Luxel Service Manual PDF
Luxel Service Manual PDF
Luxel Service Manual PDF
PLATESETTER
ENGINEERS REFERENCE GUIDE
6800101004
IMPORTANT: Fujifilm products are so designed and constructed as to be safe without risk to health when
properly used (in accordance with the supplied documentation) and when the safety precautions contained in
this document are fully observed.
This product must not be copied without prior written authorization and is subject to change without notice.
For further information, contact the Custiomer Support Manager at the address given on the front page of this
manual.
CAUTION: FUJIFILM Electronic Imaging Limited cannot be held responsible for any loss or damage
to customers data by unauthorised third parties accessing the system. In the event that Fujifilm be-
comes aware of any computer virus which will or is likely to affect the system it will take reasonable
steps to bring this to the attention of customers but advises customers to take their own precautions
against unauthorised access.
WARNING: All precautions mentioned in this document must be strictly observed at all times. Person-
nel must read the contents of any documentation supplied and used with this product BEFORE com-
mencing any work with equipment described in this document.
This product must not be copied without prior written authorization and is subject to change without notice.
For further information, contact the Customer Support Manager at the address given on the front page of
this manual.
The manual was written and illustrated using the best possible information at the time of publication. Any
differences between the manual and equipment reflect improvements introduced after publication of the man-
ual. Changes, technical inaccuracies and typographic errors will be corrected in subsequent editions. As
part of our policy of continuous improvement, we reserve the right to alter design and specifications without
further notice.
WARNING: All precautions mentioned in this document must be strictly observed at all times. Personnel
must read the contents of any documentation supplied and used with this product BEFORE commencing any
work with equipment described in this document.
NOTE: Measured noise level for this product is less than 65 dBa.
TRADEMARKS and COPYRIGHT: The name Fujifilm and the Fuji logo are trademarks of Fuji Photo Film
Co., Ltd., Tokyo; Luxel, Celix, FineScan, Celsis, C-dot, C-Scan, Quattro, Lanovia, ColourKit and Celebrant
are trademarks of FUJIFILM Electronic Imaging Ltd; Adobe, Accurate, PageMaker, Illustrator, PostScript,
Photoshop and Type Manager are trademarks of Adobe Systems Inc. that may be registered in certain juris-
dictions; Windows and Windows NT are trademarks of Microsoft Corporation that may be registered in cer-
atin jurisdictions; All other company names, products or brand names are trademarks of their respective
holders.
P RELIMINARIES
TABLE OF CONTENTS
Volume 1 Chapter 1 Introducing The Luxel System
Luxel CTP Features ..................................................................................................1-1
Introducing the Luxel CTP Configuration ...........................................................1-2
Introducing the Luxel Modules ...........................................................................1-3
Autofeeder ...............................................................................................................1-5
Elevator.................................................................................................................1-6
Trolley and Cassette..............................................................................................1-6
Plate Transport Module (PTM) .............................................................................1-7
Interleaf Bin ..........................................................................................................1-7
Plate Handling Mechanisms .................................................................................1-7
Air Knife ...............................................................................................................1-7
Imaging Engine .......................................................................................................1-7
Optics Base and Periscope ....................................................................................1-7
Loading Platform..................................................................................................1-8
Traverse Carriage .................................................................................................1-8
Drum and Input/Output Modules .......................................................................1-8
RFI Box .................................................................................................................1-8
Man-Machine Interface (MMI) Console................................................................1-8
Purified Air System ..............................................................................................1-8
Drum Vacuum System..........................................................................................1-9
Buffer........................................................................................................................1-9
Plate Processor ........................................................................................................1-9
Plate Stacker ............................................................................................................1-9
Current Limit....................................................................................................4-9
Braking .............................................................................................................4-9
Traverse Motor Control Subsystem ....................................................................4-10
Linear Encoding .................................................................................................4-10
Linear Scale ....................................................................................................4-11
Readhead........................................................................................................4-11
Traverse Servo................................................................................................4-12
Traverse Amplifier .........................................................................................4-13
Traverse Motor Assemblies ............................................................................4-13
Traverse Actuators .........................................................................................4-13
Carriage Position Encoder ..............................................................................4-14
Home Actuator...............................................................................................4-15
Index Actuator (Reference Mark) ...................................................................4-15
Overspeed and Braking ..................................................................................4-16
Optical/Traverse Synchronisation .....................................................................4-16
Traverse Diagnostics...........................................................................................4-17
Traverse Initialisation Sequence .........................................................................4-17
Edge Detect System Description .........................................................................4-18
Module Assemblies ..............................................................................................4-18
Edge Detect PCB .................................................................................................4-18
Operation...............................................................................................................4-19
EODHV PCB...................................................................................................5-17
HV Transformer .............................................................................................5-19
Optics System Configurations.............................................................................5-20
Periscope Assemblies and Operation .................................................................5-20
Top Mirror (M1) Assembly .................................................................................5-21
Laser Power Detector (LPD) Assembly...............................................................5-21
Bottom Mirror (M2) Assembly............................................................................5-22
Spinner Assembly and Operation.......................................................................5-23
Fast Photo Detect (FPD) .......................................................................................5-25
Optical Motor Control PCB (VBOMB) ...............................................................5-26
Optical Motor Control PCB Assembly ................................................................5-26
Location ..........................................................................................................5-26
Connectors......................................................................................................5-26
Fuses...............................................................................................................5-27
Links...............................................................................................................5-28
Optics Base Cabling ..............................................................................................5-28
Media Expose Control and Operation ...............................................................5-29
Expose Sequence ...................................................................................................5-29
System Calibration ...............................................................................................5-29
Expose Control Functions ....................................................................................5-29
EOD Deflection ...................................................................................................5-30
Laser Aging Control ...........................................................................................5-30
Power Balance.....................................................................................................5-32
Beam Coincidence...............................................................................................5-32
Drum Coincidence..............................................................................................5-33
Exposure Calibration ..........................................................................................5-33
4
4
Luxel CTP Features .................................................................................................... 1-1
Introducing the Luxel Modules ................................................................................. 1-3
A typical Luxel CTP system has the following standard and optional features:
A separate Raster Image Processor (RIP) server and optional client worksta-
tions.
Scanning to photopolymer plates.
A choice of RIP software applications with a Graphics User Interface (GUI).
Dual-laser beam system or an upgrade path from a single to dual-beam sys-
tem.
Variable resolutions from 48 l/mm (1219 dpi) to 144 l/mm (3657 dpi).
Media database on the Engine holding editable or seletable media data on
the plate types.
Comprehensive diagnostic self-tests and error screens for the user and engi-
neer.
RIP SERVER *
DIAGNOSTIC IMAGE
DATA DATA
MULTI-CASSETTE
HOUSING
ENGINE
BUFFER PLATE
PROCESSOR
AUTOFEEDER
PTM
STACKER
* SEE YOUR PROCESSOR NOT
RIP USER'S GUIDE COMMS SHOWN
MULTI-CASSETTE
HOUSING
BUFFER
SERVICE SIDE
AUTOFEEDER
PLATE
ENGINE USER SIDE
TRANSPORT
MODULE
(PTM)
PROCESSOR
Figure 1.2 Luxel 9600 CTP platesetter modules: B1 fully-automatic
MULTI-CASSETTE
HOUSING
BUFFER
SERVICE SIDE
AUTOFEEDER
PLATE
ENGINE USER SIDE
TRANSPORT
MODULE
(PTM)
PROCESSOR
BUFFER
PROCESSOR
ENGINE
LOADING
PLATFORM
PROCESSOR
LOADING
ENGINE
PLATFORM
Figure 1.5 Luxel 6000 CTP platesetter modules: B2 semi-automatic
1.2.1 Autofeeder
See Figure 1.2.
The Autofeeder consists of a moveable elevator frame and a set of control sys-
tems that allow a cassette to be aligned with the PTM plate feed mechanisms.
See Volume 2 Section 3.2 which describes the module in more detail.
VOLUME 1 (1-6) INTRODUCING T HE LUXEL SYSTEM
1.2.1.1 Elevator
An elevator frame (with shelves and cassettes) moves vertically up/down to
align an MMI-selected cassette with the PTM plate feed. A gear/motor and a set
of chains and pulleys raises and lowers the elevator, with space at the top pro-
tected by a multi-cassette housing assembly.
CASSETTE
TROLLEY
The trolley has two plate loading positions: horizontal and vertical, set from a
lever handle at one end. Its main function is to move the cassette from a safe-
light loading area to the Autofeeder cassette door where it docks into a set posi-
tion. This allows the operator to push the cassette onto to an empty shelf.
L UXEL P LATESETTER VOLUME 1 (1-7)
1.2.4 Buffer
The Buffer module, which operates as a band roller, holds the plate in transit
until the Processor is ready to develop the next job.
See Volume 2 Section 3.5 which describes the module in more detail.
INTRODUCING LUXEL
MODULES
This chapter introduces the main Luxel modules and variants, and briefly describes how
they function and operate.
4
4
Luxel System - Modules and Variants ...................................................................... 2-1
4
Introducing Plate Handling ........................................................................................ 2-3
4
Introducing Traverse Scanning............................................................................... 2-10
4
Introducing Image Expose....................................................................................... 2-17
Introducing Luxel Power and Control .................................................................... 2-28
4 CAN Bus.
4 PSU 1.
4 AC/DC distribution.
8 DEVELOP
SEMI-AUTOMATIC ONLY
IMAGE
7 CONVEY
BUFFER
PLATE
PLATE
6 SCAN
IS NOT SKEWED
4 CHECK PLATE
OUTPUT
5 VAC PLATE
TO DRUM
PLATE TO
REG PINS
ENGINE
PUSH
3
INPUT
2
PLATE
1 LOAD
4 NUDGE &
CASSETTE ON SHELF TAKEAWAY PLATE 11 CONVEY 12 DEVELOP
CASSETTE OPENS PLATE IMAGE
VOLUME 1 (2-4) INTRODUCING L UXEL M ODULES
INPUT
OUTPUT
PUSH
PLATE TO
REG PINS
9 PUNCH
6 PLATE *
2 FORWARD 3 RAISE
CASSETTE STACK
10 SCAN
5 REMOVE PLATE
INTERLEAF
1 SELECT CASSETTE 7 CENTRE
PLATE
8 VAC PLATE
TO DRUM * IF PUNCH IS FITTED
Note that plate handling and optics devices described in this manual use the
following notation:
Sensors: BS [Number], for example, BS51
Solenoids: BV [Number], for example, BV22
Motors: BM [Number], for example, BM3.
PLATE AT PRE-DIVERTER
STACK HEIGHT (DC)
STACK HEIGHT (HOME/TOP)
RETARD (UP/DOWN/MADE) NUDGER & TAKEAWAY (DC)
REG PIN CONTINUITY (NON-PUNCH ONLY) SWING ROLLER (DC) (NON-PUNCH ONLY)
FHMB PCB
SOL 0
DRIVERS SOL 5
SM 0
SM 3
DC 0
DC 2
to
to
to
SOLENOID
STEPPER
DRIVERS
DRIVERS
MOTOR
MOTOR
DC
(CAN OUT AND STB
POWER +24V/+36V)
SOLENOID
CONTROL
CONTROL
CONTROL
STEPPER
MOTOR
MOTOR
DC
UMBILICAL
AND EXTERNAL
PCB DEVICES
SENSORS
MEMORY
MPU
REG
+5V
CAN BUS
TX/RX
CAN
MPU
A TO D
REGISTER
& SYNCH.
PULSING
SENSOR
SENSOR
RS232
S27
S0
to
SENSOR
CAN IN
(1 & 2)
I/F
+24V
(FHMB
1 TO 4)
+36V
(FHMB 4
ONLY)
SENSORS
Diagnostic facilities are included to test the functionality and status of each
FHMB from the Main Diagnostics (via the LSB). These carry out device tests,
and allow the service engineer to manually control I/O devices in the following
ways:
A) motors on/off and move a set distance
B) sensors on/off
C) solenoids on/off.
L UXEL P LATESETTER VOLUME 1 (2-9)
The CAN bus interconnections for the FHMBs (and STB) is based on the daisy-
chain arrangement shown in Figure 2.19. CAN bus data and power to the STB is
conveyed through an umbilical cable attached to FHMB (4).
A full description of the CAN bus system is in Volume 1 Section 2.5.2.
Voltages, Filters and Interlocks:
Voltages generated by the FHMB from an external +24 V source are:
+5 V - digital/analogue circuits and CAN (supplied by on-board switched
mode, 150 KHz, regulated from +24 V).
+18 V - FPD (regulated from +24 V) on FHMB(4) only.
Two inductors on the FHMB filter the +24 V supply.
Note that the +36 V is routed through FHMB (4) to the STB is not used by the
other FHMBs.
On-Board Fusing:
The board has built-in fuse protection for the output and switching circuits, plus
spare fuses available for the service engineer. Fuses are deployed as follows:
A) one fuse for each stepper and dc motor
B) one fuse for each high-power solenoid
C) one fuse to cover all the low-power solenoids
D) four spare fuses held in holders distributed around the board.
Output Controls and Driving:
Plate handling motors and solenoids are controlled and driven from the FHMB.
Solenoids, Relays and Fans:
A single FHMB is able to drive:
High-power solenoids or relays at 24 V (2 A peak).
Low power solenoids or relays at 24 V (500 A peak).
A constant +24 V to local fans.
DC Motors:
DC motor controller/drivers can deliver up to 2.5 A peak (2 A continuous) at
24 VDC to motors via a control register.
Stepper Motors:
Stepper motor control is provided for a set of plate handling stepper motors.
Two TPU (Timer Processor Unit) channels from the MPU provide the step clock-
ing edges to each motor controller: the even channel steps the motor while the
odd channel serves as a feedback path to the TPU for pulse counting. The step-
per control circuitry provides the correct stepping sequence for each motor.
Control registers, selected by the MPU, determine the type of holding current,
motor enable and motor direction.
VOLUME 1 (2-10) INTRODUCING L UXEL M ODULES
READHEAD
TRAVERSE
ENCODER
ENCODER
SPINNER/
MOTOR
SCALE
HALL SENSE
DC
3-PH DRIVE
OUTPUT
DRIVE
COMMUTATION)
OUTPUT
DRIVE
(AND
REF
CLK
DAC
SPIN INDEX
19.2 MHz
DATA A
13.6 MHz
CONTROLLER
480 KHz
SPINNER
CONTROLLER
PRECISION
MOTOR
FAULT
LOCK/
ENABLE
INDEX/
HOME
TRAV
MPU
+5 V
5 V
MEMORY
CAN BUS
DCDC
RS232
STB
TO SSB
(VIA FHMB4)
EDGE DETECT
TO SSB
(VIA FHMB4)
+36V
+24V
TRAVERSE
MOTOR
COMPENSATION
CIRCUIT
DC
AMP
READHEAD
DAC
DIFF
PM CONTROLLER
+
POSITIONS
POSITIONS
CURRENT
GENERATOR
REGISTER
SUM
6.8MHz REF
TRAVERSE MONITOR
4.5/
DIVIDER
FREQ SEL
MHz
13.6
19.2MHz
REF
CLK
MPU
PLL
Spinner Controller
See Figure 2.8.
The spinner circuitry is designed to drive the spinner motor at a constant speed
with the minimum amount of fluctuation. This control is regulated by an optical
encoder, mounted on the spinner shaft, that provides incremental spinner posi-
tion data.
VOLUME 1 (2-14) INTRODUCING L UXEL M ODULES
REF FREQ
(480 Khz) TP11 TP9
ANALOGUE PULSE
PHASE PAL
SERVO WIDTH
DETECTOR LOGIC
MODULATOR
DATA A SENSE
+36 V
POWER
TP9 OUTPUT SPINNER OUTPUT
3-PHASE
166 microseconds
+36 V
TP11 OUTPUT
DEMAND ON MOTOR
STARTUP WINDINGS
RUNNING
DEMAND
LOWER SWITCHES
CLOSED FOR
BRAKE ON
5: Power Output. The power stage takes the six signals from the previous stage
and uses these to control the six MOSFET transistors which switch to energise
the motor windings. Hall sensors around the rotor indicate the position of the
rotor, and their outputs are decoded for switching MOSFETS in the correct
sequence to start the motor.
Spinner Braking:
When a Stop command is sent, or the PSU is interrupted, the top winding
switches are opened and the bottom switches are closed. This type of braking is
regenerative and effectively short-circuits the motor windings. Braking time for
the spinner is less than 20 secs.
Reference Clock Generation:
A single 19.2 MHz crystal generates all the reference frequencies for the spinner
and traverse. Dividers and a PLL provide the clocking signals used by the spin-
ner controller and the PM controller respectively. Synchronised clocking
between the spinner and traverse subsystems is important for obtaining exact
resolutions and image start positions.
Diagnostics:
The MPU manages the local traverse diagnostic/utility routines for checking
the presence of the linear encoder, traverse motor and amplifier. These diagnos-
tics are available from the (Main>) prompt.
Voltages and Drives:
The Traverse PCB is supplied with a single +36 V and an auxiliary +24 V from
the CAN umbilical. A separate +5 V is also supplied for exclusive use by the
CAN interface. Voltage used on the PCB are:
+5 V - digital/analogue circuits and traverse motor drive (supplied by on-
board DC-DC device converting +36 V supply).
-5 V - analogue circuits (via an on-board charge pump).
+15 V - for analogue circuits.
+36 V - spinner drive.
Analogue signal from the traverse DAC is converted to current by a linear push-
pull amplifier that is disabled by the Brake command. The traverse current is
also available for diagnostic checks.
Temperature Monitor:
A temperature device on the Traverse PCB is monitored and, if the reading is
above a set limit, triggers an error code.
SELECT
ID#3 MMI
ACTIVE ID#3
CASSETTE
DATABASE
ON DISK
MEDIA
TYPES
ON RIP
IMAGING JOB
AUTOFEEDER PLATE ENGINE
TRANSPORT IMAGE
DATA
RIP
INTERFACE
Media details are downloaded from the RIP application to the database after the
user adds new plate types and sizes to the RIP memory.
An active cassette is read by the system for its ID number allowing the MMI to
display the cassette's media details currently held on the database. Cassettes are
selected for advancement from the database details on the required type and
size of plates for the next job downloaded in the queue.
A single cassette with an ID can be refilled with the same type and size of media
and recognised immediately by the database. Cassettes loaded with a different
type or size of media need to have their database entry modified by the user
from the MMI before the system can start to use the installed plates.
A set of basic commands control the transfer of an imaged plate from the Buffer
to the Processor. Plates are held in the Buffer until the Processor develops the
previous plate and requests the next plate. While the communication link is ena-
bled, production flow is maximised; if the link is disabled, production will still
continue but is likely to be slower and more prone to plate transfer errors.
deflect them to a parallel swathe on the plate, adjust focus, illumination and
spot size.
It also houses lens for collimating the beam and a power detection to ensure
the two beams are aligned.
Periscope - an arrangement of mirrors that divert a laser beam from the optics
base to the spinner mirror. It also includes a laser power detector (LPD),
inline with the light path, to provide accurate samples of power readings for
each beam.
Two angled mirrors, M1 (top) and M2 (bottom), redirect the laser beams.
Only M2 mirror is field-adjustable using two fine-adjuster screws.
Spinner - rotates a mirror to divert the laser beams to a plate. It also includes
an encoder that provides SPIN INDEX and DATA A CLOCK signals to the
LSB for closed-loop spinner speed control.
L UXEL P LATESETTER VOLUME 1 (2-19)
SPINNER
CAN TO LUXEL
M2 STB SYSTEM
BOARD
VBOMB POSITION
APERTURE FOCUS DETECTOR
M1 (POD)
PERISCOPE ND WEDGE
FILTER
VBOMB VBOMB VBOMB
OPTICS
LASER EOD BEAM
BASE
(X) (X) COMBINER
LASER EOD
(Y) (Y)
TRANSFORMERS
X/Y
PD AND LD IMAGE
DATA & PD AND LD
PCB PCB
CONTROL EODHV
DRIVE/POWER CONTROL
APERTURE
VBOMB EODD
RFI BOX
RIP SERVER
SPINNER
L6
COLLIMATED LASER
BEAMSALONG DRUM AXIS M2 MIRROR
(FIELD ADJUSTABLE)
LASER BEAMS
FOCUSSED AT
DRUM SURFACE
The beam deflection system is based on a set of axes shown in Figure 2.12. The
axes are defined at the output of the optics base as:
X - where the beam is deflected horizontally.
Y - where the beam is deflected vertically.
Z - where the beam is along the axis of the drum.
L UXEL P LATESETTER VOLUME 1 (2-21)
Y
OPTICS BASE
DRUM
X
Z
Z
X
BEAM
DIRECTION
SPINNER
ROTATION
SCAN
DIRECTION
Y
USER
END
30 mW O/P POWER
DRIVE
CURRENT
(SWITCHED BY
IMAGE DATA)
BIAS
CURRENT
A)
IMAGE
DATA FEEDBACK
BIAS
AND
DRIVE
CURRENT
LASER
LASER
DIODE
DIODE
POD
LPD
POD I/F
LPD I/F
LASER
LASER
I/F
I/F
TEMP AND
CONTROL
LASER
MPU
VOLTAGES
CONTROL
DRIVERS
SENSOR
DRIVES
MOTOR
DATA
CAN
AND
I/F
I/F
I/F
CAN
+5V
+/-15V
+24V
WEDGE
FOCUS
APERTURE
POD LPD
LIMIT/
HOME
SENSORS
OPTICS
BASE
Diagnostics:
Routines run on the VBOMB generate error messages which are read by the
diagnostic software on the System Board.
MPU:
An MPU, clocked at 10 MHz, runs the local drive and control routines for the
optics sensors, motors and laser controls. High-level commands are received
across the CAN bus and VBOMB status messages are sent back to the System
Board. Commands move the motors to a certain position; VBOMB reports to the
System Board on whether the motors can be moved or not.
Flash Memory:
A 512 K x 8 FLASH EEPROM holds the optics control code and board diagnos-
tics. New firmware code is downloaded from the RIP server via the System
Board.
Motor Drivers
Low power (unipolar) stepper motors are driven from separate drivers control-
led by the Timer Processor Unit (TPU) channel levels on the MPU.
EODHV Operation
The EODHV provides each EOD module (X and Y) with the high voltage sine/
cosine waves required for beam deflection. The EODD supplies a single differ-
ential control voltage that consists, for each deflector, of a 667 Hz AC compo-
nent on a DC bias voltage for 40,000 spinner revolutions. The AC (sinusoidal)
part is used for beam deflection, and is synchronised with the spinner mirror
rotation. The DC part compensates for fixed angular mis-alignments in the EOD
assemblies detected by the POD and is adjusted during beam coincidence.
The EODD provides two supply voltages:
+24 VDC (and Return): EODHV PCB supply.
+12 VDC: EODHV reference voltage.
For each channel (X and Y), the composite input signal from the EODD is sepa-
rated into DC and AC components using a filter circuit. The DC component sets
a bias voltage of up to +750 V on the deflector. A bridge circuit drives each trans-
former primary using the AC component recovered from the filter. The AC volt-
age at the EOD deflectors can be varied in the range +2 Kv (pk-pk).
Figure 2.15 shows each of the EODX DIFF input signals with respect to Ground
and the signal obtained across the two EOD inputs. The voltage values are only
shown as an example.
VOLUME 1 (2-26) INTRODUCING L UXEL M ODULES
+1350 VAC
EODX+
1kV PK-PK
+750V
+350 VAC
+500 VAC
EODX-
1 kV PK-PK
(ANTIPHASE)
0 VDC
-500 VAC
+1850 VAC
ACROSS
EODX
INPUT
+850 VDC
150 VAC
A status signal is fed back to the EODD to indicate that the +24 VDC connection
is available and the HV to both channels exceeds 250 V. If the `HV-OK' signal is
LOW, then the +24 V and the HT supplies are OK; if not, an error flag is passed
from the EODD to the LSB.
HT+
DC - DC PUSH-PULL BK
+24V AMP
DC BIAS (PART OF)
+24V GND
-1 VIOL
Figure 2.16
+12V
EOD DATA BLUE
EODD
AC MODULATION TO EOD
FILTER (X OR Y)
X OR Y DATA WHITE
(AC + DC)
+1 YEL
HV STATUS
HT+
PUSH-PULL BN
AMP
DC BIAS (PART OF)
DATA CONTROL
LBUS
I/F
RTC
CAN BUS (TO SOMB/FHMB)
MBUS
I/F
DATA CONTROL
MEMORY
TEMP
FLASH/
SRAM
IC
(BRIDGE)
PCI
I/F
MPU
TO AOMD MODULE
CPU BUS
AOMD
I/F
TO CONTROL
CONSOLE
MMI
I/F
CONTROLLER
SERIAL
RS232
TO INTERLOCKS
INTERLOCKS
I/F
DIAGNOSTICS
PROCESSOR
S/W DEBUG
LBUS
I/F TO SSB
SYSTEM CONTROL
LBUS
data to the optics system.
MBUS
I/F
MBUS
SCSI CLK
I/F (FROM STB)
GEN
L UXEL P LATESETTER VOLUME 1 (2-31)
VOLUME 1 (2-32) INTRODUCING L UXEL M ODULES
Data Compression/Decompression
See Figure 2.18.
Data interfaces for compression/decompresssion devices are set at 16 bits for
maximum performance. A separate DMA controller manages the transfer of
data from the compressor to the FIFO and from there to the buffer memory on
the Mbus. Up to 16 transfers can be completed before the bus is released. The
compression technique applied is LZW. Compression/decompression data
transfers are increased in speed by DMA control of the bus and I/O FIFO buff-
ers.
1. A compression (C-FIFO) input on the DMA controller interfaces to the com-
pressor and accepts data at its the maximum rate while space exists in the
FIFO. The input data pat is 32-bits wide.
2. A compression (C-FIFO) output on the DMA controller provides a master
interface to the Mbus and the buffer memory. The output data path is 16-bits
wide.
3. The D-FIFO function for the decompression DMA controller operates in the
same way as the compression DMA controller explained in steps 1. and 2.
The length of the compressed record depends on a calculated setting for multi-
ples of input data lines. This calculation is also used by the decompressing proc-
ess.
A dual decompressor system strips alternate records from the buffer for transfer
to the output formatter.
Buffer Memory
This function provides intermediate DRAM storage between the data compres-
sion/decompression devices and the disk drives. The size of the buffer is 8
MBytes and the data burst rate is 80 Mbytes/sec. Buffer management is based
on four data streams:
odd/even compression records from the compressor are written to disk
odd/even records from the disk are written to the decompressors.
Internal SCSI Bus and Drives
A complete image is loaded into two disk drives that operate with separate SCSI
busses in order to improve performance. Each bus conforms to the single-ended
narrow standard that is also SCSI 3 (Ultra SCSI) compliant.
Output Formatter
The formatter receives decompressed data and stores it into two line-oriented
buffers (one buffer per beam) before transfer to the serialiser. Each decompres-
sor has its own set of line buffers to cater for a minimum of 90 lines of the output
image. The actual number of scan lines that the buffer holds is calculated by a
formula at the compression stage.
Data is passed to the serialiser by alternating the output from the buffer of each
decompressor. Once the requested number of lines have been written to the
buffer, and the output buffer is empty, the buffers are flipped for the next set of
decompressed lines.
L UXEL P LATESETTER VOLUME 1 (2-33)
Serialiser
The serialiser takes the two beam streams from the output decompression buff-
ers and converts them into data streams for the laser diode drivers. It uses all
the data from the output buffers on the first decompressor before switching to
the alternate output buffer on the second compressor. To avoid position errors,
and determine the start of image, a clock feeding the serialiser is synchronised
to the INDEX signal from the spinner encoder.
CAN2 CAN3
LSB FHMB(1) FHMB(2)
CAN1 CAN4
VBOMB FHMB(3)
CAN5
UMBILICAL
TRAVERSE FHMB(4)
CAN
CAN2 CAN_FHMB1_4
LSB FHMB(1)
CAN1
VBOMB
UMBILICAL
TRAVERSE FHMB(4)
CAN
CAN controller devices on node PCBs are tightly coupled to their board MPUs
which manage local board processes, and include a CAN interface.
The CAN protocol operates as peer-to-peer, but for certain tasks also operates as
master-slave when, for instance, the SSB constantly receives and transmits
frames as the master. Local data is sent from a node to the SSB. The SSB returns
high-level control signals to the nodes for synchronising the optics, scanning
and plate handling sub-systems.
The system employs a high-speed CAN version (CAN-H) where signal levels
are set at 2.75-4.5 V (HIGH) and 0.5-2.25 V (LOW). Terminations (at 120 ohms)
are provided.
L UXEL P LATESETTER VOLUME 1 (2-35)
AC AC COMPRESSOR
AC BOX
ENG_FHMBPWR
FHMB1 CTRL
DC DC
x2
INTERLOCK DC INT_EMERG
BOX FHMB2
VOLUME 1 (2-36) INTRODUCING L UXEL M ODULES
MAINS_DIST PWR3_INT
AC VACUUM
DC
FHMB3
PWR2 FHMB4
AC MAINS_RFI_IN
DC
IEC
CTRL FOR
DC LASER AUTOFEEDER
RFI BOX DIST
LSB
24V_ENG
ENG_INT
Figure 2.21 System power distribution and control (B1 and B2 fully-automatic)
ENGINE PTM BUFFER
1-3
Volume-Chapt er
4
4
Health and Safety at Work (All Variants) .................................................................. 3-1
4
Laser Safety ................................................................................................................ 3-2
4
Safety Interlocks (All Variants)................................................................................ 3-19
4
Emergency Stop Circuit ........................................................................................... 3-22
4
Mechanical Safety .................................................................................................... 3-24
Antistatic Precautions (All Variants)....................................................................... 3-24
CAUTION: This chapter must be read before working on the equipment where there are
risks from overridden interlocks.Service and installation engineers for a Luxel CTP must
be trained on the product engineering course before working on a platesetter system.
The minimum requirements for site safety, before installing the machine, are set
out in the Luxel Platesetter Pre-Installation Manual.
Operator Safety Information is included in the Luxel Platesetter Operator's Man-
ual.
Safety information in this chapter is for all three variants (Automatic, Semi-
Automatic and Manual) platesetters.
WARNING: The instructions in a warnings must be followed precisely. They are given to
avoid serious injury.
2. CAUTIONS are displayed for conditions which may cause damage to equip-
ment or materials.
CAUTION: The instructions given in cautions must be followed to avoid damage to equip-
ment or materials.
Since the Luxel CTP uses lasers it is labelled as a Class I laser product when all
the covers are closed. While the covers are opened and the interlocks defeated,
the machine is a Class IIIB laser source. Light is emitted in the violet spectrum at
405 nm. Maximum power output from the laser source is classified as Class IIIB.
DANGER
Laser radiation when open
AVOID EYE OR SKIN EXPOSURE TO
DIRECT OR SCATTERED RADIATION
OPEN CLOSED
LASER POWER
DETECTOR
ASSEMBLY
SHUTTER
WARNING: Never look directly into a laser beam. This could cause serious damage and
possible blindness.
VOLUME 1 (3-4) S ERVICING S AFETY P RACTICE
When working on a Class IIIB laser source, always wear goggles capable of attenuating
the beam to a Class II level if there is the slightest risk of direct reflection
The voltages used in the laser circuits, and power supplies, are potentially hazardous.
Exercise extreme caution while servicing the platesetter with its interlocked covers
removed.
Never place a mirror or other reflective material in the laser beam. This action can reflect
hazardous light to others working in the general area.
Laser current and beam power are always set at the factory from the optics
NVRAM parameters supplied with each laser or as part of a laser upgrade/
replacement procedure. If a laser needs replacing, only the recommended
parameters given in the supplied datasheet are entered. These parameters
include maximum power levels that need to be set for the laser.
Do not power up the platesetter with a laser disconnected.
Remove the protective lid of the optics base only in accordance with the
instructions given in the service procedure.
Attenuating laser safety goggles must be used where there is a risk of direct
reflection from a laser beam. Where there is no such danger, and when
observing diffused reflected spots from screens and targets, it is permissible
to work without attenuating laser safety goggles. Extreme care must be
taken when working with lasers.
The protective cover of the laser module should never be removed.
ETL LISTED
CONFORMS TO
UL STD 1950
C US CERTIFIED TO
92206 CAN/USA STD C22.2 NO. 950
Product: LUXEL
Serial No:
DANGER
Laser radiation when open
Figure 3.4 Drum end cap - laser and spinner rotation warning labels
Figure 3.5 illustrates the spinner, laser and moving parts risks to the engineer
after the drum end caps are removed and the interlocks are defeated.
Note that the laser radiation warning in Figure 3.5 only applies to a non-punch
machine.
VOLUME 1 (3-8) S ERVICING S AFETY P RACTICE
CAUTION
WARNING LASER RADIATION
DO NOT STARE INTO BEAM
HIGH SPEED SPINNER ROTATION
KEEP CLEAR
AVOID EXPOSURE
NOTE: LABEL ON BOTH 1250-45 BCamCP2
0.8mw 670nm
Laser radiation
Emitted from Aperture
ENDS OF BAFFLE To EN60826-1, 21CFR Part 1040.10
VECTOR
TECHNOLOGY
5794 0004 1002 LIMITED
Figure 3.5 Drum user side - spinner and moving parts warning labels
DANGER
Laser radiation when open
Attention!
high tension
Vorsicht!
Hochspannung
Prcaution!
haute tension
LASER RADIATION - AVOID EYE Precaucin!
OR SKIN EXPOSURE TO DIRECT alta tensin
OR SCATTERED RADIATION
Figure 3.6 Optics base - laser and high tension warning labels
RFI BOX
Attention!
high tension
Vorsicht!
Hochspannung
Prcaution!
haute tension
Precaucin!
alta tensin
Figure 3.8 shows the area of risk from high-tension voltage after the interlock
box lid is removed.
L UXEL P LATESETTER VOLUME 1 (3-11)
Danger
Disconnect the
mains supply before
removing this cover
Figure 3.9 shows the area of risk from high-tension voltage after the mains filter
box lid is removed.
WARNING: Both the mains filter box and the interlock box contain LIVE components
when the circuit breaker ON/OFF is in the OFF position.
VOLUME 1 (3-12) S ERVICING S AFETY PRACTICE
Danger
Disconnect the
mains supply before
removing this cover
ENGINE
(SERVICE SIDE)
SERVICE SIDE
USER SIDE
Figure 3.12 Interlock cover - interlocked warning label (semi-auto and manual)
AUTOFEEDER
(SERVICE SIDE)
WARNING
ENSURE MAINS SUPPLY DISCONNECTED
BEFORE SERVICING
Figure 3.15 warns the engineer about the risks of removing a cassette from the
Autofeeder without first locating a trolley under the cassette door.
L UXEL P LATESETTER VOLUME 1 (3-17)
Chemical.
Spinner.
Pneumatics.
Regularly verify that mains supply cables are not worn or damaged.
Make sure that water and other liquids do not come into contact with the
equipment.
Do not attempt to operate the equipment when flammable or volatile sub-
stances are present in the atmosphere.
Avoid leaving electrical cables trailing where anyone may trip over them.
The following basic precautions apply to the platesetter system. More specific
mechanical safety risks, when the safety interlocks are over-ridden, are
described in Section 3.5.
Always close and lock equipment access covers to prevent internal access
from the service side of the Engine, PTM and on the Autofeeder.
The platesetter consists of assemblies that are excessively heavy for one
engineer to lift. If a replacement or installation procedure requires that one
of these assemblies needs to be moved or lifted at any point, then make sure
assistance is available.
The platesetter has a number of motor-driven moving parts that could
present a risk to the service engineer. Make sure you are familiar with the
main areas of danger listed below, and how to carry out a recommended
service procedure when the interlocks are over-ridden.
A) elevator chain pulley system
B) spinner
C) cassette and plate transport mechanisms
D) plate push bar
E) punch and centerer.
L UXEL P LATESETTER VOLUME 1 (3-19)
NOTE: At idle speed, spinner rotation is a direct multiple of some interior lighting fre-
quencies. This could make the spinner mirror appear as stationary.
WARNING: The spinner rotates at very high speeds and can cause serious injury if acci-
dentally touched. Make sure the spinner has stopped rotating before accessing a drum
with the interlocks defeated.
WARNING: Always use appropriate ear protection devices before working on or around a
rotating spinner.
6
5 4
2
2
4
3
SERVICE SIDE
(FOR SERVICE
ENGINEER ONLY)
USER SIDE
(FOR OPERATOR)
WARNING: If the platesetter has to be run with a cover open and the interlocks overrid-
den, extreme care must be taken to avoid the following hazards: rotating spinner, laser
beam, moving plate motors.
All unqualified personnel must be prohibited from the area, while the machine is in the
overridden state and the Laser Safety Officer informed.
NOTE: The cassette door is part of the elevator interlock system. Controlled from the
MMI, the door lock switches off the elevator motor when it is opened.
Use the approved method (key-switch) for over-riding the interlocks. The
switch is located behind the Engine (service side) cover, with the facility
explained in Volume 3 Section 1.1.
Once the interlocks are defeated, there are a number of hazards that the service
engineer needs to be aware of before starting an installation or service proce-
dure.
PRESS DOWN
TO STOP
AUTOFEEDER PTM
When pressed, the two emergency stop buttons, located on the top of the PTM,
automatically remove AC power to the system (except for the mains filter and
interlock box). This facility is operated if there is an immediate risk of human
injury or machine damage and is reset to allow the supply of AC voltage after
the emergency has been cleared.
The emergency stop circuit control is housed in the interlock box and operates
as follows:
1. While the system is operating normally, the 240 VAC mains input supply to
the RFI box, vacuum pumps and elevators generates a 24 VDC steady cur-
rent to a contactor coil on the emergency safety contactor. The contactor
(type 1026-1BB40) is closed while DC supply is available.
2. Pressing on the stop button opens the 24 V circuit at the PTM, de-energises
the coil which opens the two contacts (live and neutral) for the AC supply to
the RFI box, PTM and Autofeeder. A drop in voltage to the circuit breaker is
sensed and causes the breaker to switch off.
3. Engineers also have the option of removing AC via the safety isolators at the
VOLUME 1 (3-24) S ERVICING S AFETY PRACTICE
The Autofeeder is an elevator system with a mechanical set of chains and pul-
leys that move shelves to their required position for online cassette loading.
With the top and side covers open, and the interlocks defeated, there are a
number of potential hazards for the service engineer to be aware of:
hand trapping by a moving chain
trap hazard between the elevator and the frame.
The Luxel CTP contains electronic components which are susceptible to static
damage. When clearing jams, cleaning a device, or performing routine mainte-
nance tasks, care should be taken not to touch any exposed electronics.
Before handling a board, all antistatic precautions must be followed.
L UXEL P LATESETTER VOLUME 1 (3-25)
CAUTION: Do not place a board on an unearthed surface after removing it from its protec-
tive wrapper. Do not place it on the wrapper, the outside of which could be electrostati-
cally charged.
When removing the board from its antistatic wrapper, take care not to touch any
of the board components or connector pins.
Use a Fujifilm field service antistatic kit or, if this is not available, a disposable
antistatic wrist-strap as detailed in this section.
CAUTION: Use the disposable antistatic wrist-strap. Failure to do so may result in dam-
age to the board.
EARTH STRAP
CLIPPED TO
EXPOSED
CHASSIS CHASSIS
ANTISTATIC
POWER FIELD SERVICE KIT
OFF (9998-7920)
MAINS
PLUG
EARTH WRIST STRAP
PLATESETTER DIAGNOSTICS
This chapter describes how to use the test and utility commands in Main Diagnostics
required for a service visit.
4
4
Introducing Luxel CTP Diagnostics .......................................................................... 1-1
4
Booting the Platesetter .............................................................................................. 1-2
4
Introducing Main Diagnostics ................................................................................... 1-6
4
Introducing Diagnostic Tests ....................................................................................1-6
4
Describing MMI Error Codes ................................................................................... 1-10
4
How to Use Main Diagnostics ................................................................................. 1-12
4
Running Main Diagnostics ......................................................................................1-19
4
Using Log Utils Menus .............................................................................................1-19
4
Using Test Menus ..................................................................................................... 1-27
4
Using Service Menus ............................................................................................... 1-30
4
Checking Config and NVRAM Data......................................................................... 1-60
4
Upgrading Embedded Firmware ............................................................................. 1-66
4
Setting Up Persistent Images ..................................................................................1-67
4
Running MMI Self-Tests ........................................................................................... 1-69
Using Media Tools ....................................................................................................1-70
NOTE: Platesetter diagnostics may be modified and expanded as new firmware for the
System Board is released. Check the CD Release Notes of new firmware issues for the
latest changes to error codes.
Detects system and media handling errors which are reported on an MMI
console.
Allows the engineer or operator to run a set of automated self-tests for the
system (electronics, traverse, etc).
Allow the engineer to run tests on media handling devices (sensors, motors,
etc) and move discrete mechanisms.
Includes a persistent (permanent) set of test images held on the Hard disk
and selectable from the MMI.
Allows the engineer to access PCB and system configuration files, and edit
system configuration data in a registry file whenever there is a hardware or
software change.
Allows access to the error log files held in Flash memory.
Once the application is running, the following diagnostic tools are available:
Main Diagnostics
A suite of tests and utilities for the service engineer. They run under a hierarchi-
cal menu system that include global commands.
See Section 1.3 and Section 1.6.
MMI Self-Checks
These are a suite of system tests on machine modules (PCBs, motors, optics, etc)
that give a pass/fail result. Self-tests are controlled from the MMI and initiated
by the engineer or operator.
See Section 1.14.
MMI Test Images
A set of persistent images are available for checking image quality and for com-
missioning the system.
See Section 1.5.
MMI Media Tools
A facility on the MMI that allows the operator or engineer to select/park a cas-
sette and advance/eject single plates without scanning.
See Section 1.15.
MMI Error Codes
These are a set of codes that appear on an Error handling screen when a subsys-
tem (optics, spinner, traverse, etc) reports an error.
See Section 1.5.
BOOT SYSTEM
POWER UP
CHECK FLASH
CODE
IF FLASH
CODE CORRUPTS REMAIN IN
OR CONTROL+C PRESSED BOOT MODE
OR TOUCHSCREEN (READY TO
PRESSED DOWNLOAD F/W)
SETS UP HDD
AND NVRAM
CONTROL + C
RUN
FOR BY-PASS
DIAGNOSTICS
MODE
APPLICATION SYSTEM
DISPLAY ERROR
START APPLICATION
READY TO SCAN
Figure 1.1 shows where you can press [Ctrl-c] to enter by-pass mode and run
diagnostics or modify laser parameters without affecting customer jobs.
NOTE: Enter Start to resume the application when the system is in boot mode.
VOLUME 2 (1-4) P LATESETTER D IAGNOSTICS
Application Sequence
4. Each of the node boards executes a self test on power-up to check whether
the application code is able run. The following POST (Power On Self Test)
routines automatically check:
4 operation of ROM, RAM and processor interrupts
4 communication to the node boards: System Board, FHMBs, STB and VBOMB.
4 an error code.
10. Errors are either fatal or non-fatal:
fatal error indicates a problem where the platesetter cannot continue to scan
until the fault is removed
non-fatal error indicates a transient fault or an alert but allows the platesetter
to scan.
MAIN
DEVELOPMENT
DIAGNOSTICS LOG
(R&D USE ONLY)
Test: these are test commands that can be selected individually from the
diagnostics> menu or run automatically as:
Boot-up tests (see Section 1.4 for a description).
MMI Self-tests (see Section 1.14 for a description).
Service: these are utility commands that can be selected individually (see
Section 1.10).
Log Menu
All the software error logs for each node PCB are held in local Flash memory
and downloaded to the Hard disk for checking by the engineer.
NOTE: The `Start' and `Standalone' menu options are for R&D use only.
4 RAM: 1002
4 Interrupts: 1003
2. PSU rails. Error Code: 1006.
3. Hard disk drive operation. Error Code: 1027.
4. NVRAM integrity on the System Board. Error Code: 1004.
5. System Registry. Error Code: 1005.
6. CAN network checks between the System PCB and node slave boards. Error
Code: 1028
7. All optics stepper motors can operate from a datum. Error Code: 1008.
8. All optics stepper motors are able to fully travel and limit detectors are
checked to give Error Codes:
4 LPD motor: 1009
4 ND motor: 1010
VOLUME 2 (1-8) P LATESETTER D IAGNOSTICS
The above motors are driven from the VBOMB. A fatal error is flagged if a
motor does not turn or a detector does not respond.
For a platesetter, the image will not adjust to fit whatever plate width is loaded.
Exposure levels are set from the most recent calibration settings on the RIP.
You can move an image from the RIP to the engine and scan it as a persistent
image using the procedure in Section 1.13. Alternatively, you can create an
image using a DTP application and download it as a PI to the engine.
Test strips are also exposed directly from the Engine (not downloaded from the
RIP) using the Service (optics mmi) menu.
13. Drum: 1700 - 1799. Punch, push bar, registration, chad tray, centering and
vacuum errors.
14. Output Module and Buffer: 1800 - 1899. Module and media jam errors on
and around the Buffer and output module.
NOTE: The enabled error codes depend on the machine variant and configuration.
4 Settings: Autodetect
4 Configuration: 9600 bits per sec; 8 data bits; None parity; 1 Stop bit; No flow
control.
3. If you need to transfer scrolled text to a selected file from the HyperTerminal
window, switch on the Capture Text from the Transfer menu.
To obtain a suitable width for the terminal window, set the Properties, Terminal
Settings box to 132 column mode.
NOTE: You may need to uncheck and recheck the 132 column mode box for this setting
to take effect.
L UXEL P LATESETTER VOLUME 2 (1-13)
NOTE: Only error messages (indicated with**) are logged to Flash memory.
When Verbose is off, only error messages are displayed and logged to appli-
cation, RAM or Flash.
Temperature information may be also added to the error log using the com-
mand temp_stamp.
NOTE: Always make sure that the Debug facility is disabled before the system is returned
to normal production scanning. The system operates at a slower speed when Debug is
enabled.
ddbg
Disables the diagnostic output from a machine software task. The parameter is
<software task number (see Table 1.2)>. For example, ddbg 8 disables output
from the AODs.
edbg
Enables the diagnostic output from a machine software task. The parameter is
<software task number (see Table 1.2)>. For example, edbg 8 enables information
output from the AODs.
ddeb
Enter ddeb to display all the debug task switch numbers shown in Table 1.2. This
will also indicate if the switch flags are ON or OFF.
recordscript
Use recordscript to create a new script, for example, `sol':
recordscript sol
actuators/set 10 on
time/sleep 150
actuators/set v 10 off
time/sleep 100
script end (Ctrl-X adds this line automatically)
You can use any of the commands and parameters detailed in this chapter. Type
[Ctrl-x] to terminate the script and the line `script end' appears.
showscript
Displays the text of a specified or the currently loaded script, for example, show-
script sol
runscript
Executes the currently loaded script or a specified script, for example:
runscript sol.
To run a script more than once, enter, for instance:
repeat sol 12
deletescript
Deletes the latest copy of a script name from the script file, for example:
deletescript sol
listscripts
Lists all the scripts available in the script file.
zeroscripts
Erases all scripts in the scripts file.
Log_utils menu provides a set of commands forr displaying the machine statis-
tics, accessing and updating the Registry/Configuration files and accessing the
VOLUME 2 (1-20) P LATESETTER D IAGNOSTICS
NVRAM parameters.
edit_stats
Allows you to edit the machine statistics fields using the cursor keys to move
down each field.
Use the cursor key to move up/down the column and the arrow key to delete.
Press [Return] to obtain the question:
Write change statistics back [y/n]
Parameters: [None]
save_stats
Writes the Statistics file to HDD, see Section 1.11.
Parameters: [None]
updateSysLogs
Writes the System Configuration log files for each node slave board to the HDD.
Parameters: [None]
L UXEL P LATESETTER VOLUME 2 (1-21)
save_nvram
Saves the System NVRAM parameters to the HDD, see Section 1.11.
Parameters: [None]
disp_nvram
Displays the current NVRAM parameters and their values.
disp_nvram <parameter name> - displays a specific parameter.
disp_nvram - lists all the parameters.
disp_nvram *trav* - allows you to enter wild cards for displaying all the
parameters related to a shortened syntax word.
restore_nvram
Writes the NVRAM parameters from the Hard disk (HDD) to the System PCB.
Reboot the system after restoring the NVRAM.
Make sure that the correct NVRAM configuration is currently stored on disk by
checking the Sysnvram.bin file, see Section 1.10.11.1.
Parameters: [None]
init_nvram
Initialises all the NVRAM parameters to their default values. Do not use unless
advised by FFEI (UK) Customer Support.
Parameters: [A (all parameters)]
disp_conf
Displays the System Configuration file for each node PCB, see Section 1.11. This
shows details of the main node PCBs and gives details of their serial numbers,
test dates, PCB part numbers.
Parameters: [None]
display_registry
Displays the system, slave board or HDD details held on the System Registry
showing the system serial number, build, test date, install date, change history
and change details.
Parameters: [board | system | hdd]; for example, enter display_registry board.
display_errors
Shows the number of times an error has occured, for example:
Error 139 occured 5 times
Parameters: [None]
reset_error_stats
Sets the error statistics to zero.
Parameters: [None]
configuration/
Opens the Configuration menu, see Section 1.8.2.
VOLUME 2 (1-22) P LATESETTER D IAGNOSTICS
nvram/
Open the NVRAM menu, see Section 1.8.3.
laser_x_stat
Shows the date and operating current for the laser X installed date and subse-
quent increases of current values to offset aging. It records the history of the
laser operating current with the date of when any current increases by 10 %
from the previous recorded value.
The first entry is the installed or field replacement date; each entry afterwards is
a 10% increase of current. Entries are updated by running the laser_aging com-
mand or when the application runs the diagnostic every 24 hours.
Use this data to predict when the laser will fail by determining when the operat-
ing current is 50% higher than the initial operating current value.
Parameters: [None].
diagnostics/log_utils>clear_laser_x_stat
diagnostics/log_utils>laser_x_stat
laser_y_stat
Displays the statistics for laser Y showing date and time and laser current. See
laser_x_stats above.
Parameters: [None].
clear_laser_x_stat
Clears the laser statistics file. Use this commande when a laser is replaced on an
installed machine.
Parameters: [None].
clear_laser_y_stat
Clears the laser statistics file. See the command above.
Parameters: [None].
Use the Configuration menu to save and restore configuration files to the HDD
to avoid the loss of data. These commands are normally used by the factory.
save
Saves a copy of board NVRAM data or configuration data to the HDD.
Parameters: [nvram | config]; enter, for example, save nvram.
dump
Displays all the NVRAM details on the HDD to the monitor.
Parameters: [nvram | config]; enter, for example, dump nvram.
restore
Restores the board NVRAM data or config data from the HDD to a target board.
Do not restore NVRAM data to the boards from HDD unless you are certain
these are correct for the machine configuration.
Parameters: [nvram | config]; enter, for example, restore_nvram.
writeData
This facility allows you to display and edit board Configuration files before they
are saved to the registry. The circumstances where you may need to modify
these files are exceptional; normally, the files on a site machine are updated
automatically on startup. Use the following parameters for each board:
A) <ssb_config> <REGISTRY_SSB_ID>
B) <stb_config> <REGISTRY_STB_ID>
C) <vbomb_config> <REGISTRY_VBOMB_ID>
D) <fhmb1_config> <REGISTRY_FHMB1_ID>
E) <fhmb2_config> <REGISTRY_FHMB2_ID>
F) <fhmb3_config> <REGISTRY_FHMB3_ID>
G) <fhmb4_config> <REGISTRY_FHMB4_ID>
Use the Up/Down Arrow to move between fields.
readData, wrDataArray, rdDataArray, wrCircArray, rdCircArray, init_registry
These commands are not used by service engineers, unless requested by FFEI
(UK) Customer Support.
Use this menu to view NVRAM parameters and edit values used for the:
laser module
VOLUME 2 (1-24) P LATESETTER D IAGNOSTICS
Use the cursor Arrow-Down key to move down each field, use Update to make the
change and press [Return] to exit from the menu.
fog_time
Sets the maximum time a plate can be exposed to ambient light on a Manual
machine. The current maximum setting is 6 mins on both the input and output
to the processor on a Manual machine.
Parameters: [num of minutes on input] [ num of minutes on output].
setter_to_processor
Sets the distance (in mm) for the leading edge of a plate to pass the last Engine
sensor (BS5) on a Manual machine.
Parameters: [num of mm].
set_punch
Use this command to indicate to the machine that a punch is fitted.
L UXEL P LATESETTER VOLUME 2 (1-25)
wr_image_offset
Writes a new image base offset position to NVRAM.
Parameters: [value (mm)].
power_control
R&D use only. Do not use.
cage_creep
Use this command to view/set the cage creep number of scans for checking end
positions. The default number of traverses is 35. See Volume 3 Section 1.7.2.
bearing_hold
Use to view/edit the spinner bearing hold time (in seconds). This is the time
from when an image has been exposed to when the spinner has stopped.
Parameters: [None].
nd_correction
Allows the addition of the ND correction values to the ND wedge position
passed from the RIP jobfile.
Parameters: [1 = enable | 2 = disable].
pfa_disklog
Enables/disables the post-failure analysis disk logging to the RIP SaveLog file.
The PFA_DISKLOG_ENABLED parameter is normally set as 1 to enable error
logging. Error logging creates an ASCI log file on the Engine which records the
current software status of the machine at the time of a fatal error.
Check also that the parameters PFA_DISKLOG_LEVEL and
PFA_DISKLOG_DELAY are set to 0.
Parameters: [1 = enable | 0 = disable].
pfa_disklog_level
Shows the level of error logging. The default setting is 0.
Parameters: [0 = standard | 1 = in]
preload_plate
Controls the preloading of a plate to the pre-diverter position. Normally, the
MMI media tools are used for this operation.
Parameters: [0 = do not preload | 1 = preload].
contam_chk_interval
R&D use only.
elog_evt
Defines the number of machine events to be logged by elog. A typical value is
10000.
Parameter: [value].
L UXEL P LATESETTER VOLUME 2 (1-27)
Test menus allow you to select and run tests for the devices and data paths
listed in Figure . The test results only indicate a PASS or FAIL; you need to
switch on Verbose (global command), to obtain more information about the test
results.
Typical test outputs are shown below. Test outputs show Error Code numbers, if
the tests are applicable to the System tests, and the time and date.
display_registry
Displays the system, slave board or HDD details held on the System Registry,
see Section 1.11.
Parameters: [board | system | HDD]; for example, enter display_registry board.
update_registry
Used to modify data in the System Registry after a hard/soft/firmware modifi-
cation, see Section 1.11.
Parameters: [system | HDD]; enter, for example, update_registry system. Only use
HDD for tests.
Toggle the `N' default to `Y' with the [Left/Right Arrow] keys and press [Return] to
exit, then enter Y to confirm.
If you have changed both the System Board and HDD, then the following
appears:
sysSerialNum
sysBuildDate
finalTestDate
Enter revised details (using the cursor keys to navigate) if you have changed
both the System Board and the HDD. Enter the system serial number for pro-
duction machines as PXXX. Press [Return] to exit and Y to confirm. If you have
not made any changes, a message No update to Registry required is dis-
played.
Now check that the revised details are valid by running the Reg_power test:
registry> reg_powerup
beam_conv_motor
Checks the beam converter motor.
Parameters: [None].
ND_motor
Checks the neutral density motor.
Parameters: [None].
focus_motor
Checks the focus motor.
Parameters: [None].
Parameters: [None].
reset_cont_lvl
Initilises the reference level for the contamination check.
Parameters: [None].
locate_FPD
Obtains the center position from the two edges of the FPD. The result is entered
into the NVRAM parameter: TRAV_HIGH_SPEED_POS.
VOLUME 2 (1-30) P LATESETTER D IAGNOSTICS
Parameters: [None].
chart_FPD_resp
Obtains the FPD and LPD response data. This information is only useful for
FFEI (UK) Customer Support.
Parameters: [None].
Commands useful for running service utilities are available from the menu
L UXEL P LATESETTER VOLUME 2 (1-31)
shown in Figure .
dmem
Displays the contents of System Board logical memory addresses for the appli-
cation firmware. Enter ? command for details of the parameters.
verify
Verifies the address pattern. Enter ? command for details of the parameters.
smem
Sets the memory contents. Enter ? command for details of the parameters.
sverify
Sets the memory to a pattern and then verify. Enter ? command name for details
of the parameters.
cmem
Copies memory from one address to another. Enter ? command for details of the
parameters.
compare
Displays the differences between the 1st and 2nd blocks of memory. Enter ? com-
mand name for details of the parameters. Enter ? command for details of the
parameters.
search
Displays occurrences of a specified value within a defined area of memory.
Enter ? command for details of the parameters.
NOTE: Service engineers are advised not to use the EVT commands, except for those
listed below.
ini
Event processing is normally initialised on machine startup.
Parameters: [None].
getstate
Displays the current state of each STD task on the System board. These mes-
sages are numerous and will only make sense to R&D. Capture the full display
VOLUME 2 (1-32) P LATESETTER D IAGNOSTICS
Parameters: [Resolution].
check_eodd_ok
Displays the eodd_ok status to indicate if the interlocks are overridden.
Parameters: [None].
x_beam_enable
Sets the X-beam data to 1. This gives a laser output if the laser is enabled using
the lenable command (see below).
Parameters: [None].
x_beam_disable
Sets the X-beam data to 0. This will stop the laser output.
Parameters: [None].
y_beam_enable
Sets the Y-beam data to 1. This gives a laser output if the laser is on using the len-
able command (see below).
Parameters: [None].
y_beam_disable
Sets the Y-beam data to 0. This will stop the laser output.
Parameter: [None].
set_clear_film_density
R&D use only.
set_start_patch_number
R&D use only.
set_end_patch_number
R&D use only.
set_bias_level
Displays or edits the laser bias level to set up laser extinction (see the command
measure_extinction_ratio below).
Working Laser X/Y bias DAC values are changed using the backspace and
numerical keys:
4 to increase the extinction ratio of a laser you need to decrease the bias current
4 to decrease the extinction ratio of a laser you need to increase the bias current.
Increase or decrease the Working Laser bias current DAC values by 1 unit at a
time.
Changing the bias current by a large value (greater than 5) may damage the
laser.
Press [Return] then use the side keys to select UPDATE, the press [Return] to exit.
This will update all the working laser bias values in NVRAM.
Parameters: [change].
VOLUME 2 (1-34) P LATESETTER D IAGNOSTICS
Changing values
lcpd_params
Changes the laser setup. See Section 1.8.3.
laser_stats
R&D use only.
lenable
Enables a laser module for continuous drive or bias. laser Ids are 1 (X) and 3 (Y);
insert the values in LCPD_params for full bias and drive; resolutions available
are 48, 1200, 72, 1800, 96, 100, 2400, 144.
Parameters: [laser id] [bias | drive] [resolution]
ldisable
Disables a laser module from continuous drive or bias.
Parameters: [laser id]
lstatus
Shows the status of the two X and Y laser module PCBs: Photo Diode (PD) and
Laser Diode (LD) head boards. Use to check the connection between the lasers
and the VBOMB.
laser_aging
Resets the laser current limit values and gives some guidance on when it needs
to be replaced. A more useful command to check for laser aging is laser_X_stats
L UXEL P LATESETTER VOLUME 2 (1-35)
or laser_Y_stats which show the rate of current change from the date of installa-
tion.
For example, the module is close to end of life when:
1. the read x current value is greater than or equal to end of life current value
2. the actual +ve rate of change is greater than the max rate of change. This pro-
duces a fatal error requiring a change of module when 7 has been exceeded.
Use enable debug 40 global command beforehand.
Parameter: [None].
edbg 40
diagnostics/service/optics/laser>laser_aging
ddbg 40
measure_extinction_ratio
Measures the extinction ratio of both laser modules. Use set_bias_level to adjust
the extinction ratio.
The extinction ratios should be between 180 and 220 for both lasers (if fitted).
Parameter: [None].
diagnostics/service/optics/laser>measure_extinction_ratio
service/optics/motors/move_motors (optics)
full_pod_power_pos
Moves the ND wedge to the full POD power position.
Parameters: [None].
half_pod_power_pos
Moves the ND wedge to the half POD power position.
Parameters: [None].
nd_res_pos
Moves ND wedge to a specified resolution position.
Parameters: [48 | 72 | 96 | 100 | 144 | 1200 | 1800 | 2400].
max_nd_pos
Moves ND wedge to a maximum transmission position.
Parameters: [None].
min_nd_pos
Moves ND wedge to a minimum transmission position.
Parameters: [None].
beam_res_pos
Moves beam converter and aperture control to a resolution position.
Parameters: [48 | 72 | 96 | 100 | 144 | 1800 | 1200].
focus_res_pos
Moves the focus to a resolution position for a plate thickness in microns.
Parameters: [48 | 72 | 96 | 144 | 100 | 2400 | 200 | 240 | 1800 | 1200| 200 | 240
| 300].
close_pos_lpd
Moves LPD to its close position.
Parameters: [None].
open_pos_lpd
Moves LPD to its open position.
Parameters: [None].
home_optics_motors
Moves all the optics motors to their Home positions.
L UXEL P LATESETTER VOLUME 2 (1-37)
Parameters: [None].
motors_to_scan_posn
Moves all the optics motors to their scan positions.
Parameters: [None].
service/optics/motors/simulate menu
These commands are mainly for use by R&D. Refer to Customer Support (UK)
for information on their use at an installation.
nd_simulate
Simulates the ND motor.
Parameters: [1 = on | 0 = off].
focus_simulate
Simulates the focus adjust motor.
Parameters: [1 = on | 0 = off].
beam_simulate
Simulates the beam converter motor.
Parameters: [1 = on | 0 = off].
lpd_simulate
Simulates the LPD motor.
Parameters: [1 = on | 0 = off].
This menu reveals a set of utilities for operating the stepper motors for optics
and plate handling. Before running these commands you first need to set the
current motor using the setmotor command.
init
Initialises the stepper motors.
VOLUME 2 (1-38) P LATESETTER D IAGNOSTICS
Parameters: [None].
setmotor
Enter motor name to set the current motor for the other commands, for example,
setmotor nd.
offstation
Moves the currently selected motor to a specific position relative to its Home
sensor, for example: offstation 60 400.
Parameters: [position (in steps) | move in steps (per sec) | d (optional) = motor
moves to the required position without passing through Home].
movetillsen
Moves the currently selected motor towards a sensor until an edge (rising or
falling) is reached, for instance, movetillsen 80 f 400 bs41 f.
Note that the transition detection capability for the required sensor and edge
must have been previously enabled using the en_trans command on the /sensor
menu. .
Parameters: [num = max number of steps to move if the edge is not detected | f
or b = move direction | speed (steps/secs) | sensor number | f or r = select the
edge transition to stop the motor (rising or falling)].
shpos
Shows the position of the current motor.
Parameters: [None].
shcond
Shows the status of the current motor.
L UXEL P LATESETTER VOLUME 2 (1-39)
Parameters: [None].
show
Displays the list of motor names, see Table 1.3.
Parameters: [None].
focus Focus
nd ND Wedge
slow_speed LPD
centerer centerer
bridge_feed buffer
wait
Wait for the currently selected motor to stop.
Parameters: [None].
dslog
Disables sensor timeline logging.
Parameters: [None}
dgslog
Enables sensor logging for a group of sensors called limit, input and output.
Parameters: [group]
shslg
Shows a list of sensor groupings.
Parameters: [None].
en_debounce_rd
Enables or disables debounced sensor reading. When enabled, all subsequent
sensor reads return the software-debounced value; when disabled, all sensor
reads return the current instantaneous value.
Parameters: [y or n = determines whether the subsequent sensor read returns the
debounced value (y) or the instantaneous value (n)]. The default is (y).
simulate
Enables simulation of the value returned when a sensor is read. A sensor can be
simulated at either the client node (the board running the utility) or the server
node (the board controlling the sensor).
Parameters: [c or s = for client or server local simulation | the number of the sen-
sor, for example, bs8 | the value to be returned whenever the sensor is read
where (on or off = discrete sensor; num = analogue sensor)].
This command has limited field use.
dis_simulate
Turns off sensor simulation and returns a previously simulated sensor to normal
operation.
Parameters: [c or s = to match the previous sensor parameter | sensor number,
bs8].
L UXEL P LATESETTER VOLUME 2 (1-41)
en_trans
Enables a sensor rising/falling transition edge for a discrete sensor.
Parameters: [b (both); r (rising); f (falling) | sensor number]; for instance, enter:
en_trans r bs11.
en_limits
Enables the limits detection on analogue sensor.
Parameters: [sensor name | lower limit | upper limit].
dis_evt
Disables the event generation for sensors (discrete and analogue).
Parameters: [sensor number].
show
Lists all the system sensor names if accessed from the System board.
Parameters: [None]
envsim
Controls the simulation of all environment monitoring sensors.
Parameters: [on = all sensors will be simulated to within the standard operating
ranges; off = all sensors returned to normal operation]. Enter the command
without a parameter to indicate if the simulation is currently enabled or not.
environ
Displays the temperature sensor reading on the System Board in units of 0.1C.
There are three thresholds defined by the software.
Parameters: [None].
read_con
Opens a screen showing the continuous condition of all the input and output
plate handling sensors while the machine is operating, see Figure 1.6 and
Figure 1.7.
Most of the sensors indicate YES when the sensed object (plate or motor opto-
slot sensor tab) is present and NO when it is absent. The cassette ID sensors
indicate if they are detecting BLACK or WHITE blocks.
Parameters: entered for the input and the output sensors:
read_con [fhmb1] to obtain the Manual/Semi input sensor screen, see
Figure 1.6.
read_con [fhmb4] to obtain the Manual/Semi output sensor screen, see
Figure 1.7.
read_con [ip] to obtain the Fully-Automatic sensor screen for the elevator
and PTM.
read_con [op] to obtain the Fully-Automatic sensor screen for the drum and
buffer.
VOLUME 2 (1-42) P LATESETTER D IAGNOSTICS
Press [Ctrl-c] to EXIT from a submenu or select the following options (see
Figure 1.8):
All ERR: select All ERR to switch off (remove) the displayed sensors with
error reports; reselect the option to redisplay the sensors.
Exit: to exit from the Read_con screen.
Specific Sensor: select a specific sensor to switch off (remove) the displayed
sensor output; reselect the option to redisplay the sensor output.
L UXEL P LATESETTER VOLUME 2 (1-43)
All XXX: select All XXX to switch off (remove) the displayed sensors with
indeterminate reports; reselect the option to redisplay the sensors.
init
Initialises the traverse servo motor.
VOLUME 2 (1-44) P LATESETTER D IAGNOSTICS
Parameters: [None].
datum
Moves the traverse carriage to the datum position on the service side.
Parameters: [None].
wait_datum
Use after entering the datum command to prevent any other diagnostic com-
mand from running while the carriage is reaching datum.
Parameters: [None].
goto
Moves the carriage to a position on the traverse set in microns.
Parameters: [position (in microns)]; for example, goto pos=- 610000 for approxi-
mate centre beam position.
wait_stop
Use after entering the stop command to prevent any other diagnostic command
from running while the carriage is stopping.
Parameters: [None].
stop
Stops the carriage traversing by operating as a smooth brake.
Parameters: [None].
halt
Stops the carriage traversing by operating as an abrupt brake.
Parameters: [None].
pos
Reports the position of the traverse.
Parameters: [None].
medirq
Continously monitors the edge detect interrupts. Enter Ctrl-c to abort the moni-
tor.
Parameters: [Number of edges detected].
status
Reports if the traverse is moving or stationary.
Parameters: [None].
rd_centre_posn
Reads the traverse centre position (in microns) from NVRAM.
Parameters: [None].
wr_centre_posn
Writes the traverse centre position (in microns) to NVRAM.
Parameters: [Value (microns)].
L UXEL P LATESETTER VOLUME 2 (1-45)
1.10.10 service/actuators
set_drv
Sets the solenoid (BV) and the motor (BM) drivers to on, off and disabled.
Parameters: [actuator name | on, off, disable]; enter, for example, set_drv bm28 on.
See also Figure 1.9.
set
Sets the current actuator and solenoid.
Parameters: [actuator name ] [ on, off, disable, no, sweep]; where no = no change.
cond
Reads the current state of the solenoids or actuators as on or off.
Parameters: [actuator name]; enter, for example, cond bv1.
show
Displays all the actuator (solenoid and motor) names, see also Figure 1.9.
Parameters: [None].
VOLUME 2 (1-46) P LATESETTER D IAGNOSTICS
second parameter to select the unit. A report indicates whether the stop/stop
operation is successful.
reset
Installs the SCSI driver for the default unit.
Parameters: [SCSI ID no] for example, reset 1
dfs/
Opens the disk file system utility below.
cd
Changes the file system default partitions to be either odd or even.
Parameters: [filesystem].
mv
Renames a file on a partition.
Parameters: [old filename | new filename].
rm
Deletes matching files on one or more partitions.
Parameters: [filename].
od
Displays the contents of a file.
Parameters: [filename].
partition-info
Displays information on the disk partitions as odd, even and general.
Disk information is shown as disk name, address, partition size, sector size and
sector cluster.
Parameters: [odd | even | general] to display the disk number, partition address
and size; section size; section cluster numbers; FAT size; sectors FAT.
diskspace
Displays the partition usage on the odd, even, general disk partitions. Displays
the total area (in Mbytes) for the area used and area free.
Parameters: [odd | even | general].
cmp
Compares two files on the disk.
Parameters: [number of edges].
cp
Copies a file to a directory.
Parameters: [filename | directory].
NOTE: Testpatns commands are entered using hyphens (-) and not underscores(_).
L UXEL P LATESETTER VOLUME 2 (1-49)
Test pattern outputs generated by /testpatns are from direct calls to the machine
hardware and not to the application exposer/plate handling software modules.
Use the optics_mmi facility described in Volume 3 Section 4.4 to create and out-
put a test pattern. Test strip generation from this facility include an automatic
and manual set of tests followed by a media eject.
test-patn-edit
Entering this command displays the line:
1 Beam Res 48 l/mm Vertical Lines 1 On 1 Off
Use the arrow keys to move between each setting and toggle to a new pattern
setup.
Parameters: [None].
image-params
Use the arrow keys to move up/down the menu and edit the settings. Press
Return to exit.
Parameters: [None].
power-con
Displays and edits the power control value.
Parameters: [None]
beam-buffer-select
Allows you to select beams X and Y and a buffer.
spinner-on-off
Indicates the spinner rotation is on or off.
Parameters: [None].
image-bias-posns
Displays and edits the image bias positions.
Parameters: [None]
apc-setup
Displays or edits the APC setup.
Parameters: [None].
VOLUME 2 (1-50) P LATESETTER D IAGNOSTICS
Run
Output a test pattern.
Parameters: [None]
dump-buffers
Not used for field servicing unless requested by FFEI (UK) Customer Support.
fill-buffers
Not used for field servicing unless requested by FFEI (UK) Customer Support.
init
Initialises the Job and Image Manager software.
Parameters: [None].
piejob
Use this command to create a persistent image expose job (i.e. a job linked to a
specified persistent image name is created and added to the Expose queue.
Use the procedure in Section 1.13 to create a persistent image.
Parameters: [image name | e]. The optional [e] parameter allows you to edit the
job parameters.
delete
Remove a job from the expose queue.
Parameters: [job ID].
expose
Simulates expose of all jobs on the queue. Jobs need to be queued before start-
ing.
Parameters: [None].
L UXEL P LATESETTER VOLUME 2 (1-51)
qhold
Holds the expose queue.
Parameters: [None].
qrelease
Releases the expose queue.
Parameters: [None].
jhold
Holds a job from the expose queue.
Parameters: [job id].
jrelease
Releases a job from the expose queue.
Parameters: [job id].
media
Displays the current media details on the active shelf.
Parameters: [None].
qstat
Dumps the job queue status that includes the progress, parent and sub job IDs.
Includes a history list of jobs.
Parameters: [None]
stat
Enter stat to display the status of queued jobs as a test for the Job Manager func-
tion on the MMI.
download job id: job IDs of any expose jobs
expose job id: job IDs of any downloading jobs
queued jobs: total of jobs on the Expose queue
media held jobs: number of jobs held for media
job held: held job at head of queue
queue held: job queue is held.
VOLUME 2 (1-52) P LATESETTER D IAGNOSTICS
dumpjob
Dumps the job description if it has not been processed.
Parameter: [job ID].
NOTE: In some cases, image names can be entered as (*) wildcards; they have a maxi-
mum length of 17 alpha-numeric characters.
editimage
Allows you to edit the image descriptors (pos/neg).
Parameters: [image name].
1.10.14 service/medproc/
status
Obtains the status (busy, etc) of the processor.
Parameters: [None].
takemedia
Sets the processor to expect plates.
Parameters: [None].
stop
Stops the Processor rollers.
Parameters: [None].
VOLUME 2 (1-54) P LATESETTER D IAGNOSTICS
restart
Restarts the processor after a stop.
Parameters: [None].
thickness
Sets the plate thickness (microns) for the Processor as follows:
4 0.2 plate: enter 200
init
Initialises the media transport software variables, clears any error status set-
tings, etc, without moving any motors.
Parameters: [None].
abort
Stops any active media transport.
Parameters: [None].
chkdrum
Checks for a plate in the drum by running the push bar up and down.
Parameters: [None].
prepplate
Prepares a plate at the top of the stack by removing paper.
Parameters: [None].
plateintodrum
Moves a top plate into the drum if the drum is empty.
Parameters: [None].
plateintoindsens
Moves a plate to the inductive sensor (BS50) if the plate has been advanced to
L UXEL P LATESETTER VOLUME 2 (1-55)
the nudger.
Parameters: [None].
remove_paper
Removes paper from the feeder.
Parameters: [None].
returnplate
Returns a plate in the feed head to the cassette.
Parameters: [None].
prepdrum
Prepares the drum for a plate load.
Parameters: [None].
eject
Ejects the plate from the drum.
Parameters: [None].
clear
Moves the plate from the Buffer to the Processor.
Parameters: [None].
conform
Conforms the plate to the drum by advancing it to the punch sensor, centering it
and operating the vacuum.
Parameters: [None].
prepstack
Prepares the stack by moving it to the correct position for removing a top plate.
See also Volume 3 Section 2.3.5.2 to adjust stack height.
Parameters: [None].
set_stack_height
Displays current stack height to align cassette and feeder for loading plates.
Parameters: [None].
updatefeeder
Updates the feed head status by reading the feed head sensors.
Parameters: [None].
inputstat
Displays the current status of the input module at the last update (ie whether or
not it contains a plate).
Parameters: [None].
feederstat
Displays the feed head status at the last update (ie whether or not it contains a
plate and its location).
VOLUME 2 (1-56) P LATESETTER D IAGNOSTICS
Parameters: [None].
drumstat
Displays the current drum status at the last update (ie whether or not it contains
a plate or is ready to receive a plate plus details of a plate already in the drum).
Parameters: [None].
bufstat
Displays the current Buffer status at the last update (ie whether or not it con-
tains a plate and if it is waiting for the Processor).
Parameters: [None].
setup_push_bar
Use to calibrate the distance between the push bar Home sensor and the regis-
tration pins. See Volume 3 Section 2.4.5.3 for a description of the setup proce-
dure.
Parameters: [plate height (in mm)] [plate thickness (eg 0.15)]
[reg_pin_push_bar_offset (in mm)].
medtransim
Shows or sets the media transport simulation mode.
Parameters: [1 to enable simulation or 0 to disable]. Shows the status without a
parameter.
bridgesim
Shows and sets the Buffer simulation mode.
Parameters: [1 to enable simulation or 0 to disable].
paperbin
Shows the paper bin status, indicating the number of waste sheets and whether
it is empty, full or nearly full.
Parameters: [None].
chadtray
Shows the chad tray status, indicating the number of punch chad waste and
whether it is empty, full or nearly full.
Parameters: [None].
init_elev
Sets the elevator software to expect 1, 3 or 5 shelves.
Parameters: [1 | 3 | 5].
access_door
Displays the current state of the cassette door.
Parameters: [None]. Use while media transport is being simulated; displays
locked or open.
loading
Sets or clears the internal flag used to indicate if a media load is in progress.
L UXEL P LATESETTER VOLUME 2 (1-57)
move_elevator
Moves the elevator up/down to the required shelf position for advancing the
cassette.
Parameters: [n = 0, 1, 2, 3, 4,]; enter as: move_elevator <shelf_1> (where shelves a =
0 top shelf; b = 1; c = 2; d = 3; e = 4 bottom shelf). For instance, move_elevator a
moves the elevator to the top shelf.
GetElevatorShelfStatus
R&D use only.
VOLUME 2 (1-58) P LATESETTER D IAGNOSTICS
1.10.16.1 service/dbases/cassette
init
Initialises the database.
Parameters: [None].
dumpc
Displays the entire contents of the cassette database, showing the cassette ID in
each bay.
Parameters: [None].
update
Updates the media and cassette databases with the current values found for
each shelf.
Parameters: [cassette ID | plate name | number of plates | empty (0 = no, 1 =
yes].
reduce
Reduces the number of plates on the database.
Parameters: [cassette id | number of plates].
dumpm
Displays the entire contents of the media database, showing the type of plate
and the remaining number of plates, etc.
L UXEL P LATESETTER VOLUME 2 (1-59)
deletem
Delete a media database entry.
Parameters: [entry number].
addm
Add a new media database entry.
Parameters: [media name | width | height | init quant | thickness | type].
1.10.16.2 service/dbases/elevator
init
Initialises the database.
Parameters: [None].
dumpe
Displays the entire contents of the elevator database.
Parameters: [None].
update
Updates each shelf with the current cassette details.
Parameters: [shelf (A..E) | cassette ID].
VOLUME 2 (1-60) P LATESETTER D IAGNOSTICS
BOARD CONFIG
SERIAL NUMBER
BUILD DATE
PCB PART No. ID DETAILS
MACHINE BUILD
PCB MANUFACTURER
FINAL TEST DATE
CHANGES MADE
(SYS, F/W, S/W)
MULTIPLE HISTORY
RECORDS DETAILS
DATE (NOTE) DETAILS NOTE: INCLUDES SYSTEM
(20)
ENGINEER ID SERIAL NUMBER OR
F/W, S/W USER No.
HDD SSB
GENERAL\ FHMB1-4
CONFIG
TMPREG.TXT
SOMB
GENERAL\ STB
NVRAM
REGISTRY.TXT
CONFIG
GENERAL\ SYSTEM
SYSCONFIG.TXT REGISTRY NVRAM
GENERAL\
SYSNVRAM.BIN SYS CONFIG
SYSTEM CONFIG
SYSTEM ID
BUILD DATE ID DETAILS
TEST DATE
1.11.2.1 ID Data
4 serial number (16 chars)
1.11.3.1 ID Data
4 system ID (16 chars)
4 details of change
4 date of change
4 ID of engineer that made the change.
For revision data the last 10 system changes are tracked and the last 6 system
configurations are stored.
NOTE: The registry data held on the HDD will only be different to that stored on the Sys-
tem Board if either one has been replaced.
The current registry data held on HDD is displayed on Main diagnostics after
obtaining the registry menu as follows:
diagnostics> tests
sysdiag> registry
registry> display_registry HDD
NOTE: Avoid using the command `restore board' unless you are sure the NVRAM config-
uration on the HDD is the correct version.
3. If you have changed the System Board and the HDD, then the following
appears:
sysSerialNum
sysBuildDate
finalTestDate
Enter revised details (using the Arrow keys to navigate) if you have changed
both the System Board and the HDD. Enter the system serial number for
production machines as PXXX. Press Return to exit and Y to confirm.
4. Now check that the revised details are valid by running the Reg_power test:
registry> reg_powerup
case you need to revert to the previous firmware version. The firmware
update could include new or old NVRAM parameters set to new default
values which immediately take effect once the system is restarted. Use the
following command:
log_utils> save_nvram
2. Insert the CD disk and read the appropriate firmware Release Notes. This is
accessed from the directory `SW/docs/'.
3. Shut down the system from the MMI and reboot from the power on/off
switch.
4. Press firmly the MMI screen immediately the following message appears:
Touch panel to abort
A successful abort gives the message:
Aborted
Remaining in Boot Mode
5. Close down the RIP application on the RIP server, if it is already running.
6. Open the Recorder Utilities window as a PC desktop application:
Program / FUJIFILM Electronic Imaging Ltd / Recorder Utilities / Start
7. Highlight the platesetter name in the box.
8. Select Device/Utilities Download Firmware... to open the [Platesetter Name]
Firmware window. This gives you two options for loading new (V1_xx)
.HEX files from the `SW/New Release' folder on the CD disk:
4 Full: opens a Select Folder window allowing you to access and automatically
load all the new release files, as a group, from the selected CD disk folder. Note
that the files are not displayed in this window when the directory is opened.
4 Custom: opens the Select File to Download window allowing you to select
(highlight) specific release files from the CD disk folder. Do not download any
new Boot files unless this is requested in the Release Notes.
9. Press Select Folder or OK to close the selection window, confirm the selections
when asked, and follow the set of messages that appear as files download to
completion.
10. Restart the platesetter and launch the RIP application. If there have been any
Boot sector changes then a second reboot is necessary.
11. Carry out a machine recalibration after changing the firmware.
12. When the machine is working correctly, save the new NVRAM settings
using the command:
log_utils> save_nvram
because they not deleted after imaging. If the HDD is reformatted, make sure
that these images are restored to the PC and downloaded to the Engine. You can
download any RIP image as a PI but note that too many PI files on the HDD are
likely to mean a smaller page buffer for normal jobs.
Use the following procedure to create a PI image:
1. Close the RIP application.
2. Open the File Manager and search for the file `output.cml' from the Win-
dows Find file option. The default pathname is:
Program Files/Fujifilm Electronic Imaging/output.cml
Open the file with any editor (Notepad, etc).
3. At the end of the file, add a new line as:
ImageName="xxxxx" (without spaces where "xxxxx" is any text name.)
4. Save the file and close down the File Manager.
5. Open the RIP Application again and select a job that you wish to use as a PI
image. This is normally a typical customer job or a large image that can be
used for testing purposes.
6. Download the job to the Engine and check in the Log that it has not exposed.
If it has started to expose, then it will not appear as a PI image.
7. Check from the MMI that the image name has appeared on the Run Test
Image window in the TOOLS menu.
8. Shutdown the RIP application.
9. Make sure the entered text line in the `output.cml' file is removed or is con-
verted into a comment.
To convert into a comment add:
Rem ImageName="xxxxx"
exit from the Rampage Shooter application and restart the application.
If the media size is smaller than the PI a possible Shooter error could appear. To
avoid this problem, resize the image from the diagnostics image_mgr utility
making sure that the parameter field media name is left blank. This will ensure
that the PI images on any sized plate.
ADVANCING
PLATE
ADVANCING
PLATE
4
4
Plate Handling Control Modules ...............................................................................2-1
4
Plate Handling Assemblies ......................................................................................2-13
Plate Handling Operation and Sequence ...............................................................2-18
2.1.1 Autofeeder
Figure 2.1 outlines the main Autofeeder control assemblies and their connec-
tions.
The Autofeeder consists of a frame cage, and an elevator with five cassette
shelves that move up and down as a cassette plate type is selected for forward-
ing.
Overall control of the Autofeeder and elevator movements is from FHMB2, with
AC motor drive fed through from the Engine. A separate interlock mechanism
ensures AC power to the elevator motor is switched off when:
A) the cassette loading door is open or unlocked
B) the frame travel safety limits at the top and bottom are exceeded.
VOLUME 2 (2-2) P LATE H ANDLING C ONTROL
ELEVATOR
MOTOR
BM26
CONTROL MOTOR (BM28)
BASE
DOOR LOCK
DOCKING LIGHT
CASSETTE
ELEV ABS
(BS68/69)
(BV22)
ZDIRECTION
LIMITS
(BV25)
A1
CONTACTOR
+24V
CASS DOOR LOCK
LOCK
+24V
FHMB(2)
W
U
V
MOT DSBLD
BS73
TO
H
(BS74/75)
ALARM/
OLOAD
BS78
INVERTER
ELEVATOR CONTROL PCB
CONTROL
MOTOR
P24V
BS77
FWD/REV
FST/RST
(BM26)
N
L
+24V
+24V
+24V
+24V
FILTER
CONTACTOR
BASE
BM28
BV25
BS72
BV22
BS73
E
L
SAFETY
RELAY
FHMB(2)
FHMB(2)
MAINS
INPUT
FHMB(2)
FHMB(2)
SENSOR VANE
SHELF SENSING
ELEVATOR
A: YNN
TOP
ABS B: YYN
SHELF 5
LIMIT C: NYN
D: NYY
E: NNY
4
SENSOR DISTRIBUTION PCB
BS31(BOTTOM)
ELEVATOR 3
FWD/REV
SLOW/RST BS32 BS33 BS34
BS30 (TOP)
2
1
BOTTOM
ABS
LIMIT
BS BS
AC SUPPLY
74 75 INVERTER
BM26 CONTACTOR
ELEVATOR MOTOR
KEY
CASSETTE DOOR LOCK
BS (SLOTTED)
BS BV
72 22 BS (REFLECT)
BS63 BS (REED)
2.1.1.1 PTM
Figure 2.3 shows the main control and drive signals to the PTM plate handling
devices.
TO AUTOFEEDER
ENGINE ELEVATOR
(MAINS SUPPLY) MOTOR
PLATE FEED
MOTORS
CASSETTE/X-DIRECTION SENSORS
CASSETTE/X-DIRECTION MOTORS
FHMB(2)
ELEVATOR MOTOR
ELEVATOR SOLENOIDS
CAN3 (CONTROL PCB)
FHMB(1)
ELEVATOR SENSORS
sensor status signals from PTM moving assemblies and provide the 24 V
Sensors: PTM sensors are used to determine limits, home positions and the
FHMB 2/3 PCBs: two motor handling PCBs run software routines that accept
L UXEL P LATESETTER VOLUME 2 (2-5)
KEY
BS (SLOTTED)
BS (REFLECT)
NUDGER NUDGER AND FEED HEAD BS (REED)
LIFT TAKEAWAY
(BM23) (BM22) BS (SWITCH)
BS46 VIEW ON A BS47 BS46 BS47
BS (INDUCTIVE)
BS45
BV (SOLENOID)
A
BM23 BS45
BM (MOTOR)
NUDGER
BS48
VOLUME 2 (2-6) P LATE H ANDLING C ONTROL
BS43 BM22
BS51
BS43 TAKEAWAY INPUT
DIVERTER
ROLLER
Motors: motors drive the following plate handling assemblies on the PTM:
4 X-Direction door (BM27) - moves the door flap up and down when a new cas-
sette is installed.
4 Cassette forward (BM20) - drives the two arms that pulls the cassette into the
PTM
4 Stack Increment (BM21) - drives the leadscrew mechanism to increment the
stack in small steps to activate the stack height sensor.
4 Nudger and takeaway (BM22) - drives the nudger and takeaway rollers
4 Nudger lift (BM23) - lifts and lowers the nudger roller to remove the top plate on
the stack
4 Interleave drive (BM24) - drives the two rollers that push the interleaf paper into
a bin.
Relays and Solenoids: drive the following plate handling assemblies:
4 Air Knife Control (BV23) - switches on/off the air knife
4 Centering (BM3) - drives the two centering arms for aligning the plate (along the
horizontal drum axis) before punching.
4 Punch (BM4) - drives the punch pins.
4 Registration (BM5) - drives the registration pins that operate as a mechanical
`stopper' at the leading edge to hold the plate in position for imaging.
4 Output module (BM6) - drives the module rollers for conveying plates out of the
drum.
4 Buffer Feed to Processor (BM7) - drives buffer rollers.
4 Plate Centering (BM10) - centres the plate on the manual load platen.
4 Plate Pushing (BM11) - pushes the plate from the platen to the drum.
FHMB PWR
FHMB 2/3
VACSOLS/COMPR (BV31)
EXT
I/LOCK CENTRING/REG/OUTPUT
SENSOR SENSORS
DIST
I/LOCKS CAN5 (O/P) BUFFER SENSORS
4
FPD
4
BUFFER/OUTPUT/
REGISTRATION/
FHMB(4) SWING CENTRING MOTORS
plate.
ROLLER
POWER SENSORS
PWR2 24V
FILTER PUNCH SENSORS
DIST
REG
PIN
VOLUME 2 (2-8) P LATE H ANDLING C ONTROL
PUSH BAR
REG PIN CONT SENSORS
INTERLOCK
BOX UMBILICAL
TRAVERSE CARRIAGE
ID1
CAN ID
CAN2 RTN
BV8 EXT
Figure 2.5 Engine plate control and drive (B1 and B2 fully-automatic)
ALERT
Swing Roller Motor (BM37) - operates the SRM to hold the leading edge of the
RTN
L UXEL P LATESETTER VOLUME 2 (2-9)
4 Drum Vacuum (BV5) - switches the drum vacuum motor on/off before and after
an expose.
4 Error Light (BV8) -
4 SOL 1 (Divert Valve - BV 30) - diverts air to the drum.
INPUT OUTPUT
MODULE MODULE
BM6
PTM BS5
DRUM
BM1
BS52 BS1
BS4
BS15
BS8
BS9
VIEW ON A
BS14
BM5
BM4
BS12 BS3 BM3 BS13
PUNCH/REGISTRATION/CENTERER MODULE
(BILLOWS) KEY
BS (SLOTTED)
B BS (REFLECT)
BS (MICRO SW)
BS11 BS10
BV (SOLENOID)
VIEW ON B
(UNDERNEATH) BM (MOTOR)
Figure 2.6 Engine plate handling control assemblies (B1 fully-automatic with
punch)
L UXEL P LATESETTER VOLUME 2 (2-11)
INPUT OUTPUT
MODULE MODULE
BM6
PTM BS5
DRUM
BM1
BS52 BS1
BS4
BM37 BS109/110
BS6
REGISTRATION
SWING MODULE
BS2 ROLLER
PUSH MODULE
BAR BM36
BM2
BS100/103
BS15
KEY
BS (SLOTTED)
BS (REFLECT)
BM (MOTOR)
Figure 2.7 Engine plate handling control assemblies (B1 and B2 fully-automatic
and manual without punch)
2.1.3 Buffer
Figure 2.8 shows the main Buffer drive controls and assemblies. Two types are
currently available on installed machines: old (used on early production Violet
machines) and new.
New Buffers now have the following servicing features:
Can be lowered from the Processor, in the same way as the old Buffer, to
access the rear of the engine.
The exterior cover can be removed while the Buffer is in-situ to access Buffer
parts.
VOLUME 2 (2-12) P LATE H ANDLING C ONTROL
BUFFER EXIT
ENTRANCE
INTERLOCK (B1 MANUAL INTERLOCK
BUFFER
(BS19)
(BS20)
TO PROCESSOR
BUFFER FEED
IS LINKED OUT)
DIRECTION
PLATE
(BM7)
BUFF_S19/20
BUFF_S19/20
BUFF_M7
BUFFER
ENG_INT
DISTRIBUTION
(OUTPUT)
SENSOR
PCB
RIB1/2
FHMB(4)
CONTROL
CAN
IMAGING ENGINE
INTERLOCK
BOX
TO SSB
BS19
BS20
TO
PROCESSOR
BM7
BAND
ROLLER
KEY
BS (REFLECT)
BM (MOTOR)
NOTE: The method of removing and replacing these sensors is very similar. A descrip-
tion is given in Volume 3 Section 2.1.1.
switched on and off by a train of pulses to reduce any fogging of the plate. They
are typically switched on for 200 microseconds and off for 3 ms. While a plate is
stationary, the sensors are turned off to reduce the risk of `fogging'. Where this
type of sensor is not used for detecting plates it is not pulsed.
Opto-reflective sensors detect a change of reflected light from a surface or a
passing edge. They are especially useful for determining plate presence and
lengths along a path, and are generally very sensitive to plate angle and dis-
tance.
Fixings and mountings for these sensors are mechanically set on the platesetter
so that you only need to ensure that a replacement is fitted in exactly the same
position as the old device. On replacement, reflective sensors may require cali-
bration to find the minimum level of LED drive to allow detection. Normally, a
replacement setup is not required.
Voltage supply to the sensor is set at +5 VDC and the type of switching is:
A) Plate Not Detected = LOW output.
B) Plate Detected = HIGH output.
C) Fault Condition = OFF.
Opto-reflective sensors are fitted on the Cassette ID, the Opto-Reflective Sensor
PCB and the Paper Plate Sensor PCB:
Cassette ID PCB:
Sensors read the reflective ID codes (1-31) on the cassette once it is advanced to
the feed head.
A) Light not Detected = ON
B) Voltage supply: 4.5 to 16 VDC
On fitting opto-reflective sensors, note the following:
1. As the angle of the sensor to the plate increases, the detection distance
reduces.
2. The plate angle for the reflective underside should be >45 with an allowa-
ble sensing range of 4 to12 mm.
3. The emulsion side gives a more diffused reflection with a decrease in maxi-
mum detection distance. This effect is even more evident with interleaf
paper.
4. For emulsion side and interleaf paper, the allowable sensing range is 4 mm
to 8 mm.
Opto-Reflective Sensor PCB:
This PCB (called Reflective-Opto) mechanically houses the sensor device and
detects the arrival of plate at set points on the media path, see Figure 2.10. The
PCB houses a single sensor and includes a cathode with two parallel resistors in
series.
L UXEL P LATESETTER VOLUME 2 (2-15)
R1
33R
R2
33R SW1
EE-SY313
PL1
1
2 5 3
ANODE VCC
3 C1 2
4 OUT
4 1
CATHODE GND
0.1u
25V
SUPPLY
VOLTAGE
GND
Voltage supply to the sensor is set at +5 VDC and the type of switching used is:
A) Light not detected = LOW output = read ON.
B) Light detected = HIGH output = read OFF.
VOLUME 2 (2-16) P LATE H ANDLING C ONTROL
Stepper (200 Steps): The Buffer motor includes a dual-ratio gearbox that
drives at two speeds when the stepper is in forward and reverse mode.
2.2.2.2 DC Motor
24 VDC 33 RPM: A +24 VDC used for the retard mechanism and the inter-
leaf roller. Pin 2 on the motor terminal is the supply voltage.
24 VDC 120:1 Worm: A +24 VDC used for the X-direction door.
24 VDC 7:2 Gear: A variable speed motor used for cassette forward.
24 VDC 66 RPM: Used on the output and input modules.
NOTE: This sequence applies to fully-automatic platesetters with and without a punch.
The Autofeeder module allows the operator to load and install optionally 1-to-5
cassettes that are automatically selected by the RIP, depending on the job and
plate type required. Each cassette is housed on one of the shelves tiered inside
an elevator frame that moves up and down under the control of the RIP job selec-
tions or the operator.
Plates are loaded into cassettes in a safelight area and conveyed to the Auto-
feeder on a trolley. Normally, cassettes are ALWAYS located on a trolley or on an
Autfeeder shelf to avoid being lifted manually.
Two front corner buffers on the trolley have magnetic pins detected by sensors
BS77 and BS78 as the trolley docks. If both sensors are actuated, then the trolley
is aligned at the door and the docking light turns ON.
Plates of one type are loaded into a cassette that has a designated ID number
from #01 to #31. When the cassette becomes active (selected by the RIP and
advanced to the PTM) the ID is read by a set of photo sensors on the PTM, indi-
cating to the system software the media type and size available for each of the
downloaded jobs.
NOTE: This sequence applies to fully-automatic platesetters with and without a punch.
The two cassette forward arms advance the active cassette towards the feed
head and reverse the cassette back into the Autofeeder when it is no longer
required. As the cassette moves forward, its front cover lifts up using a ramp
and wheel mechanism.
Once the cassette is in position under the feed head, the nudger roller drops
down to come into contact with the top plate or interleaf sheet. The stack incre-
ment lifts and drops the leading edge of the plate stack in increments while
checking BS47. The system checks that the cassette is not empty.
The nudger drives the plate into the takeaway nip using a combination of fric-
tion and normal force. Once detected in the nip, the nudger roller lifts clear and
stops. The takeaway roller uses friction and the force of the sprung pad under-
neath to continue removing the plate or interleaf.
In normal operation, if there is more than one plate or interleaf nudged into the
takeaway, the retard mechanism uses a sprung slope to `retard' and prevent a
multifeed. This works by using the friction of the retard pad surface against the
multifed sheet to overcome the friction between the top required sheet and and
L UXEL P LATESETTER VOLUME 2 (2-19)
REGISTRATION/
CENTERER
PUSHBAR
PUNCH
LONG BLOW
MAIN VAC
SHORT BLOW
Ejecting a small plate (B2) causes one problem that is rectified by the de-
skew and conform sequence:
4 small plates tend to jump over the registration pins when conform vacuum is
released.
REGISTRATION
MODULE
PUSH BAR
SWING ROLLER
MODULE (SRM)
LONG BLOW
MAIN VAC
SHORT BLOW
The leading edge (LE) drum vacuum channel at the far output end has three
states:
1. Conform Blow: applied to prevent plate scratching, assist the plate TE into the
drum while being pushed, and assist with de-skew continuity.
2. Eject Blow: release the LE of the plate for ejection (at the same time as drum
blow occurs for the complete plate).
3. Conform Vacuum: to hold the plate in position for imaging.
NOTE: This sequence applies to all B1 platesetters with and without a punch.
Scanned plates from the Engine are conveyed (or held in transit) by the Buffer
until the Processor clears the previous plate and sends a `READY' command to
the Engine.
The Buffer band rollers operate at dual speed: fast speed to convey the plate
from the output module and slow speed to match the Processor.
L UXEL P LATESETTER VOLUME 2 (2-21)
2. Elevator motor (BM26, elevator) moves shelf to correct position using readback
from BS32 to BS34.
VOLUME 2 (2-22) P LATE H ANDLING C ONTROL
BM27
BM20 BM21
3. Cassette arms rotate (BM20 on) to pull cassette into PTM until BS65 (cassette at
nudger) actuates.
L UXEL P LATESETTER VOLUME 2 (2-23)
4. Nudger roller drops down (BM23, nudger lift) and (BS45, nudger down limit).
Retard pad rises (BM25, retard drop, and BS56, retard up) as plate goes forward
(past the diverter) and paper is stopped.
Retard pad lowers for paper.
Nudger roller moves paper until takeaway roller and interleaf roller picks up
paper, then nudger roller lifts up. Only one roller moves paper at a time in order
to avoid a paper jam.
5. Stack rises (BM21, stack height) at quick speed to raise plates until BS47 (stack
height position) is actuated.
Stack drops and rises again slowly to re-actuate BS47.
Stack now in correct position. Only one attempt at raising the stack is carried out
before a plate feed.
BS43 (cassette empty) detects empty or loaded cassette. Empty cassette is moved
back to Autofeeder and error code is given.
VOLUME 2 (2-24) P LATE H ANDLING C ONTROL
6. Nudger (BM22, nudger and takeaway) starts to pick top plate or interleaf.
7. While raised, the retard pad operates from a spring and `retards' multifed sheets
from passing through to the takeaway roller.
If TE of top plate clears BS48 (nudger detect) and BS49 (retard made) the
takeaway motor (BM22) stops.
A plate jam causes the retard pad to lower (BS57, retard down).
9. Plate passes BS49 and nudger (BM22) is stopped then lifted (BM23, nudger lift
and BS46, nudger up limit).
Takeaway roller is in contact with interleaf or plate.
Takeaway roller (BM22, nudger and takeaway) and interleave drive (BM24)
advance interleaf.
Diverter in Home (up) position (BV20 off).
10. Interleaf sheet: BS66 (interleave nip clear) or BS53 (paper tensioner) are actuated
as interleaf drives down into waste bin.
BS50 (plate at pre-diverter) is not actuated by interleaf sheet.
BS66 indicates TE of sheet clearing drive.
BS53 operates as lazy loop sensor to stop interleave drive if paper tightens.
BS53 actuated for 2.0 second pauses interleaf drive motor for 0.1 second.
The sequence is repeated until BS66 (interleave nip clear) indicates TE of sheet.
Nudger and takeaway (BM22) stops while interleaf drive (BM24, interleave
drive) remains on for 3 seconds.
VOLUME 2 (2-26) P LATE H ANDLING C ONTROL
11. Plate: BS50 (plate at pre-diverter) actuated to indicate a plate, diverter drops
down (BV20, diverter) and plates are driven by takeaway roller (BM22) towards
BS59 (plate past diverter).
Interleave drive stops (BM24, interleave drive).
BS51 (paper past-diverter top), and BS55 (paper past-diverter under) for paper
detect paper only.
Leading edge of plate at BS50 starts air knife.
Trailing edge of plate passes BS55 stops air knife.
12. LE of plate reaches BS52 (park position) and input module rollers (BM1, friction
and band input) start if drum is clear of previous plate.
If interleaf is under takeaway it is cleared into the bin.
If a plate is still under takeaway roller, it is held at BS50 (plate at pre-diverter).
Any errors in the drum causes nudger motor to reverse plate back into cassette
and reverse cassette into Autofeeder.
Plate TE moves past diverter which returns to Home up position.
2. If the plate is large it may not clear BS2 (input exit), so push bar moves to Home
position and plate `jogging' commences:
Input module rollers turn and push bar moves down slightly.
Rollers turn again and push bar moves up and then down a little more. This is
repeated until BS2 is cleared.
If BS2 is not cleared by plate TE after 6 attempts an error code is given and plate
is recovered manually by turning the input module plate recovery handle at the
user side of the Engine.
Any plates in the PTM are reversed back into the Autofeeder after a failure
described above, see also Section 2.3.1.8.
VOLUME 2 (2-28) P LATE H ANDLING C ONTROL
3. Plate slides into drum and push bar moves to Home position (BM2, push bar
and BS6).
Registration pins are extended (BS11, registration motor in), punch pins are out
(BS9, punch pins out), centering fingers at Home (BS14, centering home) and
vacuum is off.
4. Push bar advances plate until LE is detected at punch (BS3, plate in punch).
Push bar moves back 10 mm.
L UXEL P LATESETTER VOLUME 2 (2-29)
Eject Sequence:
8. Punch pins move out (BS9, punch pind out), registration pins retract (BS10,
registration motor out) and vacuum switches off.
L UXEL P LATESETTER VOLUME 2 (2-31)
9. Output module motor starts (BM6, friction and band output) and push bar
moves forward to push plate into output rollers.
Eject blow is switched on.
Buffer rollers start (BM7, buffer feed to processor) when LE reaches BS4 (output
entrance).
10. Push bar returns to Home after BS4 and BS5 are actuated.
Switch off eject blow (non-punch) when TE reaches BS4.
Push bar is in home position (BS56 actuated).
VOLUME 2 (2-32) P LATE H ANDLING C ONTROL
BS4
See also Figure 2.7 showing the main plate handling modules on a drum with-
out a punch.
De-skew and Conform Sequence:
1. Plate LE reaches BS1 (input entrance) and BM1 (friction and band input) moves plate
into drum.
Push bar is in Home position (BS6, push bar home).
L UXEL P LATESETTER VOLUME 2 (2-33)
2. If the plate is large it may not clear BS2 (input exit), so push bar moves to Home
position and plate `jogging' commences:
Input module rollers turn and push bar moves down slightly.
Rollers turn again and push bar moves up and then down a little more. This is
repeated until plate slides into drum.
If BS2 is not cleared by plate TE after 6 attempts an error code is given and plate
is recovered manually by turning the input module plate recovery handle at the
user side of the Engine.
Any plates in the PTM are reversed back into the Autofeeder after a failure
described above, see also Section 2.3.1.8.
3. Plate slides into drum and push bar moves to Home position (BM2, push bar
and BS6).
Registration pins are extended (registration motor in).
Plate LE passes BS2 and leading edge vacuum switched on as conform blow, see
Section 2.3.0.3.
VOLUME 2 (2-34) P LATE H ANDLING C ONTROL
CONFORM BLOW ON
4. Push bar advances plate until LE reaches registration pins where it is checked
for continuity.
Swing Roller Module (SRM) is lowered and another check for continuity is
made.
5. If continuity across registration pins is made then the plate is not skewed and is
ready to be imaged.
Leading edge vacuum is switched on to conform vacuum mode and also main
vacuum.
SRM is raised.
L UXEL P LATESETTER VOLUME 2 (2-35)
CONFORM VAC ON
MAIN VAC ON
Eject Sequence:
7. Leading edge conform and main vacuum are switched off.
Leading edge eject blow is switched on and registration pins retracted.
VOLUME 2 (2-36) P LATE H ANDLING C ONTROL
8. Output module motor starts (BM6, friction and band output) and push bar
moves forward to push plate into output rollers.
Buffer rollers start (BM7, buffer feed to processor) when plate LE reaches BS4
(output entrance).
BS4
9. Leading edge eject blow switches off when plate TE reaches BS4.
Leading edge of plate reaches BS5, plate speed slows to obtain approximately
300 mm of media at the output guide (to allow manual collection).
Push bar returns to Home after BS4 and BS5 are actuated.
Push bar is in home position (BS56 actuated).
L UXEL P LATESETTER VOLUME 2 (2-37)
BS5
BS4
See Figure 2.7 showing the main plate handling modules on the drum for a small
plate.
This sequence is followed in order to overcome the small plate loading prob-
lems described in Section 2.3.0.3.
De-skew and Confrom Sequence:
1. Plate LE reaches BS1 (input entrance) and BM1 (friction and band input) moves plate
into drum.
Push bar is in Home position (BS6, push bar home).
VOLUME 2 (2-38) P LATE H ANDLING C ONTROL
2. If the plate is large it may not clear BS2 (input exit), so push bar moves to Home
position and plate `jogging' commences:
Input module rollers turn and push bar moves down slightly.
Rollers turn again and push bar moves up and then down a little more. This is
repeated until plate slides into drum.
If BS2 is not cleared by plate TE after 6 attempts an error code is given and plate
is recovered manually by turning the input module plate recovery handle at the
user side of the Engine.
Any plates in the PTM are reversed back into the Autofeeder after a failure
described above, see also Section 2.3.1.8.
L UXEL P LATESETTER VOLUME 2 (2-39)
3. Plate slides into drum and push bar moves to Home position (BM2, push bar
and BS6).
Registration pins are extended (registration motor in).
Plate LE passes BS2 and leading edge vacuum switched on as conform blow, see
Section 2.3.0.3.
CONFORM BLOW ON
4. Push bar advances plate to an intermediate position just before the registration
pins
As the Swing Roller Module (SRM) moves down, the plate is advanced slowly
towards the pins.
Just as the plate contacts the pins, the SRM touches the plate. This timing is
critical to prevent plate scratching.
5. If continuity across registration pins is made then the plate is not skewed and is
ready to be imaged.
Leading edge vacuum is switched on to conform mode and main vacuum is
switched on.
SRM is raised.
VOLUME 2 (2-40) P LATE H ANDLING C ONTROL
CONFORM MODE ON
MAIN VAC ON
Eject Sequence:
7. SRM is down.
Leading edge conform vacuum and main vacuum are switched off.
L UXEL P LATESETTER VOLUME 2 (2-41)
EJECT BLOW ON
9. Output module motor starts (BM6, friction and band output) and push bar
moves forward to push plate into output rollers.
Buffer rollers start (BM7, buffer feed to processor) when LE reaches BS4 (output
entrance).
VOLUME 2 (2-42) P LATE H ANDLING C ONTROL
BS4
10. Leading edge eject blow switched off when plate TE reaches BS4.
Leading edge of plate reaches BS5, plate speed slows to obtain approximately
300 mm of media at the output guide.
Push bar returns to Home after BS4 and BS5 are actuated.
Push bar is in home position (BS56 actuated).
BS5
BS4
BS19
BS5
BS20
3. Ready signal from Processor is received and BM7 restarts at a slower speed to
match Processor.
Processor rollers turn to accept plate.
BS20 actuates on plate TE and BM7 continues for a further 170 mm then stops.
3. Stack increment lowered to Home position (BS44 on), nudger to up (BS46 on)
and Z-direction arm to up (BS63 on).
Yes
Move plate pusher and centerer to initial load position for job.
Pusher & centerer positions help operator to load the correct size of plate.
Plate description and orientation displayed on the MMI
After 10 minutes
No WARNING 1248
Is a plate loaded on the platen (BS118)?
TIMEOUT_WAITING_FOR_
SUPPORTED_MEDIA
Yes
When Input Fogging Timer expires give audible
Start Input Fogging Timer (6 mins)
alarm.
WARNING 1281
MEDIA_FOG_AT_INPUT_ALERT
Yes
Is Autoload ON (Operator Preference)?
Yes
No
Yes
No
Plate still detected by BS118 on Input Platen? WAIT (Offline Timeout)
Yes
No
Drum ready? ERROR 1707
Yes
Plate pushed into Input rollers
Clear Input Fogging Timer
Plate pusher continues to Home position
Yes
No
Plate trailing edge past BS2? ERROR 1640 or 1600 errors for a device fault
Yes
M l Pl t L dS f Pl t
Figure 2.14 Manual plate load sequence from platen
VOLUME 2 (2-48) P LATE H ANDLING C ONTROL
Expose is complete
Yes
Yes
Yes
Manual machine?
Processor
ready?
Wait for operator to remove Plate.
Yes Drum is now empty.
Yes
Yes
Plate conforms slowly
Push bar pushes plate to 30 mm to registration pins
(fast operation)
Vacuum is applied
Registration pins ON
Drum+offset(nvram)
Push bar
Yes
Approaches plate
ERROR
Mixer fan on
If Plate Height > 350mm
Swing Roller Module
(SRM) DOWN
Note:
Check for continuity after
vacuuming. If it fails, try
Step push bar back Yes
again from the start. If it
fails again, continue
Push Bar forward - anyway
Plate Registered to pins Retry < 3 ?
If Plate Height < 350mm
Swing Roller Module
(SRM) DOWN
No, Continuity failed ERROR
after SRM moves DOWN
Check continuity
Yes
LE + Main Vacuum ON
Imaging starts
Ejection blow ON
Wait 1.5 sec (nvram)
Check continuity
Registration pins OFF
Figure 2.17 Plate load and imaging sequence (manual and semi-automatic)
2-3
Volume-Chapt er
4
4
Introducing Plate Handling Modules ........................................................................3-1
4
Autofeeder Plate Handling Modules .........................................................................3-8
4
Plate Transport Modules ..........................................................................................3-33
4
Engine Plate Handling Modules ..............................................................................3-61
4
Buffer Plate Handling Modules..............................................................................3-102
Inter-Module Connections and Control ................................................................3-105
Trolley a a
Z-Direction Arm a a
Cassette a a
Elevator (with all assemblies) a a
Control Box Assemblies a a
Plate Transport Module:
FHMB (2 and 3) a a
Cassette Forward a a
X-Direction a a
Stack Increment a a
Nudger Lift a a
Retard a a
Nudger and Takeaway a a
Interleave Diverter and Drive a a
Transport Plates Guides a a
Antistatic Brush a a
Air Knife a a
Imaging Engine:
Input Module a a a a a a
Output Module (static tray) a a a a a
Output Module (driven tray) a
Traverse a a a a a a
Registration Module a(NP) a a a a a
L UXEL P LATESETTER VOLUME 2 (3-3)
Sensors and motors used: BS44, BS61 (Stack height Home/Top Limit), BS47
(Stack Height Position); BM21 (Stack Height).
Nudger Lift: raises and lowers the nudger roller.
Sensors and motors used: BS46, BS45 Nudger Up/Down); BM23 (Nudger Lift).
Nudger and Takeaway: both rollers are driven by the same motor. The
nudger picks up the top plate/interleaf from the stack and the takeaway
nips the plate/interleaf and drives it forward. For jam clearance, the nudger
direction is reversed.
Sensors and motors used: BS48 (Nudger Detected), BS52 (Park Position); BM22
(Nudger and Takeaway).
Retard: a sloped pad, when raised during a plate feed, operates with an
adjustable spring mechanism to `retard' multi-fed sheets and prevent them
from passing through the takeaway nip roller. Only the required top plate/
interleaf is allowed to pass. During a plate/interleaf jam, the pad is lowered
from the takeaway roller to allow the top plate to be nipped back into the
cassette by the takeaway roller.
Sensors and motors used: BS56, BS57 (Retard up/down); BM25 (Retard Drop).
Interleaf Diverter: a solenoid-controlled assembly that is actuated to the
down position for a plate and remains in an up position (from a fixed counter
weight) when an interleaf is detected.
Sensors and motors used: BV20 (Diverter).
Interleaf Drive: interleaf sheets are fed from the takeaway and routed by the
diverter to the interleaf drive. Two drive rollers move the sheet towards a
waste bin.
Sensors and motors used: BS53 (Paper Tensioner), BS66 (Interleave Nip Clear);
BM24 (Interleave Drive).
FHMB (2 and 3): provides local control for the PTM and Autofeeder plate
handling mechanisms.
Plate Transport Guides: a set of plates on the PTM that provide a surface
for plates to slide across.
Air Knife: fitted on a fully-automatic machine, the air knife blows a stream
of air across the top of a plate as it advances into the engine. This reduces
plate dust and contamination entering the drum.
Sensors and motors used: BV23 (Air Knife Control).
NOTE: on later machines the air knife is fitted to the Engine instead of the PTM.
3.1.4 Engine
See Table 3.1 for variant details and Section 3.4 for a description of the module
assemblies.
Input Module: a set of friction rollers and a band roller, driven by a belt,
convey plates into the drum. Large plates that are unable to automatically
drop into the drum are `jogged' downwards by switching the rollers on/off
and moving the push bar up/down.
VOLUME 2 (3-6) P LATE H ANDLING M ODULES
FHMB (1 and 4): provides control for the engine plate handling mecha-
nisms.
Transport Push Bar: while inactive, the bar remains in a Home position. The
bar moves the plate forward, around the drum, until the leading edge is
detected at the reistration pins. After imaging, the bar pushes the plate for-
ward to the output module and then returns to the Home position. Two ver-
sion of the push bar are available: the Mark 1 which includes a
polycarbonate blade and the Mark 2 (Spring) without a blade.
Sensors and motors used: BS6 (Push Bar Home), BS15 (Push Bar Forward
Limit); BM2 (Push Bar).
Output Module: a set of friction and band rollers to convey a plate from the
punch to the Buffer. The main assemblies are common assemblies but the
output guides differ depending on the variant.
Sensors and motors used: BS4, BS5 (Output Entrance/Exit); BM6 (Friction and
Band Output).
Plate Loading Platform: fitted on Manual and Semi-Automatic platesetters
to receive manually loaded plates that are centered and pushed into the
input module. The loading operation allows for two modes of loading:
autoload enabled (no need to confirm the load) and autoload disabled.
Sensors and motors used: BS113 (Plate Centering Home); BS114/115 (Plate
centering Continuity 1 and 2); BS116 (Plate Pusher Home); BS118 (Plate on
Platen Opto); BM10 (Plate Centering); BM11 (Plate Pusher).
Chad Assemblies (B1 with punch): diverts chad from the punch pin guides
to a channel at the rear of the drum and into a tray for removal. Note that the
number of punch operations are counted to provide an alert for the user on
when to empty the tray.
Sensors and motors used: BS 79 (Chad Tray).
3.1.5 Buffer
See Table 3.1 for variant details and Section 3.5 for a description of the module
assemblies.
Roller Transport: a set of bands driven by rollers convey plates from the
output module to the Processor. The speed of the rollers is adjusted from fast
speed (to convey the plate from the output module) to slow speed (to syn-
chronise with the processing speed) If the Processor is not ready, the plate is
held in transit by the Buffer. Drive control depends on plate leading edge
detection by the buffer/output module sensors and the Processor ready
state commands to the Engine.
Sensors and motors used: BS19, BS20 (Buffer Entrance/Exit); BM7 (Buffer
Feed).
VOLUME 2 (3-8) P LATE H ANDLING M ODULES
TROLLEY
DOCKING
INDICATOR
CASSETTE
ELEVATOR Z-DIRECTION ARM DOOR LOCK
DISTRIBUTION PCB SOLENOID
ELEVATOR
CONTROL PCB
CONTROL ABSOLUTE
CABLES SAFETY
TO PTM SWITCH
(UPPER)
POWER
CONNECTION
TO MOTOR ELEVATOR MOTOR
CONTROL BOX
ABSOLUTE
SAFETY SWITCH
(LOWER) GEARBOX
4 Contactor.
Elevator Interlock Controls.
Elevator Control PCB.
Elevator Distribution PCB.
Cassette Door - the cassette door includes:
4 Cassette Door Lock Solenoid.
MOTOR
CONTROL
CHASSIS COOLING
FINS
TERMINAL
BLOCK
FILTER
DIN RAIL
END
STOP
INVERTER
(SJ100) SURGE
SUPPRESSOR CONTACTOR
Figure 3.2 Elevator control box assemblies (filter/inverter/contactor)
NEUTRAL
MAINS LIVE
SUPPLY
EARTH
AUTOFEEDER EARTH
FILTER
BASE
PLATE
EARTH
POINT
L
TO INVERTER N
CONTROLBOX PLATE
CONTROL
BOX LID
EARTH
MOTOR
3.2.1.3 Inverter
An Hitachi SJ100 inverter uses a set of four switched relays on the Elevator Con-
trol PCB (see Section 3.2.1.6) to control multispeed power sequencing for the ele-
vator motor. Inverter switching ensures the correct torque for heavy loads.
Directions are for forward (FWD), reverse (REV), fast (FST) and reset (RST).
Mains supply from the inverter is converted to vector drive signals U, V and W
for the elevator motor (gearmotor).
Inverter module functions are programmed from a digital display and keypad
that allow the service engineer to run manual tests and check for error codes.
Service engineers are recommended NOT to alter the EEPROM for the motor
function control or adjust the frequency setting.
The main servicing features of the Inverter are:
Single-phase supply at 200 - 240 VAC (50/60 Hz) to a 4-pole gearmotor.
An alarm (BS74) and overload output (BS75), via the Elevator Control PCB,
to FHMB(2) if the module develops a fault or the temperature exceeds a set
level. Power to the motor is immediately switched off when the alarm/over-
load conditions are set.
VOLUME 2 (3-12) P LATE H ANDLING M ODULES
a) ELEVATOR RED
RST
OR
FAST
YL
REV
BRN
ALARM GND ALARM I/P FWD
BLU&WH
P24V
BLK WH/BLU (2 WIRES)
BLK O/LOAD
(BS75)
WHT
ALARM
BLK (BS74)
ACCESS: BEHIND ALARM
FRONT AL1 AL0 CONTROL
PANEL
BLU
ALARM I/P
WHT/BLU
ALARM I/P
b) ELEVATOR POWER
ACCESS: LOOSEN M4
SCREW TO L1 L2 L3/N T1/U T2/V T3/W
OPEN CASE
BLK
L (BRN) BLK TO
CONTACTOR
N (BLU) BLK
BR BL
MAINS SUPPLY
(FROM FILTER O/P)
Error Codes
The inverter shows a set of error codes to indicate the state of the motor circuit.
3.2.1.4 Contactor
A safety contactor (Siemens 3RT1016) isolates the gearmotor from the mains
supply when the elevator cassette door or an interlocked panel is opened. It
includes a surge suppressor to protect local circuits from coil switching back
emf.
WHT
MOTOR SUPPLY BRN WHT
(FROM INVERTER) BS73 (TO ELEV CONTROL PL1)
BLU RD
+24V (TO ABS LIMIT)
1 3 5 21 A1
NC
CONTACTOR
22
2 4 6 NC A2
BLU BLK
+24V RTN (TO ELEVATOR
TO MOTOR BRN WHT/OR CONTROL PCB PL1)
BS73
WHT
DOOR LOCK
KEY BV22 FHMB(2)
COIL SAFETY
+24V RELAY
CONTACTOR
FHMB(2)
SURGE
SUPPRESSOR A1 21
BV22
NC
DOOR SCHMERSAL
BS
LOCK SOLENOID LOCK
72
x2
A2 22
LOCK BS72 TO
RTN FHMB(2)
ABS
LIMIT (BS68)
TOP LIVE
MAINS
NEUTRAL INPUT
EARTH
ABS FILTER
LIMIT (BS69)
BOTTOM
FHMB(2)
A1 1 3 5 21
NC CONTACTOR
BS73
A2 2 4 6 22
U V W
BS73 TOFHMB(2)
FHMB(2)
+24V RTN GEAR
MOTOR
(ELEVATOR)
PL3
ELV_CTRL SK1
(FWD/REV/ETC)
PL4
PL2
ELV_IN
PL1
ELV_CTRTL
(BS73)
Location
Mounted on the frame on the service side, see Figure 3.1.
Elevator Control Connectors
PL1: ELV_CTRL.
PL2: Not Used.
PL3: Not Used.
PL4: ELV_CTRL.
SK1: ELV_IN.
Connector Pin Descriptions
See Volume 2 Figure 9.9 showing the system cable interconnections.
Test Points
H1-H4: GND
Elevator Control PCB Operation
See Figure 3.8.
Drive control from FHMB2 is fed to the PCB where a set of relays are switched
L UXEL P LATESETTER VOLUME 2 (3-17)
to provide the drive + 24 V controls for the inverter. Two protection signals are
returned to FHMB2:
Overload: indicates the motor is overloaded and switches off power to the
motor.
Alarm: a fault has been detected on the inverter.
RELAY
(SW3-6)
+24V 4 1
SOL1-4
INVERTER
CONTROL BM2
(PL4) (SK1
REV/FAST/
RST/FWD 6 2
SOL1-4 RTN
BM26 (FWD/REV/FST/RST)
RELAY
(SW2)
+24V 1 4
ALARM_H
INVERTER
CONTROL SK1
(PL4)
ALARM 2 6
ALARM_L
BS74
RELAY
(SW1)
+24V 1 4
OLOAD_H
INVERTER
CONTROL SK1
(PL4)
OVERLOAD 2 6
OLOAD_L
BS75
SENSOR VANE
BS31
BS30
PL5
PL1 PL2 PL3 PL4
ELV_LOCK
Location
Mounted on the elevator sensor vane bracket, see Figure 3.1 and Figure 3.16.
Elevator Distribution Connectors
PL1: Not used.
PL2: Not used.
PL3: ELV_LOCK (Z-Direct UP)
PL4: ELV_LOCK (Z-Direct Down)
PL5: RIB8.
Connector Pin Descriptions
See Volume 2 Figure 9.9 showing system cable interconnections.
Elevator Distribution PCB Operation
See Figure 3.10.
Shelf positions on the elevator are determined by three optical sensors (BS32-34)
that detect the presence of vanes attached to the moving elevator. Sensors BS30
and BS31 detect the top and bottom travel limit and issue a warning before the
final absolute safety limit sensors (BS77 and BS78) are switched.
L UXEL P LATESETTER VOLUME 2 (3-19)
SHELF A
CODE:
001
101
ELEVATOR
DISTRIBUTION
PCB AND SENSORS
SENSOR VANE
SHELF E
As the elevator and vanes move up or down through the sensors (BS32-34), a
gray scale code is generated indicating the elevator position, see Table 3.3.
Shelves are accurately positioned at the edge of the relevant sensor vane. The
elevator is driven at a FAST speed until the shelf and vane edge is above the sen-
sor, then drive down at a SLOW speed until the vane edge is detected, to give
accurate and repeatable shelf alignment.
An accurate mechanical alignment between the shelf rail and the PTM feed rails
is critical for correct operation of the cassette forwarding mechanism. The align-
ment is set during the installation using a specification and an alignment proce-
dure.
VOLUME 2 (3-20) P LATE H ANDLING M ODULES
You can check the operation of the elevator sensors using the read_sensor com-
mand Main Diagnostics.
RED BK
BV22
BS72
OR WH
12 11 A1 A2
RED GN
22 21
BS78 BS77
SWITCH SWITCH
+24V
DOCK
LAMP
RTN
Figure 3.12 Docking indicator control
M6 SCREW
GUIDE ROLLER
WORMWHEEL
SPACER BS63 SENSOR
Z-AXIS ARM
BEARING
RETAINER
BEARING
BRACKET
MOTOR (BM28)
COVER BRACKET
BS70 SENSOR
WARNING: Do NOT test a limit safety switch while AC power is applied to the elevator
motor. If a fault is suspected, then investigate the problem by isolating the switch assem-
bly from the Autofeeder.
CAUTION: Make sure all precautions are followed when servicing the elevator while the
frame is being lifted under motor control. If in doubt, lift the frame by turning the elevator
motor fan.
Rotate the fan at the top of the motor to move the elevator in either direction
over a very short distance. Main Diagnostics commands, described in this chap-
ter are also used to raise or lower the elevator.
BRACKET/CAM
FOLLOWER CASSETTE
LOADING DOOR
JACKING
SCREW
JACKING
PIN
FOOT
ADJUSTER
DRIVE
SHAFT
ELEVATOR
CONTROL BOX MOTOR
BASE GEARBOX FLOOR RESTRAINT BRACKET
Figure 3.14 Main frame assemblies (without elevator frame and multi-cassette
housing)
there is a mechanical problem lifting the frame. To ensure a light-tight fit, the
housing is precisely positioned on the frame with locating dowels.
ELEVATOR WALL
FRAME (DETAIL
ELEVATOR REMOVED)
SENSOR VANE CASSETTE
AND DISTRIBUTOR LOADING
PCB (SEE
FIGURE 5.22)
ROLLER
CAM
FOLLOWER
BRACKET
SHELF
CAM
LOCATION
CHANNEL
BASE CHAIN
PLATE
ELEVATOR
DISTRIBUTOR
PCB (ATTACHED TO
FRAME BRACKET )
ELEVATOR
SENSOR
VANE
Each vane is adjusted vertically to line up each shelf with the slotted sensor and
vane switching positions. Once factory-set, they do not need to be readjusted
unless the shelf-PTM rails become misaligned, causing an obstruction for the
cassette. If there is an alignment problem use the procedure in Volume 3 Section
2.2.1.6.
CHAIN (119)
ELEVATOR
SPROCKET MOTOR (BM26)/
BEARING GEAR
CHAIN PLATE
& TENSIONER
(FIGURE 5.24)
CHAIN (119)
CHAIN
GUARD DRIVE
SHAFT
CHAIN ADJUSTER
(FIGURE 5.24)
GEAR
ABSOLUTE
LIMIT
SENSOR LOWER SENSOR
VANE
Chain links are internally self-lubricating and only need to be visually checked
during a service visit for signs of corrosion on the side plates where a machine is
operating in a humid environment.
If there are exterior signs of corrosion, carefully remove the corrosion then apply
a coating of thin oil to the affected area. The recommended lubricant is: Kluber
oil (4UH1-68) or, if this is unobtainable, any low viscosity (10-40) oil.
The chain is fixed at two points:
Adjuster end: this is adjusted by two locknuts to ensure the correct tension. A
pin at the bottom of the adjuster prevents the locknuts from coming loose.
The adjustment is factory-set and does not need to be retightened.
Tensioner end: a spring tensioner secures the chain to a fixed plate on the ele-
vator frame. This is a replaceable part.
L UXEL P LATESETTER VOLUME 2 (3-29)
TENSIONER
BUSH SPRING
PIN LINK
ASSEMBLY
SPLIT PIN
PULL OUT
TO REMOVE
LINK PLATE
MORE LINKS
3.2.2.7 Trolley
Trolley Assemblies
Figure 3.19 shows the main trolley assemblies.
Trolley Operation
The main function of the trolley is to transport a cassette between the plate load-
ing area and the Autofeeder. Cassettes are always stored either on a trolley or on
a free Autofeeder shelf. The trolley functions as follows:
A parking brake is switched on for loading and installing plates.
A trolley tray operates on a pivot mechanism that allows it to be in two plate
handling positions: horizontal and vertical.
In the vertical position it is possible to load plates located on the plate pack
support; the vertical position is offset slightly at an angle to prevent the
plates from slipping.
The Luxel Platesetter Operator's Manual explains in more detail how the trolley is
used.
VOLUME 2 (3-30) P LATE H ANDLING M ODULES
RETAINER
AND SPRING
SPACER
ROLLER LATCH
PIVOT TRAY
ASSEMBLY
LATCH
STRIKER PLATE
LATCH
PIVOT ACTUATOR ROD
BRACKET
HANDLE
BUFFER
HANDLE
SUPPORT
BRAKE
FRAME
ASSEMBLY
CASTOR
3.2.2.8 Cassette
CAUTION: Cassettes are always located on the trolley or inside the Autofeeder. They are
very heavy and, if handled or stacked on one side, could crack to break the light-tight
seal.
Cassette Assemblies
See Figure 3.20 (showing the cassette lid), Figure 3.21 (showing the cassette
body) and Figure 3.22 (showing the cassette platen).
The cassette assembly consists of:
A removable fibre-glass top lid with two sections: front and rear. The front
lid is held down by magnets and opens when the cassette is pulled towards
the feed head.
A platen sub-assembly that includes three plate guides (with clamps).
A body sub-assembly that provides the outside frame. The adjuster plates
for aligning the lid catches are factory-set, and must not be moved.
L UXEL P LATESETTER VOLUME 2 (3-31)
SNAP
CATCH
If there are problems feeding plates into the feed head it could be caused by:
Loaded plates exceed the cassette capacity limit of 60.
The plate pack is not adequately butted against the datum edge.
The plate guides are too tight against the plate pack.
Cassette ID label is damaged or removed.
Appendix B describes the possible error codes and remedies for elevator, cas-
sette and plate advancing faults.
A cassette ID label is fitted in an exact location (marked by two dimples) on the
lower side of the cassette body shown in Figure 3.21. Spare labels with adhesive
backing are easily fitted by the customer.
If there are problems with feeding plates into the feed head, it could be caused
by:
1. Loading plates that exceed the capacity limit of 60.
2. The plate pack is not adequately butted against the datum edge.
3. The plate guides are too tightly held against the pack.
The cassette ID label is fitted in an exact location (marked by two pimples) on
the lower side of the body shown in Figure 3.21. Spare labels with adhesive
backing can be fitted by the customer. The new ID is read into the database as
normal.
See the Platesetter Operator's Manual for a description on how the cassette is
operated.
VOLUME 2 (3-32) P LATE H ANDLING M ODULES
PLATEN
SUPPORT CASSETTE ID
LABEL
INTERNAL
GUIDE
LATCH
KEEPER
RAIL LIGHT SEAL
HANDLE GASKET
ADJUSTMENT
PLATE (FACTORY SET)
(LH LOWER) BUFFER
LABYRINTH
NOTE: CENTERING DOWELS, CASSETTE ADJUSTMENT BUFFER
SHELF BALLS AND FORWARD PLATE WASHER CORNER
CHANNELS ARE UNDERNEATH
SHORT PLATE
GUIDE
PLATE AT
DATUM EDGE
SCALE
LONG PLATE
GUIDE CLAMP
HANDLE
CASS ID PCB
SENSOR
DISTRIBUTION PCB
24V DISTRIBUTION
PCB
FHMB 2
SENSOR
DISTRIBUTION
AND 24V
DISTRIBUTION
PCBs
FHMB 3
Two FHMBs (2 and 3) control the plate handling devices for the PTM and Auto-
feeder. These boards hold the local motor handling software routines initiated
under the high level control of the System board. Plate Transport control
depends on the sensor signals sent from the local FHMB to the System PCB.
PL18
FS14
SK3
PL30
PL6 FS13
PL11
SK2 PL29
PL5
FS12
SK1
PL28
FS15
PL4 FS11
PL3 PL17
PL13
PL27
PL2
PL1
FS1 PL31
NOTE: Connector boxes shown as shaded in the figure above have fitted connectors.
Location
Mounted inside the PTM on the service side - righthand side PCB (see
Figure 3.23).
LEDs and Links
There are no LEDs or links.
Connectors
PL1: 8-way male Molex header type STR 6410. See Table 3.4.
PL2: 2-way male Molex 6410 straight header. Not used.
PL3: 4-way male AMP CT straight header. Not used.
PL4: 3-way male AMP CT straight header. Not used.
PL5: 6-way male Molex straight header. Not used.
PL6: 8-way male Molex minifit Jr. Not used.
PL7: 4-way male AMP CT straight header. Not used.
PL8: 3-way male AMP CT straight header. See Table 3.4.
PL9: 8-way male AMP CT straight header. See Table 3.4.
PL10: 3-way male AMP CT straight header. See Table 3.4.
PL11: 10-way male boxed header. Not used.
PL12: 4-way male AMP CT straight header. Not used.
PL13: 10-way male boxed header. Not used.
PL14: 8-way male AMP CT straight header. See Table 3.4.
PL15: 3-way male AMP CT straight header. See Table 3.4.
PL16: 3-way male AMP CT straight header. See Table 3.4.
PL17: 40-way male boxed header. Not used.
PL18: 26-way male header. RIB7 cable connection to Elevator Distribution
PCB.
PL19: 26-way male straight header. RIB6 cable connection to Box Cassette ID
PCB.
PL20: 3-way male AMP CT straight header. See Table 3.4.
PL21: 4-way male AMP CT straight shrouded header. Not used.
PL22: 3-way male AMP CT straight header. See Table 3.4.
PL23: 4-way male AMP CT straight header. See Table 3.4.
PL24: 4-way male AMP CT straight header. See Table 3.4.
PL25: 4-way male AMP CT straight header. Not used.
PL26: 4-way male AMP CT straight header. See Table 3.4.
PL27: 6-way male single in-line shrouded header top entry. Not used.
PL28: 6-way male single in-line shrouded header side entry. Not used.
PL29: 6-way male single in-line shrouded header top entry. Not used.
VOLUME 2 (3-36) P LATE H ANDLING M ODULES
PL30: 6-way male single in-line shrouded header top entry. Not used.
PL31: 8-way Molex minifit Jr. PWR3 power connection.
SK1: 15-way female D-type. CAN3 bus connection from FHMB (1).
SK2: 45-way female R/A boxed header. Not used.
SK3: 5-way female D-type. CAN4 bus connection to FHMB (3).
Connector Pin Descriptions
See Volume 2 Figure 9.8 showing system cable interconnections.
Fuses
FS1: 2A for Elevator Control
FS2: 2.5A. for Cassette Door Closed.
FS3: 2.5A. Spare.
FS4: 2.5A for Docking Light.
FS5: 2.5A for Elevator Reset.
FS6: 4 A. Spare
FS7: 4A. Z-Direction Control.
FS8: 2.5A for X-Direction Door.
FS9: 2.5A. Spare.
FS10: 2.5A for Cassette Door.
FS11: 2.5A. Not used.
FS12: 2.5A. Not used
FS13: 2.5A. Not used.
FS14: 2.5A. Not used.
FS15: 2.5A. Spare.
Main ICs
U33: Electronic Programmable Logic Device. Controls and reads sensors.
U39: Electronic Programmable Logic Device. Solenoids and DC motors.
U42: Electronic Programmable Logic Device. Stepper motors.
U43: Electronic Programmable Logic Device. Controls and reads sensors.
U27 Firmware.
Test Points
TP1: CAN Ground.
TP2: Pulsed drive to opto-reflective sensors.
TP3: CAN +5V.
TP5: A-D Converter Ground.
TP6: A-D Converter +5V.
TP8: Digital Ground.
TP9: System Reset. Out of Reset = virtually zero volts when measured from
TP23.
L UXEL P LATESETTER VOLUME 2 (3-37)
PL18
FS14
SK3
PL30
PL6 FS13
PL11
SK2 PL29
PL5
FS12
SK1
PL28
FS15
PL4 FS11
PL3 PL17
PL13
PL27
PL2
PL1
FS1 PL31
NOTE: Connector boxes shown as shaded in the figure above have fitted connectors.
Location
Mounted inside the PTM on the service side - lefthand side PCB.
LEDs and Links
There are no LEDs or links.
VOLUME 2 (3-40) P LATE H ANDLING M ODULES
Connectors
PL1: 8-way male Molex header type STR 6410. See Table 3.6.
PL2: 2-way male Molex 6410 straight header. Not used.
PL3: 4-way male AMP CT straight header. Not used.
PL4: 3-way male AMP CT straight header. Not used.
PL5: 6-way male Molex straight header. Not used.
PL6: 8-way male Molex minifit Jr. Not used.
PL7: 4-way male AMP CT straight header. See Table 3.6.
PL8: 3-way male AMP CT straight header. Not used.
PL9: 8-way male AMP CT straight header. Limit links on a plug are fitted as
follows: Pins 3 and 4 linked; pins 7 and 8 linked. These links are pull
sensor inputs to GND for BM22.
PL10: 3-way male AMP CT straight header. See Table 3.6.
PL11: 10-way male boxed header. Not used.
PL12: 4-way male AMP CT straight header. See Table 3.6.
PL13: 10-way male boxed header. Not used.
PL14: 8-way male AMP CT straight header. Not used.
PL15: 3-way male AMP CT straight header. See Table 3.6.
PL16: 3-way male AMP CT straight header. See Table 3.6.
PL17: 40-way male boxed header. Not used.
PL18: 26-way male header. RIB4 input from pulsed sensor inputs via Vertical
Distribution PCB. See Table 3.6.
PL19: 26-way male straight header. RIB5 input from pulsed sensor inputs via
24V Distribution PCB PCB. See Table 3.6.
PL20: 3-way male AMP CT straight header. See Table 3.6.
PL21: 4-way male AMP CT straight shrouded header. Not used.
PL22: 3-way male AMP CT straight header. See Table 3.6.
PL23: 4-way male AMP CT straight header. Not used.
PL24: 4-way male AMP CT straight header. Not used.
PL25: 4-way male AMP CT straight header. Not used.
PL26: 4-way male AMP CT straight header. Not used.
PL27: 6-way male single in-line shrouded header top entry. Not used.
PL28: 6-way male single in-line shrouded header. Not used.
PL29: 6-way male single in-line shrouded header top entry. See Table 3.6.
PL30: 6-way male single in-line shrouded header top entry. Not used.
PL31: 8-way Molex minifit Jr. PW3_INT connection.
SK1: 15-way female D-type. CAN4 connection from FHMB (2).
SK2: 45-way female R/A boxed header. Not used.
SK3: 15-way female D-type. CAN5 connection to FHMB (4).
L UXEL P LATESETTER VOLUME 2 (3-41)
SENSOR 24V
DISTRIBUTION DISTRIBUTION
PCB PCB
BS43 BS49
PL1
BS48 PL5
BS57 PL11
PL9
PL12
BS47 BS53
B) pin 3 = 0 V.
BS51 (FHMB3)
BS50 BS3 (FHMB4) SET CAN ID 1
24V I/P
PL11
PL8
BS55 (FHMB3)
BS18 (FHMB4)
PL3 PL12
PL5 PL7 PL10
FHMB (PL19)
PL2
BS46
The New 24 V Distribution PCB includes circuitry to attenuate the +24 V sensor
signal (from BS50/51/55) to +5V before they are passed to the FHMB.
BV24 is an on-board relay switched by FHMB 3 to connect the +24 VDC supply
to sensors BS50, BS51 and BS55. This ensures the sensor photo lights are only on
at required times and do not cause plate `fogging' by being on continuously.
Volume 2 Figure 9.8 shows system cable interconnections and Volume 2 Section
8.1 describing the pin signals.
Cassette ID PCB
Figure 3.23 shows the location of the Cassette ID PCB for a fully-automatic
platesetter before the plate feed mechanism on the service side and Figure 3.29
shows the PCB layout. The main function of the PCB is to read the cassette ID
(SW1-5) as the cassette is advanced towards the plate feed. It also routes the cas-
sette forward/reverse limit (BS41/42) and front door open (BS76) sensors to
FHMB2.
VOLUME 2 (3-46) P LATE H ANDLING M ODULES
FHMB
PL19 PL5
BS42
PL2 PL1
BS41 PL6
PL4 PL3
VIEW ON OPTO-REFLECTSWITCHES
BS40 BS39
Type: opto-slotted.
Operation: checks position of motor driving retard.
BS57 Retard Down
Location: see Figure 3.37.
Type: opto-slotted.
Operation: checks position of motor driving retard.
BS59 Plate Past Diverter
Location: see Figure 3.39.
Type: opto-reflective
Operation: detects when the leading edge of the plate has reached a
point before the diverter is raised.
BS61 Stack Height Top Limit
Location: see Figure 3.34.
Type: opto-slotted.
Operation: prevents stack stepper motor from over running.
BS62 X-Direction Door Up
Location: see Figure 3.31.
Type: opto-slotted.
Operation: detects when the door flap is raised.
BS65 Cassette at Nudger
Location: see Figure 3.37.
Type: micro-switch.
Operation: detects if the cassette has been fully pulled out to reach the
nudger.
BS66 Interleave Nip Clear
Location: see Volume 2 Figure 2.4.
Type: opto-reflective
Operation: detects if paper has failed to fully enter the bin.
BS71 X-Direction Door Down
Location: see Figure 3.31.
Type: opto-slotted.
Operation: detects if the door flap is in the down position.
BS76 Front Door Open
Location: at the bottom of the interleaf bin cover.
Type: micro-switch
Operation: paper bin sensor to detect if the bin door cover is accidentally
open.
L UXEL P LATESETTER VOLUME 2 (3-51)
INTERLEAF
DIVERTER
X-DIRECTION
DOOR ASSEMBLY
FEED HEAD
ASSEMBLY
RETARD PAD
ASSEMBLY
CASSETTE
FORWARD
ASSEMBLY
INTERLEAF DRIVE
ROLLER ASSEMBLY
STACK INCREMENT
ASSEMBLY
PIVOT R. H. SUPPORT
BLOCK BRACKET
SENSOR
BRACKET UP
SENSOR BS71
SENSOR BS62
FOLDED
FLAP
MOTOR
MOUNTING
BRACKET
SENSOR
SENSOR BRACKET DOWN
VANE
FOLDED BOX
SECTION
MOTOR BM27
F) Belt and pulleys: a set of drive/idler pulleys move a timing belt and drive
arms.
LH ARM ASSEMBLY
BEARING
DRIVE ARM BLOCK
RH ARM ASSEMBLY
BELT
FORWARD
SHAFT
ECCENTRIC MOTOR
IDLER/TENSIONER SUPPORT
PLATE
DRIVE
PULLEY
BEARING
AND CIRCLIP
CAM
FOLLOWER
DRIVE ARM
SENSOR A
TAB
GEAR
MOTOR BM20
VIEW ON ARROW A
IDLER
IDLER/
SENSOR BS42 TENSIONER
SENSOR BS41
CASSETTE
FEED
CASSETTE POSITION
REVERSE
DIRECTION
CASSETTE
ADVANCE
DIRECTION
HOME
HOME CASSETTE
FORWARD
TOP PLATE
CASSETTE
ADVANCE
DIRECTION
CASSETTE
REVERSE
DIRECTION CASSETTE
FEED
POSITION
BEARING
LIFT BAR BLOCK
BELT SENSOR
(T5/410) BRACKET
MOTOR
SUPPORT BELT
DOUBLE (T5/1500)
PULLEY
ECCENTRIC
PIN
STACK IDLER
IDLER BRACKET
PULLEY
FEED HEAD
NUDGER
INTERFACE
LIFT CAM
PLATE
SENSOR
BS48 DO NOT
(NUDGER TOUCH SCREW
DETECT)
FIXING
SENSOR BS45
(NUDGER
DOWN LIMIT) PLATE HEIGHT
SENSOR BS43 SENSOR VANE MOTOR
(CASSETTE EMPTY) BM22
ROLLER AXLE-
NUDGER LONG
LOAD BAR
TENSION DRIVE ROLLER
ROLLER CHAIN
BUSH STRIP
ROLLER AXLE- ROLLER CHAIN
SHORT
SUPPORT
BACKPLATE
FEED HEAD
ANTISTATIC BRUSH
SUPPORT ASSEMBLY
PAPER
GUIDE RETARD MOTOR MOTOR
LEAD EDGE DOWN CAM AND GEAR
SPRING GUIDE SPRING PILLAR
LOCATOR RETARD BM25
PAD
SENSOR
BS57
SENSOR
BS65
FRONT VIEW
ADJUSTING
SCREW
MOUNTING
MOUNTING PAPER PLATE
SCREWS LEAD EDGE GUIDE
SENSOR
GUIDE RETARD
BS56
PAD
END PLATE
SENSOR
BS57
SENSOR
BRACKET
SENSOR
BS65
ACTUATING
LEVER
CENTERING
PIN
CAM SHAFT
RETARD
VIEW SHOWING RETARD DOWN CAM MOUNTING DO NOT
BACKPLATE REMOVED SCREWS TOUCH
SENSOR
VANE SENSOR RETARD
BS56 INTERFACE
Spring locators and adjusters: the pad has a factory-adjusted spring mecha-
nism that is pre-set.
Centering pin: locates the cassette inline with the feed head.
VOLUME 2 (3-58) P LATE H ANDLING M ODULES
Motor and sensors: includes a motor gear (BM25) to actuate the retard pad,
and sensors (BS56 and 57) to indicate the position of the pad. BS65 micro-
switch indicates if the cassette has reached the nudger.
Since the assembly is critical for the throughput of single plates and interleaf
sheets into the PTM, it is built and set very precisely at the factory and should
not need adjusting during a service visit. Any sub-assembly failure (including
the motor) is completed by replacing the complete module.
ROTARY
SOLENOID
BV20
SOLENOID
COUPLING
STEADY
ROLLER
DIVERTER GUIDE
AND SHAFT
BEARING
RETAINER
BEARING
MOTOR/GEAR
BM24
PAPER
TENSIONER
BS53
STEADY
NIP ROLLER BRACKET
ROLLER
TUBE
DRIVE ROLLER
COUNTERBALANCE
WEIGHT
COUNTERBALANCE
BLOCK
PRE-DIVERTER DIVERTER
GUIDE (LH) SOLENOID BV20
SENSOR BS50
SENSOR BS49
FIXING BRACKETS (RH)
POST-DIVERTER
SENSOR BS52
DIVERTER
SENSOR BS55
PRE-DIVERTER
GUIDE (RH)
SENSOR BS59
ENGINE INTERFACE
A
BRACKET
COUNTER ROUTE TO
WEIGHT VALVE CAGE
(BV41)
AIR KNIFE
PRE-DIVERTER DIVERTER POST-DIVERTER ASSEMBLY
GUIDES
ENGINE
INTERFACE
SENSOR BS50
PRE-NIP
MOTOR 24V DC
INTERLEAF LOWER
GUIDE (1) DRIVE ROLLER
FHMB 1
DRUM
RFI BOX
See Figure 3.40 showing the location of the main plate control assemblies:
FHMB (1) PCB.
FHMB (4) PCB.
Sensor Distribution PCB (Output).
Sensor Distribution PCB (Input).
New 24V Distribution PCB
Registration Pin Isolation PCB (BS118).
Paper Plate Sensor PCB (see Plate Loading Platform).
Engine Motors.
Engine Solenoids and Relays.
Engine Sensors.
NOTE: The plate edge detect function is explained as part of the traverse mechanism.
Two FHMBs (1 and 4) control the plate handling devices for the PTM and
Engine. These boards hold the local motor handling software routines initiated
under the high level control of the Luxel System Board. See Figure 3.41 and
Figure 3.42 showing the PCB layouts and Volume 1 Section 2.2.1.1 describing
how the FHMB functions. Note the differences on how each variant uses both
boards - see Volume 2 Figure 9.5, etc.
PL18
FS14
SK3
PL30
PL6 FS13
PL11
SK2 PL29
PL5
FS12
SK1
PL28
FS15
PL4 FS11
PL3 PL17
PL13
PL27
PL2
PL1
FS1 PL31
NOTE: Connector boxes shown as shaded in the figure above have fitted connectors.
PL18
FS14
SK3
PL30
PL6 FS13
PL11
SK2 PL29
PL5
FS12
SK1
PL28
FS15
PL4 FS11
PL3 PL17
PL13
PL27
PL2
PL1
FS1 PL31
NOTE: All Sensor Distribution PCBs on the Engine and PTM have the same layout and
circuit design. This is also the case with all 24V Distribution PCBs.
Figure 3.43 shows the layout of the PCB drum mounting plate above the drum
on the service side of the machine.
VOLUME 2 (3-72) P LATE H ANDLING M ODULES
Figure 3.44 shows two additional Distribution PCBs attached to the top right-
hand side of the RFI box.
RFI BOX
(TOP)
SENSOR
DISTRIBUTION
(OUTPUT)
24V
DISTRIBUTION
PL1
PL5
PL2 PL3 PL4
PL12
SET CAN ID 0
PL5
SET
CAN ID 0
PL4 PL8 PL11 PL12
PL11
PL8
PL3
PL2
This PCB distributes +24 V to energise the following sensors on the Engine:
BS3 (plate in punch)
Pin connection power for the 24 V sensor plugs are:
A) pin 2 = +24 V
B) pin 4 = 0 V.
It also distributes +5 V to energise the following sensors on the Engine:
BS79: (chad tray home).
Pin connection power for the 5 V sensor plugs are:
A) pin 2 = +5 V
B) pin 3 = 0 V.
The 24 V Distribution PCB includes circuitry to attenuate the +24 V sensor sig-
nal to +5V before they are passed to the FHMB.
See Volume 2 Section 9.4 showing system cable interconnections.
The Registration Pin Isolation PCB provides electrical isolation between both
registration pins and chassis ground. An on-board PSU (5VDC to 5 VDC)
applies power across both pins in series with opto-isolators connected to FHMB
(4). This arrangement forms an electrical barrier that guarantees a completed
circuit when the pins and the plate are in contact.
PL1
PL2
PL3
NOTE: The registration pins must have clean oil-free surfaces to ensure electrical con-
tact.
Connectors
PL1: 8-way header to registration pin
PL2: 10-way header to FHMB (4).
PL3: 4-way header to registration pin.
Connector Pin Descriptions
See Volume 2 Figure 9.5 to Volume 2 Figure 9.7 showing the PCB interconnec-
tions for each variant and also Volume 2 Section 8.1 listing cables and signals.
3.4.1.5 Motors
See Volume 2 Figure 9.5 to Volume 2 Figure 9.7 showing the cable connections to
each motor.
Motors (BM) on the Engine are listed as follows:
BM1 Friction Band Input
Location: Input module - service side, see Figure 3.56.
Type: DC (66 rpm) with one-way clutch.
Operation: drives the plate into the drum.
BM2 Push Bar (Carriage)
Location: transport push bar - service side, see Figure 3.59.
Type: stepper with 5:1 gearbox and 20 tooth pinion.
Operation: drives bar and plate around the drum to the punch.
BM3 Centering (Punch)
VOLUME 2 (3-76) P LATE H ANDLING M ODULES
Location: motor replacing BM6 on the output transport, see Figure 3.57.
Type: stepper
Operation: provides more synchronised control between the output and
the processor.
3.4.1.7 Sensors
See Volume 2 Section 2.2.1 for a description of the sensor types. See also Volume
2 Figure 9.5 to Volume 2 Figure 9.7.
Sensors (BS) fitted on the Engine are listed as follows:
BS1 Input Entrance
Location: see Figure 3.56.
Type: opto-reflective
VOLUME 2 (3-78) P LATE H ANDLING M ODULES
Type: opto-slotted
Operation: indicates if the registration pins are extended.
BS104 Reg Pins Continuity
Location: Registration Module pins, see Figure 3.66.
Type: open/closed circuit detection
Operation: indicates when the plate is contacting both registration pins
and has been de-skewed.
BS109 Swing Roller Home
Location: swing roller, service side, lower sensor, see Figure 3.67.
Type: opto-slotted
Operation: detects if the plate spur rollers are up.
BS110 Swing Roller In
Location: swing roller, service side, upper sensor, see Figure 3.67.
Type: opto-slotted
Operation: detects if the plate spur rollers are down to hold the plate in
position on the drum.
BS112 Push Bar Forward
Location: drum casting, service side (Web/manual Engine only).
Type: opto-slotted
Operation: detects the travel limit of the push bar towards the output
end.
BS113 Plate Centering Home
Location: inside the loading platform, see Figure 3.55.
Type: opto-slotted
Operation: detects the return of the centering arm to the Home position.
BS114 Centering Continuity 1
Location: inside the loading platform, see Figure 3.55.
Type: opto-slotted
Operation:
BS115 Centering Continuity 2
Location: inside the loading platform, see Figure 3.55.
Type: opto-slotted
Operation:
BS118 Plate on Platen Opto
Location: inside the loading platform, Figure 3.55.
Type: opto-reflective sensor on the Paper Plate Sensor PCB. This PCB is
similar to the Reflective Opto PCB except that it is factory-calibrated to
detect the difference between a plate and paper. Do not adjust once it is
installed or replaced.
Operation: detects the presence of a plate only without attached interleaf
L UXEL P LATESETTER VOLUME 2 (3-81)
paper.
FROM PLATE
TRANSPORT
OUTPUT
TO PLATE FHMB4
MODULE
OUTPUT
FHMB1
INPUT
MODULE
BEAM
PUNCH
BS6
PUSH BAR
CENTERING AND
REGISTRATION
MODULES
CHAD TUNNELS
TO TRAY
PUNCH
MOTOR
VACUUM SUPPLY
FOR DRUM
OUTPUT
MODULE
OUTPUT INPUT
TRAY TO OUTPUT MODULE
FROM
PLATE
LOADER
BEAM
BS6
REGISTRATION
MODULE
PUSH
BAR
TRAVERSE
SWING ROLLER GEARS
MODULE
FPD
BS112
DRUM AND
BASE
COMPRESSOR BOX
VALVE CAGE
BEAM
UMBILICAL
TRAY READHEAD
FLAT DRIVE
RAIL
V-RAIL
CENTERING
MOTOR
BALL CAGE FLYWHEEL
MOTOR
PUSH BAR
PUNCH
M2 MIRROR
OPTICS
BASE
USER END
BAFFLE
Figure 3.51 Engine section view - user end (B1 fully-automatic with punch)
DISTRIBUTION
PCB'S PCB MOUNTING
PLATE
FHMB1
HOME SENSOR
(BS6)
INTERLOCK
BOX PUSH BAR
MOTOR
PUNCH MOTOR
MIXER
FAN
TRAVERSE
LIMIT SENSOR PCB
(BS15)
SERVICE END
Figure 3.52 Engine section view - service end (B1 fully-automatic with punch)
L UXEL P LATESETTER VOLUME 2 (3-85)
COMPRESSOR
VALVE CAGE READHEAD BOX
BEAM
UMBILICAL
TRAY
FLAT DRIVE
RAIL
V-RAIL
FLYWHEEL
MOTOR
BALL CAGE
SWING ROLLER
PUSH BAR & REGISTRATION
MODULE
M2 MIRROR BAFFLE
USER END
Figure 3.53 Engine section view - user end (manual and semi-automatic)
SERVICE END
FHMB 1
INTERLOCK
BOX HOME SENSOR
(BS6)
PUSH BAR
REGISTRATION MOTOR
MODULE
RFI BOX
MIXER FAN
SWING ROLLER
MODULE (SRM)
TRAVERSE PCB
LIMIT SENSOR
(BS112)
Figure 3.54 Engine section view - service end (manual and semi-automatic)
VOLUME 2 (3-86) P LATE H ANDLING M ODULES
RACK SHORT
BS113
LH CENTRING
ARM RACK SHORT
BS114
BS118
LINEAR TRACK
LONG RH CENTRING
ARM
DRAG
CHAIN
LINEAR TRACK BS115
SHORT
PLATE LIFT
ROLLER
RACK LONG
BM11
PLATE LIFT
CARRIAGE
SENSOR BS1
FROM
PTM
ROLLER
(IDLE)
BEARING
INPUT
BELT
DUCTING
PIPE ROLLER
(FRICTION)
BV41 ROLLER
(IDLE)
SENSOR BS2
TO DRUM
SIDE PLATE VIEW ON ARROW A
ROLLER
(DRIVEN)
GEAR
MANUAL
PLATE
VALVE CAGE FORWARD
(SEE CHAPTER 2-7) GEAR PULLEY
TENSIONER
SENSOR BS5
SENSOR BS4
MOTOR BM6
TENSIONER
FRICTION ROLLER
(1 PULLEY)
Figure 3.57 Common output module (without output guide) - detail view
VOLUME 2 (3-90) P LATE H ANDLING M ODULES
B1 Auto/Semi/Manual
B2 Semi
B2 Manual
3.4.2.4 Drum
See Figure 3.50.
The drum assembly is an aluminium casting fixed to the Engine base. Since it
has an anodised surface that prevents corrosion, it does not require servicing
except for periodic cleaning to remove plate dust and punch swarf. Note that
the drum surface should be cleaned after every service visit and the customer
reminded of the importance of this maintenance task.
For imaging purposes, the axes of the drum are usually defined as:
4 Slow: traverse direction
4 Fast: spinner rotation direction.
Drum functions are:
Conforming a plate for imaging: drum vacuum/air blow is across sets of
grooves directly connected to a manifold and valve system. Note that for
non-punch machines there is a leading edge zone which has three states: LE
conform blow, LE eject blow and LE vacuum conform. Pipe connections to
the drum are factor-fitted and should not normally be checked unless there
are conformance problems.
Supporting the traverse carriage: a top beam supports the carriage that holds
the spinner. To ensure that the carriage and its ball cage are properly
aligned, the drum (and Engine) must be level across the traverse axis.
L UXEL P LATESETTER VOLUME 2 (3-91)
NOTE: After completing any of the procedures below, make sure that the push bar and
drum are clean and free from obstructions.
Volume 2 Section 1.10.15 describes the Main Diagnostics commands for moving
the bar to step positions around the drum. Different size plates require a differ-
ent number of steps; as a general rule you can enter a higher number for the size
of plate and allow for the clutch to slip after the plate reaches the registration
Mechanical Conformance
For correct push bar operation, the support bar must be parallel to the pins, and
parallel to the axis of the drum. Push bar alignment is always carried out by
adjusting the gear segments ring around the drum.
Plate skew can cause poor vacuum conformance at one side of the leading edge.
As a quick check, lightly tap the leading edge of the plate at each end of the
punch and note if the sound is hollow or firm. A hollow sound indicates
there is a possible problem with conformance often caused by skew. Volume 3
Section 1.8.3.1 describes the main procedure for measuring if skew is within
VOLUME 2 (3-92) P LATE H ANDLING M ODULES
specification.
Fully-Automatic Machines Only: plate skew is sometimes caused by poor align-
ment between the PTM and the Engine after the inter-module fixing screws
have loosened, see Volume 3 Section 1.8.2.1. Check that the external frame skins
are aligned correctly using the information in the Installation Manual.
Non-Punch machines Only: use the setup procedure to ensure that the plate is cor-
rectly conformed to the registration pins, see Volume 3 Section 1.8.3.
SPRING
WHEEL SHOE
ASSEMBLY
DRIVE
SHAFT
SPUR GEAR
BLANKING
PITCH RING BRACKET
ASSEMBLY
ROLLER
PLATE
NIP ROLLER
ROLLER
PLATE
SUPPORT
BAR
HUB SPUR
DRIVE GEAR
SHAFT
PITCH RING
V3 ASSEMBLY MOTOR
PITCH RING STUB SHAFT GEAR MOTOR
BEARING MOUNTING
BRACKET
Note that typical NVRAM parameters for the Mark 2 are different to the Mark 1:
A) PUSH_BAR_CENTER_DIST_LONG_MM = 11
B) PUSH_BAR_CONF_DIST_THIN__MM=6
C) CENTERER_RELEASE_DIST_MM=1.0.
L UXEL P LATESETTER VOLUME 2 (3-93)
REGISTRATION
BS14 PIN MOTOR
CENTERER (BM5)
MOTOR (BM3)
CENTERING A
ARM (LH)
PUNCH
BS3 LOCKNUT MOTOR
BS10 (BM4)
REG PIN
CAM
SPRING
PIVOT
UNDERNEATH
VIEW ON CRANK
ARROW A ARM
MOTOR
SUPPORT
BS11 BRACKET
ACTUATING
ROD
ACTUATING ARM
VIEW ON SERVICE END OF
PUNCH ASSEMBLY
VANE EXTENSION
TAB
BS9
BS8
MOTOR
SUPPORT
PLATE
B
A
A punch assembly (with integral pins and dies) is supplied as one of the config-
urations described in Section 3.4.2.6.
Chad from the punch drops into a tray located at the base of the drum, see
Figure 3.49.
ACTUATING
LEVER
CAM
MOTOR DIRECTION
DRUM FACE
HEIDELBERG+BACHER
780 mm
748 mm
A = BACHER
425 mm B = HEIDELBERG
C = HEIDELBERG
11 mm 393 mm
PUNCH A 6.35 mm x 9.525
PUNCH B 12.68 mm x 10
A A A A PUNCH C 12 mm x 14.68 mm
B B C C
8 mm
780 mm
425 mm
11 mm
PUNCH A 12.68 mm x 10
PUNCH B 12 mm x 12 mm
A A B B
KOMORI
830 mm
550 mm
9 mm
PUNCH A 12 mm x 12 mm
PUNCH B 11.19 mm x 8
A A B B
DS400/700
700 mm
400 mm
6 - 9 mm
PUNCH A 6
PUNCH B 6 mm x 10
PUNCH B 6 mm x 8
A A B B
Dummy 7A03595
Heidelberg+Bacher 7A03596
Komori 7A03598
Custom 7A03600
CENTERING
S10 MOTOR
S14
(BM3)
REG PIN
CENTERING DC MOTOR CENTERING
ARM (LH) ARM (RH)
S13
BS3
PIN/DIE/ A
S12 CHAD WIPER
PUNCH
MOTOR
CENTERING (BM4)
MOTOR BS8/9
S11
REG PIN
CAM
UNDERNEATH
VIEW ON CENTERING ACTUATING
ARROW A PINION SHAFT
SIDE
PLATE
PLATE
GUIDE
DRUM
CASTING
REGISTRATION
MODULE
BACK
STAY
MOTOR SENSOR
BRACKET
ACTUATING
SHAFT
BEARING
BLOCK
SENSOR
GEARMOTOR
BASEPLATE
MOTOR
MOTOR
BRACKET SENSOR
(BS109)
PLATE
GUIDE
SHAFT
NIP WHEELS
CHAD TRAY
PULL
scanned plate outputs from the Engine with the transport rollers in the Proces-
sor. Plates are held in transit at the Buffer until the Processor sends a READY
request command for the next plate. Delays can be caused, for instance, when
the Processor chemical temperature needs adjusting for a different type of plate.
The Processor communication link is enabled or disabled from the TOOLS
menu on the MMI. If the link is disabled, the Processor still operates by sensing
the arrival of the plate at the input entry. However, the workflow output is likely
to be slower and more prone to jams.
BM7: Buffer Feed to Processor:
Location: see Figure 3.69.
Type: stepper and dual-ratio gearbox.
Operation: drives the plate from the output module into the Buffer at
faster speed than BM6. Stepper reverses direction and gearbox slows
bands to match speed of Processor input.
IDLER GEAR
GUIDE
SENSOR (BS19)
GEAR
SENSOR
(BS20)
DOUBLE
SPUR GEAR
BAND
SERVICE SIDE ROLLER
SENSOR
BRACKET
SIDE PLATE
DRIVE BELT
PLATE RAMP
IDLER GEAR
SENSOR
(BS20)
GUIDE
GEAR
SENSOR (BS19)
DOUBLE
SPUR GEAR
BAND
ROLLER
SCREW FIXING
VIEW FROM (SEE NOTE)
SERVICE SIDE
REMOVE SERVICE
SIDE COVER
ELV_IN ELV_LOCK RIB8
CONNECTOR
I/F PLATE PA
MAINS_ELV_IN
SCREW FIXING
(SEE NOTE)
NOTE: The Autofeeder must be mechanically coupled with the PTM so that there is no
risk of light `fogging' plates.
FHMB3
VACUUM INLET
INT_MAINS
RELAY
PTM INTERIOR
SCREW FIXING FRAME CONNECTIONS NOTE: SCREW FIXING POINTS
(SEE NOTE) ON EACH SIDE
SERVICE SIDE
BUFF_S19/20
BUFF_M7
INTERLOCKS
BUFFER
ENTRY ON
ENGINE
CONNECTOR
I/F EB
SERVICE SIDE
CONNECTOR I/F EB
BUFFER ENTRY
ON ENGINE
4
4
Introducing the Traverse Scan Modules .................................................................. 4-1
4
Media Scan System Description ............................................................................... 4-7
Edge Detect System Description ............................................................................ 4-18
NOTE: All Luxel platesetter variants use the same traverse scan modules and method of
operation.
SCALE
READHEAD ACTUATORS
LSB
FROM
OPTICS
POSITION DRIVE RAIL BASE
FLYWHEEL/ DATA
MOTOR/
CAN SHAFT LASER
BEAM
+36V SPINNER
DC DRIVE INDEX
TRAVERSE
PCB ENCODER
FHMB (4) UMBILICAL
(CAN + POWER)
MIXER
FAN
EDGE DETECT (OUTSIDE
LASER/PCB BAFFLE END CAP)
TRAVERSE
CARRIAGE WIPER
2-4-4 T RAVERSE S CAN M ODULES
BAFFLE
BRACKET
(FRONT)
L6 LENS
ASSEMBLY
SPINNER
CLAMP
EDGE DETECT
PCB AND LASER
MOTOR
MOTOR
SUPPORT
FLYWHEEL
CLAMP
BAFFLE
BRACKET FLYWHEEL
(REAR)
PL11 PL12
PROCESSOR
TP26
PL9
PL10
TP10
TP9
PL6 PL7
PL2
Location
Located on the PCB support bracket on the underside of the carriage, see
Figure 4.2.
Test Points
The most useful test points for field servicing are:
A) TP9: Sawtooth waveform. When compared with a `Demand' signal (see
TP11), produces a pulse-width modulated signal controlling spinner speed.
The sawtooth waveform is seen after the `Spinner Reset' command is
entered.
B) TP10: Demand signal. Produces a saturated voltage level on startup which
then reduces to a lower running level when the spinner is locked. If the
signal remains saturated, the Traverse PCB needs to be replaced.
C) TP26: DATA A signal (960 lines/rev).
MPU Controller
The main functions of the MPU (Motorola 68376) are:
To control the Traverse PCB locally by receiving and interpreting high-level
commands sent from the System PCB over the CAN bus. These commands
typically include, for example, Spinner Start/Stop, Traverse Datum, Fans On/
Off.
Initialises the Precision Motion (PM) Controller that operates the closed-
loop position feedback system for the traverse control.
Pass control and position data to the PM controller.
Control the flow of diagnostic data to a local VDU.
L UXEL P LATESETTER 2-4-7
Current Limit
Maximum current to the spinner from the controller output is set not to exceed
15 A (for 1.5 secs) on spinner startup, with maximum current for each phase is
limited to 8 A thereafter.
Braking
When braking is switched on, the spinner comes to rest at approximately 20 secs
from full speed. Braking is applied by shorting out the three windings and using
regenerative braking to decelerate the spinner. It is active when:
A) the spinner controller initialises
B) power is removed from the Traverse PCB (for instance, an interlock is
opened)
C) on-demand signals via the software.
Braking also occurs for the following conditions listed below:
Stalled Rotor
If the rotor fails to move following a Start command.
2-4-10 T RAVERSE S CAN M ODULES
DRUM
1,220,000 m VE
+VE
SE
EN
CARRIAGE HOME INDEX
RAIL ACTUATOR
Scanning speeds vary with resolution and the number of beams operating.
Traverse speed is directly proportional to the number of beams (for instance, a
dual-laser beam at 96 l/mm speed equals two times a single-laser beam at 96 l/
mm).
Linear Scale
The linear scale is a 6 mm wide, self-adhesive steel strip that is gold-plated and
lacquer coated. It is pressed with small corrugated pitches (facets) set at 20
microns. Gold plating on the scale assists optical reflection/diffraction from the
readhead, while lacquer coating protects the strip from minor surface damage.
It is attached to the drive rail and covers the length required for an end-to-end
carriage movement.
The design of the readhead and scale ensures it is tolerant of small amounts of
contamination or damage. It is cleaned by wiping with a cloth dipped in an
approved cleaning agent described in Volume 3 Section 1.5.2.If the scale is badly
damaged, it is possible to replace the complete strip in-situ; but this is not a
standard replacement procedure and requires advice from FFEI Customer Sup-
port.
Readhead
See Figure 4.5.
This is a position feedback transducer that supplies digital signals directly to the
PM controller. The current device is a Renishaw RGH22X that runs from a sup-
ply of 5 VDC, has a resolution of 1m, and operates an infra-red diode as a
source of illumination.
Infra-red light obliquely illuminates the scale facets which then reflect and scat-
ter light towards the readhead window. An index grating inside the device redi-
rects the light to form fringes identical to the scale pitches. Each fringe point is
the summation of light from 100 scale facets to give an averaging effect that
helps to overcome the problem of scale contamination. Photo-sensitive diodes
then generate phased currents from these fringes.
Interpolation hardware in the readhead sub-divide the composite signals to pro-
duce two quadrature square waves with a resolution of 1 m.
The readhead is a field replaceable unit that includes a plastic spacer to check
the recommended 0.8 mm distance between the head and the scale. Note that
there is a registration procedure to setup the readhead with the index actuator.
2-4-12 T RAVERSE S CAN M ODULES
READHEAD
READHEAD
WINDOW
OBLIQUE LIGHT
FROM
INFRA-RED LED
CLEARANCE
0.8 mm
CONTAMINANTS
COATING SCALE SCATTERS
GOLD PLATED LIGHT > 100
SCALE FACETS ACTIVE FACETS
RAIL
PITCH 20 M
To ensure accurate encoding, the gap between the scale and the readhead must
be set using the 0.8 mm spacer supplied with the head. When the head is
replaced, the setting should be checked over the entire length of the scale track
by observing the readhead LED as the carriage is pushed from one end to the
other.
Optical signal generated from the scale is read by a built-in monitoring circuit
that measures relative alignment and set-up conditions. Any indication of error
is shown by a bi-colour LED. As a servicing check, the diagnostic LED is visible
from the user end while the carriage travels along the complete scan distance.
LED colour indications are as follows:
Green: set-up conditions are acceptable.
Orange: conditions are acceptable but small adjustments are required for
obtaining an improvement. The manufacturer's Installation Guide explains
how to set-up the alignment.
Red: conditions are unacceptable. The manufacturer's Installation Guide
explains how to set-up the alignment.
Traverse Servo
A desired reference trajectory is generated on the PM controller as a sequence of
positions and this is compared to a register that holds data on the current car-
riage position received from the linear encoder (readhead). The resulting digital
error signal is processed as a new numerical value by the controller and sent as
an update to the DAC. Dynamic response (speed of response, etc) of this servo
loop is determined by an external compensation circuit to give an output that
drives the traverse motor from a linear power amplifier.
L UXEL P LATESETTER 2-4-13
Traverse Amplifier
Analogue signals from the servo is converted to current by a linear push-pull
amplifier, with local feedback to ensure that current through the motor is pro-
portional to the input. Output current from the amplifier is fed back to an MPU
A-to-D channel for diagnostic measurement.
Traverse Actuators
Figure 4.6 shows the position of the two reference actuators and linear scale
detected by the readhead. The end stop is fitted as a mechanical stop.
2-4-14 T RAVERSE S CAN M ODULES
BALL CAGE
(SEE FIGURE 9.19 FOR
CAGE ORIENTATION)
VIEW ON ARROW A
V-GUIDE
RAIL
CAGE
STOPPER
BEAM
UMBILICAL
TRAY
BUFFER
SIDE
DRIVE RAIL
HOME
ACTUATOR
(3-OFF)
ENDSTOP
AND BRACKET
INDEX
ACTUATOR
LINEAR
SCALE
passive actuators (magnets) fitted to the rail on the Buffer side of the beam.
Home Actuator
This sensor actuator generates a signal before the mechanical stop to define one
end of the beam, see Figure 4.7.
The Home signal is active for the final 20 mm of carriage movement until the
carriage reaches its mechanical end stop. It is used as a coarse position sensor,
determining which way to move the carriage at power up. It is also used as a
software warning flag to indicate that the Index sensor in close proximity. Note
that it is not possible to move the carriage beyond the active region of the Home
signal while it is traversing.
RAIL
BEAMS X
Y
SCAN
SWATHE Q
A
P DRUM
SCAN
SWATHE
B
REAR
BRACKET LASER
FRONT LASER LED
BRACKET
BRACKET
PCB
PCB
BRACKET
TRAVERSE
BAFFLE
PL2: To STB
PL3: To laser diode.
Connector Pin Descriptions
See Volume 2 Section 9.5 for a description of the cable interconnections.
TP2
LASER
TP4
(GND)
VR1
4.3.2 Operation
Plate edge detection is fitted on all Luxel variants other than the fully-automatic
punch machine. Effectively, it is an electronic method for determining the start
of imaging position from the plate edge inside the drum without the need to
mechanically center the plate. A plate is loaded and its edge detected by a laser
diode light pointing towards the drum. As the traverse moves towards the
plate, any change of reflected light is sensed by a phototransistor receiver which
detects the difference between the drum surface (scattered light) and the plate
surface (specular light). This method takes advantage of very precise traverse
measurement system for positioning the imaging beam along the slow scan axis.
An LED, viewed from the service end, indicates when the laser light is on the
plate (LED OFF) and on the drum (LED ON).
NOTE: Accurate detection is dependent on the correct set up and alignment of laser and
phototransistor. See Volume 3 Section 3.3.9.
2
5
3 4
IMAGE
PLATE
DRUM
4
4
Media Expose System ................................................................................................ 5-1
Media Expose Control and Operation ....................................................................5-29
FOCUS
SM4 LASER SM2 ADJUST
POWER
S6 DETECTOR
S3 POD BEAM
L3 SPLITTER L9 M3
APERTURE POD
M1 L5 L4 L3 L2 S2 LASER
VOLUME 2 (5-2) M EDIA E XPOSE M ODULES
BEAM DUMP L1
S4 S5 CONVERTER
SM3
S1 SM1
APERTURE CONTROL
ND WEDGE
FILTER
EOD X
BEAM
BEAM COMBINER
SHIFTER
LASER MODULE (X)
EOD Y
ND WEDGE
BEAM FILTER
SHIFTER
EOD (X)
BEAM
LASER COMBINER
MODULE
(X)
SM1
*
EOD (Y)
PHOTO DIODE
TEMP/HUMIDITY PCB
MODULE ELANTEC
PCB
* WAVEPLATE IS
OPTIONALLY FITTED
L UXEL P LATESETTER VOLUME 2 (5-3)
VOLUME 2 (5-4) M EDIA E XPOSE M ODULES
LASER VIEW ON
BLOCK ARROW A PELTIER
LASER DIODE
ELANTEC
PCB PCB
THERMISTOR
PHOTO DIODE
PCB PCB COVER
F60 LENS
ASSEMBLY A
CYL 22 LENS
ASSEMBLY
CYL 60 LENS
ASSEMBLY
LASER DIODE
PHOTO DIODE
DISTRIBUTION
PCB
PCB
MOUNTING
PLATE
LASER COVER
30 mW O/P POWER
DRIVE
CURRENT
(SWITCHED BY
IMAGE DATA)
BIAS
CURRENT
A)
IMAGE
DATA FEEDBACK
BIAS
AND
DRIVE
CURRENT
Laser Output
Beam divergence is corrected by two cylinder lenses: CYL22 for fast axis and
CYL60 for slow axis. Correction by these lenses are to compensate for ellipticity
and astigmatism. The initial beam from the diode is 3 mm x 1 mm which uses
the lens, LF60, to set a focus for the other two compensation lenses.
The final output from the module is a circular, collimated beam (1 mm x 1 mm)
at approximately 25 mW with a wavelength of 400-410 nm. The beam is also
modulated by image data sent from the VBOMB.
The laser module driver operates in constant power mode using feedback data
from the Photo Diode. As the diode ages over time, current is increased gradu-
ally to compensate for the loss of power.
VOLUME 2 (5-8) M EDIA E XPOSE M ODULES
Power Balance Balancing of the two beams from the LPD using a defined ND value.
LASER
ASSEMBLY
PHOTO DIODE
PCB
1 mm x 1 mm
DIODE BEAM LF60 CYL22 CYL60
THERMISTOR
SPLITTER
TEMP
SENS
IMAGE
DATA IN
CURRENT CONTROL
CURRENT LIMIT
TEMP OVER
CONTROL TEMP LIMIT CURRENT/
PELTIER & THERMISTOR OVER &
NOW GO VIA UNDER
PHOTO DIODE PCB TEMP/
OVER
POWER POWER
CONTROL
PROTECTION
VBOMB
5.1.1.6 Waveplate
See Figure 5.2.
A waveplate, located in front of EOD Y, rotates the beam polarisation plane by
90. Some machines may optionally have a waveplate for EOD X.
The waveplate is not a field replaceable unit.
CONNECTOR
WAVEPLATE
ALLEN CAPHEAD
BASEPLATE
Beam deflection is necessary for correctly aligning beam swathes on a plate and
for preventing beam cross-over caused by the circulating motion of the spinner
mirror.
VOLUME 2 (5-12) M EDIA EXPOSE M ODULES
WARNING: The cable connections from the EODHV driver to the EOD generate up to
2 Kvolts (pk-to-pk) and are potentially dangerous when the system is switched on with
the interlocks overridden.
The ND filter assembly includes a sensor (S1), which detects the Home position,
and a stepper motor (SM1) that drives the wheel in `N' number of steps from the
home position. An increasing number of steps from home gives increasing
intensity in the light beams. Fine adjustment of laser power intensity is usually
controlled at the laser module.
The SM1 motor and sensor (S1) is a field replaceable unit. After replacing the
motor or sensor, run the `ND_char' utility to setup a characterisation table of the
LPD readings against the ND setting required for exposure calibration.
The ND filter assembly is field replaceable.
L UXEL P LATESETTER VOLUME 2 (5-13)
SENSOR (S1)
SENSOR
STAY BRACKET
MOTOR
BRACKET
ND FILTER
FILTER
WHEEL
MOTOR
(SM1)
SENSOR
(S2)
L2 LENS
LENS BRACKET
SENSOR
(S3)
MOTOR BRACKET
BEARING
LEAD SCREW
HOOK FLANGE
BEARING
MOTOR
OPTICS
BASEPLATE
SPRING
POST CLAMPING
PLATE
SHAFT
FOCUS
BASEPLATE
SLIDE
APERTURE APERTURE
ASSEMBLY
BRACKET
BEARING
BRACKET BEARING
CLAMPING
PLATE
L5 LENS ASSEMBLY
(SEE NOTE)
APERTURE
SLIDE
BEAM CONVERTER
TIMING BRACKET
PULLEY
BARREL
FIXING
BARREL
SCREW
SPRING
SENSOR
(S5) BARREL
ASSEMBL
BELT
GUIDE SHAFT
MOTOR (SM3)
PIVOT L3 V-BLOCK
SHAFT
At 48 l/mm, the aperture mechanism moves back to lens (past the 96 l/mm
position) and mechanically pushes a beam converter mechanism into position.
This mechanism, which is on a pivot, maintains beam power by locating lens
(L3-48). The three possible resolutions are shown in Table 5.3.
VOLUME 2 (5-16) M EDIA EXPOSE M ODULES
Stepper motor (SM3) controls the position of the resolution changing aperture
and the operation of the beam converter. Sensor (S5) prevents the motor being
driven beyond a certain point.
The aperture control module is not a field replaceable unit and can be removed
from the base plate.
at the same height to minimise errors. Any small angular error on a mirror will
cause a much larger output error from the optics base.
See Section 5.1.3 for locations of M1 and M2 mirrors on the periscope.
Optics mirrors are not field replaceable.
EODHV PCB
See Figure 5.10.
The assembly includes a high voltage DC-DC converter that supplies the fixed
HT bias voltage. Push-pull amplifiers to drive the transformers are fixed to the
X and Y heatsinks.
VOLUME 2 (5-18) M EDIA EXPOSE M ODULES
DC - DC
PL1 CONVERTER PL2
X-BLACK Y-BLACK
PL3 PL4
X-BROWN Y-BROWN
TP1
TP7
TP4
X Y
AMP PL5 PL6 AMP
TP8
X-VIOLET
Y-YELLOW
X-YELLOW Y-VIOLET
PL7 PL8
LK1 PL9
TP10
1 2 3
OFF ON
TP11
TP12
Connectors
PL1: Push connector (black ident). X-channel HT supply.
PL2: Push on connector (black ident). Y-channel HT supply.
PL3: Push on connector (brown ident). X-channel HT supply.
PL4: Push on connector (brown ident). Y-channel HT supply.
PL5: Push on connector (violet wire). AC Modulation for X-channel.
L UXEL P LATESETTER VOLUME 2 (5-19)
HV Transformer
See Figure 5.11.
Two toroidal step-up transformers, located below the EODHV PCB, supply the
high voltage AC component of the drive to the EODs. Each TX has a single pri-
mary input and two secondary outputs; resistance for the secondary windings
are approximately 140 ohms.
The push-on connectors are colour-coded so that the wire colour corresponds to
the silk-screened legend on the PCB.
WHITE
TO EOD
(X OR Y)
(BLUE TO RED SPOT)
BLACK SLEEVE
BLACK BROWN
(PUSH ON)
(HT) (HT)
TRANSFORMER
VIOLET/YELLOW (PRIMARY)
NOTE: Note that the setup procedures for the one-beam system are not the same for a
two-beam system.
A base that does not have a beam combiner fitted is non-upgradeable in the
field.
LASER POWER
DETECTOR M1
M2 ASSEMBLY (SEE FIGURE 10.19) ASSEMBLY
OPTICAL
BEAM
NOTE: On current production machines, the LPD board is isolated from chassis ground
by a gasket mask in order to ensure accurate readings.
The LPD motor, PCB and sensors are field replaceable units.
VOLUME 2 (5-22) M EDIA EXPOSE M ODULES
SENSOR
(S6)
LENS AND
LENS FILTER MOUNT
SUPPORT
FILTER
CLIP
MANUAL
SHUTTER
DETECTOR
PCB
POWER
LENS
ND FILTER AND
'O' RING
PULLEY
MOTOR SHAFT
MOTOR
TIMING (SM4)
SUPPORT
PULLEY
Figure 5.13 Laser Power Detector assembly - general view
M2 BRACKET
ADJUSTING
SCREW
M2
MIRROR
ADJUSTING HOUSING
SCREW
See Section 4.7.2.1 for a description on how to adjust M2 for correcting image
form errors.
The spinner currently specified comprises a mirror, shaft, body, motor, encoder
and cables.
MOTOR DRIVE
SIGNALS
MIRROR
SURFACE
LASER
BEAM
DEFLECTED
LASER
BEAM SPINNER ENCODER
MOTOR
INTERFACE
CONNECTOR
TO FHMB4
NEUTRAL
DENSITY
FILTER
PHOTO SENSOR
BOARD ASSEMBLY
FPD MOUNT
NOTE: For early application software releases, the laser current limits must be manually
set at each service visit using the procedure in TIS 13887.
Location
Lower interior of the optics base, see Figure 5.2.
Connectors
PL1: 10-way. Not used.
PL2: 40-way. Not used.
PL3: 10-way. LPD sensor detector.
PL4: 8-way. Not used.
PL5: 14-way. POD sensor.
PL7: 10-way. Not used.
PL8: 5-way. Envir I/P from laser temperature/humidity PCB.
PL9: 40-way. Laser (X).
PL10: 40-way. laser (Y).
PL11: 10-way Molex minifit. +5V, +15V, +24V and -15V DC supplies from the PWR
FILTER PCB.
PL12: 3-way. Fan.
PL13: 24-way. Motor sensor inputs.
PL14: 6-way. ND Filter motor drive.
PL15: 6-way. LPD motor drive.
PL16: 6-way. Aperture control motor drive.
PL17: 6-way. Focus motor drive.
PL18: 6-way. Not used.
SK1: 8-way. Image data
L UXEL P LATESETTER VOLUME 2 (5-27)
PL8
PL5 PL3
PL9
(x)
PL12 PL10
TP6
(y) +15V
PL13
FRONT VIEW
SK1
PL11
FS1
PL14
LK1
PL15
PL1
PL16
TP1
+5V
PL17
PL18
PL2
SK2 LK2
PL7
Fuses
FS1: 3A slow-blow (97280015).
VOLUME 2 (5-28) M EDIA EXPOSE M ODULES
Links
LK1: Link is removed.
LK2: Link is removed.
VBOMB_IHPEN
LD PCB PD
VBOMB_IHPEN
LD PCB PD
RFI BOX
LSB VBOMB_LPD
ND FILTER
LSB_DATA VBOMB_NDM HOME
SK1 PL14
S1
VBOMB
APERTURE
POWER VBOMB_PWR VBOMB_ADM HOME
FILTER PL11 PL16
S5
FOCUS S3
VBOMB_FOCM HOME
PL5 PL17
VBOMB_POD FOCUS
PL8 PL12 LIMIT
PL13 S2
VBOMB_
POD ENVIR_ VBOMB_SENSORS
MON
EOD deflection.
Laser aging control.
Power balance.
Beam coincidence.
Drum coincidence.
Exposure Calibration.
SPINNER
CAN TO LUXEL
M2 STB SYSTEM
BOARD
VBOMB POSITION
APERTURE FOCUS DETECTOR
M1 (POD)
PERISCOPE ND WEDGE
FILTER
VBOMB VBOMB VBOMB
OPTICS
LASER EOD BEAM
BASE
(X) (X) COMBINER
LASER EOD
(Y) (Y)
TRANSFORMERS
X/Y
PD AND LD IMAGE
DATA & PD AND LD
PCB PCB
CONTROL EODHV
DRIVE/POWER CONTROL
APERTURE
VBOMB EODD
RFI BOX
RIP SERVER
drive values.
Y2
COINCIDENCE
POINT
X
X1 X2
Y1
POD DETECTOR
TRAV_HIGH_SPEED_POS
3. Set the optics motors to 48l/mm.
4. Measure the powers in the X-beam and the Y-beam.
5. Calculate the ND adjustment required to give the correct exposure at 48 res.
6. Calculate the ND offset to give the correct exposure for 1200 res.
7. Set the optics motors to 72l/mm.
8. Measure the powers in the X-beam and the Y-beam.
9. Calculate the ND adjustment required to give the correct exposure at 72 res.
10. Calculate the ND offset to give the correct exposure for 1800 res.
11. Set the optics motors to 96l/mm.
12. Measure the powers in the X-beam and the Y-beam.
13. Calculate the ND adjustment required to give the correct exposure at 96 res.
14. Calculate the ND offsets to give the correct exposures for 2400, 100 and 144
res.
15. Store all 8 ND values into NVRAM.
Volume-Chapt er
4
4
Introducing Power and Control Modules ................................................................. 6-1
4
System Power Distribution ........................................................................................6-2
4
Interlock Box Modules ...............................................................................................6-6
4
RFI Box Modules ...................................................................................................... 6-16
4
RFI Box - DC Power Modules ..................................................................................6-19
4
RFI Box - Image Processing Modules ....................................................................6-23
MMI and External Alert .............................................................................................6-30
(18-off posidrive screws) to access the RFI box assemblies. Interface connectors
between the RFI box and the rest of the system are on the service side of the Engine,
accessed after removing the side cover.
Mains filter box: located on the Engine service side. The unit is a field replaceable
unit (FRU) with a cover plate that can be removed for inspection (4-off posidrive
screws). Always remove the mains power lead first before servicing the mains
filter box.
Interlock box: located on the Engine service side. This box houses FRUs and is
accessed by opening a front cover plate (2-off posidrive screws) shown in
Figure 6.4.
INTERLOCK
BOX
ACCESS TO
RFI BOX
I/F CONNECTOR
MAINS
FILTER
BOX
USER SERVICE
SIDE SIDE
B) An external pump for drum vacuum is supplied with the equipment. Mains
supply and control is a direct 230 VAC connection from the platesetter.
C) Other platesetter equipment (PAT, processor, RIP PC and plate stacker) have
separate AC supply points.
2. The site must include safety isolators and equipment circuit breakers that conform to
local regulations.
A slow-acting dedicated circuit breaker (or fuse) should be fitted to the local distri-
bution supply for the platesetter. The type of fuse protection should be within local
regulations. Recommended rating for the fuses are:
3. A safety isolating switch must be mounted within 4 m (158 in) of the mains input
connection on the Engine. The switch should be marked `ON' and `OFF'.
4. A low impedance and interference-free earthing system must be provided. Earthing
requirements are:
A) The platesetter requires a dedicated system earth via a common earth point.
B) Earth circuit resistance less than 0.5 Ohm from the platesetter to common earth.
5. All platesetter equipment must be connected to the same phase if the site has a 3-
phase supply. Do not use extension cords to supply AC mains to platesetter equip-
ment.
WARNING: Always remove the mains power lead first before servicing the mains filter
box.
A mains filter box, rated at 20 A (250 VAC), protects the system electronic modules
from external glitches before supply reaches the interlaock box.
The mains filter box is replaced as a single module in the event of failure.
the Engine and two emergency stop buttons on the PTM. While the emergency stop cir-
cuits are not activated, AC supply is distributed to each module from interconnecting
cables.
The PTM and Autofeeder have separate panel AC connectors that can be disconnected
to isolate supply as:
Engine-to-PTM AC supply (INT_MAINS): see Volume 2 Figure 3.72.
PTM-to-Autofeeder AC supply (MAINS_ELV_IN): see Volume 2 Figure 3.71.
Engine-to-Buffer DC supply (ENG_M7): see Volume 2 Figure 3.73.
The Processor and Plate Stacker supply have separate AC connections described in the
Luxel Platesetter Pre-Installation Manual.
+24V
+5V MOTORS
+5V +5V
SENSORS
+24V
+15V BUFFER
-15V (ENG_FHMB PWR) +24V +5V SENSOR +5V
+12V DIST AND SENSORS
(EOD) 24V DIST +24V
+24V SENSORS
SENSORS
+24V
Z-DIRECTION
+24V
DOCKING
LIGHT
CASSETTE
FHMB2 DOOR LOCK
(INT_OUT)
+24V
ABS LMT CONTACTOR
CONTACTOR_24V
(ELV_LOCK)
ELEVATOR
MOTOR
MOTOR
CONTROL ELEVATOR
CONTROL
+24V
INVERTER
AC AC
PTM MAINS
AUTOFEEDER
WARNING: Ensure that the platesetter is powered off but still connected to the AC mains
source to maintain Earth/Ground continuity if PCB static protection is required. Note the
WARNING below.
A mains filter box, rated at 20 A (250 VAC), protects the system electronic modules from
external glitches before supply reaches the interlock box.
This unit is replaced as an FRU in the event of failure.
L UXEL P LATESETTER VOLUME 2 (6-7)
The interlock box houses devices and circuits described in the following sections:
External interconnections: see Section 6.3.2.
Mains power input and emergency stop control: see Section 6.3.3.
Interlocks control: see Section 6.3.5.
Drum vacuum control.
Interconnect wiring between the interlock assemblies is shown in Figure 6.7.
INTERLOCK
FUSEHOLDERS
AND 3-OFF FUSES
INTERLOCK
CONTACTOR
INTERLOCK PWR 1
COMPRESSOR
MONITORING
RELAY (BV31) INTERLOCKS
MODULE
DISTRIBUTION
TERMINAL
BLOCK SHUTTER
(LASER ON/OFF)
END STOP
SURGE
SUPPRESSOR
NL N L
RAIL
PWR 3
PWR 2
PSU
(30W +24V)
POWER IN
LINKS
PSU MAINS EMERGENCY
COVER
VAC
VAC OVERCURRENT
ON/OFF SWITCH CIRCUIT BREAKER
(CIRCUIT BREAKER (8A)
24V FUSE
& RELEASE COIL) (0.5A 250V)
VAC PUMP
RELAY (BV5)
LED
DIAGNOSTICS
PUMP (2)
(MAINS TO PTM) MAINS_RFI_IN
(MAINS TO RFI BOX) COMPRESSOR BOX
MAINS_DIST (MAINS TO COMP)
(FROM MAINS FILTER) PUMP (1)
(MAINS TO VAC PUMP)
(LASER ON/OFF)
SHUTTER
INTERLOCKS
PWR 1
PWR 3
PWR IN
PWR 2
EMERGENCY
CIRCUIT BREAKER
RESET BUTTON
VAC PUMP
(0.5A 250V)
FUSE 24V
VAC PUMP
CONTROL
See also Volume 2 Chapter 2-10 for views of the interlock box cable interconnections
and Volume 2 Section 8.1 for a description of the cable pin voltages and signals.
The interlock box has an external panel with I/O connections for:
1. VAC PUMP CONTROL: input from FHMB4 controls the vacuum relay to switch
mains supply to the drum vacuum pump while the system is scanning.
2. PWR IN: input from +36 and +24 VDC supply, via the Power Filter PCB and the
laser EODD interlock control signals.
3. INTERLOCKS: input from interlock panel sensor connections to the box interlock
controls.
4. EMERGENCY: emergency stop circuit to/from the PTM via ENG_FHMBPWR.
5. PWR 1: output cable for +24 VDC to FHMB(1) via ENG_FHMBPWR.
L UXEL P LATESETTER VOLUME 2 (6-9)
WARNING: AC Mains supply is still live at the interlock box when the emergency stop has
been pressed. Make sure the AC supply is removed or switched off at the mains outlet
before accessing the box.
While the system is operating normally the mains supply from the mains input filter
generates a +24 V DC supply from the +24 V PSU (Emergency). This voltage is routed
through to the emergency safety contactor coil which switches the contactor.
6 WAY
CONNECTOR
2
5 +24V
EMERGENCY
1 STOP
99700424
99700243
TERMINAL
BLOCKS 99700447 NOTE: 0455 FEEDS INTO TOP OF
TERMINAL BLOCKS.
N L
1 2 0122 FEEDS INTO BOTTOM
OF TERMINAL BLOCKS
+24
CIRCUIT VDC
BREAKER +
UNDERVOLTAGE
COIL NEUTRAL LIVE 24V GND ENG 24V_GND
SIE A2
+24V ENG 24V SIE 21NC
C/B N L (OUT)
VOLUME 2 (6-10) P OWER AND C ONTROL M ODULES
2 4
99700444
+24V
LINKS LINKS CONNECTOR
99700455 NEUTRAL
(NOTE) WIRES SOLDERED TO PSU
LIVE
99700444 CONNECTOR
4 +OUT
A 3 1
99700444 24V DC
BV31 COMP 99700310 09700310
1 4 SUPPLY
(FHMB4) 24V RELAY
SEE 'A' (BV31) -OUT
8
B 4 6 A
VAC PUMP
24V RELAY EARTH CONNECTED TO CASE
(BV5)
99700454 7 9 B
99700424 0.5A FUSE
99700444 8-WAY
99700122 (NOTE) CONNECTOR
VAC PIN 2
CIRCUIT
BREAKER 99700456 BV5
PIN 6
(5A) (FHMB4)
CHASSIS CHASSIS CHASSIS CHASSIS
CHASSIS PIN 1
'A' PIN 4
BV31
Figure 6.6 Interlock box - mains wiring, vacuum and emergency stop control
MAINS TO MAINS TO RFI BOX MAINS TO PTM MAINS TO PUMP LIVE & NEUTRAL FROM (FHMB4)
'A' PIN 8
COMPRESSORS 99700122 99700150 (ENGINE) MAINS FILTER
99700150 99700243
L UXEL P LATESETTER VOLUME 2 (6-11)
While closed, the contactor routes +24 V to the circuit breaker (On/Off switch). At the
same time the circuit breaker switchs AC voltage to the drum vacuum relay, the RFI
box, the PTM and the Autofeeder.
Pressing the emergency stop button causes a +24 V undervoltage to the circuit breaker
which trips the AC supply. The drop in voltage to the circuit breaker is sensed internally
by its integral undervolt detector and causes the circuit breaker to switch off.
Supply is not restarted until the steps below are completed in the following sequence:
1. The pressed emergency stop red button is turned in a clockwise direction to its reset
position.
2. The ON/OFF circuit breaker is switched on again.
This resumes the +24 VDC supply and re-energises the emergency stop contactor.
Interlock Replacements
Use the information in Section 6.3.5 above to replace an interlock assembly.
Interlock Checks
The interlock operation for the safety relay is tested by opening and closing each cover
in turn to check if the safety relay automatically operates when a cover is shut. Any
functional failures disables the circuit until the fault is fixed. To check the contactor,
open a cover and determine if power has been removed from the MMI Error Handling
screen.
Interlock Operation
See also Volume 2 Chapter 2-10 for views of the interlock cable interconnections and
Volume 2 Section 8.1 for a description of the cable pin voltages and signals.
The safety relay monitors inputs from the interlock sensors (covers, external interlock
and override keyswitch). If the inputs indicate a suitable state (covers closed, override
not on), then the two safety relay contacts are closed.
Contact 2: routes +24 V from the Power Filter PCB to energise the two interlock contac-
tors, one in the interlock box and the other in the Autofeeder.
Interlock Box Contactor: when energised by the +24 V from the safety relay contact
routes:
L UXEL P LATESETTER VOLUME 2 (6-13)
I/LOCKS
+36V
+24V
PWR1
VOLUME 2 (6-14) P OWER AND C ONTROL M ODULES
A1+ 13 23 A2- 22NC 6T3 4T2 2T1 51C F1A F2A F3A
A2- Y1 X1
CONTACTOR
(SIE 3RT 1016-1BB42)
SAFETY RELAY
FUSE FUSE FUSE PWR2
(AES 1235) PLUG IN SURGE (1A) (1A) (1A)
SUPPRESSOR 3RT
1916-1BB00
S13 S21 S22
S14 14 24 A1+ 21NC 5L3 3L2 1L1 52C F1B F2B F3B
PWR3
External Interlocks
See also Volume 2 Chapter 2-10 for views of the interlock cable interconnections and
Volume 2 Section 8.1 for a description of the cable pin voltages and signals.
An external laser interlock is fitted as an option by the customer to any suitable area
where personnel need protection from accidental laser risks. This facility is disabled/
enabled by the wiring connections to the external laser connector at the rear of Engine
external connector plate.
The lock needs to be a 2-way switch with one way normally closed and the other nor-
mally open. Switch toggling for each way should be at the same time, or else the safety
relay will indicate faulty wiring.
Operate machine without an external interlock: this is the normal setup and uses an
override plug on the connector.
Operate machine with an external interlock: this may be required if the Class IV
laser is seen as an unacceptable risk. The wiring arrangement on the external plug is
as follows:
Door is closed in the safe condition: pins 2 and 7 are shorted and pins 4 and 9 open.
Door is open in an unsafe condition: pins 2 and 7 are open and pins 4 and 9 shorted.
SENSOR DISTRIBUTION
PCB ASSEMBLY 24V DISTRIBUTION
PCB ASSEMBLY
MAINS INLET
DC CABLE
(10A 250V)
PSU POWER
FILTER
PCB
POWER
FILTER PCB
INTERFACE
DONGLE
(OLD PCB ONLY)
EXTERNAL
ALERT
RELAY
DISK DRIVE
MOUNTING
BRACKET
SYSTEM (LSB)
PCB
INTERFACE
SYSTEM (LSB)
PCB
RFI BOX
LSB FAN
Figure 6.8 RFI Box assemblies - location view
POWER
FHMB POWER
VBOMB
POWER
MAINS INLET
PSU CONTROL
(TO LSB)
24V
INTERLOCKS
EXTERNAL
ALERT
RELAY SIGNAL
RIP (SCSI)
MMI
CAN2 (FHMB1)
CAN1 (VBOMB)
PLATE
PROCESSOR
DIAGNOSTICS
(RS232)
PSU
CONTROL
IMAGE
EODD IMAGE (VBOMB)
(VBOMB)
RFI
BOX
6.5.1 PSU 1
See Figure 6.10 and Figure 6.11.
See also Volume 2 Chapter 2-10 for views of the PSU cable interconnections and Vol-
ume 2 Section 8.1 for a description of the cable pin voltages and signals.
This is a switch mode PSU rated at 800 W (max) with built-in power factor correction
and internal cooling fans. Once factory-fitted (or supplied as a spare) it does not need to
be adjusted in the field for the correct DC supply voltages. In the event of a failure, the
PSU is replaced as a unit.
+15V/-15V PL17
+24V PL3
EODD
+24V
FAN 1 (PIN 2)
-15V
SENSE
0V
0V
0V 0V 0V 0V
+36V
+5V +24V +24V +15V
EODD
4 2 A A/S (FS2 and 4) - 97280005.
Location
Mounted inside the RFI box at the back of the upper shelf, see Figure 6.8.
Connectors
See Figure 6.12.
PL1: 8-way Molex to FHMB (via Interlock Box).
PL2: 10-way Molex to VBOMB_PWR.
PL3: 4-way Molex to interlocks.
PL4: 10-way Molex to PSU 1.
PL5: 6-way Molex to PSU 1.
PL6: 6-way Molex to PSU 1.
PL7: 3-way Molex to PSU 2.
PL8: 14-way Molex to EODD.
SK1: 15-way D-type to LSB.
SK2: 26-way D-type to Interlock box.
PL1
PL4
PL2
PL5
PL6
TP1 SK1
TP4
PL8
PL3
SK2
TP8
TP13
TP11
PL9 TP14 PL6 TP3
TP6
TP20 TP9
TP12
TP17 TP10 FS2 FS1
PL10
PL2
FS3
PL3
TP15
FS4
TP16 TP7
PL14 PL4
SK4
TP18
PL13
SK2
TP19 PL8 TP2 TP1
SK1 TP4
PL11
SK3 TP5
PL5
PL12
Location
Mounted inside the RFI box on the lefthand side, see Figure 6.8.
Connectors
PL1: Not Used.
PL2: Not Used.
PL3: 8-way Molex Minifit. PSU connection to PSU 1.
PL4: 14-way Molex. Interlock sensor status routing to LSB.
PL5: Not used.
PL6: 6-way Molex. EOD (X) and EOD (Y) signals.
PL8: Not used.
PL9: Not used.
PL10: Not used.
PL11: Not used.
PL12: Not used.
PL13: Not used.
PL14: Not used.
SK1: D-type 37-way. EODD_IF connection to LSB.
SK2: Not Used.
SK3: Not Used.
SK4: Not Used.
Fuses
FS1: 5 A anti-surge (97280004)
FS2: 5 A anti-surge (97280005)
FS3: 5 A anti-surge (97280004) - Spare
FS4: 5 A anti-surge (97280005) - Spare.
Test Points
TP1: OV
TP3: +24 V
TP5: 0V
TP6: +12 V
L UXEL P LATESETTER VOLUME 2 (6-25)
TP7: +5 V
TP8: Y-DEFL
TP9: X-DEFL
TP11: O V.
OK
LSB
PANEL
POWER I/LOCKS
FILTER 6 PANEL REGISTER
I/LOCKS
EODD
STATUS
+5V
+8V
+24V EODD
BUS
Figure 6.14 EODD functions - block view
Status signals are passed to the monitoring LSB which, if necessary, returns an Error
Code to the MMI.
An OK signal line is returned to the LSB if any one of the interlocked covers are opened.
This signal, and the interlock status signals from th interlock covers, allow the LSB to
generate the appropriate icon on the MMI showing which cover needs to be closed for
scanning to continue.
VOLUME 2 (6-26) P OWER AND C ONTROL M ODULES
Location
Mounted in the RFI box at the rear of the Engine, see Figure 6.8.
Connectors
PL1: Not used.
PL2: 50-way male vertical header. Data to/from local SCSI disk drive 2.
PL3: 40-way male header. Used for dongle on old PCBs; not fitted on new PCBs.
PL4: Not Used.
PL5: Not Used.
PL6: 4-way male vertical header. +12V and +5VDC DC supplies to SCSI disk
drive1.
PL7: Not Used.
PL8: 4-way male vertical header. +12V and +5VDC supplies to SCSI disk drive2.
PL10: 6-way DIL male header. +15V DC supply from PSU to on-board regulators
supplying +12V to disk drive(s)
PL11: 12-way DIL male PCB header. -15V, +15V from the PSU.
PL12: Not Used.
PL13: 14-way DIL male PCB header. +5V from the PSU.
PL15: Not Used.
PL16: Not Used.
PL17: 10-way DIL male header. -15V, +15V from the PSU.
PL18: Not Used.
PL19: Not Used.
PL20: 9-way male D-type. RIP serial diagnostics.
PL21: 9-way male D-type. Processor serial connection to plate processor.
L UXEL P LATESETTER VOLUME 2 (6-27)
Fuses
FS1: (5V, 2A) - Anti-surge. SCSI Power Termination.
RL1
PL11 PL13 PL17 PL18
PL3 SK8
(DONGLE) TP15
TP3
TP12
SK7
TP14
SK6
PL2 LK6
LK7
U76
PL21
PL19
PL16 PL20
TP18
TP2 U70
PL1
U113
SK5
TP7 TP9
U69
PL6 PL8 LK2 TP6 TP8 TP16
SK4
TP10
PL5
PL10 LK1 LK3 LK4 LK5 PL15
PL4
LEDs
D2: Red LED. Illuminated = System board in Reset.
D3: Green LED. For S/W purposes.
D4: Green LED. For S/W purposes.
Links
LK1: Not fitted.
LK2: Pins 1 and 2 connected (on-board program enabled).
L UXEL P LATESETTER VOLUME 2 (6-29)
Test Points
TP1: Digital Ground.
TP2: Digital Ground.
TP3: Digital Ground.
TP4: Digital Ground.
TP5: Reset.
TP7: Digital Ground.
TP8: Not used.
TP9: Not used.
TP11: Digital Gnd
TP12: Digital Gnd.
TP13: Not used.
TP14: PLL_LOCKED
TP15: Not used.
TP16: Digital Ground.
TP17: Digital Ground.
TP18: TTL pixel clock (fast clock for image data output to VBOMB.
TP19: ECL Ground.
6.6.2.2 Dongle
A Dongle PCB is stacked on the LSB PL3 header (see Figure 6.15) to enable the soft-
ware for a dual-beam system.
SK1 SK2
U1
PL1
WD1
(BUZZER)
SK4
SK3
FS1
MMI PCB
Location
Mounted inside the MMI Display console on the Engine.
MMI Connectors
PL1: 3-way. Supplies +5V, Ground and on/off control signal to Inverter board.
SK1: 4-way. Signals from touchpanel.
SK2: Not used.
SK3: 14-way. Routes drive signals to the LCD.
SK4: 26-way D-type. +22V, +5V and data lines from System board.
Connector Pin Descriptions
The console (including MMI board, LCD, Inverter and touchpanel) is supplied and fitted
as a complete FRU assembly.
See also Volume 2 Chapter 2-10 for views of the MMI cable interconnections and Vol-
ume 2 Section 8.1 for a description of the cable pin voltages and signals.
Fuses
1A Fast-acting (97280008). Protects 5V DC supply to the LCD.
MMI Operation
See Figure 6.17.
The MMI PCB is located underneath the console and provides mechanical support for
the connectors from the System Board, a buzzer (beeper) for operator alerts, the LCD
and touchpanel. It is a non-serviceable unit replaced as part of a `sandwich' assembly
that includes the console, LCD, Inverter board and touchpanel.
The PCB includes buffers for the touchpanel data sent to the System Board, and receiv-
VOLUME 2 (6-32) P OWER AND C ONTROL M ODULES
ers for the returned LCD control data. A cable link to the System board supplies voltages
and control signals for operating the touchpanel soft buttons and LCD display. An LCD
controller device, on the System Board, initialises the display and controls the output of
pixel bitmaps.
Voltages supplied to the MMI PCB include:
+5 V: converts +5 V to 300 V for the cold fluorescent lamps used by the LCD as a
backlight. The +5 V voltage is also used for the on-board electronic devices and the
LCD.
+22 V: a nominal voltage for the LCD contrast which is adjusted by the user and is
typically set at +17 V by the System Board.
TO LCD
U1
PL1
INVERTER
PCB
WD1
(BUZZER) CAUTION
HIGH
VOLTAGE
SK4
SK3
FS1 CN1
MMI PCB
ENGINE
EXTERNAL
PLATE
ENGINE
EXTERNAL
ALERT
RELAY
PIN 7 PIN 2
ALERT
CONTROL PIN 3
FROM FHMB1
PIN 4
REMOTE LIGHT
9-WAY OR
COIL A D-TYPE AUDIBLE ALARM
ALERT (FEMALE)
RELAY
(ON RFI UP TO 36V DC SUPPLY
BOX) (24V TYPICAL)
RATING LESS THAN 2A
COIL B
PIN 7
PIN 4
4
4
Vacuum and Contamination Control ........................................................................ 7-1
4
Drum Vacuum and Drum Blow .................................................................................. 7-4
4
Air Knife..................................................................................................................... 7-18
Air Purifier (PAT) ....................................................................................................... 7-21
FHMB1
SHORT BLOW
VOLUME 2 (7-2) VACUUM AND A IR C ONTROL
BV30
BV5
L RELAY
MAINS PL1 PL10
INLET L
AIR KNIFE
PL8 PL16 BV41
LONG BLOW
FHMB4
VALVE CAGE
BV31
RELAY FUSE NOTE: SYSTEM SHOWN:
L B1 FULLY AUTO,
COMPRESSOR
INTERLOCK SEMI, MANUAL
BOX (NO PUNCH)
COMPRESSOR BOX
FUSE: 6.3 x 32 250V 2A A/S
L UXEL P LATESETTER VOLUME 2 (7-3)
2. Air Purifier (PAT): distributes filtered air into the drum compartment and optics
base. This module, located outside the Engine, is not controlled by the platesetter
system. It operates by supplying a constant flow of high quality clean air which also
raises positive air pressure inside the Engine compartment.
See Section 7.4.
4 external dust
4 PVA debris
4 paper debris
NOTE: To ensure contamination is reduced to the minimum, all scheduled service clean-
ing procedures, described in Section Volume 3 Section 1.5, must be followed.
LEAD EDGE
VALVE
CAGE
MAIN VAC
SHORT BLOW
LONG BLOW
Figure 7.2 Drum holes and manifolds (new drum with manifolds)
LEAD EDGE
VALVE CAGE
MAIN VAC
SHORT BLOW
LONG BLOW
Figure 7.3 Drum holes and manifolds (new drum with chambers)
manifolds and solenoids distribute vacuum/air to a drum with the new configura-
tions shown in Section 7.2.3. Control of vacuum and air to the drum is from sets of
solenoid switches that regulate the precise time and flow of vacuum and air to the
drum for improved registration and ejection.
During a routine service these assemblies are checked for correct operation.
3. Compressor box: uses two compressors (Nitto) to provide air for drum blow and the
air knife. This box is located on the user side above the periscope on the righthand
side. The compressors are switched on by BV31 located inside the interlock box.
INPUT
VAC PUMP P A
LE
BLOW
BV5 A
MANIFOLD
R
BV30 MAIN
VAC
COMPRESSORS
(x 2)
R
MANIFOLD
A P
BV31 BV41
AIR KNIFE
VALVE CAGE
(P = PRESSURE; R = RETURN)
P
A AIR KNIFE
COMPRESSOR
BLOW
R
NOTE: RETURN IS NEAREST
TO VALVE CAGE PLATE BV41
P
VAC PUMP A
LEAD EDGE
R
BV40
P
VAC PUMP A
MAIN VAC
COMPRESSOR
R
BV30
Figure 7.4 B1 Fully-Auto and Manual without punch - vacuum circuit (Old 1)
L UXEL P LATESETTER VOLUME 2 (7-9)
BV40
INPUT
VAC PUMP P A
LE
BLOW
BV5 R A
MANIFOLD
BV30 MAIN
VAC
COMPRESSORS
(x 2)
P
MANIFOLD
A R
BV31 BV41
AIR KNIFE
VALVE CAGE
(P = PRESSURE; R = RETURN)
P
A AIR KNIFE
COMPRESSOR
BLOW
R
NOTE: RETURN IS NEAREST
TO VALVE CAGE PLATE BV41
P
VAC PUMP A
LEAD EDGE
R
BV40
P
VAC PUMP A
BLOW
R
BV30
Figure 7.5 B1 Fully-Auto and Manual without punch - vacuum circuit (Old 2)
VOLUME 2 (7-10) VACUUM AND A IR C ONTROL
INPUT
VAC PUMP
LE
LONG
BV5 R A
BLOW
BV40 MAIN
VAC
SHORT
BLOW
R A
MANIFOLD
BV30
COMPRESSORS
(x 2)
P
MANIFOLD
A R
BV31
BV41
AIR KNIFE
VALVE CAGE
(P = PRESSURE; R = RETURN)
P
A LONG BLOW
COMPRESSOR
AIR KNIFE
R
NOTE: RETURN IS NEAREST
TO VALVE CAGE PLATE BV41
P
LE & VAC A
MAIN VAC
AND BV30 (P)
COMPRESSOR
R
BV40
P
MAIN VAC A
(BV40) SHORT BLOW
COMPRESSOR
R
BV30
Figure 7.6 B1 Fully-Auto & Manual without punch - vacuum circuit (New 1)
L UXEL P LATESETTER VOLUME 2 (7-11)
Table 7.1 Solenoid logic table for B1 fully-auto and manual - no punch (Old 2)
Eject Blow
Main Vac
Solenoid
Function
Air Knife
Neutral
LE Vac
Blow
BV5 Vac Pump 0 0 0 1 1 0
BV31 Compressor 0 1 1 0 0 1
BV40 LE Valve 0 0 0 1 1 0
BV30 Vac Divert Valve 0 1 0 0 1 0
BV41 Blow Divert Valve 0 1 1 0 1 0
Table 7.2 Solenoid logic table for B1 fully-auto and manual - no punch (New 1)
Short Blow
Long Blow
Eject Blow
Main Vac
Solenoid
Function
Air Knife
Neutral
LE Vac
VAC PUMP
P BLOW
MANIFOLD
MAIN
R VAC
BV30
BV5
AIR KNIFE
A P
COMPRESSORS
(x 2)
R
MANIFOLD
BV41
VALVE CAGE
BV31
(P = PRESSURE; R = RETURN)
P
A AIR KNIFE
COMPRESSOR
BLOW
R
BV41
BV30
P
VAC PUMP A
MAIN VAC
COMPRESSOR
R
INPUT
VAC PUMP
LONG
MANIFOLD BLOW
MAIN
VAC
SHORT
BLOW
MANIFOLD
A R
AIR KNIFE
BV41
P
COMPRESSORS
(x 2)
R A
MANIFOLD
PLUG BV30
VALVE CAGE
BV31
(P = PRESSURE; R = RETURN)
P
A SHORT BLOW
COMPRESSOR
AIR KNIFE
R
BV41
BV30
P
COMPRESSOR A
LONG BLOW
PLUG
R
INPUT
VAC PUMP
LONG
MANIFOLD BLOW
MAIN
VAC
SHORT
BLOW
A
BV5 MANIFOLD
R
BV41 P
A R
AIR KNIFE
BV41
P
COMPRESSORS
(x 2)
R A
MANIFOLD
PLUG BV30
VALVE CAGE
BV31
(P = PRESSURE; R = RETURN)
P
A SHORT BLOW
COMPRESSOR
AIR KNIFE
R
BV41
R
SHORT BLOW A
P
COMPRESSOR A
LONG BLOW
PLUG
R
BV30
Table 7.3 Solenoid logic table for B1 fully-auto - with punch (Old 1)
Eject Blow
Main Vac
Solenoid
Function
Air Knife
Neutral
Blow
BV5 Vac Pump 0 0 0 1 0
BV31 Compressor 0 1 1 0 1
BV30 Vac Divert Valve 0 1 1 1 0
BV41 Blow Divert Valve 0 1 0 1 0
Table 7.4 Solenoid logic table for B1 fully-auto - with punch (New 1)
Long Blow
Eject Blow
Main Vac
Solenoid
Function
Air Knife
Neutral
Table 7.5 Solenoid logic table for B1 fully-auto - with punch (New 2)
Long Blow
Eject Blow
Main Vac
Solenoid
Function
Air Knife
Neutral
LE
VAC PUMP
MANIFOLD
P
A
PLUG LONG
R MANIFOLD BLOW
BV30
BV5 MAIN
VAC
AIR KNIFE
COMPRESSORS
(x 2)
P
A
MANIFOLD
R
BV41
VALVE CAGE
BV31
(P = PRESSURE; R = RETURN)
P
A AIR KNIFE
COMPRESSOR
MAIN VAC
R
BV41
BV30
P
VAC/LE A
MAIN VAC/SHORT BLOW
PLUG
R
Figure 7.10 B2 Semi-auto and Manual without punch - vacuum circuit (Old 1)
L UXEL P LATESETTER VOLUME 2 (7-17)
INPUT
LE
VAC PUMP
MANIFOLD
P
A
PLUG LONG
R MANIFOLD BLOW
BV30
MAIN
VAC
SHORT
BLOW
AIR KNIFE
COMPRESSORS
(x 2)
P
A
MANIFOLD
R
BV41
VALVE CAGE
BV31
(P = PRESSURE; R = RETURN)
P
A AIR KNIFE
COMPRESSOR
MAIN VAC/SHORT BLOW
R
BV41
BV30
P
VAC/LE A
MAIN VAC/SHORT BLOW
PLUG
R
Figure 7.11 B2 Semi-auto and Manual without punch - vacuum circuit (New 1)
VOLUME 2 (7-18) VACUUM AND A IR C ONTROL
Table 7.6 Solenoid logic table B2 semi-auto and manual without punch (Old 1)
Eject Blow
Main Vac
Solenoid
Function
Air Knife
Neutral
Blow
BV5 Vac Pump 0 0 0 1 0
BV31 Compressor 0 1 1 0 1
BV30 Vac Divert Valve 0 1 0 1 0
BV41 Blow Divert Valve 0 1 0 1 0
Table 7.7 Solenoid logic table B2 semi-auto and manual without punch (New 1)
Long Blow
Eject Blow
Main Vac
Solenoid
Function
Air Knife
Neutral
LE Vac
BV5 Vac Pump 0 0 0 1 1 0
BV31 Compressor 0 1 1 0 0 1
BV30 Vac Divert Valve 0 1 0 0 1 0
BV41 Blow Divert Valve 0 1 0 0 1 0
PLATE ADVANCING
FROM AUTOFEEDER
AIR KNIFE/CURTAIN PIPE
DUCTING
PIPE
BV41
AIR KNIFE
PIPE
PLATE
ADVANCING
FROM
AUTOFEEDER
DUCTING
PIPE AV MOUNTS
OUTLET
DUCT
CONTROL
RELAY
(BV23)
FAN BLOWER
AND HOUSING
PTM INTERIOR
(SERVICE SIDE)
FHMB3 (PL1)
9970-0198
+24V
PTM AIR KNIFE
CONNECTOR FAN
PANEL 9970-0156
0V 0V
+24V
A B
BV23 RELAY
FRONT
NOTE: The PAT module is always located at the side of the Engine and not be positioned
under the Buffer. Make sure the module is positioned away from any heat sources, such
as, the vacuum pump and processor.
Two types of Air Purifiers are available, depending on the local AC supply:
1. 110 VAC
2. 230 VAC.
VOLUME 2 (7-22) VACUUM AND A IR C ONTROL
CAUTION: Failure to replace filters as recommended could result in lower optics effi-
ciency and increased service visits.
Instructions on using the Air Purifier are in a separate OEM Installation and
Operation Guide. On installation, the PAT unit needs to be registered, via the
Internet, with the manufacturers before it is able to start operating.
The PAT 506id has a tricolour LED display that indicates the status of each filter stage as
follows:
1. Green: the purifier is operating normally.
2. Yellow: specific filters have two weeks before their scheduled replacement
3. Red: filter replacement is overdue but the customer is allowed a two week period
before the PAT shuts down automatically.
NOTE: Note that on later Engines (serial no.100 onwards), automatic shutdown is disa-
bled. However, for these machines FFEI recommend the filters are replaced before the
two week period has finished. For earlier machines, automatic shutdown is disabled by
contacting PAT and replacing the control panel.
SERVICE
OPTICS MANIFOLD
BASE
DUCTING
TO PAT
SYSTEM CABLING
DESCRIPTIONS
This chapter describes the system cables, their signal descriptions and pin numbers.
See the next chapter for diagrammatic views of how the cables are interlinked.
M4 FORKS M5 FORKS
70 mm
BLUE 270 mm 70 mm
Label 3R 5L3" BLUE
BROWN Label 3R 1L1" BROWN
Label C/B IN"
45 mm 45 mm BLADES
BLUE
150 mm Label NEUTRAL FEED" BLUE
BROWN Label LIVE FEED" BROWN
Label C/B OUT"
0.25" FASTONS
40 mm 40 mm BLADES
Label REL 4" BLUE
150 mm
Label NEUTRAL" BLUE
Label REL 6" BROWN Label LIVE" BROWN
0.25" FASTONS
80 mm 80 mm
Label DISK LEFT
Label SSB PL8
400 mm
600 mm
PIN2 CAN GND PIN2 BLACK / RED (TWISTED PAIR WITH PIN 3)
BLACK / WHITE
PIN 11 E_CLK- PIN 11 BLACK / BLUE (TWISTED PAIR WITH PIN 12)
pin 1 pin 1
1550 mm
VOLUME 2 (8-4) S YSTEM C ABLING DESCRIPTIONS
PIN 8 XR PIN 8
PIN 17 YD PIN 17
pin 1 pin 1
PL4 PIN 4 CASS FWD LIMIT SIGNAL S41 PIN 3 TWISTED PAIR WITH S41 PIN 2
PL2 PIN 4 CASS REV LIMIT SIGNAL S42 PIN 3 TWISTED PAIR WITH S41 PIN 2
Label S41
900 mm
Label S42
30 mm 50 mm
M4 FORKS M5 FORKS
70 mm
BLUE 270 mm 70 mm
Label 3R 5L3" BLUE
BROWN Label 3R 1L1" BROWN
Label C/B IN"
45 mm 45 mm BLADES
BLUE
150 mm Label NEUTRAL FEED" BLUE
BROWN Label LIVE FEED" BROWN
Label C/B OUT"
0.25" FASTONS
40 mm 40 mm BLADES
Label REL 4" BLUE
150 mm
Label NEUTRAL" BLUE
Label REL 6" BROWN Label LIVE" BROWN
0.25" FASTONS
B EXTERNAL INTERLOCK
D LOCKS
VOLUME 2 (8-6) S YSTEM C ABLING DESCRIPTIONS
CN6 PL 3
PIN2 CAN GND PIN2 BLACK / RED (TWISTED PAIR WITH PIN 3)
BLACK / WHITE
PIN 11 E_CLK- PIN 11 BLACK / BLUE (TWISTED PAIR WITH PIN 12)
pin 1
Label I/LOCK BOX EMERG
pin 1 220 mm
PIN 4
PIN 5
PIN 6
PIN 9
PIN 10
PIN 3 PIN 3
PIN 4 PIN 4
PIN 6 PIN 6
PINS 3 TO 6
PINS 8 TO 10
VOLUME 2 (8-10) S YSTEM C ABLING DESCRIPTIONS
PINS 3 TO 6
PINS 8 TO 10
PIN2 CAN GND PIN2 BLACK / RED (TWISTED PAIR WITH PIN 3)
BLACK / WHITE
PIN 11 E_CLK- PIN 11 BLACK / BLUE (TWISTED PAIR WITH PIN 12)
pin 1 pin 1
900 mm
L UXEL P LATESETTER VOLUME 2 (8-11)
BROWN
30 mm
30 mm
220 mm BROWN
BLUE
1550 mm
150 mm BLUE
300 mm
Label NEUT DIST
GREEN/YELLOW
600 mm
250 mm
Label: PTM NTERLOCK
400 mm
PIN 1 PIN 1
PIN 5 PIN 5
pin 1 pin 1
PLG SKT
820 mm
PIN2 CAN GND PIN2 BLACK / RED (TWISTED PAIR WITH PIN 3)
BLACK / WHITE
PIN 11 E_CLK- PIN 11 BLACK / BLUE (TWISTED PAIR WITH PIN 12)
pin 1
Approx 50 mm Cable tie
1700 mm Label FHMB2 PL31
Label REL 7
760 mm 25 m m
Label REL 9
PIN 2 +24V FHMB 2 PL31 PIN 2, WHITE/ORANGE TWIST WITH FHMB 2 PL31 PIN
REL 7 (FASTON) 6, TWIST WITH REL 9
PIN 3 +24V FHMB 3 PL31 PIN 2 WHITE/ORANGE TWIST WITH FHMB 3 PL31 PIN 6
PIN 4
PIN 5
PIN 8
320 mm Cable 2
Tie wraps every 100mm
Label FHM B3 SK1
PIN2 CAN GND PIN2 BLACK / RED (TWISTED PAIR WITH PIN 3)
BLACK / WHITE
PIN 11 E_CLK- PIN 11 BLACK / BLUE (TWISTED PAIR WITH PIN 12)
L a b e l F H M B 4 P L 3 0 L a b e l P R O C P A N E L
M 7
p in 1
9 5 0 m m
350 mm
pin 1
270 mm
100 mm
520 mm
Label S71
30 mm
Label S65 - 1
Cable 2 Label S65 - 4
Label FHMB 2 390 mm Cable 2
PL23"
PL 6 PIN 4 RETARD UP SIGNAL S56 PIN 3 TWISTED PAIR WITH S56 PIN 2
PL 9 PIN 4 RETARD DOWN SIGNAL S57 PIN 3 TWISTED PAIR WITH S57 PIN 2
PL 23 PIN 3 CASS AT NUDGER GND S65-1 FASTONTWISRED PAIR WITH OTHER FASTON
120 mm
24V DIST PL7"
Label S50
Label
Table 8.25 INT_S49/S50
AMP CT SIGNALS AMP CT
PL 8 PIN 1 RETARD MADE PUL_GND S49 PIN 1 TWISTED PAIR WITH S49 PIN 2
PL 8 PIN 3 RETARD MADE GROUND S49 PIN 3 TWISTED PAIR WITH S49 PIN 4
PL 7 PIN 1 NO CONNECTION
Label S5
730 mm
PL8 PIN 1 PLATE LEFT OUTPUT S5 PIN 1 WISTED PAIR WITH S5 PIN 2
PUL_GND
PL8 PIN 3 PLATE LEFT OUTPUT GROUND S5 PIN 3 TWISTED PAIR WITH S5 PIN 4
PIN 1 PARK POS PRE INPUT PUL_GND S52 PIN 1 TWISTED PAIR WITH S52 PIN 2
PIN 3 PARK POS PRE INPUT GROUND S52 PIN 3 TWISTED PAIR WITH S52 PIN 4
30 mm
Label S10" 50 mm Label DIST O/ P PL6"
230 mm
Label DIST O/ P PL9"
Label S11"
50 mm 80 mm
Label DIST O/ P PL12"
PL6 PIN 4 REG MOTOR OUT POS SIGNAL S10 PIN 3 TWISTED PAIR WITH S10
PIN 2
L UXEL P LATESETTER VOLUME 2 (8-19)
PL9 PIN 4 REG MOTOR IN POS SIGNAL S11 PIN 3 TWISTED PAIR WITH S10
PIN 2
PL12 PIN 1
580 mm 670 mm
Approx 344 mm
Approx 344 mm
800 mm
Label S13
Label S12
550 mm
310 mm 210 mm This end piece has the pins fo
130 mm
Label S14
100 mm Label DIST O/P PL7"
Label S3
50 mm Label 24V DIST PL2"
This end piece has the pins for the links Label DIST O/P PL11"
Label PL11"
Label DIST O/P PL10"
Label SK11"
Cable free to move within the chain 50 mm
Label PL10"
Label SK10"
28 mm radius
12 mm
PL7 PIN 4 CENTERING HOME SIGNAL S14 PIN 3 TWISTED PAIR WITH S14 PIN
2
PL2 PIN 1 DETECT LE PUNCH PUL GND S3 PIN 1 TWISTED PAIR WITH S3 PIN 2
PL2 PIN 3 DETECT LE PUNCH GROUND S3 PIN 3 TWISTED PAIR WITH S3 PIN 4
Label
(PL9) PIN 4 PUNCH MOTOR OFF SIGNAL S9 PIN 3 TWISTED PAIR WITH
S8 PIN 2
PL12 PIN 1
Label BM 22
20 mm 30 mm Sleeve
70 mm 530 mm
PL15 PIN 3 DC_MOT_A BM24 PIN 3 RED TWISTED PAIR WITH BM24 PIN 3
PL20 PIN 3 DC_MOT_A BM22 PIN 2 RED TWISTED PAIR WITH BM22 PIN 3
PL22 PIN 3 DC_MOT_A BM23 PIN 2 RED TWISTED PAIR WITH BM23 PIN 3
PL10 PIN 2 DC_MOT_A BV20 PIN 2 RED TWISTED PAIR WITH BV20 PIN 3
8 W MOLEX
PL1 PIN 5 +24V PUMP REL A GREEN TWISTED PAIR WITH BV23 -
PL1 PIN 7 +24V (BV24) PL 8 PIN 2 YELLOW TWISTED PAIR WITH BV8 PIN 3
2 W MOLEX
PL9 PIN 1 PLATE PAST DIVERTER S59 PIN 1 TWISTED PAIR WITH S59 PIN 2
PUL_GND
PL9 PIN 3 PLATE PAST DIVERTER S59 PIN 3 TWISTED PAIR WITH S59 PIN 4
GROUND
AMP CT
PL12 PIN 1
100 mm 60 mm
910 mm
2 PIN
Label S53
Label DIST PL11
PL6 PIN 1 INTERLEAF NIP CLEAR PUL_GND S66 PIN 1 TWISTED PAIR WITH S66 PIN 2
AMP CT 2 W MOLEX
PL11 PIN 4 NUDGER DOWN LIMIT SIGNAL S53 PIN 2 TWISTED PAIR WITH S53 PIN 1
30 mm
Cable ties every 100mm
Label INT-SYSTEM
350 mm
240 mm
10
Label FHMB2 PL1
70 mm 100 mm 15 mm 40 mm 15 mm 80 mm
110 mm 50 mm
40 mm
Label ELV PAN
14W MOLEX
580 mm
pin 1
st nd
1 Fold 2 Fold
L UXEL P LATESETTER VOLUME 2 (8-25)
PIN 16 5V PIN 27
PIN 20 5V PIN 29
PIN 24 5V PIN 31
pin 1 pin 1
750mm
PIN 3 RX PIN 3
PIN 4 PIN 4
PIN 6 PIN 6
PIN 7 PIN 7
PIN 8 PIN 8
PIN 9 PIN 9
Label ALERT
270 mm REL PIN 4
50 mm
Table 8.37 ALERT
9 WAY D SKT SIGNALS
PIN 1 SPARE
PIN 2 ALERT IN REL PIN 7 FASTON TWISTED PAIR WITH OTHER FASTON
PIN 4 SPARE
PIN 5 SPARE
PIN 6 SPARE
PIN 7 SPARE
PIN 8 SPARE
L UXEL P LATESETTER VOLUME 2 (8-27)
240 mm
Label PUMP REL 4
80 mm
25 mm 55 mm BLUE
BLUE
900 mm BROWN
BROWN
PIN 16 5V PIN 27
PIN 24 5V PIN 31
Tie wraps
PL4 PIN 1 P24V 6MM TINNED BLUE LABEL: INV-P24 TWISTED WITH PIN 8
PL4 PIN 2 FWD 6MM TINNED BROWN LABEL: INV-1 TWISTED WITH PIN 4
PL4 PIN 10 ALARM 6MM TINNED WHITE LABEL: INV-12 TWISTED WITH PIN 12
PL1 PIN 2 BS73 BLADE WHITE LABEL: SIE-21NC TWISTED WITH PIN 3
LABEL INV AL2 ALARM INPUT 6MM TINNED WHITE/BLUE LABEL INV-4
LABEL INV AL0 ALARM INPUT 6MM TINNED BLUE LABEL INV-P24
GREEN/YELLOW 100 mm
750 mm BLUE
0.25" FASTON
0.25" FASTON
55 mm BLUE
40 mm
BLUE M4 INSULATED FORK
Label FILTER"
Label INV N"
Label E LV C T RL SK 1 Label PT M PA N EL
pin 1 pin 1
500 mm
50 mm 50 mm
Label S70
Label TOP 1250 mm 230 mm Label BS78
60 mm
LIMIT 11
1600 mm Label DOCK
80 mm LIGHT 50 mm
Label ELV
DIST PL4
450 mm 70 mm
Label ELV Labe
700 mm 760 mm
DIST PL3
PL4 PIN 4 Z DIRECT DWN SIG S70 PIN 3 TWIS PAIR WITH S70 PIN 2
PL3 PIN 4 Z DIRECT UP SIG S63 PIN 3 TWIST PAIR WITH S63 PIN 2
PIN 3 RX PIN 3
PIN 4 PIN 4
PIN 6 PIN 6
PIN 9 PIN 9
Label CHASSIS"
30 mm
FUSE HOLDER
Label PSU 3 PIN 25 mm
20 mm 260 mm
BROWN 1
4.8x0.5 FASTONS
2
3 70 mm
BLUE Tie wrap at branch points and
connector and every 100mm
30 mm
50 mm
BROWN BROWN Label 3R 2T1
Label FILTER
430 mm
BLUE BLUE
100 mm 30 mm
Label 3R 6T3
GREEN/YELLOW
Label CHASSIS Label FILTER
100 mm
M5 M4
310 mm
750 mm
Label EMERG 50 mm
STOP SWITCH
PIN 1
PIN 3
PIN 4
PIN 6
100 mm
15 mm AES S14
30 mm 15 mm
70 mm
AES A1+ 30 mm
70 mm
40 mm AES S13
5 mm AES A2- 40 mm
30 mm AES 14 5 mm
70 mm AES 13 110 mm
40 mm
5 mm AES S21
30 mm AES 24 5 mm
70 mm 30 mm
AES 23
70 mm
40 mm
AES S22 AES X1 40 mm
10 mm
10 mm
40 mm 40 mm 40 mm 40 mm
SIE A1+ SIE A2-
30 mm 30 mm
100 mm
80mm
52 NC
25mm
40 mm 30 mm
Label 24V PSU Label EMERG
(4 way) (6 way)
220 mm
PIN 3
PIN 4
PIN 6
Label BM 25
Label FHM B3 PL16 220 mm 420 mm
300 mm
PIN 1 OUT A PIN 6 TWISTED PAIR WITH PIN JST 6WAY PIN 5
PIN 2 OUT C PIN 5 TWISTED PAIR WITH PIN JST 6WAY PIN 6
PIN 3 +24 V PIN 4 TWISTED PAIR WITH PIN JST 6WAY PIN 4
pin 1
300 mm
Part number here
Tie wrap at each end
close to the connector
1150 mm
25 mm sleeve at each end
PIN 1 OUT A PIN 6 TWISTED PAIR WITH PIN JST 6WAY PIN 5
PIN 2 OUT C PIN 5 TWISTED PAIR WITH PIN JST 6WAY PIN 6
PIN 3 +24 V PIN 4 TWISTED PAIR WITH PIN JST 6WAY PIN 4
pin 1
1100 mm
Part number here
Tie wrap at each end
close to the connector
70 mm
24V PL4 PIN 4 NUDGER DOWN LIMIT SIGNAL S45 PIN 3 TWISTED PAIR
WITH S45 PIN 2
24V PL1 PIN 4 NUDGER UP LIMIT SIGNAL S46 PIN 3 TWISTED PAIR
WITH S46 PIN 2
24V PL10 PIN 4 PAPER POST DIVERTER SIG- S51 BLUE WIRE
NAL
3450 mm
PIN 1 CHASSIS M5
PIN 3
PIN 4
PIN 5
PIN 7
PIN 8
L UXEL P LATESETTER VOLUME 2 (8-41)
pin 1
PIN 2 BUFFER ENTRANCE PUL_GND S19 PIN 1 TWISTED PAIR WITH S19 PIN 2
PIN 3 BUFFER ENTRANCE GROUND S19 PIN 3 TWISTED PAIR WITH S19 PIN 4
PIN 4 BUFFER EXIT PUL_GND S20 PIN 1 TWISTED PAIR WITH S20 PIN 2
PIN 5 BUFFER EXIT GROUND S20 PIN 3 TWISTED PAIR WITH S20 PIN 4
PIN 2 BUFFER ENTERANCE PUL_GND PL4 PIN 1 TWISTED PAIR WITH PL4 PIN 2
PIN 3 BUFFER ENTERENCE GROUND PL4 PIN 3 TWISTED PAIR WITH PL4 PIN 4
PIN 4 BUFFER EXIT PUL_GND PL3 PIN 1 TWISTED PAIR WITH PL3 PIN 2
PIN 5 BUFFER EXIT GROUND PL3 PIN 3 TWISTED PAIR WITH PL3 PIN 4
1350 mm
30 mm
Label S79 -4
800 mm
Label 24V
DIST PL6
Label S79 -1
PL 6 PIN 3 CHAD TRAY HOME S79 -4 FASTON TWISRED PAIR WITH OTHER FASTON
PIN 1
PIN 2 FAN +24V PL2 PIN 1 TWISTED PAIR WITH PL2 PIN 2
PIN 3 FAN DETECT PL23 PIN 3 TWISTED PAIR WITH PL23 PIN 4
PIN 4
30 mm
Label FAN +
150 mm
Label MIX
FAN Label FAN -
PIN 1
PIN 4
500 mm
4.5 metres
PIN 3 RX PIN 2
C a b le 2
100 m m
M 5 L a b el FR A M E M 4 La b e l P SU
C a b le 3
25 m m 35 m m
1 0 m m T in n e d e n d L a b el + O U T
30 m m
La b e l + 2 4 V
1 0 m m T in n e d e n d L a b el -O U T
CABLE 3
4 W PIN 2 WH / OR +OUT
L UXEL P LATESETTER VOLUME 2 (8-45)
100 mm 80 mm
10 mm 10 mm 5 mm
2.4m 50 mm
340 mm 500 mm
140 mm
30 mm
Label FHMB4 PL8 Place as near
to the connector as possible
Label DRUM BLOW Place as Label FHMB4 PL10 Place as
Part number label
near to the connector as possible near to the connector as possible
VOLUME 2 (8-46) S YSTEM C ABLING DESCRIPTIONS
PL8 PIN 2 SOL BV31 DRUM BLOW PIN 2 RED TWIST WITH PL8 PIN 3
PL10 PIN 2 SOL BV30 DRUM VAC PIN 2 GREEN TWIST WITH PL10 PIN3
Approx 344 mm Approx 344 mm This end piece has the pins for the links
790 mm 60mm
Label S13
Label S12
540 mm Chain must be able to bend in
155 mm Label Punch Frame this direction.
This end piece has the pins for the links Part number here Label 24V DIST O/P PL2
40 mm
Label PL10
Label SK10
28 mm radius 30mm Example 20mm
12 mm
Labels to be position as shown Use tie wraps every 100 mm where shown
above from their connector
65 mm
Label S110 720 mm
PL9 PIN 4 SWING ROLLER IN DRUM SIGNAL S110 PIN 3 TWISTED PAIR WITH S110 PIN 2
PL9 PIN 8 SWING ROLLER HOME SIGNAL S109 PIN 3 TWISTED PAIR WITH S109 PIN 2
60 30
Label S100
Cable jacket only to cover this Label 24V DIST PL1
section with part no in centre
475
PL4 PIN 4 REG PIN MTR HOME SIGNAL S100 PIN 3 TWISTED PAIR WITH S100 PIN 2
PL1 PIN 4 REG PIN MTR OUT SIGNAL S103 PIN 3 TWISTED PAIR WITH S103 PIN 2
VOLUME 2 (8-48) S YSTEM C ABLING DESCRIPTIONS
100 mm
Suppliers part
Label INLET
number etc Label CHASSIS
100 mm
Cable 1
M5
150 mm Green/Yellow
M5
Green/Yellow
Cable 2
Label CHASSIS RFI BOX (20mm from end) Suppliers part number etc in centre Label INLET (20mm from end)
100 mm
M5
Green/Yellow M5
Cable 3
Label CHASSIS PSU TRAY (20mm from end) Suppliers part number etc in centre Label CHASSIS RFI BOX (20mm from end)
pin 1
120 mm 100 mm
Label PWR FILT PL4
80 mm pin 1
40 mm
Label PWR FILT PL5
Label SL2 +36V
Place labels close to the
Label SL2 0V connector and then a cable tie
A 30 mm to stop the wires straining the
Label SL3 +5V (2 off) labels
70 mm Label SL3
Label SL3 0V (2 off)
25 mm
Label SL4 +24V (2 off)
50 mm 25 mm
Label SL6 +15V(1)
40 mm
Label SL6 0V(1)
40 mm
Label SL6 +15V (2)
50 mm
Label SL6 0V(2)
L UXEL P LATESETTER VOLUME 2 (8-49)
Label next to
connector, then a Label SSB PL17
cable ties and then at
100mm spacing
Label Part No 100 mm
Next to PL11 branch point 2 cable ties at 50mm
Label EODD PL3 spacing along this
50 mm 200 mm 150mm section
pin 1 50 mm
70 mm 80 mm 80 mm
300 mm TO REFERENCE
POINT A
2 cable ties at 50/60
170 mm Label next to
mm spacing along this pin 1 pin 1 connector, then a
157mm section
Label LSB PL 11 Label LSB PL13 cable ties
Label FAN1 80 mm
200 mm
pin 1
130 mm
Label LSB PL 10
M5 RING (SL2+36V) +36V PL4 PIN 10 WHITE/ TWIST WITH PL4 PIN4
BROWN
SL3 +5V +5V PL5 PIN 3 RED TWIST WITH PL5 PIN 1
USE ABOVE FASTON +5V PL13 PIN 3 RED TWIST WITH PL13 PIN
10
SL3 +5V +5V PL13 PIN 4 RED TWIST WITH PL13 PIN
11
USE ABOVE FASTON +5V PL13 PIN 5 RED TWIST WITH PL13 PIN
12
PL13 PIN 6 LINK 5V PL3 PIN 6 RED TWIST WITH PL3 PIN 2
SL3 PIN1 +5V SENSE PL13 PIN 2 RED/WHITE TWIST WITH PL13 PIN
9
USE ABOVE FASTON +24V PL4 PIN 6 WHITE/ TWIST WITH PL4 PIN 9
ORANGE
SL4 +24V +24V PL3 PIN 7 WHITE/ TWIST WITH PL3 PIN 3
ORANGE
SL5 +24V +24V PL4 PIN 2 WHITE/ TWIST WITH PL4 PIN 3
ORANGE
PL4 PIN 2 +24V PL4 PIN 7 WHITE/ TWIST WITH PL4 PIN 8
ORANGE
Equates to pin 1
M5 100 mm M4
L UXEL P LATESETTER VOLUME 2 (8-51)
pin 1 20 mm pin 1
20 mm
100 mm
1800 mm
PIN2 CAN GND PIN2 BLACK / RED (TWISTED PAIR WITH PIN 3)
PIN 10 SPARE PIN 10 BLACK / WHITE (TWISTED PAIR WITH PIN 15)
PIN 11 E_CLK- PIN 11 BLACK / BLUE (TWISTED PAIR WITH PIN 12)
pin 1 pin 1
20 mm 20 mm
100 mm
2500 mm
VOLUME 2 (8-52) S YSTEM C ABLING DESCRIPTIONS
L a b el V B O M B P L 1 3
200mm
560m m 200m m
300 mm 500 mm
200mm Label N D H O M E
P a r t N o et c 600mm
L a be l F O C U S O P R
Label SE N S LPD
C o nn e c to r L a be ls 2 0 m m fr o m c o n n e ct o r. P a r t nu m b e r 7 0 m m
fro m V B O M B P L 1 3
P in 2 fro m c a b le
e n tr y sid e
V B O M B PL13
o rien ta tio n
P in 1 fro m c a ble
e nt ry sid e
PIN 1 +5V
PIN 2 0V
PIN 3 SPARE
PIN 5 0V PIN 2
AMP 3W ND HOME
PIN 8 0V PIN 2
PIN 10 +5V
PIN 11 0V
PIN 12 SPARE
AMP 3W AP HOME
PIN 17 0V PIN 2
PIN 20 0V PIN 2
PIN 22 NC
PIN 23 NC
PIN 24 NC
Label LPD
100mm Part no etc 100 mm
pin 1 pin 1
25mm
1000 mm
Label VBOMB
PL3 Max deviation is 45 degrees
from the horizontal
PIN 1 0V PIN 1
PIN 3 0V PIN 3
PIN 5 0V PIN 5
Lab el LP D M O T O R P L1 5 P a rt N o e tc Lab el LP D M O T
p in 1
p in 1
25 m m
100 mm
25 m m
2450 mm
L a b e l A P E R T U R E M O T O R
P a rt N o e tc Lab el A P M O T
PL16
p in 1
p in 1
25m m
25m m
100 mm
1570 mm
25 mm
100 mm 25m m
780 mm
100 mm 25m m
1550 m m
200 m m 450 m m
L a b e l K E Y N /O P IN 4
p in 1 F e r r it e
p in 1
150m m
10 m m L a b e l I/L C O N T A C T O R
900 m m p in 1
300 m m
L ab el L S B P S U C T R L
L a b e l I/ L O C K S H U T T E R
1170 mm
VOLUME 2 (8-58) S YSTEM C ABLING DESCRIPTIONS
PIN 3 0V PIN 3
PIN 5 0V PIN 5
PIN 7 0V PIN 7
PIN 9 0V PIN 9
55 mm
SOLDERED TAILS
40 mm
Label REL 4 150 mm
BLUE Label NEUTRAL BLUE
Label REL 6 BROWN Label LIVE BROWN
0.25 FASTONS Cable 3
PL 7 PIN 4 PUSH BAR HOME SIGNAL S6 PIN 3 TWISTED PAIR WITH S6 PIN 2
PL 12 PIN 4 PUSH BAR FWD LIMIT SIGNAL S15 PIN 3 TWISTED PAIR WITH S15 PIN
2
50 mm
100mm 60mm
20mm
PIN 2 MAIN VAC MANI- BV30 PIN2 TWIST WITH BV30 PIN 3
FOLD
VOLUME 2 (8-60) S YSTEM C ABLING DESCRIPTIONS
MOLEX MINIFIT
JR
BV31 PIN 1
40 mm AES S21
5 mm
30 mm 5 mm
AES 24
70 mm 30 mm
AES 23
70 mm
40 mm AES S22
AES X1 40 mm
10 mm
10 mm
40 mm 40 mm 40 mm 40 mm
SIE A1+ SIE A2-
Label 24V PSU
SIE 21NC SIE 22NC 20 mm
20 mm
40 mm 40 mm SIE 6T3 40 mm 40 mm
SIE 5L3
60 mm 60 mm 60 mm
40 mm 40 mm 40 mm 40 mm
40 mm
30 mm 30 mm 30 mm 52NC
100 mm 90 mm 51NC
24V PSU 4W PIN 2 (2) ENG_24V SIE 21NC (2) 24 RED / BLACK
24V PSU 4W PIN 4 (2) ENG_24V_GND SIE A2- (2) 24 WHITE / BLUE
RELEASE COIL 2 (1) ENG_24V 24V PSU 4W PIN 2 (2) 24 RED / BLACK
L UXEL P LATESETTER VOLUME 2 (8-63)
Pin 2
Label STB PL6 20 mm
20 mm Pin 1
20mm 20mm
Part number etc (in centre)
Label STB PL3 Label ED PL1
110mm 40mm 30mm
PIN 3
PIN 4 0V PIN 9
L ab e l L S B IM A G E
( 2 0 m m fr o m c o n n e c t o r ) L abel V B O M B S K 1
P a r t n u m b e r e tc ( 2 0 m m fro m c o n n e c t o r)
p in 1
26 W ay
70m m
2100 m m
Label
PD BRD
315mm 120mm
150mm Pins up
Pull off loop
50mm Label Part No etc
PIN 5 PIN 5
Label
REGPIN
20mm RIGHT
520 mm 1000 mm
400mm
PIN 3 0V PIN 2
GREEN / YELLOW
RING TERM M4 RING TERM M5
110 mm Cable 1
COMP 2
GREEN / YELLOW
RING TERM M4 RING TERM M5
180 mm Cable 2
GREEN / YELLOW
FASTON RING TERM M5
420 mm Cable 3
FUSE 1
BROWN
PIGGY BACK FASTON
400 mm Cable 4
BROWN FUSE 2
FASTON
360 mm Cable 5
200 mm
60 mm
240 mm
BLUE 4.3 m
Label REL 7
100 mm 30mm from end View from
GN/YL connection side
Label CHASSIS
Label REL 9
30mm from end part number etc Label Compressors
200 mm
60 mm
240 mm
BLUE 4.3 m
Label REL 7
100 mm 30mm from end View from
GN/YL connection side
Label CHASSIS
L UXEL P LATESETTER VOLUME 2 (8-67)
40 mm Label REL B
300 mm
Label PUMP CTRL
10 mm 150 mm
Label REL A
50 mm
Fastons
Label REL B
40 mm
Label PUMP
100 mm
M5
tie wrap
Label CHASSIS
PIN 1 CHASSIS M5
PIN 3
PIN 5
PIN 7
L a b el M IX R EL A 50 m m
L a b el M IX R EL 7
L a b el M IX R EL 4
La b e l M IX REL B
La b e l M IX REL 6 100 m m L a b el M IX FA N
La b e l M IX REL 9 600 m m
50 m m
430 m m L a b el FH M B 1 P L2 3
260 m m
La b e l FH M B 1 P L2
60 m m
L a b el A LE R T R E L
C O IL A
La b e l FH M B 1 P L1
1200 m m L a b el A LE R T R E L
C O IL B
50 m m
40 m m
P a rt N o etc
PIN 1 SPARE
PIN 2 SPARE
PIN 3 SPARE
PIN 4 SPARE
VOLUME 2 (8-68) S YSTEM C ABLING DESCRIPTIONS
PIN 7 ALERT COIL A FASTON ALERT REL COIL A T/PAIR WITH BLUE
ALERT REL COIL B
FHMB1 PL2 2
WAY
PIN 1 +24V FASTON MIX REL 4 T/PAIR WITH MIX REL 6 WH/OR
PIN 1 SPARE
PIN 2 +24V FASTON MIX REL 7 T/PAIR WITH MIX REL 9 WH/OR
PIN 3 FAN DETECT PL23 PIN 3 T/PAIR WITH PL23 PIN 4 GREEN
PIN 4 SPARE
4 20 m m
L abel FH M B P O S 1 P L 1 8
80 m m
L abel I N P U T D IS T P L 5 And p art nu mber
60 mm Label S1
Label INPUT DIST PL4
1020 mm
PL4 PIN 1 LE PLATE IN INPUT NIP PUL_GND S1 PIN 1 TWISTED PAIR WITH S1 PIN 2
PL4 PIN 3 LE PLATE IN INPUT NIP GROUND S1 PIN 3 TWISTED PAIR WITH S1 PIN 4
L UXEL P LATESETTER VOLUME 2 (8-69)
PL3 PIN 1 TE PLATE PAST PUSH BAR PUL_GND S2 PIN 1 TWISTED PAIR WITH S1 PIN 2
PL3 PIN 3 TE PLATE PAST PUSH BAR GROUND S2 PIN 3 TWISTED PAIR WITH S1 PIN 4
100mm 1175 mm
PIN 1 SPARE
PIN 2 SPARE
PIN 4 PUMP RELAY RTN 8 W MOLEX PIN 6 BLACK ( TWIST PAIR PIN 2)
PIN 5 SPARE
PIN 6 SPARE
PIN 7 SPARE
FHMB4 PL8
PIN 3 COMP RELAY RTN 8 W MOLEX PIN 8 (2 WIRES IN PIN 8) BLACK ( TWIST PAIR PIN 4)
BV31 SOL
PIN 2 COMP RELAY RTN 8 W MOLEX PIN 8 BLACK ( TWIST PAIR PIN 4)
VOLUME 2 (8-70) S YSTEM C ABLING DESCRIPTIONS
Part No etc
PIN 1 PLATE ON PLATERN PUL_GND S118 PIN 1 TWISTED PAIR WITH PIN 2
PIN 3 PLATE ON PLATERN GROUND S118 PIN 3 TWISTED PAIR WITH PIN 4
740 mm
Label FHMB1 PL28
Label M10
100mm
Part No etc
2300 mm
Label FHMB1 PL30
Label M11
100mm
Part No etc
L ab el FH M B 1 P L1 4
60 m m
150 m m
L ab el S 1 1 3 1080 m m
180 m m
L ab el FH M B 1 P L2 5
15 0mm 1 50 mm
Lab el S 1 1 6 6 30 mm 35 0m m
130 m m 590 m m
Lab el D IS T I/P P L1 0
Lab el S 1 1 4 L L ab el P art N o etc
P lace 7 0 m m from ju n ctio n
L ab el S 1 1 4 R
VOLUME 2 (8-72) S YSTEM C ABLING DESCRIPTIONS
PL25 PIN 4 PLATE PUSHER HOME SIGNAL S116 PIN 3 TWISTED PAIR WITH S10 PIN 2
PL10 PIN 4 CENTERING HOME SIGNAL S113 PIN 3 TWISTED PAIR WITH S10 PIN 2
PL14 PIN 1
PL14 PIN 2
PL14 PIN 3 CENTERING CONTINUITY GROUND S114R TWISTED PAIR WITH S114L
PL14 PIN 5
PL14 PIN 6
PL14 PIN 7
PL14 PIN 8
Label M37
300 mm Label FHMB4 PL20
40 mm
850 mm
880 mm 40 mm
Label M36
Label FHMB4 PL22
Tie wraps every
100mm Part No etc
M4 M5
145 mm 145 mm
Label INV GND M4 60 mm
Label SCREEN (x2)
170 mm
1000 mm
L UXEL P LATESETTER VOLUME 2 (8-75)
PIN2 CAN GND PIN2 BLACK / RED (TWISTED PAIR WITH PIN 3)
BLACK / WHITE
Label CHASSIS GREEN/YELLOW Suppliers part number etc in Label PUMP OUTLET
centre
VOLUME 2 (8-76) S YSTEM C ABLING DESCRIPTIONS
70mm
PIN 3
PIN 4
PIN 5
PIN 6
PIN 8
PIN 9
PIN 10
PIN 1
PIN 2
PIN 5
PIN 6
PIN 9
PIN 10
L UXEL P LATESETTER VOLUME 2 (8-77)
PIN 1
PIN 2
PIN 5
PIN 6
PIN 1 PLATE ON PLATERN PUL_GND S118 PIN 1 TWISTED PAIR WITH PIN 2
PIN 3 PLATE ON PLATERN GROUND S118 PIN 3 TWISTED PAIR WITH PIN 4
Part No etc
Label S2
60 mm 500 mm 900 mm
Label INPUT DIST PL3
60 mm Label S1
Label INPUT DIST PL4
1260 mm
PL4 PIN 1 LE PLATE IN INPUT NIP PUL_GND S1 PIN 1 TWISTED PAIR WITH S1 PIN 2
PL4 PIN 3 LE PLATE IN INPUT NIP GROUND S1 PIN 3 TWISTED PAIR WITH S1 PIN 4
PL3 PIN 1 TE PLATE PAST PUSH BAR PUL_GND S2 PIN 1 TWISTED PAIR WITH S1 PIN 2
PL3 PIN 3 TE PLATE PAST PUSH BAR GROUND S2 PIN 3 TWISTED PAIR WITH S1 PIN 4
PIN 1
PIN 2
PIN 5
PIN 6
L ab el F H M B 1 PL 1 4
1 30 m m
2 70 m m 2 40 m m L ab el FH M B 1 PL 25
L abel S1 13 8 00 m m
1 00 m m 40 0m m 50 m m
60 0 m m L ab el D IS T I/P PL 10
L abel S1 16 90 0m m 4 00 m m
13 0 m m 50 m m
L ab el Part N o etc 2 cab le ties
L abel S 11 4L Place 7 0m m fro m jun ction
L abel I/P D IS T PL 12
L ab el S 11 4R
PL25 PIN 4 PLATE PUSHER HOME SIGNAL S116 PIN 3 TWISTED PAIR WITH S10 PIN
2
PL10 PIN 4 CENTERING HOME SIGNAL S113 PIN 3 TWISTED PAIR WITH S10 PIN
2
PL14 PIN 1
VOLUME 2 (8-80) S YSTEM C ABLING DESCRIPTIONS
PL14 PIN 3 CENTERING CONTINUITY GROUND S114R TWISTED PAIR WITH S114L
note 1 note 2
90 mm 300mm
240 mm 100 mm
267mm long
1170mm
400 mm
Wire with cable wrap free to move within the chain
Cover this single wire with cable wrap Chain must be able to bend in this direction.
PL6 PIN 4 REG MOTOR OUT SIGNAL S10 PIN 3 TWISTED PAIR WITH S14 PIN
2
PL7 PIN 4 CENTERING HOME SIGNAL S14 PIN 3 TWISTED PAIR WITH S14 PIN
2
PL9 PIN 4 REG MOTOR IN SIGNAL S11 PIN 3 TWISTED PAIR WITH S14 PIN
2
PL2 PIN 1 DETECT LE PUNCH PUL GND S3 PIN 1 TWISTED PAIR WITH S3 PIN 2
PL2 PIN 3 DETECT LE PUNCH GROUND S3 PIN 3 TWISTED PAIR WITH S3 PIN 4
PL12 PIN 1
PIN 3 SCREEN
EMERG SWITCH
Label I/LOCK BOX EMERG Part no. here
pin 1
150mm 450mm
50mm
PIN 1
PIN 3
PIN 4
PIN 6
65 m m
L ab el S 1 1 0 720 m m
L ab el FH M B 4 P L9
PL9 PIN 4 SWING ROLLER HOME SIGNAL S109 PIN 3 TWISTED PAIR WITH S109 PIN 2
PL9 PIN 8 SWING ROLLER IN DRUM SIGNAL S110 PIN 3 TWISTED PAIR WITH S110 PIN 2
850 m m
880 m m 40 m m
L abel M 36
L abel FH M B 4 PL 22
T ie w ra p s e v e ry
100m m P a rt N o e tc n e x t to th is
c a b le tie
100MM
LABEL 24VDIST PL1
40MM
LABEL part no etc
LABEL 24VDIST PL4
C bl Ti h
PIN 1
VOLUME 2 (8-84) S YSTEM C ABLING DESCRIPTIONS
AMP CT PL4
PIN 1
PIN 2
40MM
LABEL part no etc
LABEL DIST PL9
PIN 1
PIN 2
AMP CT PL9
PIN 1
PIN 2
Label
FHMB1 PL30
850 mm Label EXTEN M11
100mm
Part No etc
L UXEL P LATESETTER VOLUME 2 (8-85)
FHMB1 PL30 PIN 1 OUT A EXTEN M11 PIN 1 TWIST WITH M11 PIN 5
FHMB1 PL30 PIN 2 OUT C EXTEN M11 PIN 2 TWIST WITH M11 PIN 6
FHMB1 PL30 PIN 3 +24V EXTEN M11 PIN 3 TWIST WITH M11 PIN 4
Lab el FH M B 1 P L1 4
130 m m
240 m m Lab el FH M B 1 P L2 5
100 m m
Lab el Sen sor
E x ten sio n 50 m m
6 00 m m L ab el D IST I/P PL 1
L ab el P art N o etc 50 m m
2 cab le ties
P lace 7 0 m m from ju n ctio n 1000 m m
PL25 PIN 3 PLATE PUSHER HOME GROUND SENSOR EXT PIN 2 TP WITH PIN 3
PL10 PIN 3 CENTERING HOME GROUND SENSOR EXT PIN 5 TP WITH PIN 3
PL14 PIN 1
PL14 PIN 2
PL14 PIN 5
PL14 PIN 6
PL14 PIN 7
PL14 PIN 8
PL23 PIN 1 PLATE ON PLATERN PUL_GND SENSOR EXT PIN 7 TP WITH PIN 8
PL12 PIN 1
Lab el S1 1 8
1 9 0m m
Lab el S1 1 3 900 m m
Lab el Sen sor
270 m m E x ten sio n
10 0m m 40 0m m
Lab el S1 1 6 90 0m m 4 00 mm
130 m m
SENSOR EXT PIN 3 PLATE PUSHER HOME SIGNAL S116 PIN 3 TWISTED PAIR WITH S116 PIN 2
SENSOR EXT PIN 6 CENTERING HOME SIGNAL S113 PIN 3 TWISTED PAIR WITH S113 PIN 2
SENSOR EXT PIN 7 PLATE ON PLATERN PUL_GND S118 PIN 1 TWISTED PAIR WITH S118 PIN 2
SENSOR EXT PIN 9 PLATE ON PLATERN GROUND S118 PIN 3 TWISTED PAIR WITH S118 PIN 4
SENSOR EXT PIN 11 CENTERING CONTINUITY S114R TWISTED PAIR WITH S114L
GROUND
L ab el S 1 1 8 150m m
Lab el S1 1 3 900 m m
Lab el Sen sor
150 m m E x ten sio n
15 0m m 15 0m m
Lab el S1 1 6 63 0m m 3 50 mm
130 m m
SENSOR EXT PIN 3 PLATE PUSHER HOME SIGNAL S116 PIN 3 TWISTED PAIR WITH S116 PIN 2
SENSOR EXT PIN 6 CENTERING HOME SIGNAL S113 PIN 3 TWISTED PAIR WITH S113 PIN 2
SENSOR EXT PIN 7 PLATE ON PLATERN PUL_GND S118 PIN 1 TWISTED PAIR WITH S118 PIN 2
SENSOR EXT PIN 9 PLATE ON PLATERN GROUND S118 PIN 3 TWISTED PAIR WITH S118 PIN 4
SENSOR EXT PIN 11 CENTERING CONTINUITY GROUND S114R TWISTED PAIR WITH S114L
Part No etc
2000 mm
Label EXTEN M11
Label M11
100mm
600 mm
Part No etc
EXTEN M11 PIN 1 OUT A M11 PIN 6 TWIST WITH M11 PIN 2
EXTEN M11 PIN 2 OUT C M11 PIN 5 TWIST WITH M11 PIN 1
EXTEN M11 PIN 3 +24V M11 PIN 4 TWIST WITH M11 PIN 3
580 mm
780mm 150mm
50mm Label FHMB4 PL16
2150mm (sleeved)
Label BV41
50 mm
Label BV30
Label FHMB4 PL10
125mm
Label BV40 Part number label 50 mm
PIN 2 DIVERT VALVE BV30 PIN2 RED TWIST WITH BV30 PIN 3
PIN 2 LEADING EDGE BV40 PIN 2 RED TWIST WITH BV40 PIN 3
PIN 2 AIR KNIFE BV41 PIN 2 RED TWIST WITH BV41 PIN3
PIN 2 DIVERT VALVE BV30 PIN2 RED TWIST WITH BV30 PIN
3
PIN 2 LEADING EDGE BV40 PIN 2 RED TWIST WITH BV40 PIN
3
100mm 1075 mm
PIN 1 SPARE
PIN 2 SPARE
PIN 4 PUMP RELAY RTN 8 W MOLEX PIN 6 BLACK ( TWIST PAIR PIN 2)
PIN 5 SPARE
PIN 6 SPARE
PIN 7 SPARE
FHMB4 PL8
PIN 3 COMP RELAY RTN 8 W MOLEX PIN 8 (2 WIRES IN PIN 8) BLACK ( TWIST PAIR PIN 4)
BV31 SOL
PIN 2 COMP RELAY RTN 8 W MOLEX PIN 8 BLACK ( TWIST PAIR PIN 4)
L UXEL P LATESETTER VOLUME 2 (8-91)
CHAS
10 mm tinned ends M5
70mm
See Note 1
Cable 2
120mm brown
LDIST FUSE1
FASTON
Cable 3
120mm brown
LDIST FUSE2
M5 RING (unless otherwise stated)
Cable 4 M4 200mm G/Y M5
10 MM TINNED
COMP1E CHASSIS
Cable 5
M4 250mm G/Y M5
COMP2E CHASSIS
Cable 6
M5
500mm G/Y M5
LID CHASSIS
4
4
System functional view (all variants)........................................................................ 9-2
4
System DC cabling view (fully-automatic) ............................................................... 9-3
4
Engine cabling view (System PCB - all variants) .................................................... 9-4
4
Engine cabling view (Interlock box - all variants) ...................................................9-5
4
Engine cabling view (FHMB - fully-automatic with punch).....................................9-6
4
Engine cabling view (FHMB - fully-automatic without punch) ............................... 9-7
4
Engine cabling view (FHMB - B1/B2 manual/semi-automatic without punch) ..... 9-8
4
PTM cabling view (fully-automatic with/without punch) ......................................... 9-9
4
Autofeeder cabling view (fully-automatic with/without punch) ...........................9-10
Interlocks system view (all variants) ...................................................................... 9-11
PLATE HANDLING, VACUUM CONTROL
ENCODER
AUTOFEEDER
ELEVATOR ELEVATOR
DISTRIBUTION CONTROL
CASSETTE
MMI DOOR
OPTICS ND FOCUS,
SENSORS APERTURE MOTORS OPTICS
RFI BOX BASE
PD
PD BD
DISTRIBUTION
VOLUME 2 (9-4) S YSTEM C ABLING VIEWS
LASER BASE Y
PD
PD BD
EODD_IF DISTRIBUTION
CAN2
DISK_PWR PSU_CTRL
OPTICS V_VBOMB_SENSORS
DISK 1 SYSTEM BOARD
DISK_DATA LSB_DATA_VBOMB ENCLOSURE
IEC FAN
INLET CAN1
MAINS_RFI_IN LPD_HOME
SCSI MMI LCD VBOMB_FAN
MMI LCD
LPD
(B2 MAN) ENG_DIAGS VBOMB_LPD
APERTURE HOME
ND HOME
TO PUMP PUMP
(3) (5, 6, 7)
PSU_CTRL OVERRIDE
(3) (5, 6, 7)
SWITCH
(5, 6, 7)
ENG_INT ENG_FHMBPWR
(3)
USER
SERVICE DOOR DOOR
INTERLOCK INTERLOCK
24V_ENG
(3)
8A VAC PUMP
CIRCUIT BREAKER
PUMP I/LOCKCTRL
VAC (5, 6, 7)
RELAY AIRKNIFE_VAC
BV5
MAINS_RFI_IN DIST
(3)
2A FUSE
SCHMERSAL
PSU_I/LOCK AES 1235
I/LOCK_DC
INTERLOCK BOX
FUSES
COMP_MAINS
COMP 1
NOTE 1: B1 MAN & SEMI-AUTO
HAVE I/LOCK LINK COMP_PANEL
COMP 1
NOTE 2: B2 MAN & SEMI-AUTO
WITHOUT COMP BOX COMPRESSOR BOX
(SEE NOTE 2) ENG_FHMBPWR
(5, 6, 7)
CAN2
(3) (5, 6, 7)
(4) PUMP
ENG_INT
FRAME
(4) EMERG WITH
PANEL
ENG_FHMBPWR CONNECTORS
(4) (TO PTM)
CAN3_ENG
TO (8)
CAN5_ENG
ENG_M6
BM6 FRICTION BAND OUTPUT MODULE
BM5 REGISTRATION PINS BUFFER
ENG_M3/5 INTERLOCK
BM3 CENTERING ARMS
ENG_M7 BUFF_M7
PWR2 BM7 BUFFER FEED
TO PROC
ENG_M2
BM2 PUSH BAR BS19 BUFFER ENTRANCE
CARRIAGE
PCB
ENG_S19/20 BUFF_S19/20
SENS PCB
FHMB ENG_FPD_S21
BS21 FPD DIST BD SET CAN ID 0 BS20 BUFFER EXIT
BOARD 4 BUFFER
ENG_S10/11 BS10 REG MOTOR OUT POSITION
BS11 REG MOTOR IN POSITION
(4) ENG_S4
PCB BS4 OUTPUT ENTRANCE
RIB1/RIB2 ENG_S5
PL18 PCB BS5 OUTPUT EXIT
(OUTPUT)
BV41 PUNCH_LINK BS13 CENTERING LH DETECT
(4) PL19
BS12 CENTERING RH DETECT
BS14 CENTERING HOME
NEW ENG_S14/12/3
24V PCB BS3 PLATE IN PUNCH
DIST BD ENG_S79
BS79 CHAD TRAY HOME
BS112 PUSH BAR FWD LIMIT TRAVERSE ENCODER (READ HEAD)
ENG_S6/S112
BS6 PUSH BAR HOME
TRAVERSE MOTOR
UMBILICAL
STB
SPINNER MOTOR
ENG_BLOW BV30
BV41 (2) SPINNER ENCODER
CONTROL
VAC/AIRKNIFE_VAC RELAY
(BV3)
BS80
MIXER FAN
DETECT
(4) PUMP
ENG_INT
FRAME
EMERG WITH
(4)
ENG_FHMBPWR PANEL
(4) CONNECTORS
(TO PTM)
CAN3_ENG
TO (10.8)
CAN5_ENG
ENG_M6
BM6 FRICTION BAND OUTPUT MOD
BM36 REGISTRATION PINS BUFF_LOCK BUFFER
ENG_M36/37 INTERLOCK
BM37 SWING ROLLER
ENG_M7 BUFF_M7
PWR2 BM7 BUFFER FEED
TO PROC
ENG_M2
BM2 PUSH BAR CARRIAGE
ENG_S21
BS21 FPD
BS80
MIXER FAN
DETECT
(4) SOL_CTRL
ENG_EARTH
ENG M1
BM1 FRICTION BAND INPUT MODULE
ENG_INT
(4) ILOCK_LINK
MAN_STOP
BS80
MIXER FAN DETECT
ENG_M38
BM38 OUTPUT MOTOR
CAN4
24V 36V DIST
ENGINE BM20 CASSETTE FWD BOARD SET CAN ID 1
INT_M20/27
BS55 PAPER POST DIVERTER
INT_EMERG BM27 X DIRECTION DOOR INT_S55/59
TO EMERG PCB BS59 PLATE PAST DIVERTER
BM62 X DIRECTION
DOOR UP
INT_S62/71 BS71 X DIRECTION
TO CAN5_ENG
DOOR DOWN RIB6 BS41 CASS FWD LIMIT
PL19 CASS ID BOARD INT_S41/42
TO PWR3_INT BS42 CASS REV LIMIT
BV22 CASS DOOR LOCK BS36 CASS ID1
ENG_FHMBPWR INT_S76
BS72 CASSETTE DOOR CLOSED BS37 CASS ID2 PCB BS76 FRONT DOOR OPEN
BS38 CASS ID3
CAN3_INT FHMB BV25 DOCKING LIGHT
TO CAN3_ENG BS39 CASS ID4
BOARD 2 BM28 Z DIRECTION CONTROL BS40 CASS ID5
FROM BM26 ELEVATOR STOP
(5, 6, 7)
BM26 ELEVATOR STOP
FEED_INT BS74 VECTOR DRIVE ALARM
TO ENG_INT
BS75 VECTOR DRIVE OVERLOAD INT_OUT
TO ELEVATOR DIST BD
RIB7
FRAME WITH PL18 TO ELEVATOR CTRL BD
PANEL
CONNECTORS
(ENGINE) PTM INT_OUT
I/LOCK TO (9)
(EARLY MACHINES ONLY)
24V BV23 AIR KNIFE
PTM AIR KNIFE
ELEVATOR DISTRIBUTION BD
DOCKING INDICATOR
BS63 Z DIRECTION UP
VOLUME 2 (9-10) S YSTEM C ABLING VIEWS
RED
TOP LIMIT
FRAME WITH PANEL ORANGE
CONNECTORS
ELV_CTRL ELV_CON_24V BOTTOM LIMIT
(PTM)
RED
SIEMENS
MAINS_ELV_IN HITACHI RFI PART OF FILTER INV_MOTOR INV_MOTOR ELEVATOR
INVERTER CONTACTOR
FILTER CABLE 2 3RT1016- CABLE 1 MOTOR ELEV_EARTH
1BB42
inc BS74 and BS75
Contacts for BS73
PIN 7
CABLE 'ENG_INT' 1-6 SWITCH POSITION WITH PANELS CLOSED AND NOT OVERRIDDEN
ROUTINE MAINTENANCE
This chapter describes the required service tools, the service schedule and the main
service procedures for a site visit.
4
4
Field Service Tools ..................................................................................................... 1-1
4
Overriding the Interlocks ...........................................................................................1-2
4
Opening Service Covers ............................................................................................ 1-3
4
Maintenance Schedule ...............................................................................................1-4
4
Cleaning Procedures.................................................................................................. 1-5
4
Maintenance Procedures ...........................................................................................1-9
4
Checking the Traverse .............................................................................................1-14
Checking the Platesetter Output............................................................................. 1-16
Microscope (x100).
Spirit level, approximately 610 mm (24 in) long.
Antistatic mat.
Torch.
Interlock override key.
Vernier gauge to 25 m.
Glass ruler to 450 mm (with magnifiers).
Vernier ruler.
Film comparison ruler.
Edge detect laser setup tool (if supplied).
Cassette door lock (Schmersal) manual release key.
Small hand-held vacuum cleaner with plastic attachments.
10 mm spacer for setting up BS51 and BS55.
KEYSWITCH
(IN OVERRIDE
POSITION)
KEYSWITCH IN
INTERLOCKS
ENABLED
POSITION
In the interlock override state, the MMI display shows a background pattern of
laser warning symbols.
After completing the service work, return the interlocks to their enabled state by
removing the key and replacing the engine side cover. Note that you cannot
install the cover if the key is still in the lock.
1.3.2 Fully-Automatic
All service covers are locked by screw fixings that are only removed by an
approved engineer. The location and number of the fixings is shown in
Figure 1.2 below.
SERVICE SIDE
RFI BOX
(LID ONLY)
OPTICS
BASE
LOWER COVER
USER SIDE
NOTE: CASSETTE DOOR LOCK BOTTOM SCREW LOCK
IS S/W CONTROLLED
TOP SCREW LOCK
NOT LOCKED
Removing Covers:
1. Unlock the cover using a pozi-screwdriver to remove the M4 Panhead screw
fixings at the top and bottom.
2. Remove the cover by lifting it up and then away from the frame.
3. Avoid damaging the screw lock tabs on the bottom of the cover when it is set
aside.
Replacing Covers:
4. After completing a service visit, make sure that the removed covers are replaced
and securely locked again. This is to ensure the safety of the operator.
NOTE: The engine doors can be lifted off their frame hinges to allow better access to the
machine.
NOTE: The cleaning procedures in the Operators Manual are carried out weekly, or more
often if the machine scans more than 200 plates a day. For high volume production,
inspection of the platesetter should determine if daily cleaning is required.
TRAVERSE
CARRIAGE
L6 LENS
BAFFLE
ASSEMBLY
CLEAN
REAR
CLEAN
FRONT
Avoid solvents for cleaning the scale. Do not use solvents, such as, Acetone,
Benzine, Methylated Spirits, chlorinated solvents or any lubricants - since these
are likely to damage the lacquer.
If the scale needs to be de-greased as a result of handling or replacement, use N-
Heptane.
1.5.2.2 Readhead
This procedure can be completed when the traverse carriage has been removed
from the platesetter, or when the carriage is moved to the service side.
1. Remove the readhead from the carriage using the procedure in Volume 3
Section 3.3.8.
2. Clean the readhead window with a cotton bud soaked in IPA.
3. Replace the readhead.
Feed Head
Clean the nudger and takeaway rollers with a damp lint-less cloth rinsed in
warm water.
Retard Pad
Clean with a TAK cloth or a damp lint-less cloth soaked in warm water. Clean in
the direction of the loading plate.
Air Knife
This module does not require maintenance but check for any accumulated con-
taminants inside the system.
VOLUME 3 (1-8) R OUTINE MAINTENANCE
Punch
Clean the punch surfaces with a soft brush and a TAK cloth.
LPD
1. The LPD lens and the box assembly interior surfaces are cleaned with Ethyl-
alcohol.
2. Carry out the setups in Table 4.1 on page 3-4-3.
MMI Touchpanel
The panel is cleaned by gently wiping with a soft cloth, tissue or absorbent cot-
ton in order to remove surface dust. Use a proprietary glass cleaner if further
cleaning is required. Make sure the surface is not rubbed with any hard mate-
rial.
The pitch ring on the push bar includes a material called delrin that tends to
break into small flakes during normal use. This can sometimes result in drive
errors while the push bar is moving in the drum.
1. Remove the plastic flakes with a sharp instrument from the pitch ring -
especially from the corners of the pitch ring profile.
2. Vacuum clean the inside of the drum with a soft brush attachment.
3. Apply small amounts of Vaseline (see TIS 13886-01) in the pitch ring grooves,
opposite the eight gear track joins.
4. Move the push bar by hand to distribute the Vaseline along the grooves.
5. Check that the Vaseline is evenly distributed around the grooves and is not on
the casting.
diagnostics/service/optics/laser>measure_extinction_ratio
2. The extinction ratios should be between 180 and 220 for both lasers (if fitted). If
they are not then adjust them as follows:
L UXEL P LATESETTER VOLUME 3 (1-11)
4 to increase the extinction ratio of a laser you need to decrease the bias cur-
rent
4 to decrease the exctinction ratio of a laser you need to increase the bias cur-
rent.
3. Adjust the bias current of the required laser(s) as follows:
diagnostics/service/optics/laser>set_bias_level change
Changing values
Working Laser X/Y bias DAC values are changed using the backspace and
numerical keys:
4 to increase the extinction ratio of a laser you need to decrease the bias cur-
rent
4 to decrease the exctinction ratio of a laser you need to increase the bias cur-
rent.
Increase or decrease the Working Laser bias current DAC values by 1 unit at a
time.
Changing the bias current by a large value (greater than 5) may damage the
laser.
Press [Return] then use the side keys to select UPDATE, the press [Return] to exit.
This will update all the working laser bias values in NVRAM.
save_nvram
cp general/sysnvram.bin general/nvram****.rmv
where **** is the year and month of the visit - for example, 0210 is October 2002
and .rmv indicates routine maintenance visit.
4. Note and reset the error counts. Set Capture Text on the diagnostics terminal
and enter:
display_errors
reset_error_stats
Print out the captured text and store it in the Machine Logbook.
3. While the elevator is moving, trip one of the limit sensors by hand.
4. Check if MMI error 1351 appears and the inverter displays error 01.
5. Reset the inverter (press Reset), reboot the platesetter and reset the limit sensor.
6. Repeat steps 2) to 5) for the other limit sensor.
Cassette
Service engineers need to check periodically for the following problems:
1. Light-tight seals are effective. Normally, a full cassette should not be left in
daylight conditions for too long since this is likely to cause fogging on the top
plate. All loaded cassettes need to be housed inside the Autofeeder. If there is a
problem with plate fogging, load a single plate into the cassette and put the
cassette under a strong light for more than an hour and process to check for
light-tightness.
2. Check the outer buffers for signs of damage.
3. Check that the ID label is in place.
4. Check that the top lid fits properly.
L UXEL P LATESETTER VOLUME 3 (1-13)
1.6.9.1 Modules
Check that all the covers, cover linings and doors close properly, and all the
external cable entry points are light-tight. Modules should be coupled with their
interconnected frames aligned without gaps. Adjust the module interconnect
screw fixings to ensure the frames are parallel.
1.6.9.2 Cassette
If there has been a report of media fogging and the cassette is suspected, use the
following procedure:
1. Place a single plate in the cassette and lock the top lid.
2. Shine a strong lamp light around the cassette for several minutes.
3. Develop the plate and check for signs of `fog'.
On a Manual and Semi-Automatic machine, fogging may be caused by leaving
the plates on the input platen or in the machine output. The diagnostic com-
mand, fog_time, will allow you to change the fog warning settings.
VOLUME 3 (1-14) R OUTINE MAINTENANCE
CARRIAGE
RAIL
BALL
CAGE
SERVICE
END
VIEW
2. Check that the spinner and traverse are disabled. (They are enabled if the
application has been running). Select the following from Main Diagnostics:
diagnostics/service/spinner> stop
diagnostics/service/traverse> halt
3. Align the ball cage and carriage rail, see Figure 1.5.
4. Measure the distance between the end of the carriage rail/ball cage and the end
of the V-groove, see Figure 1.5.
CARRIAGE
RAIL
ALIGN AND
1 MEASURE
BALL CAGE
V-GROOVE
5. Run one of the following tests that moves the carriage 20 times up and down the
beam length:
diagnostics/test/traverse/trav_test
if the carriage and ball cage were aligned at the service end, or enter:
diagnostics/test/traverse/trav_test R
if the carriage and ball cage were aligned at the user end.
6. Release the traverse servo-drive by entering:
diagnostics/service/traverse/halt
7. Align and measure as in steps 2. and 3. above.
8. If the distance between the measurements is greater than 0.5 mm, then an engine
level adjustment is required. For instance, the ball cage extends beyond the
carriage towards the service end, so the service end needs to be adjusted
upwards.
Loosen the PTM-Engine fixing bolts (4-off, M5).
Adjust the feet to minimise creep and obtain an improved level. A small
adjustment of 1/4 to 1/2 (0.25-0.5 mm) turn on the adjust nut is usually
sufficient. See the table below.
VOLUME 3 (1-16) R OUTINE MAINTENANCE
2 mm 1 TURN 2 mm 1 TURN
3 mm 11/2 TURN 3 mm 11/2 TURN
BACKGROUND SATURATED
(0%) (100%)
IMAGE
TINT
(50%)
is not loaded in the centre, then large plates (1160 mm wide) could be offset to
one side and cause a centering arm error (code 1750). For a 1160 mm plate, the
feed margin at the punch is 7.5 mm on each side of the plate.
1. Using the largest plate available, mark a centre line from the plate lead edge to
the trailing edge.
2. Load the plate into a cassette (widest side as leading edge).
3. Make sure the engine top covers are removed.
4. Advance the plate from the cassette to the drum.
5. Observe the plate loading into the engine and measure the distance the plate has
offset from the centre of the drum. Plate centre alignment should be within 0.5
mm of the drum centre.
FIXING
BOLT
(4-OFF)
caphead bolts securing the PTM main frame to the PTM cross members, see
Figure 1.7, and move the PTM main frame so that it is aligned with the
Engine.
A B
IMAGE
PLATE
A B
PLATE
A B
PLATE
Figure 1.10 Full punch centering
3. For a Heidelberg punch format with 1030 wide plates, the dimension:
A = 119 mm (1 mm).
This is calculated as (A - B/2) - C where:
A = plate width.
B = centre distance between punch crops, depending on the punch proto-
cols.
C = half width of the punch crop; for instance, for a Heidelberg square crop
L UXEL P LATESETTER VOLUME 3 (1-21)
PLATE
0 m CENTRE 1220000
LEFT RIGHT
(PERISCO
END)
IMAGE
PLATE
TRAV_CENTRE_POSITION = -610000 m
or to move the image 10 mm (10,000 m) to the left of the plate, use the formula:
-6100000 - (- 10000) = -600000
5. If the machine has a punch fitted then make sure the image is centered at equal
distance from the outer crop marks, as shown in Figure 1.12. Use the method is
step 5. above to move the image.
PUNCH
CENTRE
A B
IMAGE
PLATE
+ ERROR
VALUE
PUNCH END
IMAGE_ 25000 m
BASE_
OFFSET =
680000 m
ERROR
VALUE
IMAGE START
SCAN
POINT
PLATE
305 mm FOR B2
470 mm FOR B1 LEAD EDGE OF
REGISTRATION PINS
A B
IMAGE
PLATE
3. Check that the difference between the two lines is less than or equal to 50
microns ( 25 microns).
4. Expose and measure 4 plates and check that repeatability is less than or equal to
30 microns.
5. A possible cause of error could be poor push bar alignment.
A 305 mm FOR B2 B
470 mm FOR B1
2 mm ( +- 25 m)
67 mm
1 mm
(+- 25 m)
IMAGE
PLATE
Figure 1.15 Edge detect and image accuracy
+ERROR
VALUE
IMAGE_BASE_
OFFSET = 2 mm
( +- 25 m)
- ERROR
VALUE
IMAGE START
SCAN
POINT
PLATE
4
4
Starting the Service Procedures ............................................................................... 2-1
4
Autofeeder Servicing ................................................................................................. 2-4
4
Plate Transport Module Servicing .......................................................................... 2-15
4
Engine Servicing ...................................................................................................... 2-27
Buffer Servicing ........................................................................................................2-57
BUTTON RIVET
CONNECTOR
PCB
INSERT
SENSOR MOUNTING
SNAP RIVET
CONNECTOR
PCB
INSERT
PUSH OUT
3. Reconnect the lead and fit the new sensor in the same location.
4. Check that the metal tab moves freely in the sensor slots.
5. Use diagnostics to confirm that the new sensor operates correctly.
SENSOR
MOUNTING
BRACKET
LOCATING
DIMPLE
SCREW METAL
FIXING TAB
(M4)
CONNECTOR
Check the Configuration data from the Registry, see Volume 2 Section 1.11, and
change the firmware level from the supplied Luxel Firmware CD. Use the
procedure explained in Volume 2 Section 1.12.
ELEVATOR MOTOR/GEAR
ELEVATOR DIST/CONTROL PCB's
INVERTER
I/L CONTACTOR
ABSOLUTE LIMIT SENSORS
SERVICE SIDE I/F CONNECTORS
CHAIN SPRINGS/
TENSIONERS CHAINS
CHAIN SPRINGS/
TENSIONERS
ON/OFF LAMP
INVERTER
POWER
RUNNING
LAMP DIGITAL DISPLAY
RUN Hz
FREQUENCY OR
CURRENT DISPLAY
SETTING PRG A LAMP
PARAMETER
LAMP
STOP
RUN RESET
SETS FREQUENCY
RUN KEY DO NOT TOUCH
TO START MIN MAX
STOP/RESET
KEY
FUNCTION CONTRO
DO NOT TOUCH
Inverter Replacement
See Volume 2 Figure 3.2.
NOTE: The inverter is supplied with its cables and the software already loaded.
CAUTION: Do not touch the cooling fins while the elevator motor is operating.
Autofeeder cassette shelves and the PTM cassette guide rails if one or both of
the modules has been moved.
1. From Main Diagnostics enter the following command to drive the elevator to
shelf 3 (or a middle shelf):
service/medtran> move_elevator c
where shelf a = 0 (top); b = 1; c = 2; d = 3; e = 4.
Adjust the PTM rail, shown in Figure 2.6, so that the distance apart is initially
5 mm. This is to avoid damaging the rails if the two modules are misaligned and
the elevator is moving under motor control.
2. Measure the difference in height between the Autofeeder shelf and the PTM rail,
and enter it in the table above.
3. Measure the distance between the Autofeeder shelf and the PTM rail, and enter it
in the table above.
4. Repeat steps 2) and 3) for each shelf.
5. From this table you will be able to make adjustments to ensure errors are within
the specification of:
Level: 1 mm vertical range between rails.
Distance Apart: +2 mm (maximum)/+1 mm (minimum) horizontal range
between rails.
AUTOFEEDER
DISTANCE APART = +2 mm SHELF RAIL X-DOOR
(max) FLAP
LEVEL = 1 mm
ADJUST DISTANCE
PLATE
TRANSPORT
CASSETTE
GUIDE RAIL
6. Decide on the adjustments to achieve the Level specification; for instance, the
values in Table 2.3:
A) Shelf A: user side, change +0.8 mm to +0.4 mm; then service side will
change 0 to -0.4 mm.
B) Shelf B: does not require adjustment.
C) Shelf C: does not require adjustment.
D) Shelf D: user side, change -0.5 mm to +0.25 mm; then service side will
change -1.0 mm to -0.25 mm.
E) Shelf E: does not require adjustment but could be possibly set to +01 mm
and -0.1 mm.
Level adjustment is from the sensor vanes. Each vane is adjustable in the vertical
direction by loosening its top and bottom screws. The correct vane for each shelf
is the one where the lower vane edge is just entering into its PCB sensor. Adjust
as follows:
If ALL the shelves need adjusting by the same amount, then the Elevator
Distribution PCB can be adjusted vertically. Its mounting bracket is fitted on
slotted holes.
For some levels you may have to move the elevator up a shelf to access the
lower screws hidden by the PCB. Slacken the hidden screw, move back to the
original shelf and adjust using only one of the vane screws. Tighten the other
screw when it appears.
NOTE: When aligning the shelf to the PTM rail on an uneven floor surface outside the
FFEI pre-install specification, always adjust the autofeeder feet to offset tilt differences.
Even if the cosmetic fit between module frames is slightly altered, a large clearance hole
for the interconnecting bolts allows for poor matching. The main priority is to ensure that
the cassette always runs freely between the two modules for each shelf and any tilt
between the shelf and runners is avoided.
PTM
SKIN
FRAME
EDGE
CAM FOLLOWER
BRACKETS
1. Open the cassette loading door from the MMI menu option for installing the
cassette.
2. Remove the lamp holder front filter lens with a small sharp knife.
3. Remove and replace the bulb (you may require a lamp extraction tool).
WARNING: Testing absolute limit switches exposes you to danger from moving elevator
parts. Always plan ahead to avoid danger. Before starting this procedure, ensure you
know which parts will move, and how you access the switches while they move.
C) While the elevator is moving, trip one of the limit sensors by hand.
D) Check if MMI error 1351 appears and the inverter displays error 01.
E) Reset the inverter (press Reset), reboot the platesetter and reset the limit
sensor.
F) Repeat steps 2) to 5) for the other limit sensor.
4. Insert wood safety blocks (approximately 13 cm high) under the four corners of
the elevator frame, see Figure 2.8.
5. Lower the elevator onto the blocks until the chains are slack by rotating the
motor cooling fan in the anti-clockwise direction using an Allen key through the
hole in the top of the motor cover.
6. The chain attached to the spring should be loose enough for you to detach from
the plate. As an extra security measure, use a G-clamp to clamp the link to the
sprocket.
SPRING
TENSIONERS
BLOCK
SUPPORTS
(4-OFF, 13cm HIGH)
To initiate a media transport. Ensure the cassette is reversed from the feed head
and the X-door is down.
move_elevator <shelf letter> (where a = 0 or top; b = 1; c = 2; d = 3; e = 4)
AIR KNIFE
FHMB 2 & 3
DISTRIBUTION PCB's
CASSETTE ID
I/F CONNECTORS
SERVICE SIDE
DIVERTER
PLATE GUIDES
CASSETTE FWD
FEED HEAD
INTERLEAF DRIVE ROLLER
X-DIRECTION DOOR
SENSORS/MOTORS
USER SIDE
BS76
DIVERTER
STACK INCREMENT
RETARD PAD
RELEASE SCREW X-DIRECTION DOOR
AT USER END SENSORS/MOTORS
AND SLIDE OUT
UNDER TRAY TO
ACCESS ASSEMBLIES
CAUTION: Lifting the guide plate with the machine powered on could damage the sen-
sors by shorting them to the frame.
1. While the machine is powered down, remove the 2-off M4 posidrive screws
holding the post-diverter guide plate in place.
2. Without removing any connections, position the plate so that you can access the
potentiometer. Locate a strip of plate where it can be detected by the sensor.
3. Power up the machine but prevent the main application from loading by
pressing Ctrl-c at the second prompt. This will stop the machine from generating
errors.
4. Power up the sensor using the command:
diagnostics/service/sensors> read_con ip
This utility polls the sensor to indicate its change of status. Check power is
applied to the sensor, indicated by an illuminated green LED.
5. Turn the pot fully anti-clockwise to the 11 o'clock.
6. Position a plate (with paper fixed to the underside of the plate) over sensor BS55
so that it covers the sensing aperture.
7. Raise the plate 20 mm above the guide plate, keeping the printing plate parallel
to the guide.
8. Adjust the sensor pot clockwise until the orange sensing LED is permanently
ON (not flickering).
9. Lift the plate until it is 35 mm above the guide plate.
10. Check that the sensor can still detect paper in this position, giving a 15 mm
operating margin.
The orange LED may flicker indicating that the sensor is still detecting paper.
L UXEL P LATESETTER VOLUME 3 (2-17)
11. If paper has not been detected, increase sensitivity (clockwise) until the orange
indicator starts flickering. Repeat this test several times to ensure adjustment
repeatability.
12. Remove the interleaf paper from underneath the plate.
13. Check that BS55 does not detect the underside of the plate (orange LED OFF).
Move the plate up and down parallel to the sensor and ensure that it does not
detect the plate in any position up to 35 mm from the sensor.
14. Power down the machine, replace the guide, and power up the machine again.
15. Confirm correct operation with both plates and paper.
NOTE: This spacer is used to increase the detection range of the sensor to approximately
54 mm and increase the operating sensitivity margin.
1. Power up the machine but prevent the main application from loading by
pressing Ctrl-c at the second prompt for bypass mode.
2. Power up the sensor using the command:
diagnostics/service/sensors> read_con ip
This utility polls the sensor to indicate its change of status. Check power is
applied to the sensor, indicated by an illuminated green LED.
3. Position a sample of paper on top of a plate (emulsion side up) on the plate tray.
Ensure they are parallel to the sensor.
4. Place a spacer under the sensor bracket, as shown in Figure 2.10.This will
increase the sensors range and sensitivity margin.
5. Turn the sensor potentiometer fully anti-clockwise to the 11 oclock.
6. Adjust the sensor clockwise until the orange indicator is fully on (not flickering).
7. Remove the paper and the spacer.
8. Keep the plate in position and check that the sensor does not detect the presence
of a plate (orange LED OFF).
9. Move the plate up to the sensor and further away as possible, keeping the plate
parallel to the sensor at all times. Check that the sensor is not activated at any
point.
VOLUME 3 (2-18) P LATE H ANDLING S ERVICE P ROCEDURES
10. Recheck the sensor with paper. Move the paper up to the sensor and further
away as possible, keeping the paper parallel to the sensor at all times. Check
that the sensor is always activated. Repeat this check several times.
11. The sensor is now set up.
.
PTM FRAME
CROSSBAR
SENSOR
BS51
FEED HEAD
ASSEMBLY
11. Ensure that the arms are synchronised and pointing towards each other by
adjusting the torque screw on the bearing at the user side. To align arms, the
sensor vane at the service side can be set to operate the sensors correctly.
Close the X-direction door using the command:
service/actuators> set bm27 off
12. Check the cassette forward operation without the cassette using the command:
service/actuators> set bm20 on/off
13. Check the cassette forward operation with the cassette using the command:
service/medtran> load_cassette
service/medtran> unload_cassette
NOTE: Before removing the assembly, raise the stack increment to the top position by
manually moving the drive belt.
4. Remove the 8-off M4 caphead screws securing the stack increment to the cross-
bar.
5. Tip the assembly away from the cassette centering locators.
6. Lift out the assembly.
NOTE: Do not remove the feed head interface plate from the cross-bar assembly. This is
factory-set.
5. Remove the 4-off M5 x 8 mm long caphead screws securing the feed head
assembly to the support backplate, see Volume 2 Figure 3.35. Avoid dropping
the screws into the machine.
6. Hold the assembly by the two motors and lift away from its two locating dowel
pins.
7. Place the assembly on a clean surface, ensuring that it is not resting on the
nudger detect bracket.
WARNING: If using the set_stack_height command, wait for the nudge roller to lift clear
of the stack before reaching into the PTM.
5. Reach into the PTM and feel if the top plate is higher than the top of the lead edge
guide, see Figure 2.11.
You can also shine a torch light along the direct line of the two edges to check
levels by removing the feed head viewing plate behind the interleaf bin door.
PLATE STACK
STACK
INCREMENT
RETARD ASSEMBLY
6. If the stack is lower, adjust the stack height sensor bracket towards the Engine
and re-enter the command:
VOLUME 3 (2-24) P LATE H ANDLING S ERVICE P ROCEDURES
diagnostics/service/medtran> set_stack_height 0
7. Repeat steps 3) to 5) until the stack is higher than the lead edge guide.
8. Adjust the stack height offset by entering a value, for instance, set_stack_height -
0.5 (in mm). Each time you enter a value it updates the NVRAM parameters for
each plate size and thickness. The minimum increment is 0.1 mm.
9. Continue the adjustment until the top plate is level with the lead edge guide.
10. Push the top plate forward by applying downward pressure to the centre of the
plate and check if it butts against the lead edge. If the plate feeds across then
continue the adjustments.
NOTE: Do not remove the retard interface plate from the cross-bar assembly. This is fac-
tory-set.
PRE-DIVERTER
GUIDE
7. Check the operation of the diverter while feeding plates and paper.
FHMB 4
FHMB 4
OUTPUT MODULE
INPUT MODULE
SWING ROLLER MODULE
UMBILICAL CABLE
REGISTRATION MODULE
USER SIDE
VACUUM SOLENOIDS
COMPRESSOR BOX
SCREW LOCKED PERISCOPE MECHANISMS
NOT LOCKED PUSH BAR
PUNCH
Figure 2.13 Accessing Engine assemblies
COVERS REMOVED
3
4
2
3
COVER
REMOVED
NOTE: If you are replacing the photo sensor (BS118), make sure the MMI indicates an
error if interleaf paper is loaded with the plate, and the plate is placed polymer side down.
CAUTION: Always make sure you release a roller from BOTH ends before replacing a
drive belt. Do NOT attempt to replace the belt from one end only as you will strain the
bearing at the other end.
1. Unclip the roller bearing circlip at both ends of the roller and pull out the
bearing by hand.
NOTE: If the roller has a pulley or gear wheel, remove the wheel making sure the pin
inside is not mislaid.
3. Input Only: remove the 2-off M3 Allen screws retaining the cross member at the
bottom of the input rollers.
4. Input Only: Disconnect the drive belt from the manual winding handle (inside
the drum) by loosening the 4 mm shoulder bolt. Note the two washers under the
head of the bolt.
5. Remove the belt.
6. Refit the new belt and ensure that all the belts are running on rollers with the
rough side as the outer side.
Fully-Automatic:
The output module is removed as a complete assembly to access the punch, reg-
istration and centering mechanisms:
1. Put the Buffer into its service position, see Section 2.5.1.
2. Mark the position of the module on its support bracket slot.
3. Using a 5 mm Allen key, remove the 2-off screws at the module brackets on each
side, see Figure 2.16.
4. Disconnect cables to the following devices:
A) BS4 (output entrance)
B) BS5 (output exit)
C) BM6 or BM38 (friction and band output motor).
5. Remove the output guide, see Section 2.4.4.2. Do NOT touch any height
adjusting nuts between the mounting bracket and the support bracket.
6. Lift out the module.
7. Replacement is the reverse of removal. Check that the rollers inside the drum
are correctly located and run a plate to the output.
Make sure the plates are not scratched and not skewed by the output rollers.
L UXEL P LATESETTER VOLUME 3 (2-33)
SPRING
WHEEL SHOE
ASSEMBLY
DRIVE
SHAFT
SPUR GEAR
BLANKING
PITCH RING BRACKET
ASSEMBLY
ROLLER
PLATE
NIP ROLLER
ROLLER
PLATE
SUPPORT
BAR
HUB SPUR
DRIVE GEAR
SHAFT
PITCH RING
V3 ASSEMBLY MOTOR
PITCH RING STUB SHAFT GEAR MOTOR
BEARING MOUNTING
BRACKET
2. Loosen the 2-off M3 socket screws holding the shoes to the support bar.
3. Remove and replace the shoes and secure. Note that the distance between the
shoes depends on the maximum size of the plate (B1 or B2).
4. Replace the push bar and check for alignment using a plate.
NOTE: Only one of the plate wheels will be in contact with the drum as the bar moves
around the drum.
Use the smallest size and thinnest plate available. This ensures all plates will be
loaded without damage.
2. Load the plate manually into the drum and not from the cassette or plate loader.
3. Disconnect the mains cable supplying the compressors from the users side, see
Volume 2 Figure 9.4.
4. Run the medtran utility using a registration pin/push bar offset of -5:
service/medtran> setup_push_bar 400 0.15 -5
VOLUME 3 (2-36) P LATE H ANDLING S ERVICE P ROCEDURES
ADJUSTMENT
SCREW
RETAINER
SCREW
METAL INSERT
(BETWEEN SCREW
AND SEGMENT)
GEAR
SEGMENT
Figure 2.18 Push bar gear segment and retainer - detail view
2. Remove each segment in turn from their drum grooves to access the faulty
segment.
3. Replace the segments and secure by adding the metal insert.
The retainer screw is used to adjust the segment rings towards or away from the
L UXEL P LATESETTER VOLUME 3 (2-37)
punch.
4. Carry out the push bar setup procedure.
CAUTION: Removing the punch from the drum is a two-man operation using the supplied
lifting handles. Always make sure the drum surface is protected before starting a punch
service procedure.
3. Protect the inside of the drum with any heavy-duty material that can take the
dropped weight of the punch.
4. Move the traverse carriage to the user end.
5. Remove the stretcher panel on the Buffer side of the Engine by removing the 2-
off screws at the top of the optics base cover and the 4-off M5 Allen bolts
holding the panel in place, and the cables at the service end.
6. Remove the output module, see Section 2.4.4.1 .
DRUM
CASTING
DOWEL DOWEL
LOWER
BEAM
SUPPORT
SERVICE
SIDE
LOWER
LOWER
BEAM
BEAM
SUPPORT LOCATION FOR SUPPORT
LIFTING HANDLE
LOCATION FOR
LIFTING HANDLE
LIFTING
HANDLE
PUNCH
(USER END)
LOWER BEAM
UPPER BEAM
LATERAL
FEET
DIRECTION
PLATE
DIRECTION
DRUM FACE
number of operations.
They are also carried out after the complete punch assembly has been removed
and replaced.
Figure 2.21 shows a typical view of the pins, guide and die for a full punch
mechanism.
4 plate lead edge to the image start position is inside the specification, see
Volume 3 Section 1.8.3.3.
4 image is centred on the plate.
5. Adjust the punch pins (see Section 2.4.7.5) if there is a problem with the pins.
7. Retract the registration pins and punch an 0.3 mm plate to obtain holes. Look for
non-uniform burring around the punched hole edges which indicates non-
concentric pins/dies.
BALLSCREW ACTUATING
SHAFT
PUNCH
KEYHOLE PUNCH
M6 SCREW
PUNCH GUIDE
PUNCH STRIPPER
LOWER BEAM
PUNCH DIE
Figure 2.21 Punch pins, guides and dies
3. Operate the punch actuating lever by hand to ensure that the punch pins are
free to move - a smooth movement should be possible with reasonable force. If
the pins are hard to move it could be due to:
A) Damaged pins that need replacing.
B) Pins are coated with aluminium oxide.
4. Remove each pin in turn and check the condition of the pin sponge accelerator
and replace as required.
5. Refit the punch arm shoulder bolt, power up the platesetter and check punch
operation using the diagnostic commands:
set bm4 on
set bm4 off
Punch Checks
After replacing a punch sub-assembly run the following checks:
Punch centering, see Volume 3 Section 1.8.2.4.
Image position and skew, see Volume 3 Section 1.8.3.1.
Image traverse center position, see Volume 3 Section 1.8.2.5.
VOLUME 3 (2-44) P LATE H ANDLING S ERVICE P ROCEDURES
Sensors (BS10/11)
This procedure is completed without removing the punch assembly.
1. Remove and replace the sensor (opto-slotted).
2. Check the extend/retract positions of the pins.
Sensors (BS14)
After replacing this opto-slotted sensor, check that the arm tab slides into the
slot correctly.
L UXEL P LATESETTER VOLUME 3 (2-45)
Sensors (BS8/9)
These are opto-slotted sensors. Make sure the tabs do not move beyond the A
and B points shown in Volume 2 Figure 3.61.
Sensor (BS3)
See Volume 2 Figure 3.60.
This procedure is completed after removing the punch assembly, see Section
2.4.7.2. Consult FFEI Customer Services (UK) for further advice on how to
replace this sensor.
VOLUME 3 (2-46) P LATE H ANDLING S ERVICE P ROCEDURES
DRAG CHAIN
M3 CAPHEADS
POSI-SCREWS
(BRACKET)
SENSOR AND
GROUND
Motor (BM5)
This procedure is completed without removing the punch assembly.
1. Access the motor assembly.
2. Remove the complete motor bracket (centerer and registration motors) as
follows:
A) Remove the registration cam tab (1-off M4).
B) Loosen the centerer rail guides screws (2-off posidrives, top and bottom).
C) Remove the bracket (1-off posidrive) from the casting.
3. Remove the motor and gear head (4-off posidrive screws).
4. Replace the motor and check that the pins retract/extend using the command:
VOLUME 3 (2-48) P LATE H ANDLING S ERVICE P ROCEDURES
Sensors (BS10/11)
This procedure is completed without removing the punch assembly.
1. Remove and replace the sensor (opto-slotted).
2. Check the extend/retract positions of the pins.
Sensors (BS12/13)
See Volume 2 Figure 3.60.
1. Remove the sensor (micro-switch) device from the centering arm.
2. Adjust switching on the centering finger by checking that the range of
movement furthest from the pivot end is 1 mm, with the switching point mid-
way.
3. Complete the adjustment check in Section 2.4.7.14.
L UXEL P LATESETTER VOLUME 3 (2-49)
Sensors (BS14)
After removing this is an opto-slotted sensor, check that the arm tab slides into
the slot correctly.
CENTERING
S10 MOTOR
S14
(BM3)
REG PIN
CENTERING DC MOTOR CENTERING
ARM (LH) ARM (RH)
S13
BS3
PIN/DIE/ A
S12 CHAD WIPER
PUNCH
MOTOR
CENTERING (BM4)
MOTOR BS8/9
S11
REG PIN
CAM
UNDERNEATH
VIEW ON CENTERING ACTUATING
ARROW A PINION SHAFT
M6 BOLTS M6 BOLTS
LOWER
BEAM
SUPPORT
DRUM
CASTING
DOWEL LOWER
BEAM
SUPPORT
SERVICE
SIDE
diagnostics/log_utils> dis_stats
Note that the punch pins can be removed and replaced with the opposite end
operating as the punch surface. `Replacing the Punch Pins' on page 2-52.
Figure 2.21 shows a typical view of the pins, guide and die for a full punch
mechanism.
NOTE: Refer to Fujifilm Customer Support for more information on removing pins, dies
and guides if there is a problem in setting up the punch mechanism.
CAUTION: Do not operate BM4 and BM5 manually. This could damage the wipers and
cause chad to drop into the drum.
Punch Checks
After replacing a punch sub-assembly run the following checks:
Punch centering, see Volume 3 Section 1.8.2.4.
Image position and skew, see Volume 3 Section 1.8.3.1.
Image traverse center position, see Volume 3 Section 1.8.2.5.
1. Remove the punch support plate and motor using the procedure in `Removing the Punch
Motor ' on page 2-53.
2. Gradually move the actuating lever until the stud appears at the stud clearance hole
(top).
3. Using an 8 mm Allen key (T-bar or right-angled key) remove the stud from the hole.
NOTE: The stud is secured by Loctite and requires extra force to break the seal.
4. Extract the pin from the pin clearance hole directly behind, turn the pin around and
replace.
5. Refit the stud (with Loctite) and screw down until it stops, then wind back back one half
screw turn.
6. Replace the punch motor support plate.
7. Check that the punch pins actuate correctly by manually moving the actuating lever.
CAUTION: Do not use the BM4 and BM5 motor commands. This could cause damage to
the wipers and eventually chad dropping into the drum.
ACTUATING
LEVER
ACTUATING
SHAFT
REMOVE
STUD
REMOVE
PIN
CAUTION: Do not use the BM4 and BM5 motor commands. This could cause damage to
the wipers and eventually chad dropping into the drum.
PUNCH MOTOR
BS8
SUPPORT PLATE
(ON)
MOTOR/GEAR BS9
(BM4) (OFF)
If the punch is a a DS type then trim the wiper for the round punch holes, as
shown in Figure 2.27.
3. Refit the wiper and rivet making sure it is seated on top of the bracket.
Refit the shield.
4. Run a plate job from the RIP and check that the chad does not drop into the
drum.
CHAD
WIPER
SNAP
RIVET
PUNCH DIE
6 mm
CHAD
CUT CUT WIPER
WIPER
MOUNTING
BRACKET
DS (ROUND) CHAD DEFLECTOR
WIPER TRIM SHIELD
2. Protect the inside of the drum with any heavy-duty material that can take the
dropped weight of the punch.
3. From the service end, detach the two sensor connectors and motor.
4. Lower the Buffer to its service position, see Section 2.5.1
5. Remove the stretcher panel on the Buffer side of the Engine by removing the 2-
off screws at the top of the optics base cover and the 4-off M5 Allen bolts
holding the panel in place.
6. Remove the output module and guide plate, see Section 2.4.4.1.
7. Remove the 4-off M5 Allen screws holding the SRM side plates to the drum
casting.
SIDE
PLATE
PLATE
GUIDE
DRUM
CASTING
REGISTRATION
MODULE
BACK
STAY
2. Make sure the critical timing sequence operates where the spring rollers contact
a small plate as the plate contacts the registration pins.
2.4.11 MMI
2.4.11.1 MMI ReplacementM
The console (including MMI board, LCD, Inverter and touchpanel) is supplied
and fitted as a complete FRU assembly. The internal assemblies are similar for
all variants.
1. Switch off the machine.
2. Remove the 4-off M4 screws at the back of the MMI.
3. Lift off the front panel.
4. Disconnect the cable to SK4.
5. Replace the new console and check that it shows the correct display when the
system is switched on.
PROCESSOR ENTRY
SHOULDER LOWER
SCREW
FIXING
BUFFER
a) LOWER BUFFER FROM ENGINE
SERVICE SIDE
ENGINE
ENTRY
SLIDE
LABYRINTH *
SLIDE ADJUSTER
BUFFER FIXING FIXING HEIGHT
ADJUSTER RAIL SCREW (1) SCREW (2) ADJUSTER
SERVICE SIDE
b) DISCONNECT BUFFER FROM ENGINE LABYRINTH
* LABYRINTH
NOT FITTED ON
LATER MACHINES
PROCESSOR ENTRY
SHOULDER RAISE
SCREW
FIXING
BUFFER
SERVICE SIDE
ENGINE
ENTRY
STRETCHER
BAR
SLIDE ADJUSTER
BUFFER FIXING FIXING
ADJUSTER SCREW (1) SCREW (2) SERVICE SIDE
2. Old Buffer: loosen the 2-off M6 screws holding the slide adjuster rail inside the
Buffer, slide the rail back and tighten.
3. Old Buffer: push back the labyrinth from the Engine interface.
4. New Buffer: remove the upper cover, see Section 2.5.2.1, and slide the adjuster
rail towards the Buffer.
5. While supporting the Buffer, repeat step 2 on the other side.
6. Lower the Buffer.
7. The Buffer is now supported by two M5 shoulder screw fixings on the Processor
allowing access to Buffer assemblies.
VOLUME 3 (2-60) P LATE H ANDLING S ERVICE P ROCEDURES
DRIVE BELTS/ROLLE
I/F CONNECTORS SENSORS
MOTOR
SERVICE SIDE
USER SIDE
Figure 2.31 above shows how to access the Buffer when replacing an FRU
assembly.
If you need to move the Buffer to its service position (detached from the
Engine), use the information in Section 2.5.1.
SERVICE SIDE
CONNECTOR I/F EB
BUFFER ENTRY
ON ENGINE
7. Check the operation of the drive by feeding a plate into the Buffer.
4
4
Starting Scan System Replacements ....................................................................... 3-1
4
Accessing Traverse Scan Modules .......................................................................... 3-1
Replacing Traverse Assemblies ............................................................................... 3-4
TRAVERSE MOTOR
TRAVERSE BEAM
FLYWHEEL
TRAVERSE
READHEAD CARRIAGE
DRIVE RAIL
TRAVERSE PCB
EDGE
DETECT
(LASER/PCB)
SPINNER
BAFFLE
(FIXED)
CAUTION: Failure to follow the correct replacement procedures can cause exposure
errors.
As a final task, at the end of each one of these procedures, return the carriage to
the rail and make sure that the ball cage and carriage are aligned correctly, see
Volume 3 Section 1.7.2.
BEAM
UMBILICAL
TRAY
SERVICE
EXTENSION
(V-GROOVE)
END STOP
DRIVE
RAIL
SERVICE
EXTENSION
(FLAT)
7. Hold the carriage by its casting and pull it very carefully on to the extenders.
The ball cage will stop at the end of the V-groove rail.
At this point, you can start to remove the carriage assemblies listed above.
Removing the Carriage from the Platesetter
1. To replace the motor, you will need to remove the entire carriage assembly from
the extenders.
2. Release the umbilical cable from the Traverse PCB and its support bracket, see
Section 3.3.5.
CAUTION: Do not hold the traverse carriage by its flywheel, spinner, L6 lens or readhead.
Make sure the motor drive shaft and beam actuators are not knocked or damaged while
removing the carriage.
3. Grip the carriage by its casting or the baffle and lift away.
4. Place the carriage on a nearby work surface with thick cardboard or a cloth
underneath. The baffle can be positioned to hangover the side of the surface
holding the traverse casting.
At this point, you can start to remove the motor.
Replacing the Carriage in the Platesetter
1. Put the carriage back on the extenders.
2. Make sure all the connectors are fitted after the service procedure.
3. Replace the umbilical cable.
4. Move the carriage from the service extenders onto the V-groove rail. Carefully
slide the carriage back into the drum until the ball cage appears in the V-groove
underneath the carriage.
5. Replace the end stop and push bar motor cables.
6. Remove and store the service extensions.
7. Complete the ball cage and carriage alignment procedure in Volume 3 Section
1.7.1 and then the cage creep check.
a) REMOVEABLE BAFFLE
REMOVEABLE
BAFFLE
FINGER-TIGHT SCREW
(2-OFF)
USER SIDE
b) FIXED BAFFLE
SERVICE SIDE
FIXED
BAFFLE
M5 SCREW
(4-OFF)
The Traverse PCB, located on spacers on the support bracket and baffle, is
removed from its mounting while the carriage is on extenders.
1. Disconnect the umbilical cable (PL10), see Section 3.3.5.
2. Disconnect all other board cable connectors.
3. Remove the 4-off M3 caphead screws holding the PCB to the baffle and support
bracket.
4. Slide the PCB out of the support bracket.
5. Replacement is the reverse of the removal procedure.
6. Download the firmware level on the newly-installed Traverse PCB to match the
levels on the other PCBs. If they do not match, the system will not function
correctly. See Volume 2 Section 1.12.
7. Update the machine system registry file:
test/registry> update_registry system
8. Expose and test a plate to confirm correct operation.
5. Replacement is the reverse of the removal procedure. Make sure the traverse
initialises correctly on power up and then expose a test plate.
MOTOR
BEARINGS FLYWHEEL
SHAFT
BEARING
PLATE
FLYWHEEL
NOTE: THE TRAVERSE MOTOR/SUPPORT CASTING CLAMP
IS REPLACED AS A COMPLETE FRU
FLYWHEEL
SHAFT
WIPER
MOTOR
SUPPORT
CASTING
BUTTON
CLIP
TO
FHMB (4)
PCB SUPPORT
BRACKET
UMBILICAL
CABLE
TRAVERSE
PCB
3.3.6 Spinner
CAUTION: Read the spinner disposal notices in Volume 1 Section 3.2.18 before starting
this procedure.
CARRIAGE DOWELS
CASTING
PADS
(4-OFF)
1 LOCATE ON THE
FOUR PADS 2 ROTATE TO
ENGAGE LUG
VIEW ON ARROW A
LUG
LUG
SPINNER
SPINNER
CLAMP
A
CLAMP DOWEL SPINNER
3. Loosen the 4-off M4 screws holding the spinner spring clamps to the casting.
4. Extract the spinner by rotating it anticlockwise and drawing it back.
5. Replace the new spinner as follows (see Figure 3.7):
A) Insert the spinner between the clamps so that the lug is top left of centre (1).
B) Rotate the spinner clockwise to engage the lug behind and left of the dowel
pins on the casting (2).
C) Hold the spinner in position with one thumb, grip the casting with the other
four fingers so that it does not move, and tighten the spring clamp screws
(3).
L UXEL P LATESETTER VOLUME 3 (3-11)
6. After replacing the new spinner, make sure that it is aligned exactly as the old
spinner. It should fit accurately onto the four pads, as the spring clamps are
closed, and then secured without the need for further checks. Push the spinner
very gently against the four pads and check that there is no movement.
7. Reconnect the cable connectors to the Traverse PCB.
8. Run the following optical checks for:
A) Focus and Beam Deflection Absolute Phase (see Volume 3 Section 4.4).
B) Image Form Adjustment (see Volume 3 Section 1.8.1.1).
C) Image base offset (see Volume 3 Section 1.8) for the type of machine.
D) Traverse centre position (see Volume 3 Section 1.8.2.5) or check edge detect
sensor offset for the type of machine.
CARRIAGE
RAIL
BALL CAGE
TRAVERSE
RAIL
3.3.8 Readhead
CAUTION: When touching or handling the readhead, make sure all antistatic precautions
are followed.
NOTE: When the carriage arrives at the Index actuator, the LED blinks red or orange and
off. These indications are correct and show that the head has `recognised' the actuator.
L UXEL P LATESETTER VOLUME 3 (3-13)
READHEAD
INSERT
FEELER
LINEAR
SCALE
REAR
BRACKET LASER
FRONT LASER LENS
BRACKET
BRACKET
PCB
PCB
BRACKET
TRAVERSE
BAFFLE
8. Check that the image is 1 mm 25 microns from the plate edge using the
procedure below. A typical value is 3,500 microns. Increase the value to push the
image further onto the plate.
A) Open the optics_mmi setup screen from:
main>diagnostics/service/optics/optics_mmi
B) Run a test pattern with the Scan Start position as 0 mm.
L UXEL P LATESETTER VOLUME 3 (3-15)
C) Eject and process the image and check that it is exactly 1 mm from the edge
of the plate.
D) If it is not then find the current parameter EDGE_SENSOR_OFFSET value
(in microns) as follows:
diagnostics/log_utils> disp_nvram <EDGE_SENSOR_OFFSET>
E) If the image is more than 1 mm then decrease the parameter value; if it is less
than 1 mm then increase the parameter value. Use the following command:
diagnostics/log_utils/nvram> wr_edge_sensor_offset <required offset in microns>
Repeat this command until the offset is correct.
LENS
LASER
BRACKET
WASHER
NOTE: If the lens window has been handled or looks marked then clean with cotton buds
and IPA.
NOTE: Supplied lasers are pre-focused at the factory to obtain the required laser spot
size.
1. Reboot the machine if you have been running optics_mmi test patterns.
2. Move the traverse to a set position at the service end:
traverse/datum
traverse/goto pos=-1200000
3. Switch on the laser and release the traverse:
traverse> medirq
traverse/halt
4. Set the vertical position of the laser on the drum. Slacken the 2-off screws
holding the laser bracket and rotate the laser until the beam is in the centre of
the gap between the leading and trailing edges vacuum grooves, see Figure 3.12.
Retighten the bracket screws.
LASER
BEAM
LE VAC
GROOVES
GAP
DRUM TE VAC
GROOVES
ALIGNMENT TOOL
BETWEEN GROOVES
TURN
LENS
(A) (B)
BEAM IN OFFSET BEAM IN VERTICAL
POSITION POSITION
NOTE: Make sure the line formed by the lens is exactly aligned with the vacuum grooves.
An error of 2.5 degrees will affect edge detect performance.
5. With alignment tool: Insert the alignment tool into a groove and check that the
beam is vertically aligned with the tool markings, see Figure 3.13:
Loosen the lens until the line formed by the lens is aligned with the lines on the
tool. The angle of the line on the face of the tool must be within 1 mm at points
10 mm either side of the centre of the tool.
6. Without alignment tool: Adjust the lens until it is vertical. It should align exactly
to the vacuum grooves above and below the edge detect gap. Stray light should
disappear into the grooves above and below the gap. You can check this by
gently moving the carriage. An error of 2.5 degrees will affect the repeatability
of the edge detect function.
7. Move the traverse to the datum point on the other side of the machine:
traverse/datum
8. Switch the multimeter to DC and connect to the test connectors to TP 2 and TP 4
(GND) on the Edge detect PCB, see Volume 2 Figure 4.10.
9. Turn the PCB potentiometer fully clockwise.
10. Load a small plate into the machine from the MMI.
11. Select traverse/halt to allow the machine to be moved by hand.
12. Select traverse/medirq to turn on the laser, if it is off.
13. Move the carriage until the spot is on the plate.
14. Adjust the potentiometer until the voltage reading is 1. 7 V.
VOLUME 3 (3-18) TRAVERSE S CAN S ERVICE P ROCEDURES
OPTICS SERVICE
PROCEDURES
This chapter describes how to replace optics field replaceable units (FRUs), how to
setup FRUs, run optics test strips and adjust image forms.
4
4
Starting Optics Module Replacements ........................................................... Page 4-1
4
Optics Replacement Setups ............................................................................ Page 4-3
4
Optics Base Replacements ........................................................................... Page 4-15
4
Exposing Test Strips ...................................................................................... Page 4-31
4
Check Raster Quality ..................................................................................... Page 4-50
4
Calibrate Exposure Level............................................................................... Page 4-51
B1 and B2 Image Form Adjustments ............................................................ Page 4-54
NOTE: Do not touch any optical surfaces such as mirrors and lenses. If a modules is
fixed to the baseplate with a shoulder bolt that has a spring and a washer, make sure that
its washer is replaced.
This chapter describes how to replace Field Replaceable Units (FRUs), how to
set them up and test them for correct operation:
Optics sensors - Section 4.3.1.
Optics motors - Section 4.3.2.
Laser Module - see Section 4.3.3.
EOD Module - see Section 4.3.4.
POD Module - see Section 4.3.5.
Optics base FRUs are accurately aligned with other optical mechanisms on the
engine at manufacture and should only be removed or adjusted using the rec-
ommended service procedures.
VOLUME 3 (4-2) O PTICS SERVICE PROCEDURES
After replacing an optics base module you will need to run the setup and diag-
nostic procedures shown in Table 4.1.
USER SERVICE
SIDE SIDE
After cleaning any of the optics base modules make sure the setup procedures in
Table 4.1 are carried out.
L UXEL P LATESETTER VOLUME 3 (4-3)
NOTE: Note that this table shows the order of testing from top to bottom.
NOTE: If you are replacing the Focus, ND and LPD motors or sensors, run the setup
shown for the main module assembly shown in Table 4.1.
Aperture Assys
Laser (1-Laser)
Laser (2-Laser)
EODHV TX X/Y
Focus Assys
EODD PCB
LPD Assys
ND Assys
EOD X/Y
VBOMB
Spinner
EODHV
POD
FPD
Setups and Tests:
Find LPD position
(Section 4.2.1)
a
Update laser parame-
ters (Section 4.2.2)
aa
Clear laser aging stats
(Section 4.2.3)
aa
Set up laser current
limit (Section 4.2.4)
aa a
Check power balance
(Section 4.2.5)
a aa a a a
Set laser extinction
(Section 4.2.6)
aa a
Reset beam
coincidence
aa aaaa a
(Section 4.2.7)
Run Beam_co
(Section 4.2.8)
aaa aaaa a
Setup and locate FPD
(Section 4.2.9)
a
Setup ND characterisa-
tion (Section 4.2.10)
aa
Reset the spinner con-
tamination check
aa a
(Section 4.2.11)
VOLUME 3 (4-4) O PTICS SERVICE PROCEDURES
Aperture Assys
Laser (1-Laser)
Laser (2-Laser)
EODHV TX X/Y
Focus Assys
EODD PCB
LPD Assys
ND Assys
EOD X/Y
VBOMB
Spinner
EODHV
POD
FPD
Setups and Tests:
Exposure calibration
(Section 4.2.12)
aaaaaaaaaaaaaaa
Auto focus
(Section 4.2.13)
aaa a a
Auto ND wedge
(Section 4.2.14)
a a
Auto threshold wedge
(Section 4.2.15)
a a
Auto coincidence Y & X
(Section 4.2.16)
aa aaa a
Auto deflection abso-
lute phase for confi-
aaa
dence (Section 4.2.17)
Auto deflection abso-
lute phase setup
a
(Section 4.2.17)
Auto deflection ampli-
tude Y/X
aa aaa a
(Section 4.2.18)
Image form adjust-
ment (Section 4.2.19)
aa a
Expose calibration
(Section 4.2.20)
aaa aaaa a aa
Image base offset
(Section 4.2.21)
a
Edge sensor offset/trav
centre position
a
(Section 4.2.22)
Image check
(Section 4.2.23)
aa aaaaaaaaaaaa
L UXEL P LATESETTER VOLUME 3 (4-5)
NOTE: The software utility above turns on all available lasers, tries various LPD stepper
motor positions and finds the best position for maximum power in both beams.
When fault-finding, run this utility to check if both lasers are able to turn on successfully
and laser light arrives at the LPD.
diagnostics/log_utils>clear_laser_x_stat
diagnostics/log_utils>laser_x_stat
diagnostics/log_utils/nvram>clear_laser_y_stat
diagnostics/log_utils/nvram>laser_y_stat
NOTE: These should only show invalid dates and laser power values.
edbg 40
diagnostics/service/optics/laser>laser_aging
ddbg 40
See also Volume 2 Section 1.10.4.1 for a description on how to use this com-
mand.
Procedure:
1. Run the following command:
edbg 24
diagnostics/service/optics/laser> power_balance 48
2. Check that the power balance utility passes without error messages.
diagnostics/service/optics/laser> power_balance 72
3. Check that the power balance utility passes without error messages.
diagnostics/service/optics/laser> power_balance 96
4. Check that the power balance utility passes without error messages and enter:
ddbg 24
diagnostics/service/optics/laser>measure_extinction_ratio
2. The extinction ratios should be between 180 and 220 for both lasers (if fitted). If
they are not then adjust them as follows:
4 to increase the extinction ratio of a laser you need to decrease the bias cur-
rent
4 to decrease the extinction ratio of a laser you need to increase the bias cur-
rent.
3. Adjust the bias current of the required laser(s) as follows:
Working Laser X/Y bias DAC values are changed using the backspace and
numerical keys:
Increase or decrease the Working Laser bias current DAC values by 1 unit at a
time.
Changing the bias current by a large value (greater than 5) may damage the
laser.
Press [Return] then use the side keys to select UPDATE, the press [Return] to exit.
This will update all the working laser bias values in NVRAM. Enter the
following:
diagnostics/service/optics/laser> set_bias_level change
VOLUME 3 (4-10) O PTICS SERVICE P ROCEDURES
Changing values
ORIGINAL_ND_P_POD updated...
FPD_GAIN updated...
where the <factory value> is a value of about 10.0 determined at the factory and
written on the FPD PCB.
3. Enter:
edbg 23
and run the following:
diagnostics/service/utils> setup_fpd_offset
diagnostics/test/spinner> locate_FPD
to obtain:
4. Enter:
ddbg 23
VOLUME 3 (4-12) O PTICS SERVICE P ROCEDURES
NOTE: The Allen screw for sensor, S3, is difficult to access and requires a right-angled
Allen key.
CAUTION: On opening the optics modules enclosure, shown in Figure 4.1, fit the service
manifold tool (Part No 7A04975) to ensure that clean air from the PAT is distributed inside
the optics base.
SENSOR (S1)
SENSOR
STAY BRACKET
MOTOR
BRACKET
ND FILTER
FILTER
WHEEL
MOTOR
(SM1)
OLD BASE
FIXING
NEW BASE
LOCATING FIXING
DOWEL
SPRING
MOTOR
SCREWS
MOTOR
BRACKET
SM2 MOTOR
BRACKET
SCREWS
Setup SM2
1. Run the setups for the Focus Assys shown in Table 4.1.
2. Output a customer job and check for quality.
SPRING
BELT
MOTOR
S6 SENSOR
BASEPLATE SCREW
(4-OFF)
Figure 4.4 Replacing the SM3 motor (Aperture Control)
Setup SM3
1. Run the setups for the Aperture Assys shown in Table 4.1.
2. Output a customer job and check for quality.
VOLUME 3 (4-20) O PTICS SERVICE P ROCEDURES
CAUTION: Always follow the antistatic precautions when unpacking, handling and
replacing the laser diode module.
NOTE: After a laser module has been removed make sure it is returned to FFEI (UK) for
disposal.
CAUTION: Make sure the new data values are entered BEFORE the replaced diode is
switched on.
FIXING
SCREWS
(3-OFF)
BASEPLATE
DOWELS
DOWELS DOWEL
FIXING SCREW FIXING SCREW
NOTE: Do not switch on the new laser until the new NVRAM parameters, supplied on the
data sheet, are entered.
1. Reboot the machine and stop the application from running by pressing Ctrl-c at
the second reminder message. This will stop the machine software turning on
the laser while the old laser parameters are held in NVRAM.
2. Carry out the setups required for the laser module in Table 4.1. Choose either
the 1-laser or 2-laser machine setups, depending on how many lasers are fitted
in your machine.
3. Output a customer job and check for quality.
SHOULDER
BOLT
(3-OFF)
EOD (X)
DOWEL (1)
PLAN VIEW ON
A ARROW A
ALLEN
EOD (Y)
CAPHEAD
DO NOT
ADJUST
FACTORY-SET
BASEPLATE DO NOT ADJUST
ALLEN
CAPHEAD
DOWEL (1) (LOWER)
OPTICS BASEPLATE
POSITION DETECTOR
BOARD ASSEMBLY
PCB
BASEPLATE
ALLEN SCREW
(& CAPTIVE
WASHER)
DOWEL
Figure 4.7 Positioning the POD module
M4 CAP HEAD
OPTICS SCREW
COVER (4-OFF)
SPACER
DC - DC
CONVERTOR
TRANSFORMERS
TRANSFORMER
SHIM
DETACH
HERE
AMPLIFIER
TO EOD
(X OR Y) M4 CAP HEAD
SCREW
(2-OFF) HEATSINK
EODHV
PCB
Figure 4.8 Replacing the HV EODD PCB
ND FILTER
LENS AND
DETECTOR
FILTER MOUNT
PCB
GASKET
MASK
(BOTH SIDES)
PULLEY
SHAFT
MOTOR SUPPORT
BRACKET
TIMING
BELT
SM4 MOTOR
SECURING
SCREW
(4-OFF)
NOTE: The LPD board is always fitted with a gasket mask to isolate the PCB from chassis
ground. This is to ensure accurate beam power readings.
3. Loosen the M3 caphead screw holding the lens/filter mount on the pulley shaft.
4. Remove the mount to access the PCB.
5. Remove the PCB (4-off posidrive) and the gasket mask.
6. The replacement procedure is the reverse of the removal.
When replacing the M3 screw, make sure it grips the flat side of the pulley shaft.
SENSOR
MOUNTING
BRACKET
SECURING
SCREW
S6 SENSOR
4. Remove the 4-off M4 Allen screws (front and rear) holding the PCB support
bracket to the base.
5. Detach the PCB from the bracket.
6. Replacement is the reverse of the removal procedure.
NOTE: Test strips can be run at any of the 8 resolutions that the Engine supports. How-
ever, only test strips at 48, 72 and 96 resolutions are required to perform a 2-beam setup.
Strip patterns are run from the following macros selected on the Test Pattern
Setup screen:
Auto Quick Focus
This pattern determines the coarse focus at 48 and 96 resolutions using vertical
lines and Y-beam only.
Auto Focus
This pattern determines the focus at 48 and 96 resolutions in more detail than
the Auto Quick Focus. It generates 5 sets of strips:
1. 96 vertical X-beam
2. 96 horizontal X-beam
3. 96 vertical Y-beam
4. 96 horizontal Y-beam.
5. 48 vertical Y-beam.
Auto ND Wedge Density
This pattern is used to find the best ND Wedge setting for equal mark/space
ratio for 1ON 1OFF vertical lines at 48, 72 and 96 resolutions. These values are
used in the ND settings field of the Final Values table.
Auto Threshold Wedge Density
This pattern is used to find the best ND Wedge settings for black at 48, 72 and 96
resolutions. These values are used in the Threshold ND Settings field of the
Final Values table.
Auto Coincidence X/Y
These patterns are used to determine the drum coincidence values for X- and Y-
beams at 48, 72 and 96 resolutions.
VOLUME 3 (4-32) O PTICS SERVICE P ROCEDURES
Step Value
The number which determines the incremental change in the position from the
Start value for a motor, deflection, etc (see Figure 4.15 which shows the ND filter
with a step value of 2).
Number of Steps
This is the number of positions that the optical device is moved. A test strip is
exposed at each position.
START
VALUE
76 74 72 70 68 66 64 62 60
SCAN
8 mm 2 mm
START
STRIP WIDTH STEP VALUE
POSITION
(mm)
NOTE: These values are not intended to be typical values. They are for example purposes
only.
Resolution
Select a resolution: 48, 72, 96, 100 144 l/mm 1200, 1800 or 2400 lpi.
Pattern Type
Select a pattern type: Vertical Lines, Horizontal Lines, Static Align Pattern, Grid,
Dots or Black.
Lines
The line pattern generated can be from 17 different selections (including
BLACK):
1 ON 15 OFF to 15 ON 1 OFF.
Beam X/Y
Decide if Beam X and Beam Y are ON or OFF for the test. If a beam is Not Avail-
able, the display shows N/A
Traverse
Set the speed of the traverse: 1 beam speed or 2 beam speed where 2 beam speed
is twice as fast as 1 beam speed.
Use Threshold
Selecting Y to this option forces the exposure to use the threshold wedge posi-
tion specified in the Final Values screen. This exposure gives the best separation
of black lines.
Selecting N to this option forces the exposure to use the ND wedge position
specified in the Final Values screen. This exposure gives more laser power for
equal mark/space ratio 1ON 1OFF lines on a plate.
Start Scan
Selecting Y starts the scan.
Media Eject
Choose Y to eject a plate to the processor after the scan.
Extra Options
Selecting Y opens the Extra Options screen when the cursor is moved down, see
Figure 4.14.
Final Values
Selecting Y opens the Final Values screen when the cursor is moved down.
Machine Setup
Selecting Y opens the Machine Setup screen when the cursor is moved down.
Run Beam-co(incidence)
Runs an automatic procedure which aligns Beams X and Y to be co-incident on
the POD.
L UXEL P LATESETTER VOLUME 3 (4-37)
Exit
Choose this option to exit from the program after the scan.
1: Auto Focus
See Table 4.4 below.
This procedure allows you to verify and change the NVRAMs for the focus lens
so that it moves to the optimum focus position for all resolutions (res) and plate
thicknesses.
Use the largest available plate for these checks, making sure the minimum plate
height is:
A) B1: 770 mm
B) B2: 600 mm.
1. Calibrate the platesetter at a setting of 50.
2. Find the ND settings values for 96 and 48 resolutions from the MMI ND Settings
screen.
3. From Main diagnostics open the test pattern setup screen:
main> diagnostics/service/optics/optics_mmi
4. Enter the 96 and 48 res values into the Final Values table for the ND 96 and ND
48 resolution fields.
5. Expose 5 blocks of 9 test strips (right to left) from the Auto Focus macro. This will
use the values shown in the table below.
2-Beam machine: runs the five test strips (A to D at 96 and E at 48 resolution).
1-Beam Machine: this only runs tests C to E.
NOTE: The focus offset is 30 steps per 100 m change in the plate thickness. Thinner
plates should have higher focus numbers.
For instance, if the 0.3 plate is set at 1200 steps the other plate steps are:
A) 0.24 mm = 1218
B) 0.2 mm = 1230
C) 0.15 mm = 1245.
B) Finish the required setups as well as possible and check the resulting quality
using an S&T page. If it is unsatisfactory and cannot be improved, consult
FFEI Customer Services.
NOTE: focus conditions are only important if there is unacceptable image quality for the
customer.
14. Store all focus positions for all resolutions in NVRAM using the Final Values
menu.
1 ON/
1 OFF
Since it is difficult to visually check if two beams are on top of each other, a spe-
cial test pattern is used. This pattern generates beam X on one rotation of the
spinner followed by a one line gap on the second. On the third rotation, beam Y
is put down followed by a one line gap on the fourth. This is then repeated. The
result is a 1 ON/1 OFF vertical line pattern using alternate beams. When the
lines are equal spaced, then drum coincidence is achieved.
96 72 48 96 72 48
320 mm (PUNCH)
298 mm (NO PUNCH)
DEFLECTOR
POINT (Y)
432 mm
DEFLECTOR
POINT (X)
X-BEAM Y-BEAM
TEST STRIPS TEST STRIPS
For a B2 machine (Vx-6000), open the Final Values screen and set X Off EOD to 0
for resolutions 48, 72 and 96.
1. Output test strips using the table below (after running beam_co):
Check at the Y deflection point for the best equal spaced lines. On a B2 machine,
the plate is not high enough to view the patterns at the X-deflector operating
point. Instead, find the best equal spaced lines at the top and bottom of the plate
and take the average. Note that the co-incidence Y numbers must be inserted
into the Final Values table before doing Auto Coincidence Beam X.
3. Enter values into the Final Values table.
A) Enter the 48 resolution value into the 1200 and 48 positions for the X OFF
EOD line.
B) Enter the 72 resolution value into the 1800 and 72 positions for the X OFF
EOD line.
C) Enter the 96 resolution value into the 2400, 96, 100 and 144 positions for
the X OFF EOD line.
1. Examine the plate in the first test pattern to check if there are two vertical bands
with dark lines at approximately 400 and 1100 positions shown in Figure 4.19.
TEST STRIPS
1400 1300 1200 1100 1000 900 800 700 600 500 400 300 200 100 0
2. If the bands run diagonally, then there is a fault in either the X-deflection or Y-
deflection system or setup. For a 1030 x 800 plate, an X-deflection fault produces
a dark band from top right corner to bottom middle of the plate. A Y-deflection
fault produces a dark band from top centre right to bottom centre left of the
plate, see Figure 4.20.
L UXEL P LATESETTER VOLUME 3 (4-47)
L D
D
L
L
D
D
L
3. The second test pattern (1ON 3OFF) is for best horizontal lines which should
appear as a line of horizontal dots when examined by a x100 microscope, see
Figure 4.21.
4. Find the best horizontal lines; if the dots are either side of the correct position,
the lines appear jaggied, see Figure 4.21.
5. Enter the setting for the best horizontal lines into the Final Values screen for the
Deflection Absolute Phase field.
2. Punch machine: Mark a horizontal line across the Y beam test strips at 320 mm
down from the registration pin edge of the plate. The images should only be
inspected at this position. See Figure 4.22.
96 72 48
320 mm (PUNCH)
298 mm (NO PUNCH)
DEFLECTOR
POINT (Y)
Y-BEAM
TEST STRIPS
Figure 4.22 Auto Deflection Amplitude test strips (Y)
L UXEL P LATESETTER VOLUME 3 (4-49)
Non-punch machine: Mark a horizontal line across the Y beam test strips at 298
mm down from the registration pin edge of the plate. The images should only be
inspected at this position. See Figure 4.22.
3. Find the strip where the black lines are visible. This may be difficult to see if the
processor is not set up correctly. An alternative method is to increase the ND
Threshold values by 20 and measure the density of the strips. The strips should
have the highest density at 1.1 and be lighter either side. Pick the strip with the
highest density for 48 resolution and repeat this for the 72 and 96 strips.
4. Insert these values into the Y AMP EOD fields of the Final Values table for the
resolutions:
A) 48 into columns 1200 and 48
B) 72 into columns 1800 and 72
C) 96 into columns 2400, 96, 100 and 144.
2. Punch machine: Mark a horizontal line across the X beam test strips at 752 mm
down from the registration pin edge of the plate. The images should only be
inspected at this position. See Figure 4.23.
Non-punch machine: Mark a horizontal line across the X beam test strips at 730
mm down from the registration pin edge of the plate. The images should only be
inspected at this position. See Figure 4.23.
VOLUME 3 (4-50) O PTICS SERVICE P ROCEDURES
3. Find the strip where the black lines are visible. This may be difficult to see if the
processor is not set up correctly. An alternative method is to increase the ND
Threshold values by 20 and measure the density of the strips. The strips should
have the highest density at 1.1 and be lighter either side. Pick the strip with the
highest density for 48 resolution and repeat this for the 72 and 96 strips.
4. Insert these values into the X AMP EOD fields of the Final Values table for the
resolutions:
A) 48 into columns 1200 and 48
B) 72 into columns 1800 and 72
C) 96 into columns 2400, 96, 100 and 144.
On a B2 machine, the plate is not high enough to view the patterns at the X-
deflector operating point. Instead, find the correct strip at the top and bottom of
the plate and take the average. If there is a large skew between the top and
bottom, then repeat Coincidence Beam X first. Note that the Amplitude Beam Y
numbers must be entered into the Final Values table before doing the Amplitude
Beam X test.
96 72 48
752 mm (PUNCH)
730 mm (NO PUNCH)
X-BEAM
TEST STRIPS
47 50 13.2
VOLUME 3 (4-52) O PTICS SERVICE P ROCEDURES
48 50 13.0
71 50 10.6
72 50 10.4
94 65 11.0
96 65 10.8
100 65 10.4
144 65 7.2
1. Display the TOOLS menu and press Exposure Calibration (lower righthand side
button) to obtain the Exposure Calibration screen:
EDIT EXPOSURE
LEVEL
START
CALIBRATION CURRENT
EXPOSURE LEVEL
ND SETTINGS
2. Press Start Calibration to measure the exposure level at the drum and calculate the
ND settings of the filter wheel for all resolutions.
3. The screen shows a Wait Timer icon during the calculations and then indicates:
A) Successful calibration: a tick appears on the Exposure Calibration screen.
None of the resolutions have failed.
B) Failed calibration: an ND Values screen appears showing a Warning icon
next to the resolution(s) that failed because insufficient power is
available. If any of these resolutions are used by the customer then clean
the spinner mirror and repeat the calibration. Call FFEI Customer
Support (UK) if the calibration fails again.
The ND Values screen only appears automatically if there is a lack of
power. To view this screen, press ND Settings.
L UXEL P LATESETTER VOLUME 3 (4-53)
NOTE: The ND settings for exposing RIP images are stored directly on the Engine HDD
and are not supplied by the RIP.
4. When exposure calibration has been performed, linearise the %dots at the
required resolutions and screen rulings using the RIP Calibration Manager.
VOLUME 3 (4-54) O PTICS SERVICE P ROCEDURES
ADJUSTING
SCREW (VERTICAL)
LOCKNUT
M2
MIRROR
ADJUSTING
SCREW (HORIZONTAL) HOUSING
STRIP 0
CUT
APPROX. 100 mm
STRIP 1 WIDE STRIP
CUT
STRIP 2
CUT
STRIP 3
CUT
1130 mm
STRIP 1
B1 RULER
STRIP 2
TAPE
1223 mm
STRIP 0 B2 RULER
940 mm
865 mm (B1) B
A 665 mm (B2)
IMAGE
MEASURE
X
865 mm (B1)
665 mm (B2)
B A
FILM COMPARISON
RULER
GRID CROSS POINT
ON CORNER
PLATE
GRID IMAGE
A B
865 mm (B1)
665 mm (B2)
865 mm (B1)
665 mm (B2)
GRID IMAGE
A B
5. If A is greater than B, as in Figure 4.31, then adjust the M2 horizontal screw anti-
clockwise.
L UXEL P LATESETTER VOLUME 3 (4-59)
GRID IMAGE
A B
6. B1 Plate: Loosen the adjuster locknut and re-adjust as follows (see Figure 4.26):
A) One division turn on the horizontal adjuster screw = 50 m correction.
B) Ten divisions turn on the horizontal adjuster screw = 500 m correction.
C) Twenty divisions turn on the horizontal adjuster screw = 1 mm
correction.
7. B2 Plate: Loosen the adjuster locknut and re-adjust as follows (see Figure 4.26):
A) One division turn on the horizontal adjuster screw = 47 m correction.
B) Ten divisions turn on the horizontal adjuster screw = 470 m correction.
C) Twenty divisions turn on the horizontal adjuster screw = 0.94 mm
correction.
8. After making the adjustment, gently tap the mirror housing to settle the M2
spring mechanism and then re-lock the setting.
9. Replace the periscope cover.
GRID IMAGE
FILM
COMPARISON
RULER
4. Turn the ruler over on its long edge and repeat step 4. to obtain a new
measurement value B (for instance, 60 m).
Measurement B could be slightly different from A because the centre line on the
ruler might be slightly bowed. By taking an opposing ruler reading it is possible
to find the average error value.
5. Calculate the magnitude of the bow by adding A and B and dividing the result
by two. For example: 100 + 60 = 160/2 = 80 m.
6. Complete the M2 correction procedure in Section 4.7.3.1 from step 3. onwards.
L UXEL P LATESETTER VOLUME 3 (4-61)
GRID IMAGE
STRAIGHT
LINE OF
SERVICE FILM GRID VERTICAL PERISCOPE
END CENTRE LINE BOW END
LINE
(B2 RULER)
FILM GRID
5. If the vertical bow is away from the periscope end, then adjust the M2 vertical
screw clockwise.
GRID iMAGE
SERVICE PERISCOPE
END END
6. If the vertical bow is towards the periscope end, then adjust the M2 vertical screw
anti-clockwise.
GRID IMAGE
SERVICE PERISCOPE
END END
7. B1 Plate: Loosen the adjuster locknut and re-adjust as follows (see Figure 4.26):
A) One division turn on the vertical adjuster screw = 15 m correction.
B) Ten divisions turn on the vertical adjuster screw = 150 m correction.
C) Twenty divisions turn on the vertical adjuster screw = 300 m correction.
8. B2 Plate: Loosen the adjuster locknut and re-adjust as follows (see Figure 4.26):
A) One division turn on the vertical adjuster screw = 8 m correction.
B) Ten divisions turn on the vertical adjuster screw = 80 m correction.
C) Twenty divisions turn on the vertical adjuster screw = 160 m correction.
9. After making the adjustment, gently tap the mirror housing to settle the M2
spring mechanism and then re-lock the setting.
10. Replace the periscope cover.
L UXEL P LATESETTER VOLUME 3 (4-63)
ND_MAX_TRANSMISSION updated...
2. Run the nd_char utility and check that it has run successfully:
diagnostics/service/utils> edbg 33
diagnostics/service/utils> nd_char
Wait a few minutes for the utility to run:
VOLUME 3 (4-64) O PTICS SERVICE P ROCEDURES
3. Ignore the error message shown above but do not ignore any other errors.
4. Check that the nd_char table has been correctly generated.
diagnostics/service/disk/dfs> ls
B) the date and time of general/nd_char is the same as Time: recorded near
the end of the nd_char text.
C) the maximum X and Y beam power is at least 800
These checks confirm that the file has been successfully created.
6. If necessary, you can chart the nd_char values obtained in MS Excel. For
instance, the plot of values for above are:
nd_char
1800
1600
1400
Laser Power (LPD)
1200
1000
800
600
400
200
0
20 40 60 80 100 120 140 160 180 200 220 240
ND filter position
NOTE: The working range of the ND filter wheel is from step 20 to the first step where the
power drops (normally 180-220). Above this the power is uneven, then drops sharply to a
low value (corresponding to light being blocked by the edge of the ND filter glass). After
this the laser light passes through a clear section in the ND filter wheel (without glass and
hence no light attenuation). Normally, only the working range is used.
ND_MAX_TRANSMISSION updated...
4
4
Starting the Service Procedures ............................................................................... 5-1
4
Replacing RFI Box Modules ...................................................................................... 5-2
Replacing Interlock and Power Modules..................................................................5-2
SENSOR DISTRIBUTION
PCB ASSEMBLY 24V DISTRIBUTION
PCB ASSEMBLY
MAINS INLET
DC CABLE
(10A 250V)
PSU POWER
FILTER
PCB
POWER
FILTER PCB
INTERFACE
DONGLE
(OLD PCB ONLY)
EXTERNAL
ALERT
RELAY
DISK DRIVE
MOUNTING
BRACKET
SYSTEM (LSB)
PCB
INTERFACE
SYSTEM (LSB)
PCB
RFI BOX
LSB FAN
-15V
SENSE
0V
0V
0V 0V 0V 0V
+36V
+5V +24V +24V +15V
5. Start to connect the Power Filter DC wires to the PSU before fixing the plate to the box.
6. Switch on the system and check for the correct voltages listed in Volume 2 Section
6.5.1.
7. Run an image and check for quality.
6. Switch on the system and check for the correct voltages listed in Volume 2 Section
6.5.1.
7. Run an image and check for quality.
System crash!!
Forcing GDB breakpoint (interrupt masked)....
A) Switch off the machine at the mains and reboot, stopping at the first Ctrl-c message
on your terminal.
B) Type machine at the prompt to get the following options:
main> machine
Use <- or -> to select the machine type
L UXEL P LATESETTER VOLUME 3 (5-5)
WARNING: Make sure the power supply is switched off at the mains distribution or the
power cord is detached from the machine before servicing the mains filter box.
FUSEHOLDERS
AND 3-OFF FUSES
(SEE NOTE)
INTERLOCK
CONTACTOR
INTERLOCK PWR 1
COMPRESSOR
MONITORING
RELAY (BV31) INTERLOCKS
MODULE
TERMINAL
BLOCK SHUTTER
(LASER ON/OFF)
END STOP
SURGE
SUPPRESSOR
RAIL
PWR 3
PWR 2
PSU
(30W +24V)
POWER IN
OVERCURRENT
ON/OFF SWITCH CIRCUIT BREAKER
(CIRCUIT 24V FUSE
BREAKER) (0.5A 250V)
VAC PUMP
RELAY (BV5)
LED
DIAGNOSTICS
VAC PUMP (2) MAINS_RFI_IN COMPRESSOR
MAINS_DIST
VAC PUMP (1)
4
4
Useful Service Commands ..................................................................................................... A-1
4
Useful Service Sensor Tests .................................................................................................. A-2
4
Sensor Listing.......................................................................................................................... A-2
4
Solenoid Listing....................................................................................................................... A-4
sensors/read_s bs47 Stack position BS47 Paper in front (on); paper removed (off)
sensors/read_s bs65 Cassette at nudger BS65 Hold in microswitch (off); release microswitch (on)
actuators/set bv20 on Diverter BV20 Paper under diverter (down); remove paper (up)
sensors/read_s bs53 Paper tensioner BS53 Paper under diverter (on); remove paper (off)
sensors/read_s bs66 Interleave nip clear BS66 Paper under diverter (on); remove paper (off)
sensors/read_s bs43 Cassette empty BS43 Paper in front (off): remove paper (on)
sensors/read_con ip Cassette IDs BS36 to BS40 Paper in front (off); paper removed (on)
BS30 ELEVATOR FHMB 2 BS70 Z DIR DOWN FHMB 2 BS110 SWING ROLLER FHMB 4
OVER TOP IN (WEB)
BS32 ELEVATOR FHMB 2 BS72 CASS DOOR FHMB 2 BS112 PUSH BAR FWD FHMB 4
SHELF 1 CLOSED (WEB)
BS36 CASS ID 1 FHMB 2 BS76 FRONT FHMB 2 BS116 MANUAL PLATE FHMB 1
DOOR PUSHER HOME
BS38 CASS ID 3 FHMB 2 BS78 DOCKING LH FHMB 2 BS118 MANUAL PLATE FHMB 4
ON PLATEN
OPTO
BM2 PUSH BAR FHMB 1 motors>setmotor BM22 NUGER & FHMB 3 actuators>set_drv
TAKAWAY
BM19 BM39
Once the pages are downloaded and printed, insert them into your Engineers Reference
Guide.
4
4
Luxel System PCB Replacement ........................................................................................... B-1
4
Laser Temperature and Humidity Control............................................................................. B-4
4
Aperture Control Replacement .............................................................................................. B-6
4
Punch, Registration and Centerer (Fuji)................................................................................ B-9
CAUTION: Make sure the firmware on the newly-installed LSB matches the CAN node
PCBs. Failure to match will cause the system to malfunction.
TP1 TP2
TEMP
SENSOR
HUMIDITY
SENSOR
PL2
B.3.1 Preparation
1. Record the Power Margin figures in NVRAM.
log_utils> disp_nvram POWER_MARGIN_LO
log_utils> disp_nvram POWER_MARGIN_MID
log_utils> disp_nvram POWER_MARGIN_HI
Record the Power Balance working drive figures in NVRAM.
log_utils> disp_nvram LD*DRIVE*DAC
2. Save a text copy of the NVRAM as a precautionary measure, using the RIP
Savelog function.
3. Prepare the PAT Optics Service Manifold and turn on the PAT.
11. Replace the mechanism into the optics, locating on the dowel pins and replace
the fixing screws.
12. Attach the Aperture Home and Aperture motor cables to the mechanism.
L UXEL P LATESETTER B-7
NOTE: The lasers may turn off after some time (software timeout). If this happens then
you will need to repeat the 3 optics/laser> commands above to restore laser light.
motors> setmotor nd
motors> offstation 80 600
5. Set both deflectors to 800 (a hexadecimal value, equivalent to zero deflection).
development/optics/eodd> eodx_deflect 800
development/optics/eodd> eody_deflect 800
6. Set the aperture mechanism to the 72 res position.
optics/motors/move_motors> beam_res_pos 72
7. Block the X beam using a card so that only the Y beam passes through the optics.
8. Observe the laser light falling on the aperture.
9. Adjust the aperture position by eye to centre the Y laser beam halo around the
aperture.
The two screws holding the aperture to the bracket will need to be loosened but
still retain some spring pressure.
10. Increase the ND position to 150:
motors> offstation 150 600
11. Read the Y beam LPD value:
sensors> read_sensor pdet
NOTE: If a single beam machine, adjust the aperture position to maximise the LPD read-
ing, then continue from step 27.
12. Move the card to allow the X beam to pass and to block the Y beam
B-8 G UIDE TECHNICAL U PDATES
13. Read the X beam LPD value and compare with the Y beam value
sensors> read_sensor pdet
14. Alter the position of the aperture until the X beam and Y beam values are within
5% of each other.
15. Tighten the screws holding the aperture to the bracket.
16. Set the aperture to the 48 res position (step 630).
17. Visibly check on L5 that the small 48 res beam is fairly well centred on the L5
lens and the washer underneath the shoulder bolt is free-moving (this means
that the lens is firmly sitting on the V-grooves). The lens position will have been
set correctly in the factory.
18. Turn off the lasers:
laser> ldisable 1
laser> ldisable 3
19. Refit the aperture cover.
20. Refit the optics cover.
21. Run the set-up procedures (see Volume 3 Table 4.1), for the aperture assemblies,
in order to correctly set up the optics and NVRAM.
22. Run exposure calibration again (run it as part of the aperture assemblies set up
procedures, see Volume 3 Table 4.1.
23. Check the Power Margin figures in NVRAM.
log_utils> disp_nvram POWER_MARGIN_LO
log_utils> disp_nvram POWER_MARGIN_MID
log_utils> disp_nvram POWER_MARGIN_HI
A significant improvement in any of the power margin figures indicates that a
problem in that resolution, caused by the aperture mechanism, has cleared. The
Power Margin figures should all be positive numbers for successful exposure
calibration.
L UXEL P LATESETTER B-9
CENTERING
S10 MOTOR
S14
(BM3)
REG PIN
CENTERING DC MOTOR CENTERING
ARM (LH) ARM (RH)
S13
BS3
PIN/DIE/ A
S12 CHAD WIPER
PUNCH
MOTOR
CENTERING (BM4)
MOTOR BS8/9
S11
REG PIN
CAM
UNDERNEATH
VIEW ON CENTERING ACTUATING
ARROW A PINION SHAFT
M6 BOLTS M6 BOLTS
LOWER
BEAM
SUPPORT
DRUM
CASTING
DOWEL LOWER
BEAM
SUPPORT
SERVICE
SIDE
Note that the punch pins can be removed and replaced with the opposite end
operating as the punch surface. See`Replacing the Punch Pins' on page B-12.
Volume 3 Figure 2.21 shows a typical view of the pins, guide and die for a full
punch mechanism.
4 crops are equal depth when measured between left and right (specifica-
tion is 50 microns)
4 crops are cleanly cut without debris in corners or burrs (See `Replacing
the Punch Pins' on page B-12.
4 plate lead edge to the image start position is inside the specification, see
Volume 3 Section 1.8.3.3.
4 image is centred on the plate.
4. Check for correct chad removal, making sure the chad is `flicked' off each pin by
the strips.
NOTE: Refer to Fujifilm Customer Support for more information on removing pins, dies
and guides if there is a problem in setting up the punch mechanism.
NOTE: Do not operate BM4 and BM5 manually. This could cause the wiper to be damaged
and chad to drop into the drum.
2. Gradually move the actuating lever until the stud appears at the stud clearance hole
(top).
3. Using an 8 mm Allen key (T-bar or right-angled key) remove the stud from the hole.
NOTE: The stud is secured by Loctite and requires extra force to break the seal.
4. Extract the pin from the pin clearance hole directly behind, turn the pin around and
replace.
5. Refit the stud (with Loctite) and screw down until it stops, then wind back one half
screw turn.
6. Replace the punch motor support plate.
7. Check that the punch operates (without a plate) by manually operating the punch from
the actuating lever.
CAUTION: Do not operate BM4 and BM5 from Diagnostics or manually. This could cause
damage to the wiper and eventually lead to chad inside the drum.
ACTUATING
LEVER
ACTUATING
SHAFT
REMOVE
STUD
REMOVE
PIN
2. Remove the punch motor support plate assembly with its motor and gear (4-off M5
bolts). You do not need to retract the pins beforehand.
3. When replacing the motor and plate assembly, add a small amount of light engineering
grease to the cam/lever slot hole. Make sure the DC wires are correctly orientated.
4. Check that the punch pins actuate correctly by moving the actuating arm.
CAUTION: Do not operate BM4 and BM5 from Diagnostics or manually. This could cause
damage to the wiper and eventually lead to chad inside the drum.
PUNCH MOTOR
BS8
SUPPORT PLATE
(ON)
MOTOR/GEAR BS9
(BM4) (OFF)
4. Run a punch job from the RIP and check that chad does not drop into the drum.
CHAD
WIPER
SNAP
RIVET
PUNCH DIE
6 mm
CHAD
CUT CUT WIPER
WIPER
MOUNTING
BRACKET
DS (ROUND) CHAD DEFLECTOR
WIPER TRIM SHIELD
F H
Fans Hazards, 1-3-17
RFI box, 2-6-20 Chemical, 1-3-18
Fast Photo Detect Laser Radiation, 1-3-17
description, 2-5-25 Spinner, 1-3-18
replacement, 3-4-30 HDD
1-4 I NDEX
W
Warning Notices, 1-3-4
WARNINGS
hazardous voltages, 1-3-4, 1-3-18
Health and Safety at Work, 1-3-1
laser radiation, 1-3-3
laser safety officer
Laser Safety Officer, 1-3-21
unqualified personnel, 1-3-21
Waveplate
functional description, 2-5-11
1-10 I NDEX