES AS REDID CAR CAR CAR Pen ce Printware ASSY SHROUD 18 DUAL CASSETTE 808447 XXX REVISION C Sheet of 1 JOTTOM BRACKET Printware Confidential Find Number 001 002 003 004 005 006 007 009 010 011 012 013 014 015 016 017 018 019 020 021 022 023 024 025 025 026 026 027 029 030 031 032 033 034 035 036 037 038 039 040 041 042 Quantity Component Used N e N e e N e N A A e e ANA e e e C e e 9 Assembly Number 808155 001 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 807206 001 807328 001 807205 001 807327 001 900060 002 806701 001 806702 001 806725 001 900338 002 806793 001 806794 001 900040 003 600330 001 806831 001 806704 001 806705 001 806788 001 806789 001 806790 001 ASSY PROCESSOR Revisio
102. SSEMBLY E 2 PLACES R ALIGNMENT USE 120 D A DRILL BI Qe Printware ASSY TRANSPORT ROLLER 18 D C dans ue ASSEMBLY 808444 XXX REVISION G Sheet 2 of 4 Printware Confidential ud SEMBLY Printware ASSY TRANSPORT ROLLER 18 D C G 808444 XXX REVISION Sheet 3 of 4 Printware Confidential U ND MEDIA BACKSID D LOOP BACKSIDE ASSEMBLY U 2 PLACES ASSEMBLY M SSEMBLY SSEMBLY 3 PLACES ASSEMBLY P 2 PLACES ASSEMBLY N Printware Confidential ASSEMBLY Q Printware ASSY TRANSPORT ROLLER 18 D C 808444 XXX REVISION G Sheet 4 of 4 2 PLACES Find Number 001 002 003 004 005 006 008 009 010 011 012 013 014 015 016 018 019 020 021 022 023 024 025 026 027 028 029 030 031 Quantity Component Used UU QV U N OO QN WA W BA BPW N YN CO NR RRR Assembly Number 804627 001 ASSY CAPSTAN DRIVE 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 900016 000 900226 004 900340 003 900160 006 Revision K Co
103. 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 32 PlateStream 46 Platesetter Dual Cassette Operator Manual Printware LEADERS IN COMPUTER TO PLATE Manual 700610 Rev A 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 implied 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 O 1999 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 regis
104. T STEEL 8 SCREW SET CUP POINT 6 32 X 375 Parts List Page 1 of 1 Printware Confidential TAB BLOCK DOMESTIC INTERNATIONAL 808243 001 808243 002 ASSY CASSETTE SUPPLY 280 808243 XXX REVISION E 14 ud Sheet of Printware Confidential
105. This allows selection of the correct spool folder at print time 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 46 the default printer name is PlateStream 46 when using the PlateStream 46 PPD Select the ZAPrip HQ and the appropriate hot folder GTO2up2400dpi in our example as the destination by browsing Network Neighborhood Select the PlateStream 46 PPD if the applica tion supports PPDs Do not specify screens or resolution in the application 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
106. Tightening the screw clockwise moves the punch pattern toward the operator side To move the punch pattern toward the non operator side loosen the screw counterclockwise and move the punch Each turn moves the punch approximately 0 030 5 Tighten the two screws on the non operator side of the punch assembly Leave the two screws on the operator side loose for adjusting skew Punch Skew 1 Loosen the two screws indicated in Fig I 6 on the operator side if they have not been loosened for lateral adjustment 2 Measure the location of the punch pattern relative to the grid pattern on the test plate Refer to Fig I 7 f A gt B non operator side deeper loosen the 4 locking screws and turn the Skew Adjustment Screw clockwise Each turn moves the punch approximately 0 030 0 08 cm If A B operator side deeper turn the Skew Adjustment Screw counterclockwise 3 After adjustment run another plate to check for punch skew 4 Continue adjusting punch skew until the punch pattern is sufficiently parallel to the cut edge 5 Tighten the two screws indicated in Fig I 16 on the operator side Operator side notch arid Pattern Non operator side notch lt Lateral Punch Alignment gt Figure 1 7 Punch Alignment and Skew 1 26 INSTALLATION GUIDE Adjusting Punch Length 1 To enable the punch from the Main Menu on the control panel Press 4 More Information Press 8 Punch Press
107. UFFLER PNEUMATIC ASSY PUNCH 2 HOLE SOLENOID AIR VALVE ASSY CABLE SOLENOID SCREW SHC 8 32 X 75 BRKT PUNCH MTG NON OP SIDE BRKT PUNCH MTG OP SIDE V SEAL BROWN GUIDE LOWER PUNCH GUIDE UPPER PUNCH PANEL I O PUNCHSTREAM BRKT PUNCH PLATE GUIDE UPPER CUTTER GUIDE LOWER CUTTER ASSY SWITCH ASSY CROSSOVER GUIDE PANEL FLAT WASHER FENDER 500 X 189 X 125 WASHER FENDER 749 X 203 X 156 WASHER EXTERNAL LOCK 8 SCREW B H TORX 8 32 UNC X 500 LOCKTITE SMALL SCREW SCREW SOCKET HD SHLD 8 32 X 2505 SCREW SHC 8 32 X 50 SCREW SHC 8 32 X 5 8 NUT LOCK K 8 32 NUT LOCK 48 32 SCREW SHC 8 32 X 75 CLAMP FIXED DIA 250 SCREW PAN PPH 6 32 X 7 16 WASHER FLAT STEEL 6 RING GRIP NUT SELF LOCKING HEX 6 32 UNC 3B Printware Confidential Assembly Number 807425 XXX ASSY PUNCH PS46DC 2 HOLE Revision C 060 2 900287 025 SCREW PAN PPH 6 32 X 1 25 061 1 807352 002 SHAFT 25 063 1 807413 001 ASSY PLATE COLLECTOR CHIP Printware Confidential ASSY PUNCH PS46DC 2 HOLE 807425 XXX REVISION C Sheet 1 of Printware Confidential Assembly Number 806817 001 ASSY TANK EFF W CART 24 Revision D Find Quantity Component Component Number Used Number Description Parts List Page 1 of 1 001 1 807083 001 ASSY CART EFFLUENT 002 1 806816 001 ASSY TANK EFFLUENT Printware Confidential n SS N N zr k H A 2 M s S x x 2574 Wed Nero di M E l
108. UIDE A2 ASSY SWITCH BRACKET GUIDE ADJUST SCREW PPH 10 32 X 1 5 SPRING COMPRESSION 750X 240X 029 BRKT GUIDE ADJUST SPRING COMPRESSION 750X 360X 042 ASSY SOLENOID CAPSTAN GUIDE ASSY SOLENOID CAPSTAN GUIDE SPRING TRACTION CONTROL LABEL SENORS UPPER NO MEDIA LABEL SENSORS UPPER FD LOOP LABEL SENSORS UPPER LOAD OK LABEL SENSORS LOWER FEED LOOP LABEL SENSORS LOWER NO MEDIA LABEL SENSORS LOWER LOAD OK SCREW B H TORX 8 32 X 250 SCREW SOCKET HEAD SHOULDER 8 32X 125 LUBRICANT W TEFLON Printware Confidential 1 0 SEE NOTE 1 THIS SIDE ASSEMBLY S 2 L ASSEMBLY P ASSEMBLY R 44 a NL ASSEMBLY ASSEMBLY LI ASSEMBLY L ASSEMBLY ER 107 em ASSEMBLY R ASSEMBLY D MBLY iE 2 ASSEMBLY ASSEMBLY A ASSEMBLY D ASSEMBLY E ASSEMBLY F ASSEMBLY I Bb e Ei ES i N ASSEMBLY U N ASSEMBLY K ASSY TRANSPORT ROLLER 18 D C 808444 XXX REVISION G Sheet of 4 Printware Confidential ASSEMBLY C2 ASSEMBLY F ERI cL M ASSEMBLY D A
109. X LOOP ASSY SWITCH ARM IDLER BRKT IDLER SHAFT IDLER E RING SAE 1 4 SHAFT PULLEY MOD SCREW SHC 6 32 X 25 ASSY MOTOR MOUNT BRKT BEARING SUPPORT BRKT GAS CYLINDER PHO 05235 WASHER FLAT STEEL 10 WASHER FLAT STEEL 25 DIA SCREW SOCKET HD SHOULDER 10 32 X 2505 WASHER EXTERNAL LOCK 10 SCREW PPH 10 32 UNF X 1 2 BEARING OIL LESS BRONZE DB1122 SHAFT MARKER 5 BEARING MODIFIED SELF ALIGNMENT SPACER SHAFT INNER 1 2ID X 1 16 SPACER 171 ID 25 OD 25 HT PULLEY DUAL CAPSTAN PIN DOWEL SST 1250 DIA X 625 LG Printware Confidential 154 158 160 161 163 164 165 166 167 170 171 172 173 174 175 177 178 181 182 185 186 187 188 189 193 194 195 198 206 209 250 251 253 254 261 262 263 264 265 267 268 269 270 271 BRN FN D E NN NN 9 Ne DANI a OQ WN Q L N Rh 12 12 70 108 14 14 28 14 Assembly Number 808444 XXX 806331 002 808152 001 806360 001 806381 001 807066 001 806945 001 900223 004 900235 005 900236 002 806946 001 900276 007 900236 009 900236 900275 003 900222 002 900324 001 900235 035 803456 001 900406 002 900235 001 900229 003 901024 001 804703 001 804704 001 900319 002 803697 001 806304 001 900235 007 900223 000 900160 009 900233 900229 009 900229 008 900236 008 900287 004 900287 017 900233 002 900445 006 900047 000 900261 004 900875 002 900958 001 900839 002 900277 023 ASSY XPORT ROLLER 46 DUAL C
110. YER HEATER B 806712 001 TT PEYO WMS 320 99 ENG PRINTWARE INC I o 85 I ili E neo ST PAUL MN L L 2 MATERIAL BLUE EN A 5 TOLERANCE UNLESS OTHERWISE SPECIFIEI A ANGLES E BROWN m m POWER SUPPLY m 1 PLACE DECIM 2 z9 FINISH 2 PLACE DECIMALS 02 YELLOW GREEN 220V 5 3 PLACE DECIMALS 010 Z Title REPLENISHMENT ij E WIRING DIAGRAM PlateStream DC46 PUMPS 806843 001 m Z COMM CODE Size INSP VERSION REV FIRST USED ON B 700607 001 B SCHEMATIC PAGE 6 Teproduced copied disclosed to others or disposed SCALE NONE tion from Printware Inc Both the document and its contents are to be treated as confidential amp Sheet 6 of 7 proprietary and may not be used in any manner not consistent with the rights of Printware Inc 3 4 5 6 LIQUID CRYSTAL DISPLAY 522540 LCD ASSY 802533 KEYPAD 523180 001 UM OPERATOR PANEL ASSY 807148 001 SUPPLY DRAWER 6 XD3 XD2 ES ve XDO lt 5 XSCL o NI lt VLCD x7 E EI ES CAES IS x nj YO lt x i loja E N v 11 11 11 oo 20 BROWN RED ORANGE YELLOW GREEN BLUE VIOLET GRAY WHITE BLACK BROWN RED ORANGE YELLOW GREEN BLUE VIOLET GRAY WHITE BLACK CABLE 803311 003 10
111. 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 Media not loaded far enough messages 55 Verify that there is media in the machine Manually feed the media up to the capstan roller Check for faulty Load OK switch 3 Remove media 3 2 View Sensor Status on Operator Panel 1 means media present 3 3 actuate the Load OK switch If it 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 OK switch and cable test good but there are still spurious No media or Media not loaded far enough messages bend the Load
112. al 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 in gear breakage 34 PREPARING FOR OPERATION Loading Plate Material PREPARING TO LOAD 1 Open the platesetter top cover Raise the marker by pulling the marker lever towards the front of the platesetter until the lever stops Gently lift up the marker 2 Pull out the load knob on the left side of the platesetter CHANGING BOTTOM CASSETTE MEDIA WIDTH if necessary 1 Unload top cassette before adjusting the rear edge guides 2 From inside of the platesetter carefully remove the three cables from the three switches on the underside of top guide A1 and remove guide A1 3 Adjust the two rear edge guides by loosening the 3 16 Allen screw on the top guide and the knob bottom guide slide the guides to the positon closest to the plate media width Tighten the Allen screw LOADING THE BOTTOM CASSETTE 1 Adjust the two front edge guides by loosening the 9 64 Allen screw on top guide and the knob on the bottom guide and slide the guides all the way to the front of the machine 2 Open the feed cassette by lifting the back of the lid and sliding forward at the same time 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 fr
113. assures high quality printing plates and printed output The Platesetter is designed to image silver halide coated plate material The Image default for silver halide material is 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 9 to 18 1 22 9 cm to 46 cm The maximum roll length is 280 85 M 52 SUPPLIES RECOMMENDED CONSUMABLES FOR PLATESTREAM 46 MITSUBISHI SILVER DIGIPLATE INFRA RED PLATE MEDIA 5 mil paper 0 12 mm SDPRD125 7 mil paper 0 18 mm SDPRD175 4 mil polyester 0 1 mm SDP FD100 7 mil polyester 0 18 mm SDPFDI75 CHEMISTRY Emulsion In SPEC28 SPEC 28 SPEC 820 SPEC 820 ACTIVATOR SLM AC STABILIZER SLM ST AGFA SETPRINT Emulsion Out SPEC28R SPEC28R SPECS20R SPEC820R RED LIGHT PLATE MEDIA Emulsion In 5 mil 0 12 mm polyester SET HN LL 13 8 mil 0 2 mm polyester SET HN LL 20 CHEMISTRY ACTIVATOR G260b STABILIZER G360b 53 RED LIGHT PLATE MEDIA SDPRR125 SDPRRI75 SDP FR100 SDP 175 Emulsion In SPEC28 SPEC28 SPEC820 SPEC820 Emulsion Out SPEC28R SPEC28R SPECS20R SPECS20R 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 eStore media rolls upright on end not on
114. ating 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 Setup Image Ne Resolution Image Power Verify that exposure is set correctly by checking see Operator Guide for detail Laser power too high can cause text to break up on press output not the plates Reduce laser power Verify that exposure is set correctly by checking Laser power too low can cause plugged images and excessive background on press output not the plates Increase laser power ESC to exit gative Right Reading 1800 DPI 5 Spool Pos 13 Media Upper Spool Input Spool A Destination Display Units 1 2 3 Media Width 13 12 6 7 Processor English ON ESC OFF ENTER Setting laser power setup menu item 3 43 EXPOSURE PROBLEMS cont Uneven density from center to edges Hazing on fine print or fine lines Going around in circles adjusting laser power 1 x 1 SERVICE MANUAL 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
115. cassette and plate material in the other the plate material must be loaded first without any film in the imager Complete the loading of the plate material before attempting to load the film in cassette mode QS 3 QUICK START GUIDE Control Panel Setup Menu The control panel Setup Menu below lists six options for changing various Platesetter parameters Setup ESC to exit Image Negative Right Reading Resolution 1800 DPI Image Power 5596 Media Width 13 12 Spool Pos 13 Media Upper Spool Input Spool A 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 9 00 to 18 10 22 90 cm to 46 00 cm Spool Pos 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 9 to 18 5 Media Upper Spool Choices are upper and lower Input Spool Choices are A B C or D 6 Destination Sets output destination for the imaged media The choices are Processor Processor Minip
116. 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 Checkoillevel 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 GUIDE F PINS 7 WIRE GUIDES 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 S
117. ckground Smeared Images 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 IN CASE OF TROUBLE General Troubleshooting PROBLEM PROBLEM SOLUTION 2 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 Ensure that the Platesetter is plugged in 2 Check the fuse or breaker for the outlet Try unplugging the 1 Platesetter and plugging another electrica
118. control panel Main Menu will cut and feed any print jobs remaining in the Platesetter plus a leader into the take up cassette Using the FilmOption 1 Place the slot on the take up cassette over the imager exit guide Place the top two metal pins attached to the take up cassette in the slot in the two black take up receptacles and push down see figure 2 Set destination in set up menu to cassette mode Press the load key 5 on the control panel Main menu and wait until the idle message appears Set the plate width from the control panel set up menu The platesetter is now ready to image 3 To remove imaged film for processing press the Cut Fd 6 on the control panel Main Menu Open the processor top cover and remove the take up cassette by lifting the cassette off the two black take up receptacles Note The take up cassette will hold up to 25 of printed jobs however the cassette will hold only one piece of media at a time 3 11 PREPARING FOR OPERATION Take up cassette Figure 3 3 Location of Optional Take up Cassette 3 12 OPERATING THE PLATESETTER 4 1 CHAPTER 4 OPERATING THE PLATESETTER 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
119. cription 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 the 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 S2 1 This will break the warranty void seals Inspect the surfaces of the galvanometer window the reversing mirror spherical mirror and the folding mirror Refer to Figure S2 1 If no dust particles or other particles are present on the mirror surfaces reinstall the marker assem bly unit lower cover If this is the case the cause of the plate quality problem is not mirror cleanli ness 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 procedure only if 1
120. ct the ribbon cables from J8 on the PCA and J9 on the PCA d Disconnect the orange and white wires from the connector located towards the front of the Marker next to the fan e Bubble wrap the ends of the disconnected cables e INSTALLATION GUIDE 2 Prepare to remove the marker a Raise marker by pulling marker lever towards the front of the Platesetter until lever stops and lift the front of the marker b Place a 26 by 1 66 cm x 2 5 cm piece of tape on the bottom of the laser marker over the slot for the laser light c Detach the right cover strut on the marker end by removing the cap and pulling the strut off the ball joint d Detach the strut on the laser end while holding the marker in the upright position by removing the cap and pulling strut off the ball joint e Fasten the shipping brace to the laser right end of the marker with eight screws NOTE If the marker is being repackaged without separating the Imager and Processor modules the marker must be removed before installing the shipping brace f Detach the strut from the galvo left end of the marker g Reattach cap to struts 3 Remove the marker a Place blue plastic bag and two DESI PAK bags in the marker assembly carton with the bag laid open b Using two people remove the marker from the Platesetter c Slide the marker assembly off the brass pivot bushing located furthest from the processor section left without moving the bushing d
121. de D pins Lever Load Knob Guide C2 pins fe Upper A N el Cassette J 9 SL 1 Pon Activator Stabilizer Lower Cassette A Guide pins Optional Effluent Tank Figure 1 3 PlateStream 46 Dual Cassette Media Path 14 GENERAL INFORMATION Features Overview Figure 1 4 illustrates the following features I O Panel High Speed Control Panel Power Switch Options The I O panel is located on the bottom rear of the Platesetter This I O panel is used to connect the Platesetter to an external RIP The Platesetter images plates at a rate of 120 plates per hour and up to 36 inches per minute 91 cm min Plates emerge right reading for easy proofing and final plate checks The Platesetter can image any width from 9 to 18 1 22 9 to 46 cm Plates can be any length from 12 to 22 30 5 to 56 cm The maximum roll length is 275 84 M The control panel is located on the top front of the Platesetter The control panel keys allow you to perform a number of adjustment and diagnostic functions and the 8 x 40 character liquid crystal display LCD screen displays status error messages and func tion 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
122. e Physical Calibration in the INSTALLATION GUIDE It also adjusts the gap between jobs in Cassette Mode 7 Guide B Sensor When the Guide B Sensor is turned off this enables the sensor 8 Punch Only if punch option installed turns the punch on and off 2 10 CONTROL PANEL Run Hardware Menu Run Hardware ESC to exit Feed Motor OFF 7 Reset Proc Transport Motor OFF 8 Start Proc OFF 9 Prime Pump Exit Motor 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 CONTROL PANEL Calibrate Menu Calibrate ESC to exit Calibrate Transport Calibrate Marker Input Spool Manager Marker Position 00 00 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 acces
123. e after a load misregistered on process color jobs 47 x 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 Xx 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 either side of the roller pairs to set correct tension Correct roller tensions are as follows nfeed rollers approx 4 Ibs 18 N First pinch rollers approx 4 5 Ibs 20 N Second pinch rollers 8 14 Ibs 50 N note tensi
124. e 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 dryer 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 Laser power too high can cause short run lengths 3 Reduce laser power 72 CABLE 803314 001
125. e network interface connector on the back of the RIP CPU Plug in the RIP electrical power cord s Connect the video interface cable between the RIP CPU and the Platesetter The Platesetter I O Panel 1s located on the bottom rear of the machine INSTALLATION GUIDE Turning On the Platesetter 1 The power switch for the Platesetter is located on the left side 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 46 Operator Manual If the display stops at any initialization point for more than five minutes turn off the Platesetter and call for authorized service The 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 12 30 cm Rear clearance gor 24 60 cm A Left clearance Marker Lever Load Knob 47 119 cm Power Switch IN Y pr d 24 60 cm Upper Cassette Right clearance mounting brackets Lower Cassette mounti
126. e pack from contents The contents should include a A PlateStream 46 Platesetter Quick Start Guide Installation Guide Operator Manual and Service Manual b A small replenishment cart and tank wire tray and tray stops d Optional take up and supply cassettes e Optional punch chip collector and punch hoses f Tube with plate samples g Optional effluent cart and tank h Black tank cover input guide crossover guide and overflow tubes INSTALLATION GUIDE Joining the Imager and Processor Modules 1 Before joining the two modules route the processor power cable through the hole in the lower portion of the chassis and make the appropriate connections to the power supply Align the pins in processor module with the holes in the imager module Remove the plastic bag taped to the inside front of the Imager which contain the four sets of hardware 9 16 x 1 bolts to attach the Processor to the Imager Boltthe Processor to the Imager modules together using the four clearance holes located on the left side ofthe Processor and threading into the four threaded holes located on the right side of the Imager Replace the Imager front and rear panels Route the processor ribbon cable to the connector on the left side of the processor Plug in the three pin connector labeled EXIT CAS to the optional film cassette sensor located on the left side of the processor Insert wire tray into slots located on the top
127. e plastic wrapping from the unit Remove the front panel and the three strips of bubble pack Remove the metal shipping brace at the bottom of the Processor by removing the screws located above the front casters Remove and unwrap the bubble pack from the two replenishment tanks and the optional effluent tank located underneath the Processor Attach the ramp to the bottom of the crate using the two nails located in the front of the crate Close the top cover Remove the screws from the four wood blocks mounted to the bottom of the crate Remove blocks by slightly lifting the Processor Roll the Processor down the ramp and onto the floor carefully INSTALLATION GUIDE Assembling the Platesetter 1 Remove the screws holding the top and sides of the marker crate Carefully open the carton containing the marker assembly Remove the second cardboard cover from the marker assembly Cut the tie strap 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 Remove the foam block from the marker E O CAUTION Do not set the laser marker assembly down on flat surface This can damage the resonant galvanometer on the side of the assembly 10 11 12 13 Open the Imager top cover and remove the strips of bubble pack Remove tie straps and bubble
128. e three cables from the three switches on the under side of top guide Al and remove guide Al 3 Adjust the two rear edge guides by loosening the 3 16 Allen screw on the top guide and the knob bottom guide slide the guides to the positon closest to the plate media width Tighten the Allen screw LOADING THE BOTTOM CASSETTE 1 Adjust the two front edge guides by loosening the 9 64 Allen screw on top guide and the knob on the bottom guide and slide the guides all the way to the front of the machine 2 Open the feed cassette by lifting the back of the lid and sliding forward at the same time 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 media 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 media see Figure QS 1 Insert the loaded spool assembly back into the feed cassette with 12 of media remaining outside the cassette 5 Place the cassette onto the cassette mounting brackets 6 Feed media through the first set of edge guides and rollers 7 Rotate the cassette up and lock into place on the platesetter Ensure the media is not pinched between the cassette and the platesetter 8 From inside the platesetter push the media up through the next edge guides into the
129. edia Silver halide polyester or paper plates 0 004 to 0 008 thick Imagesetting film with film handling option set Integrated Processor 2 bath design Adjustable automatic replenishment Adjustable developer bath temperature 75 F 95 F 24 C 35 C Adjustable dryer temperature 75 F 140 F 24 C 60 C PunchStream Integrated Punch Option Integrated punch option for Heidelberg GTO Ryobi 3300 series Hamada H234 and similar landscape and portrait presses Punching repeatability 20 001 25 microns Film handling Option Processor bypass take up cassette for up to 25 8M A 3 SPECIFICATIONS ZAPrip Raster Image Processor Options Adobe PostScript ZAPrip ZAPrip HQ Harlequin interpreter ZAPrip 200 Hy Way interpreter RIP Network Protocol Options Novell NetWare Mac AppleShare Physical Dimensions Dimensions 47 hx 52 wx 35 d 119 cm x 132 cm x 89 cm Weight 750 Ibs 340 kg Environment 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 Relative Humidity 45 to 70 operating non condensing A 4 CALIBRATION B 1 CALIBRATION APPENDIX B CALIBRATION Introduction This appendix provides tips for calibrating the PlateStream Following these procedures will provide the best results especially when printing screens Calibration has two major steps I Setting maxi
130. esetter 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 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 46 DC 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 LOW PROC TEMP HIGH EFF LOW REPL 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 Sets the Platesetter to either on line or off line The Platesetter must be on line in order to accept print jobs from the RIP The Platesetter cannot be set On Line if there is an error present Advancing the display to any of the sub menus automatically takes the Platesetter Off Line 24 CONTROL PANEL 4 More Information This selection provides access to several menus 5 Load This selection loads the media 6 Cut Fd Thi
131. etter If the 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 Replace all guides in the original positions Gently close the MARKER and lock it by pushing down the MARKER LEVER Reload the plate material 7 10 IN CASE OF TROUBLE Processor Working Tanks Cover E Imager Cover Guide D pins Lever Load Knob Upper Cassette Activator Stabilizer pins Lower Cassette lt Guide pins Optional Effluent C J i is Replenishment Tanks Figure 7 1 Clearing Media Path 741 IN 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 service Use the procedures and troubleshooting guidelines outlined in this manual If the 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 Wrte down the Platesetter model number and serial number located on the rear cover 4
132. ev x vpejcejvjoeisi lIcejlelxivpiscejeiji baal Ron Koa bad Leal ol oad bani kani bani bani bani kani kani bani ALALNTATATAT calan kaal bud bod bud bud bud xu up TO INTERFACE PCA J12 CABLE 803311 003 AH SCHEMATIC PAGE 3 DRAWN x WMS 7 18 99 ENG PRINTWARE INC ENG APPVL DO NOT SCALE DRAWING ST PAUL MN MFG QA MATERIAL TOLERANCE UNLESS OTHERWISE ANGLES 1 PLACE DECIMAL 2 PLACE DECIMALS 3 PLACE DECIMAL 5 DEG FINISH 02 010 WIRING DIAGRAM PlateStream DC46 COMM CODE Size 7 0 0 6 0 7 0 0 1 INSP VERSION REV FIRST USED ON B P B This document and the information it contains is the property of Printware Inc and may not b E reproduced copied disclosed to others or disposed of directly or indrectly without authoriza SCALE NONE tion from Printware Inc Both the document and its contents are to be treated as confidential amp Sheet 3 of 7 proprietary and may not be used in any manner not consistent with the rights of Printware Inc 5 6
133. f 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 To adjust the SOT sensor scan width Figure 1 11 Adjusting Scan Width and Linearity 1 From the RIP output the Grid18 ps file 2 Measure the distance between points A and C see Figure I 13 If the distance between A and C is 217 000 43 18 cm turn the sensor position screw counterclockwise If the distance between A and C is 17 000 43 18 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 13 If the distance between and B is 28 500 21 59 cm turn the sensor position screw counterclockwise f the distance between A and B is 8 500 21 59 cm turn the SOS screw clockwise One full turn is approximately 0 015 0 04 cm Marker Position Ad
134. face 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 3 Examine each surface with a flashlight to ensure that the entire surface is clean 4 Reinstall the Marker lower cover Do not operate the Platesetter with the lower cover removed Lower the marker and close the top cover 5 Print plates to determine if print quality has improved 12 SERVICE MANUAL Marker Focus adjustment Procedure 1 Contact Printware Technical Support at 1 800 456 1400 to obtain authorization to access the factory menu Follow the procedures outlined previously in this chapter 2 Image a 4 pixel on focus test plate from the control panel Test Plate Menu 3 Open the top cover and remove the red plug from the right side of the marker See Figure S2 1 4 Use a 5 32 Allen wrench to carefully turn screw inside the focus hole 1 8 turn counter clock wise 5 Replace red plug and close cover Run another 4 pixel on focus test plate Compare to previous plate 6 Repeat steps 4 a
135. foreach 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 II Calibrating the ZAPrip HQ Harlequin RIP The goal of calibrating the RIP is to linearize the transfer curve Figure 1a shows a calibrated transfer curve and Figure 1b shows a non linear uncalibrated transfer curve E Linear Output E Non Linear Output E 100 E 100 o o 5 50 5 50 0 0 0 50 100 0 50 100 REQUESTED REQUESTED Figure la Figure 1b B 3 CALIBRATION The ZAPrip HQ Harlequin RIP Print Calibration menu allows you to print test strips calibra tion targets Calibration Manager allows you to create and edit calibration sets and to enable or disable particular sets Xitron RIP xiton RIP Edit Preview Color Output Fonts GUIA ERES Calibration Dot Gain Manager displays calibration sets grouped by device When you select from the Device drop down list all of the 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 se dC a JL LE JL Li JL JL IL ROS EEE man May 15 1960 120522 Figure 2 Calibrat
136. h the solutions Remove the bubble pack from 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 INSTALLATION GUIDE 6 Label the replenishment tanks and replenishment probes following the instructions supplied with the processor labeling kit note that the color codes are different for Mitsubishi and Agfa chemistry Attach one end of the 6 long 114 180 cm x 3 cm diameter 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 Replace the right front panel Rotate the gears in the activator and stabilizer racks several times to free them up before operating the Platesetter Close the top covers Installing the Raster Image Processor RIP 1 Unpack the RIP central processing unit CPU and inspect it for any 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 th
137. he 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 If 220V is present replace pump assembly If 220V 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 pinched hoses Adjust pump rate see Installation Guide hapter 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 Replace temperature probe SERVICE MANUAL PROCESSOR ELECTRICAL PROBLEMS cont Processor drive motor does not work 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 If voltage reads 220V with motor on but the motor is not spinning replace motor ther
138. hing the caps to lock the strut INSTALLATION GUIDE 14 Remove bubble pack from cables Connect the cables to the marker assembly as follows 15 16 17 18 Connect the orange and white wires to the connector located towards the front of the Marker next to the fan 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 on top of the marker assembly Connect the connector with a single ribbon cable to the connector J8 on the PCA Connect the connector with three ribbon cables to J9 on the PCA Remove the Imager front and rear panels Remove the bubble pack from the black power cord located on the left side of the Processor Feed the black power cord through the large hole located on the right side of the Imager Plug the black power cord into the side of the power supply located in the bottom rear of the Imager Remove the bubble pack from the ribbon cable located underneath the processor Connect the ribbon cable into the connector located in the right side of the Imager Check the level of the Processor and the Imager If the Processor or Imager is not level use the casters to raise or lower the Processor or Imager If the top covers touch when the covers are opened or closed use the Processor front right caster to raise or lower the Processor Open accessory boxes and remove bubbl
139. hird of a revolution 1 2 If switch is activated the wheel should turn 2 to 4 revolutions without stopping 2 Switch failed 2 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 2 Laycutter on a table with cutter blade facing up 3 Turn blade by spinning silver shaft on back of motor by hand clockwise until blade comes down to lowest point in its rotation 4 Loosen set screws on arm with a metric Allen wrench 5 Rotate cutter blade shaft on opposite end with pliers until blade is 34 of the way through the silver plate on the inside 6 Tighten set screws on arm and test the cutter before reinstalling cutter in machine PUNCH PROBLEMS 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 Punch does not operate or does not punch all the way through 2 1 2 2 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 If air pressure
140. hort 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 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 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
141. icants 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 SERVICE MANUAL 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 Operator Maintenance Schedule recommendations based on 8 hours per day use 5 days a week 1 Imager section maintenance Roller cleaning only when necessary damp cloth light D ink no alcohol or solvents 2 Processor section maintenance a Roller cleaning weekly with warm water or mild soap no alcohol film processor cleaner or solvents b Guide cleaning weekly with warm water 3 Marker assembly mirrors Inspect every 6 months use canned air to remove dust particles only as needed SERVICE MANUAL Procedures to Raise and Lower the Marker Open the top cover and raise the marker by pulling marker 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 a Assembly Spherical Mirro
142. ine will arrive and can be moved to its final location loading dock clear hallways etc before scheduling installation The Platesetter should be installed by an authorized service technician 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 24 60 cm on the left 24 60 cm on the right 24 60 cm in front and 12 30 cm in the rear see Figure I 1 on page 9 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 114 180 cm x 3 cm outer diameter and 1 inner diameter Precautions 1 Dueto the 750 Ib 340 kg weight of the Platesetter use caution when removing Platesetter from pallet 2 Follow electrostatic discharge ESD protective procedures when connecting cables or working near Platesetter PCAs including
143. ion Parts List Page 1 of 1 ASSY IMAGER PS46 DUAL CASSETTE INTERNATIONAL ASSY IMAGER PS46 DUAL CASSETTE DOMESTIC ASSY MARKER IR ASSY MARKER RED ASSY CABLE POWER DOMESTIC ASSY CABLE POWER INTERNATIONAL ASSY SHROUD DUAL CASSETTE INTERNATIONAL ASSY SHROUD DUAL CASSETTE DOMESTIC Printware Confidential ASSY PS46 DUAL CASSETTE C 808440 XXX REVISION Sheet 1 of 1 Printware Confidential Find Number 001 002 002 003 004 005 006 007 007 009 010 013 014 015 016 017 018 020 022 023 024 025 026 027 029 030 031 033 034 035 036 037 038 040 041 042 043 044 045 046 047 048 Quantity Component Used CO N N N e e N N apa ON 00 bb B Be 0 CON BN N Assembly Number 808441 XXX ASSY IMAGER PS46 DUAL CASSETTE Number 808143 001 808444 001 808444 002 807529 001 803287 007 804140 004 808155 001 808243 001 808243 002 806005 001 806386 001 900270 009 900270 008 900270 007 900257 900222 003 900223 007 808202 001 523 190 006 523060 001 900261 004 900958 001 806843 001 803769 001 806709 001 900047 000 900445 006 900233 003 807222 001 806866 001 804569 003 900223 006 900725 001 900287 007 900215 006 900341 003 806269 001 806494 001 806333 001 900222 007 900651 008 900173 001 Revision C Component Description ASSY CHASSIS ASSY TRANSPORT RO
144. ion Target 2 Measure the density of each square of the 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 B4 CALIBRATION 3 Click New to create a new calibration set for the first time The RIP manual describes how to use all the items in the Edit Calibration dialog box but the essential items are as follows a Set PlateStream for negative right reading b Set Measurements as negative 96 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 Enterthe dot percentages from the densitometer readings f Inthe 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 can 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 Print a calibrated target to check calibration A single pass new calibration should be accurate to within about 2 For greater accuracy
145. 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 shutter 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 If a 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 The current design has the
146. ish o Q gt Q N Test P late M Inform ation 1 Run 01 Plates Run H arw are 8 Punch O FF 2 Choose Pattem Com posite Pattem Calibrate 3 Choose Length 13 Status Backup Feed Transport M iniplate CutLength 12 M iniplate Backup ON GuideB Sensor ON YAO gt Q N C 7 Run are Calibrate Status 1 FeedM otor OFF 7 ResstProc 1 Calibrate Transport 1 Sensor Status 2 TransportM otor OFF 8 StartProc 2 Calibrate M arker 2 Takeup Cassette Remaining 25 3 ExitM otor OFF 9 PrmePump ds put Spool anager 3 CumentPlateCount 125 4 CutP hte 4 M arkerPosition 00 00 TotalP late Count 1234 5 Shutter Close M aterialU sed 1200 6 Punch Plate IX p UpperC assettes A orB U pperC assette Status Low erC assettes C orD Low erC assettesStatus 2 u 5 Status Calibrate Transport E Input SpoolM anager are 1 Calibrate Processor LOAD KNOB RKGN TANK LOW 0 2 M anualLength A d 0 000 A Doo ee FEED LOOP 00 TANK LOW 0 3 CutLength Ad 1950 rop EXITLOOP 0 EFFLTANKHIGH 0 4 Overlap Length Ad 0 725 2 es 2000 MAGEREXITO PROC TEMPLOW 0 5 Backup Length Ad 1350 NOMEDIA 00 PROC EXIT 0 6 Punch Length Ad 1 500 LOAD OK 00 TAKEUP CASSETTE 0 7 M Backup Len A d 0031 GUDEB 0 Figure 2 1 Control Panel Functional Flowchart 2 3 CONTROL PANEL The Power Up Sequence When the Plat
147. istry 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 Imager section maintenance Roller cleaning only when necessary damp cloth light D ink no alcohol or solvents 2 Processor section maintenance a Roller cleaning weekly with warm water or mild soap no alcohol film processor cleaner or solvents b Guide cleaning weekly with warm water 3 Marker assembly mirrors Inspect every 6 months use canned air to remove dust particles only as needed 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 imager top cover Raise the marker by pulling marker lever towards the front of the Platesetter until lever stops Lift up marker gently see Figure 6 1 Dryer Processor Cover G y Working Tanks Marker Cover E Imager Cover Guide D pins Lever ee Guide A1 C2 pins f NC pins i Upper 4 N CH Cassette gl S OJA h T Activator Stabilizer Lower pa Cassette NO Guide pins Optional Effluent Tank
148. ity Component Used OF A e me LA Assembly Number 806701 001 ASSY ACTIVATOR TANK Number 806735 001 806774 001 900291 009 901089 003 901083 001 900303 600335 001 Revision D Component Description Parts List Page 1 of 1 TANK ACTIVATOR FITTING DRAIN O RING SCREW STNLSS TAP FORM 10 24 X 75 FITTING COMPRESSION SST TAPE TEFLON 1 2 X 260 HEATER BLANKET Printware Confidential SEE NOTE 1 Pr 3 504 12 ii J ay 22 1 0 THIS SIDE 38 00 SEE NOTE 3 2 AR Pte Printware ASS Y ACTIVATOR TANK 806701 001 REVISION D Sheet of Printware Confidential Assembly Number 806702 001 ASSY STABILIZER TANK Revision C Find Quantity Component Component Number Used Number Description Parts List Page 1 of 1 001 1 806734 001 TANK STABILIZER 002 1 806774 001 FITTING DRAIN 003 1 900291 009 O RING 004 4 901089 003 SCREW STAINLESS TAP FORM 10 24 X 75 Printware Confidential C ES Printware ASSY STABILIZER TANK 806702 001 REVISION Sheet 1 of 1 Printware Confidential Find Number 001 002 003 004 005 006 007 008 009 011 012 013 014 017 018 019 020 021 022 023 027 028 Quantity Component Used N N CO COR Re A A e me q Q Assembly Number 806708 001 ASSY ELECTRICAL PANEL Numbe
149. justment 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 be moved up to 0 05 40 13 cm A positive value moves the image towards the non operator side a negative value moves it towards the operator side 1 20 INSTALLATION GUIDE Adjusting Image Length This procedure enables you to fine tune the image length setting of the Platesetter to Leading Edge 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 Grid18 ps file Operator Side front of Platesetter 2 Measure the distance between points A and B see Figure I 14 Use a preci sion steel ruler or digital measuring de vice to check this distance a digital mea suring device is more precise Figure I 14 Adjusti
150. l 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 If an error is reported on the control panel correct the problem following the procedure in Chapter 4 then press ESC and Ensure that the interface cable between the RIP 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 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 Ensure that plate media is properly loaded 2 Clean the rollers see Chapter 6 3 Replace 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
151. late with Miniplate option or Cassette with film option 7 Display Units Toggles between English and Metric display units QS 4 QUICK START GUIDE ZAPrip HQ Harlequin RIP Setup Imaging Plates 1 QS 5 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 Create appropriate page setup s in Page Setup Manager a Ensure that the Negative box is unchecked b In the Configure Device Menu ensure that the dual cassette box is checked Specify upper or lower cassette as needed c Specify plate size and image positioning in the page layout menu d You can specify screens in the Screening menu or leave it at factory defaults Over ride frequency and spot function Euclidean Spot Function 100 to 150 Ipi frequency depending on resolution the default Angles Use Harlequin Precision Screening and Rotate screens according to Page Rotation 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 GTO2up2400dp1 Choose Start Inputs the green traffic light icon from the RIP menu Set up the front end computer
152. latesetter Air should be clean and oil free and air pressure should be 80 Air can be supplied either from shop air or an optional auxiliary compressor The punch waste chip bin is attached magnetically to the wall in the back of the load compartment It should be removed and emptied periodically Punch Adjustment There are two physical calibration adjustments for the punch lateral side to side alignment and skew or parallelism to the cut edge Additionally the punch depth longitudinal position can be adjusted in the Opera tor Panel NOTE Before adjusting the punch ensure that the cutter has been adjusted correctly see previous sec tion Because the punch adjustment uses the cut edge as a reference the cutter must be adjusted first Lateral 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 B o _ S 2 g _ Q O Non operator side LT Adjustment Figure 1 6 Lateral and Skew Punch Adjustments 1 25 INSTALLATION GUIDE 2 Run a test plate with the punch on NOTE Use the intended plate width for these adjustments Lateral alignment depends on the plate width 3 With a 9 32 Allen wrench loosen the two screws on either side of the punch assembly see Fig I 6 4 Centerthe punch pattern on the plate by adjusting the Lateral Adjustment Screw with a Phillips screwdriver
153. latesetter 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 CONTENTS Chapter 1 General Information Introduction Rer 1 2 Features Overview 2 2 2 0 0 1 5 Operator Safety iii terne dcs 1 7 Chapter 2 Control Panel The Control Peludo ee nee dadas 2 2 Control Panel Menus and Functions 2 4 Chapter 3 Preparing for Operation Preparing to Make 32 Filling the Processor 24 4 4 3 3 Loading Plate 3 5 166 22 e e ae 3 8 Miniplate 3 10 FIM S dip EE 3 11 Chapter 4 Operating the Platesetter Controlling Image 4 2 Adjusting 4 2 Responding to Control Panel Error Messages 4 3 Chapter 5 Supplies Introduction cC 5 2 Recommended 5 3 Tips on 5 4 CONTENTS CONTENTS Chapte
154. lling the Raster Image Processor RIP Turning On the Platesetter Loading Plate Material Setting Replenishment Rates Changing Processor for 50 60 Hz Operation Physical Calibration Overview Cutter Skew Transport Skew Image Skew Scan Width and Linearity Adjustment Marker Position Adjustment Adjusting Image Length Adjusting Overlap Adjusting Cut Length Adjusting Backup Length Adjusting Miniplate Backup Length Punch Setup and Alignment Punch Adjustment Adjusting Punch Length De Installing the Platesetter Serial Numbers and Factory Settings L2 13 L4 L4 1 4 1 10 I 11 1 13 1 14 1 16 I 16 I 16 1 17 I 18 I 20 I 20 I 21 1 22 1 22 1 23 1 23 1 25 1 25 1 27 1 28 1 32 INSTALLATION GUIDE PLATESTREAM 46 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 3 meters The power
155. log into Windows NT c Log in as Administrator with password printware d Double click on the Navigator icon to launch the RIP Create appropriate page setup s in Page Setup Manager a Ensure that the Negative box is unchecked b In the Configure Device Menu ensure that the dual cassette box 1s checked Specify upper or lower cassette as needed c Specify plate size and image positioning in the page layout menu d You can specify screens in the Screening menu or leave it at factory defaults Override frequency and spot function Euclidean Spot Function 100 to 150 Ipi frequency depending on resolution the default Angles Use Harlequin Precision Screening and Rotate screens according to Page Rotation 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 GTO2up2400dp1 Choose Start Inputs the green traffic light icon from the RIP menu Set up the front end computer to print to the RIP For best results use the Adobe print driver and PlateStream 46 PPD These are provided with the RIP If you don t have the Adobe driver the Linotype 630 driver can be used 3 8 PREPARING FOR OPERATION Note On Windows front ends specify the platesetter as a Local Printer not a Network Printer
156. m 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 and 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 close the bottom front doors PREPARING FOR OPERATION Processor Cover G Working Tanks N Marker Cover E Imager Cover Guide D pins Lever n 2 Guide F pins Load Knob y 2 a Guide C2 pins m Upper 4 gt Cassette J j Du 2 A lt j Activator Stabilizer Lower a Cassette G id Boi 3 uide pins Guide Cl pins Q Optional Effluent Tank gt AN AN a AN D V w A 7 Tank amp Cart Optiona Replenishment Tanks Cart Optional Figure 3 1 Side View of the Dual Cassette PlateStream 46 Note If the processor has not been in use for sever
157. 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 con trol panel Main Menu and watch the media Once you have determined that the edge guides are prop erly in place follow the procedure below to optimize transport skew UJ 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 D E D N O O c 9 O Q O 2 Once the plate has been imaged and processed measure the angle E see Figure I 8 Adjust roller pressure to eliminate transport skew as follows see Figure I 9 E Figure I 8 Checking for Transport Skew f angle E is gt 90 tighten the roller pressure on the 5 87 front operator end of second pinch roller If angle E is lt 90 tighten the roller pressure on the rear end of the second pinch roller Imager Cover Lever Marker oi Oss v L3 Guide A pins l Pinch Rollers o sot Media path Guide B pins Load Knob Guide C2 pins Guide C1 pins Figure I 9 Location of the Pinch Rollers INSTALLATION GUIDE Image Skew Leading Edge UJ 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
158. 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 Manual 4 2 Inspect marker mirrors and clean if necessary see Chapter 2 gt 23 Adjust laser focus see Chapter 2 White black or silver streaks 1 Set Density Dot calibration see Installation Guide Ses Increase exposure control panel setup menu ak 3 Inspect marker mirrors and clean if necessary see apter 2 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 plat
159. mponent Description PLATE DRIVE MTG PLATE PULLEY MTG BASE PLATE PULLEY MTG LEFT SIDE PLATE PULLEY MTG RIGHT SIDE PLATE MOTOR BRKT MTG BRKT MOTOR MTG CAPSTAN CAPSTAN DRIVE BRG ADJUST PULLEY COATED CAPSTAN LOWER BELT FLAT BELT FLAT 11 50 X 400 X 018 ASSY MOTOR STEPPING GROMMETS VIBRATION ISOLATOR BEARING BALL FLANGED SFR4LL E RING SAE 1 4 SHAFT SCREW SKT HD CAP UNIF 10 32 X 1 2 SCREW SHC 6 32 X 25 WASHER EXTERNAL LOCK 6 SCREW PAN PPH 8 32 X 1 00 WASHER FLAT STEEL 8 NUT SELF LOCKING HEX 8 32 UNC 3B WASHER EXTERNAL LOCK 710 SPACER ROUND 8 X 1 4 SCREW PPH 10 32 UNF X 1 2 SCREW B H TORX 10 32 X 625 WASHER LOCK HELICAL SPRING 10 REG LOCKTITE SMALL SCREW SPACER SHAFT SS3 5 SCREW SKT HD CAP UNIT 10 32 X 3 4 WASHER FLAT STEEL 10 Parts List Page 1 of 1 Printware Confidential Printware ASSY CAPSTAN DRIVE K 804627 001 REVISION Sheet of 1 Printware Confidential Find Number 001 002 003 004 005 006 007 008 014 016 018 800 Quantity Component Used ON HR A OR KR 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 901020 001 807439 001 Revision N Component Description ASSY MOTOR TAKEUP DRIVE BRKT MOTOR MOUNT PULLEY MOD GROMMETS VIBRATION ISOLATOR SPACER ROUND 8 X 1 4 SCREW PAN PPH 6 32 X 1 00 WASHER FLAT STEEL 6 NUT S
160. mposite Pttrn Half BIK Wht All Black Plate Wide Vert Lines Thin Vert Lines Wide Horiz Thin Horiz Small White Sqs Small Black Sqs Large White Sqs Large Black Sqs Dark Gray Tone Light Gray Tone Press Pattern Horz Line Res Screen All White Plate Calib Screen 3 Choose Length Sets the length of the test plate The allowable range is 12 to 22 in processor mode and 2 to 27 in cassette or Miniplate modes CONTROL PANEL More Information Menu More Information ESC to exit Run Hardware 8 Punch OFF Calibrate Status Backup Feed Transport Miniplate Cut Length 12 Miniplate Backup ON Guide B Sensor ON 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 12 13 14 15 16 17 or 18 The 18 setting cuts all plates greater than 17 5 6 Miniplate Backup Enables calibration or elimination of the gap between jobs in Miniplate mode se
161. mum density D in solid black areas by adjusting the laser power II Linearization of the dot percentage transfer curve by calibrating the RIP PlateStream users doing critical screens have found it helpful to calibrate the platesetter weekly and replace the processing chemistry every two weeks I Setting Maximum Density Before calibrating dot density maximum density D set by adjusting laser power on the PlateStream operator panel using a reflective densitometer a Run acalibration target or a test plate and measure the density ofa solid black area b SettheD according to the media manufacturer s recommendations referto manufacturer s documentation or see the table below Optimal D Film 3 50 0 20 Mitsubishi Silver DigiPlate 1 34 0 02 Agfa SetPrint Multi Quicksilver 1 24 0 02 B 2 CALIBRATION c The values in the table may be higher than the manufacturer s recommendations Because of the quality of its laser spot the PlateStream can be set higher to yield better solids without sacrificing fine lines d If the 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 less than optimal D increase the laser power If the reading is greater than optimal reduce the laser power Tip as a rough rule of thumb change the laser power by 1
162. n E Component Description PANEL SUPPORT RACK ASSY CLUTCH SHAFT BEARING ROLLER BRKT CLUTCH BEARING FLANGE MOD BUSHING GROMMET ASSY TEMP PROBE ACT 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 PLT1 5M C ASSY DRAIN CLAMP HOSE SWITCH WIRE FORM SWITCH SNAP LEVER DUCT VERTICAL ASSY STABILIZER TRANSPORT ASSY STABILIZER TRANSPORT ASSY ACTIVATOR TRANSPORT ASSY ACTIVATOR TRANSPORT ADHESIVE RTV BLACK 5223 ASSY ACTIVATOR TANK ASSY STABILIZER TANK RAIL LEFT MOUNT TIE ASSY CABLE ACTIVATO STABILIZER LEVEL ASSY CABLE INTERFACE CLIP CORD ADHESIVE SENSOR THERMISTOR DISK SHIM SUPPORT RACK PROC ASSY HEATER COVER ASSY HEATER BLOWER ASSY CABLE DRY TEMP PROBE ASSY CABLE FILM SWITCH ASSY CABLE REPL LEVEL Parts List Page 1 of 2 Printware Confidential 043 044 045 046 047 048 049 050 051 052 053 054 055 056 057 059 060 061 062 063 064 067 068 069 074 075 076 077 079 089 090 102 103 105 106 107 800 0 me me m m UY OF BN DR ON TODD LN Assembly Number 808155 001 523150 001 806708 001 806703 001 900271 003 806739 001 900967 010 900214 004 806750 001 901089 004 900967 003 901072 005 900968 005 900967 006 901072 006 901092 001 900967 007 900967 001 901071 010
163. n to the main menu xc Stabilizer Rack Activator Rack Rack Drive Gear Drive Motor Belt Drive Shaft Worm Gear Figure I 3 Inside view of the Processor module Heater Element PROC ESIN Switch _ A Drive R42 RAS 2 Motor MK 52 9 Processor PCA 21 N p 7 PCA Screws Blower Figure I 4 Right side view of the PlateStream 46 Platesetter 1 15 INSTALLATION GUIDE Physical Calibration Overview Follow the procedures 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
164. n 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 with the Miniplate option and Cassette with the film option For a standard PlateStream 46 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 Test Plate ESC to exit Run 01 Plates 2 Choose Pattern Composite Pattern 3 Choose Length 13 On Line Transporting 1800 DPI g PROC 5 ON ESC 0 OFF ENTER 1 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 Co
165. nd 5 until test plates are in focus 7 If focus is worse then the previous plate turn screw clockwise 2 full turns and counter clockwise 3 4 turn Repeat steps 4 5 and 6 13 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 damaged 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
166. nd swing Guide B to the left Remove the lower roller by sliding towards the front of the Platesetter until it clears the frame 8 Install the new rollers in reverse order 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
167. nd 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 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 S4 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 Exitstepper motor J3 Feed stepper motor JA 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 Control Panel PCA Location and Function The control panel PCA is mounted behind the control panel display in the left front portion of
168. neath 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 dryer sensor monitors the temperature of the media dryer A 0 indicates that the current temperature is okay a 1 indicates that the dryer is still warming up or that there is a problem with the dryer PROC EXIT Indicates the presence or absence of media at the processor exit sensor 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 A 0 indicates that the film takeup cassette is not present 2 16 PREPARING FOR OPERATION 3 1 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 Platesette
169. ng Image Length 3 If the distance between points A and B is 215 000 38 10 cm increase the Manual Length Adj value if the distance between A and B is 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 2 Calibrate Press 1 Calibrate Transport 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 enter 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 The specification for image length accuracy is 0 003 75 microns 1 21 INSTALLATION GUIDE Overlap Adjustment In waste reduction mode the Platesetter scans the leading and trailing edges of the plate causing a black area
170. ng brackets pd a wee P 132 cm 24 60 cm Front clearance Figure 1 Location of the Power Switch on the Platesetter 1 10 INSTALLATION GUIDE Loading Plate Material PREPARING TO LOAD 1 Open the platesetter top cover Raise the marker by pulling the marker lever towards the front of the platesetter until the lever stops Gently lift up the marker 2 Pull out the load knob on the left side of the platesetter CHANGING BOTTOM CASSETTE MEDIA WIDTH if necessary 1 Unload top cassette before adjusting the rear edge guides 2 From inside of the platesetter carefully remove the three cables from the three switches on the under side of top guide A1 and remove guide A1 3 Adjust the two rear edge guides by loosening the 3 16 Allen screw on the top guide and the knob bottom guide slide the guides to the positon closest to the plate media width Tighten the Allen screw LOADING THE BOTTOM CASSETTE 1 Adjust the two front edge guides by loosening the 9 64 Allen screw on top guide and the knob on the bottom guide and slide the guides all the way to the front of the machine 2 Open the feed cassette by lifting the back of the lid and sliding forward at the same time 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 media on
171. nit 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 the 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 Processor Working Tanks Marker Cover E Imager Cover Gui
172. o 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 Platesetter 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 Jobstream character codes PEL plus command codes f External RIP File reconfigured commands interpreted
173. 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 dryer sensor monitors the temperature of the media dryer A I indicates that the current temperature is okay a 0 indicates that the dryer is still warming up or that there is a problem with the dryer 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 40 SERVICE MANUAL 41 This page intentionally left blank SERVICE MANUAL CHAPTER 5 TROUBLESHOOTING Introduction This chapter contains procedures for isol
174. 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 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 Pinch Roller Traction Centrol Belt Capstan Roller Belt Tensioner Fa Pinch Roller Cutter 79 Imager Exit Rollers A B Feed Rollers Belt Tensioner Feed Belts Imager Exit Belts 8 Feed Motor Imager Exit Motor a Service Loop Exit Rollers Figure S3 1 Back View of the Imager 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
175. om the shaft by lifting the clip and sliding it off the shaft Slide the media 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 media see Figure 3 2 Insert the loaded spool assembly back into the feed cassette with 12 of media remaining outside the cas sette 5 Place the cassette onto the cassette mounting brackets 6 Feed media through the first set of edge guides and rollers 7 Rotate the cassette up and lock into place on the platesetter Ensure the media is not pinched between the cassette and the platesetter 35 PREPARING FOR OPERATION 8 From inside the platesetter push the media up through the next edge guides into the the pinch roller nip 9 Set the front edge guides up against the media and tighten the screws 10 Re install guide A1 if necessary reconnecting the three cables to the three switches LOADING THE TOP CASSETTE 1 From inside the platesetter pull the rear edge guide knobs and slide the edge guides to the position closest to the plate media width 2 Adjust the two front edge guides by loosening the knobs and moving the guides all the way to the front 3 Follow steps 2 through 7 above COMPLETE LOADING 1 From the op panel main menu select 1 setup 5 media or to choose between using the upper or lower cassette enter 2 Select or to choose spool A or B for top cassette C or
176. on this Platesetter 4 Compare the measured volume to the table outlined below Recommended replenishment rates are as follows Mitsubishi Silver DigiPlate Activator 0 47 ounces ft 150 mI M Stabilizer 0 63 ounces f 200 mI M2 Agfa Setprint Activator or Stabilizer 0 37 ounces ft 120 ml M Average Plate Size 0 6 f 0 8 f 1 0 fe 1 2 f 1 4 f 1 6 fe 1 8 f 2 0 f 2 5 ft 0 06M2 0 07M 0 09 M 0 11 M 0 13 M 0 15 M 0 17 M 0 19 M 0 23 M Mitsubishi Silver DigiPlate Activator ounces Stabilizer ounces 50 63 Activator milliliters 11 2 13 9 Stabilizer milliliters 14 9 18 6 Agfa Setprint Activator amp Stabilizer oz 30 38 Activator amp Stabilizer ml 8 9 11 2 5 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 6 If the average plate size changes the replenishment rate should be adjusted 1 13 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 adjus
177. oner 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 beeps 1 continuously after initialization 2 Check voltages at controller PCA Replace Operator Panel Note The machine is designed to beep continuously every 5 seconds if a job is sent with an unsupported resolution Buttons on Operator Panel don t work or are touchy 1 Re seat cables in J1 and J2 on the Operator Panel 2 Wiggle the Operator Panel cables to determine whether there is a short in a cable 3 Replace Operator Panel assembly Operator Panel blanks out occa sionally when loading media 1 Install static control kit if not already in place 2 Checkfor faulty power supply amp U 2 rom te Operator Panel tum on alt motors jd cycle the cutter several times If the Operator Panel blanks out the power supply is being overloaded You can increase the voltage by removing the power supply and turn the 5V potentiometer 2 hours 60 clockwise 2 2 If adjusting the 5V does not solve the problem replace the power supply assembly Operator Panel locks up 1 Install static control kit if not already in place 2 Replace the Operator Panel assembly 49
178. onfidential S STAMP OR OTHE N TER ITEM 3 IS INSTALLED Printware ASSY TRANSPORT DRYER ROLLER C 808228 001 REVISION Sheet of 1 Printware Confidential Find Number 001 002 003 004 005 006 007 008 009 010 011 012 013 017 020 021 022 023 024 026 027 028 029 030 031 037 040 041 042 043 044 045 046 047 048 049 050 051 052 053 054 055 Quantity Component Used N a a N N NDN A NBO WN NO WW Ne C A CON NR gt h 9 9 Assembly Number 807425 XXX ASSY PUNCH PS46DC 2 HOLE Number 807415 002 901051 005 901051 004 901051 007 901051 008 900940 003 900940 004 900940 005 901051 009 901053 001 807460 003 901052 003 807301 001 900235 000 806935 002 806957 001 900610 003 808210 001 808211 001 808230 001 807412 001 808213 001 808212 001 807091 001 806806 001 806269 001 90065 1 022 90065 1 020 900047 000 900445 007 900016 000 900236 008 900235 002 900235 040 900233 003 900233 003 900235 000 900369 001 900287 029 900160 004 900005 002 900336 000 Revision C Component Description Parts List Page 1 of 2 ASSY COMPRESSOR MODIFIED DOMESTIC FITTING TUBE QUICK STRAIGHT FITTING TUBE QUICK STRAIGHT FITTING TUBE QUICK ELBOW FITTING TUBE QUICK STRAIGHT TUBING POLYURETHANE RED EA FT TUBING POLYURETHANE ORANGE TUBING POLYURETHANE GREEN FITTING TUBE QUICK BULKHEAD UNION M
179. onsistent with the rights of Printware Inc 6 1 2 3 4 5 6 WHEEL CUTTER 15 o o SHEAR CUTTER 10 Zon DECURL EXIT 1 o STEPPER BOARD D gi CABLE 803118 001 LOWER FEED STEPPER PAPER FEED 803666 001 1 GND BROWN 5 2 FD STEP RED 2 GR 3 FD STEP ORANGE 3 4 OND YELLOW 4 WHEEL CUTTER 1 BLACK 803323 002 1 1 WHITE BLU 5 RESET GREEN 5 2 YELLOW 2 2 RED MARKER TRANS 6 FD RESET BLUE 6 J1 3 RED 3 3 YELLOW a H 7 GND VIOLET 7 4 WHITE 4 4 Brack 8 TR STEP GRAY 8 ENGINE STEPPER PCA 9 TR STEP WHITE 9 UPPER FEED STEPPER 10 GND BLACK 10 523190 004 803666 001 11 TR RESET BROWN 11 12 TR RESET RED 12 ki 13 GND ORANGE 13 14 EX STEP YELLOW 14 PAPER FEED 1 BLACK 803323 002 1 WHITE BLU 15 EX STEP GREEN 15 2 YELLOW 2 2 RED 16 GND BLUE 16 J3 3 RED 3 3 YELLOW EH a 17 EX RESET VIOLET 17 4 WHITE 4 4 BLACK 18 EX GRAY 18 9 19 GND WHITE 19 CAPSTAN STEPPER CUT 8 20 CUT STEP BLACK 20 804628 001 BORD 9 21 CUT STEP BROWN 21 9 22 GND RED 22 PF 7 23 CUT RESET ORANGE 23 MT J 1 24 CUT RESET YELLOW 24 MARKER TRANS 1 BLACK 803323 002 1 1 BLUE WH INTERFACE PCA J11 25 GND GREEN
180. op is formed 1 indicates that a loop is not present EXIT LOOP Indicates the status of the exit loop sensor in the exit section of the Imager 0 indicates that a loop is formed 1 indicates that a loop is not present IMAGER EXIT Indicates the presence of media at the imager exit A 0 indicates the media is present e g during imaging A 1 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 1 indicates that the media supply is empty 0 indicates that the amount is sufficient LOAD OK Indicates the status of media loading 1 indicates the media is loaded a 0 indicates the media is not loaded GUIDE B Indicates the presence of media at Guide B A 0 indicates that media is present e g during imaging A 1 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 a 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 17 indicates a low solution level in one or both or the tanks 38 SERVICE MANUAL EFL TANK HIGH This sensor monitors the level
181. or D for bottom enter Select 6 to choose destination you must choose processor if using plate material and must choose cassette if using film Select enter esc 3 Load media into capstan roller by selecting 5 load from the op panel main menu enter 07 LOADING TIPS When selecting 5 load from the main menu the media will backup the op panel will display unload ing for a few seconds to correctly position the media This is normal Both cassettes must be present on the left side of the machine even if only using one cassette Other wise light leaks will fog the media If loading film in one cassette and plate material in the other the plate material must be loaded first without any film in the imager Complete the loading of the plate material before attempting to load the film in cassette mode Cut off 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 I 12 INSTALLATION GUIDE Setting Replenishment Rates 1 Open top cover 2 Remove replenishment hoses from the working tanks inside the processor Place the replenishment hoses in measurement containers 3 From the control panel run a test plate that represents the average plate size that will be run
182. otor 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 temperature 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
183. owchart of the control panel menus The panel consists of an 8 x 40 character LCD display which shows status messages and menu options and the following 18 keys an ON key 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 press the numeric key for that item or use the arrow keys to move the blinking cursor to the item number and press ENTER To scroll through the choices of the selected item press the or OFF keys To change numbers in 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 If a key is pressed that has no effect the control panel will emit a beep CONTROL PANEL UppenLowerCasseteActive 2 4 M ore Infom ation Printw are P lateStream 46D Active Cassette 1 Setup 2 TestP late 3 f Line 5 Load 6 7 M edia aning UX00007 Statusm essages E PROC W aming m essages Setup In age N egative R ightR eading Resolution 1800DPI age Pow er 25 M ediaW idth 13 12 SpoolPos 13 M edia UpperSpool InputSpoolA Destination Processor D isplay U nits Engl
184. r Mirror hiatus Lower Cover 7 Galvanometer Screws Aperture r Folding Lower Mirror Screws Figure 82 1 Side View of PlateStream 46 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 operator periodic maintenance has been performed 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 ape
185. r 806736 001 900040 003 806795 001 806796 001 806797 001 900289 003 806810 001 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 CLIP CORD ADHESIVE ASSY CABLE HEATER CONTROL ASSY CABLE MOTOR CONTROL ASSY CABLE DRYER HEATER BUSHING GROMMET LABEL POWER SUPPLY ASSY STRIP TS1 ASSY STRIP TS2 ASSY CABLE GROUND ASSY CABLE POWER CONTROL SCREW STAINLESS 4 40 X 375 NUT STAINLESS 4 40 X HEX LOCKNUT SCREW STAINLESS 8 32 X 500 PPH WASHER EXT STAINLESS 8 MOUNT TIE TIE NYLON PLT1 5M C ASSY CABLE JUMPER 3 50 ASSY CABLE JUMPER 4 50 ASSY CABLE PROCESSOR MOTOR ASSY CABLE JUMPER 3 50 ASSY CABLE JUMPER 3 75 Parts List Page 1 of 1 Printware Confidential FROM REFERENCE P8 1 TSI 4 806827 003 ITEM 27 GND 1 B06826 001 ITEM 11 TSI 6 806827 001 ITEM 21 P8 3 P8 4 182 3 806827 004 ITEM 28 DRIVE MOTOR 806830 001 ITEM 23 BLOWER FAN MOTOR BLACK 5 1 Sr BLOWER FAN MOTOR BLACK TS2 1 806827 002 ITEM 22 DRIVE MOTOR 806830 001 ITEM 23 BLOWER FAN MOTOR GREEN YELLOW DRIVE MOTOR 806830 001 ITEM 23 P8 2 TS2 6 806827 001 ITEM 21 5 2 152 8 806827 003 ITEM 27
186. r 6 Preventive Maintenance Aus EE 6 2 Maintenance 6 3 Chapter 7 Troubleshooting Print Quality 7 2 General 7 7 Clearing Media 7 10 Galling fot ServlIGe siete tee ete Hen e acia 7 12 Appendix A A 2 Appendix B 2 Appendix C Halftoning C 2 GENERAL INFORMATION GENERAL INFORMATION CHAPTER 1 GENERALINFORMATION Introduction The Printware PlateStream 46 Dual Cassette Platesetter is a compact high resolution digital Platesetter forarange of small format printing applications Plates are exposed using a patented laser imaging system and automatically 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 Pla
187. r must be Both cassettes present and at least one loaded with media see Loading section Chapter 3 Connected to the RIP I O panel is located on the bottom 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 Filling the Processor Tanks Chapter 3 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 on 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 bottom front doors 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 fro
188. 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 RIP Accurate Screens on the Adobe PostScript ZAPrip and Harlequin Precision Screens HPS on the ZAPrip HQ Harlequin Xitron RIP C4 PlateStream 46 Platesetter Dual Cassette Service Manual Printware LEADERS IN COMPUTER TO PLATE CONTENTS Chapter 1 General Information 044 2 4 mm Dan aulas qusay au ay 2 Construction of the Platesetter 4 Chapter 2 Maintenance Approved Lubrieanis 6 Cleaning 6 Platesetter Maintenance
189. roups 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 10046 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 related to line screen Cell spacing 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 as screen frequency and the screen angle as shown in Figure ApB 2 Screen angle Figure ApB 2 Screen Angle 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
190. rture 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 S2 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 Support by tele phone or FAX message Toll free U S A only 1 800 456 1400 FAX Number 651 454 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 Des
191. s 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 10 Current marker state displayed only during a marker error or while the marker is either calibrating or initializing On Line Idle Current imager state the messages displayed as a single plate is fed through the Platesetter in processor mode are On Line Idle Imager ready to start imaging imager and processor are idle except possibly for the last several inches of the last plate exiting the processor On Line Busy Imager communicating with the RIP On Line Backing Up Backing up leader of plate from cutter to start of image point On Line Marker Hold Marker getting ready to image On Line Imaging Imaging current plate On Line Image Leader Imaging leader of next plate On Line Advancing Advancing plate to cutter On Line Cutting Cutting plate On Line Punching Punching Plate CONTROL PANEL On Line Ready Pause 0 5 sec pause between plates On Line Ready Trans Imager ready to start imaging plate s still in imager On Line Ready Proc Imager ready to start imaging pla
192. s 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 calibration 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 Controller PCA Interface PCA Engine Stepper PCA Control Panel PCA
193. s 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 image away from the operator side decreasing the value moves the image towards the operator side to accommodate the physical position of the marker CONTROL PANEL Calibrate Transport Menu Calibrate Transport ESC to exit 1 Calibrate Processor Manual Length Adj Cut Length di Overlap Length Adj Backup Length Adj Punch Length Adj 500 Miniplate Backup Leng Adj 0 134 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 Platesetter must be in Processor mode not cassette or Miniplate mode to calibrate the processor 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
194. setter until it clears the frame 4 Install the new rollers in reverse order Replace the panels lower the marker and close the top left cover Replacing the Imager Exit Rollers Imager Exit Motors and Imager Exit Belts 1 Open the top cover and raise the marker assembly Remove the back panel 2 Rotate the belt tensioner down and then slide the long imager exit belt off the pulley 3 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 4 Rotate the I shaped bracket located behind the pulley 90 and then slide the belts off of the gear 5 To replace belts install new belts in reverse order 6 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 7 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 a
195. shutter 1 Verify that edge guides are aligned with spool see Op ratur Guide tol losa procedure Check adjustment of Feed Loop Switch Verify that feed rollers are turning 2 3 4 Verify that feed are backing up 5 Check that marker transport belts aren t slipping 6 Adjust Marker Transport motor speed 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 prompts the user just to back up and not cut after certain errors 1 Adjust the 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 SENSOR STATUS LOADKNOB 0 FEEDLOOP 00 EXITLOOP 0 IMAGER EXIT 0 NOMEDIA 00 LOAD OK 00 GUIDE B 0 ESC to exit WRKNG TANK LOW REPLN TANK LOW EFFL TANK HIGH PROC TEMP LOW PROC EXIT TAKEUP CASSETTE ON OFF ENTER 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
196. solutions This allows a different image power to be set for film in the Cassette mode compared to plate material in the Processor 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 9 00 to 18 10 22 90 cm to 46 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 9 to 18 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 Media Position Spool Choices are upper and lower Input Spool Choices for upper spool are A or B choices for lower spool are 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 selectio
197. sor up off of the wheels by 1 Placing the 18 by 6 3 4 46 cm x 17 cm wood block with lip underneath the brace in the bottom front of the Processor The frame must rest on the foam 2 Placing the 18 by 6 3 4 46 cm x 17 cm wood block underneath the bottom back of the Processor The frame of the Processor must rest on the foam 3 Placing the two 24 by 6 3 4 61 cm x 17 cm wood blocks underneath the bottom sides of the Processor The frame must rest on the foam 4 Attaching all four wood blocks to the crate by using two wood screws in each block 5 Replace the front and rear panels Place three strips of bubble wrap on the front panel Plastic wrap the entire Processor Place the foam cap over the Processor Place the 33 84 cm wide plywood with notches on the front of the crate with the boards facing inside the crate and the notches on the bottom Place the 33 84 cm wide plywood on the back of the crate with the boards facing inside the crate Place the two 50 127 cm wide plywood on the sides of the crate with the boards facing inside the crate and flush with the bottom Screw the top and the sides together Make sure the top cover and the sides are very secure B Package the marker 1 29 1 Disconnect cables B Disconnect the grounding strap from the imager section frame b Disconnect the 10 wire connector from J6 on the printed circuit assembly PCA located on top of the laser marker assembly Disconne
198. ssembly 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 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 JA Not used J5 Shutter solenoid J6 Micro stepping controller J7 Not used J8 Not used J9 Not used J10 Not used J11 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 a
199. t i SL ig IA 2 ZA q B 4 s P E ES Pd N ES 7 A MEN zd ket UE md IN 4 x u N xx N ier V a P di ASSY TANK EFFLUENT WITH CART 806817 001 REVISION D Sheet of Printware Confidential Assembly Number 807083 001 ASSY CART EFFLUENT Revision C Find Quantity Component Component Number Used Number Description Parts List Page 1 of 1 001 1 807097 001 CART EFFLUENT 002 4 900832 003 CASTER TWIN WHEEL W O BRAKE 003 4 900223 007 WASHER LOCK HELICAL SPRING 5 16 REG 004 12 900222 003 NUT HEX UNC 5 16 18 Printware Confidential 1 LABEL PART NUMBER AND REV LEVEL ON BOTTOM CENTER OF 2 EN N S u 5252 LACE x i gt a Sg Na i 3 4 PLACES N 2528 E Ber E 3 N 2 BEN N NS gt N N i N IN N IN EN S S Co a Pat C Cw Printware ASSY CART EFFLUENT 807083 001 REVISION C Sheet of 1 Printware Confidential Find Number 001 002 003 004 005 006 007 Quantity Component Used FP OF ee Assembly Number 806816 001 ASSY TANK EFFLUENT Number 900937 002 806718 001 806815 001 806803 001 806804 001 900303 901118 001 Revision E Component Description Parts List Page 1 of 1 TANK 24 GALLON ASSY DRAIN VALVE ASSY PROBE EFFLUENT LEVEL PLATE TANK SUPPORT GASKET FITTING TAPE TEFLON 1 2 X 260 NUT PLASTIC Printware Confidential
200. t 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 on and Heater Up To Temperature light not on If LEDs 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 Remove dryer heater assembly from processor 4 2 Check heater element resistance with an ohmmeter Normal values are Pin 1 to Pin 2 450 Pin 1 to Pin 3 459 Pin 2 to Pin 3 88Q Pin 1 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 1s full the pumps will not come on If the replenishment tanks are low t
201. te s in processor only 0075 Approximate number of feet of media left on input spool if length of media on the spool was entered when the spool was loaded 1800 dpi 2 Current resolution NO MEDIA No media detected at sensor closest to input spool LOW WORKING Either or both of the processor working tanks are 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 PANEL PROC Imager destination lower right corner of operator panel PROC MINI MINI3 CAS 500 521 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 1 Image Negative Right Reading 2 Resolution 1800 DPI 1 Image Power 2 5 6 7
202. ted 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 nectthe 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
203. tered 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 amp page description language copyrighted by Adobe Systems Inc PRINTWARE INC 1270 Eagan Industrial Road St Paul MN 55121 Phone 651 456 1400 Part Number 700610 Rev A Sept 14 1999 CAUTION The 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 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 P
204. tesetter where the file is imaged onto a plate Figure 1 2 illus trates the basic system set up received the Feed Rollers The mediais engage to pull the media pulled around the forward Capstan Roller Thelaserlightbeam strikes and exposes selected areas of the EN FERN media The plate is fed through Once the entire page is the imager exit rollers imaged the media into the integrated advances to the cutter processor The media is cut to a specified plate length and punched ZN 6 The plate is developed The finished plates fixed and dried are collected in a basket Figure 1 1 Flowchart of the Platemaker Process 12 GENERAL INFORMATION ASS HostComputer Jobstream character codes plus command codes gt Extemal RI File reconfigured commandsinterpreted 1 Host Computer Figure 1 2 Interface Between the Host Computer RIP and PlateStream 46 1 3 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 u
205. the pinch roller nip 9 Set the front edge guides up against the media and tighten the screws 10 Re install guide Al if necessary reconnecting the three cables to the three switches 05 2 QUICK START GUIDE Emulsion out Emulsion in Side View of Supply Cassette Figure QS 1 Loading Cassettes LOADING THE TOP CASSETTE 1 From inside the platesetter pull the rear edge guide knobs and slide the edge guides to the position closest to the plate media width 2 Adjust the two front edge guides by loosening the knobs and moving the guides all the way to the front 3 Follow steps 2 through 7 above COMPLETE LOADING 1 From the op panel main menu select 1 setup 5 media or to choose between using the upper or lower cassette enter 2 Select or to choose spool A or B for top cassette C or D for bottom enter Select 6 to choose destination you must choose processor if using plate material and must choose cassette if using film Select enter esc 3 Load media into capstan roller by selecting 5 load from the op panel main menu enter NOTES When selecting 5 load from the main menu the media will backup the op panel will display unloading for a few seconds to correctly position the media This is normal Both cassettes must be present on the left side of the machine even if only using one cassette Otherwise light leaks will fog the media If loading film in one
206. the shutter isn t Shutter problems 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 4 Open and close the shutter from the Operator Panel hardware menu a Run Hardware ESC to exit 1 Feed Motor OFF id isn X Transport Motor OEE amp 4 1 If the shutter solenoid isn t j Exit Motor OFF operating check the solenoid 5 Shutter Close with an ohmmeter for a short or O uneh Plate open its resistance should be approximately 55 ohms If the solenoid is open or shorted replace the solenoid OFF ENTER 4 2 If the solenoid is OK but not being actuated replace the interface PCA 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 53 SERVICE MANUAL GENERAL IMAGER PROBLEMS cont Light leaks 1 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
207. their sides To prevent the crushing of media avoid placing other objects on top of the media rolls eStore 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 eStore 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 1 PREVENTIVE MAINTENANCE CHAPTER 6 PREVENTIVE MAINTENANCE 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 chem
208. 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 jobs 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 MINT 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 the Platesetter and if more than 9 miniplates are present the digit will be replaced by a Printware PlateStream 46DC l Setu 5 Load 2 Test Prate 3 On Off Line 5 More Information 6 Cut Fd n Line Transporting A0075 1800 DPI MINI3 ON ESC OFF ENTER PREPARING FOR OPERATION Film Option With this option the Platesetter will image film any width from 9 to 18 1 22 9 cm to 46 cm 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 a light tight take up cassette which is easily removed and taken to another area for processing The take up cassette will hold up to 25 of film The cut Fd Key 6 on the
209. to print to the RIP For best results use the Adobe print driver and PlateStream 46 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 at print time 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 46 the default printer name is PlateStream 46 when using the PlateStream 46 PPD Select the ZAPrip HQ and the appropriate hot folder GTO2up2400dpi in our example as the destination by browsing Network Neighbor hood Select the PlateStream 46 PPD if the application supports PPDs Do not specify screens or resolution in the application PlateStream 46 Platesetter Dual Cassette Installation Guide Printware LEADERS IN COMPUTER TO PLATE INSTALLATION GUIDE Contents Pre Installation Checklist Confirm Electrical Requirements Recommended Supplies Scheduling Installation Verify Final Location Precautions Unpacking and Inspection Assembling the Platesetter Joining the Imager and Processor Modules Assembling the Processor Insta
210. 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 1 18 INSTALLATION GUIDE Leading Edge UJ a 55 N Open Top Cover Laser Marker Assembly Fxedpoint 9 Capstan Roller Media E Frame Rear Side Front Operator Side Operator Side front of Platesetter G Je Figure I 11 Image Skew Laser marker assembly too high in front diagonal D E lt diagonal C F Turn adjustment screw clockwise to correct Leading Edge UJ i Open Top Cover Laser Marker Assembly Fixed point gt S G c D o c E o LL Capstan Roler C Media Front Operator Side Operator Side front of Platesetter G I Figure 1 12 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 o
211. to 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 media see Figure I 2 Insert the loaded spool assembly back into the feed cassette with 12 of media remaining outside the cassette 5 Place the cassette onto the cassette mounting brackets 6 Feed media through the first set of edge guides and rollers 7 Rotate the cassette up and lock into place on the platesetter Ensure the media is not pinched between the cassette and the platesetter 8 From inside the platesetter push the media up through the next edge guides into the the pinch roller nip 9 Set the front edge guides up against the media and tighten the screws 10 Re install guide Al if necessary reconnecting the three cables to the three switches LOADING THE TOP CASSETTE 1 From inside the platesetter pull the rear edge guide knobs and slide the edge guides to the position closest to the plate media width 2 Adjust the two front edge guides by loosening the knobs and moving the guides all the way to the front 3 Follow steps 2 through 7 above 1 11 INSTALLATION GUIDE Emulsion out Emulsion in Side View of Supply Cassette Figure I 2 Loading Cassettes COMPLETE LOADING 1 From the op panel main menu select 1 setup 5 media or to choose between using the upper or lower cassette enter 2 Select or to choose spool A or B for top cassette C
212. up Length Punch on Punch Length Punch on Miniplate Backup Length Image Power Processor amp Mini Plate Image Power Cassette MT Speed 1 Turn 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 J1 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 S4 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 a
213. vironmental codes Individually bubble wrap the cart s and tanks Place cart s in the accessory box Remove 6 long 114 180 cm x 3 cm diameter vinyl hose from underneath the processor Place in accessory box 1 28 INSTALLATION GUIDE 6 Disassemble the Processor Remove the left front and rear panels Disconnect the ribbon cable from the connector located in the left side of the Processor Bubble wrap the end of the ribbon cable Unplug the three pin connector labeled EXIT CAS from the optional film cassette sensor located on the left side of the processor Separate the Processor from the Imager by unbolting the four bolts located on the left side of the Processor that attach the Processor to the Imager Place the four sets of hardware in a plastic bag and tape to the inside front of the Imager Unplug the black power cord from the power supply located in the bottom rear on the Imager Bubble wrap the end of the cable and place inside the Processor Remove the wire tray located on the right side of the Platesetter Bubble wrap and place in accessory box 7 Package the Processor Close the top cover of the Processor Place two DESI PAK bags on the Processor crate Roll the Processor up the ramp onto the Processor crate b Attach the metal shipping brace to the inside bottom of the front with screws Place replenishment and optional effluent tanks underneath Processor c Support the Proces
214. wave washers spacer roller bearing bearing clip 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 front and rear panels Replacing the Service Loop Exit Rollers See Figure S3 1 1 Open the top left cover and raise the marker assembly Remove the rear and front left panels 2 Rotate the belt tensioner down and then slide the long Imager Exit belt off the pulley 24 SERVICE MANUAL 3 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 roller shaft Remove the bushings from each end of the roller shaft Access the upper roller from the hole in the front of the Platesetter Access the two shoulder screws holding the guide below the upper roller from the front and rear of the Platesetter and remove Remove upper roller by sliding towards the rear of the Platesetter until it clears the frame Access lower roller from the hole in the front of the Platesetter Remove the lower roller by sliding towards the rear of the Plate

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